Introduction to Programmable Logic Controllers (PLCs)

• What is a PLC?

• Hardware components of a PLC

• Memory structure of a PLC

• PLC Modes of Operation

• Wiring Diagram
• Digital Inputs/Outputs

ACOE345 Introduction to PLCs 1

What is a PLC?
• A Programmable Logic Controller (PLC) is
– a microprocessor based control system,
– designed for use in an industrial environment,
– programmed to sense, activate and control industrial equipment.

PLC Controlled System

ABC ABC

Control Panel
2
Start
1 3
Stop Run Empty Done
Size

ACOE345 Introduction to PLCs 2

Hardware components of a PLC

DC Voltage Input
Digital Input
CPU
Interface
AC Voltage Input
Relay Output
Digital Output
ROM
Interface
Transistor Output
Triac Output

Analog Input
RAM

Internal Bus
Programming Console
Output Interface

Pulse Counter
EAPROM
and Timer

Computer
Additional Digital
Programming Port Input/Output
Interface

Communication
Hand-held Terminal
Interface
PLC

ACOE345 Introduction to PLCs 3

Memory structure of a PLC

The operating system of a PLC operates in one of two modes: the

Programming mode and the Run mode.
ROM In the Programming mode it communicates with the programming device
Operating System
(hand-held terminal, programming console or PC) to download the user's
program in the user's program space.
In the Run mode it executes the instructions stored in the user's program area.

Memory Mapped Memory area that holds an image of the state of the inputs as well as the
Input/Output values to ne to be output.
RAM

System Data Memory area used by the operating system to store system data

EAPROM
User's Program
or Flush
Space
Memory area that holds the instructions of the user's program.
EPROM

ACOE345 Introduction to PLCs 4

PLC Mode of Operation

• A PLC operates in one of two modes:

– Program Mode: Download the user’s program from
the programming device to the memory of the PLC. Program Mode
Mode
– Run Mode: Execute the user’s program using the Control
scan-based execution model, in three phases:
• Read the state of the inputs and store them Run Mode
in the RAM referred to as the input image Scan inputs
memory.. and store states
• Execute the user’s program and update the in RAM
state of the outputs in the RAM (output
image memory).
• Copy the states of the outputs from the Execute user's 1 Scan Cycle
RAM to the physical output devices. program
– The time needed to complete one scan cycle depends
on the length and complexity of the user’s program.
– PLC manufacturers specify the maximum number of
program steps (say 1000) and the average scan time Update outputs
(few ms).

ACOE345 Introduction to PLCs 5

Wiring Diagram

PLC
Com
O:1/00

Item Pusher
Start I:1/00 O:1/01

Stop I:1/01 M Belt Motor

O:1/02
I:1/02
Run
O:1/03
Size Selector I:1/03
Empty
I:1/04 O:1/04

Empty Sensor I:1/05 Done

O:1/05
Item Sensor I:1/06
O:1/06
I:1/07

O:1/07

ACOE345 Introduction to PLCs 6

DC Voltage Digital Input

• The optoisolator isolates the internal • When the switch is closed, current flows
components of the PLC and the external through the status LED and the opto-
input devices. isolator, giving a logic 1 to the input
• Diode D1 provides protection during port.
switching from inductive devices.
24Vdc 24Vdc
Input Device
Status LED
Terminal Connections on PLC
R1 D1

To Input Port
R2

Status LED
R2

Input Device R1 D1

Terminal Connections on PLC To Input Port

DC Voltage Digital Input:- Sink Input Circuit DC Voltage Digital Input:- Source Input Circuit

ACOE345 Introduction to PLCs 7

Connecting DC Proximity Switches

Proximity 24Vdc
24Vdc Switch

Status LED
Terminal Connections on PLC

R1 D1

To Input R2
Port

Status LED
Proximity R2
Switch
R1 D1

To Input
Terminal Connections on PLC Port

Connecting an NPN Proximity Switch Connecting a PNP Proximity Switch

ACOE345 Introduction to PLCs 8

AC Voltage Digital Input
• AC input devices switch On and Off the • An AC proximity switch switches On and Off
mains voltage. the mains voltage by triggering (firing) a triac.
• The mains voltage must be reduced using a The proximity sensor controls the gate current
voltage divider. of the triac.
• The mains voltage must be converted to DC
using a rectifier and a smoothing circuit.

Proximity
Input Device

Switch

Terminal Connections on PLC

Terminal Connections on PLC

240Vac Status LED 240Vac Status LED

To Input To Input
Port Port

AC Voltage Digital Input Circuit Connecting an AC Proximity Switch

ACOE345 Introduction to PLCs 9

Digital Output (Relay and Transistor)
• Most PLCs have relay outputs.
• Relay outputs have the advantage that they
can control DC as well as AC loads at
relatively high currents.
• The disadvantages of relays are due to their
mechanical contacts.
• Transistor outputs provide higher switching
speeds with more switching life.
• Transistor outputs can only be used with DC
loads and are polarity sensitive. A diode is
usually used for reverse polarity protection.
• Another diode is usually used to protect the
output transistor when switching inductive loads.

+Vdc AC or DC
+Vdc
Supply

Load
Status LED
Load
From
From Output
Output Status LED Port
Port

Relay Output Circuit NPN Transistor Output Circuit

ACOE345 Introduction to PLCs 10

Digital Output Using Triacs
• Triac outputs are used to avoid the problems due to the mechanical contacts of relays.
• An opto-diac is used to fire the triac.
• An RC circuit is usually used to avoid problems due to the phase difference between the
voltage and the current when driving inductive loads.

Status LED AC Supply

Load
From
Output
Port

Triac Output Circuit

ACOE345 Introduction to PLCs 11