Chapter Five

• Introduction to Automation

1
Content of the chapter

•Conventional control system/Hard wired systems

•Hardware and Software Concept
•Spectrum of modules and connection
•Software language: FBD, LAD, STL
•Programming of Basic Functions (AND, OR, RS-SR-Flip-Flop)
•Programming of Timer, Counter and Comparison instructions
•Documentation and Save projects
•Trouble shooting
•Simulation with PLC SIM

2
 Objectives
At the end of this course the trainee will be able to:
Compare the performance of manual, hardwired,
electronics and PLC methods of control and automation
List application of PLC

Identify components of PLC and their functions

Explain PLC programming methods using ladder

diagram, statement list and functional block diagram
Develop PLC using : Bit logic, Timer, counter,
comparison and integer function
Run and test the program

3
Automation
Automation or automatic control, is the use of
various control systems for operating equipment
such as machinery, processes in factories, boilers
and heat treating ovens, switching in telephone
networks, steering and stabilization of ships,
aircraft and other applications with minimal or
reduced human intervention.
4
Advantages of automation:
 Higher productivity
 Superior quality of end product
 Efficient usage of energy and raw material
 Improved safety in working conditions
 Time saving

5
History Automation

6
 Conventional /Hard wired Control System

•First step towards automation

•Here contactor and relays together with timers and
counters were used in achieving the desired level autom
ation

7
Contd.

1. Direct on line starting of three-phase induction motor

8
a) Power Circuit b) Control Circuit
Reversing the direction of three-phase induction motor

a) Power Circuit b) Control Circuit 9

10
•Limitation of hardwires(conventional control) syste
m:
 Bulky and complex wiring
 Involves lot of rework to implement changes in control logic
 The work can be started only when the task is fully defined and this le
ads to longer project time
 Higher power consumption
 Modification can be quite difficult
 Troubleshooting can be quite troublesome
 Machine downtime is usually long when problem occurs, as it takes a l
onger time to troubleshoot the control panel
11
Electronics control
 With the advent of electronic, the logic gates
started replacing the relays and auxiliary
contactors in the control circuit
 The bimetallic and motorized timers were
replaced by electronic timers, counters
 With incorporation of these changes, we got the
benefits of: reduced space requirements, energy
saving, less maintenance and hence great
reliability, easy fault finding 12
Programmable Logic Controller
 With the advent of microprocessor and
associated peripheral chips, the whole process
of control and automation underwent a radical
change
 As the desired logic control is achieved through
a “program”, these controller are referred to as
Programmable Logic Controller

13
 Advantages of PLCs
Reduced space
PLCs are fully solid state and hence extremely
compact as compared to hard-wired controller
wherein electromechanical devices are used
Energy saving
Average power consumption is just 1l10th of power
consumed by an equivalent relay logic control
Ease of maintenance
 Modular replacement
 Ease troubleshooting
 Error diagnostics with programming unit
Economical
 Considering one time investment; PLC is
most economical system
 Cost of PLC recovers within a short
period(Low pay back period)
Greater life and reliability
 Static device hence lesser number of moving
parts, reduced wear and tear

15
Tremendous flexibility
 To implement changes in control logic no
wiring is required so considerable time is
saved
 PLC can carry out complex functions such as
generation of timers delays, counting,
comparing, arithmetic operation etc
 “On-Line”(i.e without disturbing the process)
as well as “Off-Line” programming is possible
 High processing speed and great flexibility in
the processing of both analog and digital
signals
 Suitability for closed loop tasks with several
loop and high sampling frequencies 16
Shorter project time
•The hard wired control system can be constructed
only after the task is fully defined. In the PLC,
however, the construction of the controller and
wiring are independent of control program
definition. This means that the total hardwired is
standard and desired control is achieved though
program
17
Easier storage Archiving and documentation
•This is due to its compatibility with hard copy
•Pen drive, CD, DVD , and Hard disk

18
 Summery

Basic PLC Advantages

• Ease of programming
• Ease of maintenance
• Designed forindustrial
environment
• Quick installation
• Adaptable tochange
Other Advantages of PLC

In addition programming flexibility, PLC System offers:

•High reliability

•Reduced costs

•Expandability

•Computing capabilities

•Small space requirements

Advantages of PLC over Relays

• All the capabilities of the earlier systems

• Dramatic performance increase over the relay
logic systems
• Greater reliability
• Little maintenance due to no moving parts
• No special programming skills required by
maintenance personnel
• Physical size of the PLC system is much
smaller than the conventional relay based
logic
• And most importantly much lower cost
Conversion of conventional control circuit to PLC

Eg. Starting and stopping of a three-phase motor

a)Conventional control system

22
Contd.
b) PLC based system

23
Eg.2 Sorting Machine. PLC ladder program control circuit

24
Wiring circuit of PLC for sorting machine

25
PLC Origin

• Developed to replace relays in the late 1960s

• Costs dropped and became popular by 1980s
•Now used in many industrial designs
Historical Background
The Hydramatic Division of the General Motors
Corporation specified the design criteria for the first
programmable controller in 1968

Their primary goal:

To eliminate the high costs associated with

inflexible, relay-controlled systems.

27
Programmable Controller Development
1968  Programmable concept developed
1969  Hardware CPU controller, with logic
instructions, 1 K of memory and 128 I/O
points
1974  Use of several (multi) processors within a
PLC - timers and counters; arithmetic
operations; 12 K of memory
and 1024 I/O points
1976  Remote input/output systems introduced
1977  Microprocessors - based PLC introduced

28
Programmable Controller Development
1980  Intelligent I/O modules developed
Enhanced communications facilities
Enhanced software features
(e.g. documentation)
Use of personal microcomputers as
programming aids
1983  Low - cost small PLC’s introduced
1985 on  Networking of all levels of PLC, computer
and machine using SCADA
software.

29
 Programmable Logic Controllers
( Definition according to NEMA standard ICS3-1978)
A digitally operating electronic apparatus which
uses a programming memory for the internal
storage of instructions for implementing specific
functions such as logic, sequencing, timing,
counting and arithmetic to control through digital
or analog modules, various types of machines or
process.

30
Leading Brands Of PLC
AMERICAN 1. Allen Bradley
2. Gould Modicon
3. Texas Instruments
4. General Electric
5. Westinghouse
6. Cutter Hammer
7. Square D

EUROPEAN 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique

31
Leading Brands Of PLC
JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi

32
 Application of PLC
• Examples of industries where PLC’s are used for control
and automation purpose:
 Tyre industry

 Food processing plant

 Bulk material handling system at ports

 Ship up loader and wagon loader

 Steel plants and blast furnace charging

 Brick molding press in refractories

 Galvanized plant

 Dairy automation

 Aviation industry

 Etc

33
 Sizing of PLC

Micro PLCs: I/O up to 32 points

Small PLC: I/O up to 128 points

Medium PLC: I/O up to 1024 points

Large PLC: I/O up to 4096 points

Very Large: I/O up to 8192 points

34
Siemens PLC family
1. Logo
2. S7-200
3. S7-1200
4. S7-300/400

35
Contd.

36
Contd.

37
Contd.

38
Contd.

39
Application: Tank Used to Mix Two Liquids

MOTOR
A
FS FLOAT SWITCH

SOLENOIDS B

C SOLENOID
TIMER
1 -MINUTE

40
Tank Used to Mix Two Liquids
A tank is used to mix two liquids. The control circuit operates
as follows:

1.When the start button is pressed, solenoids A and B

energize. This permits the two liquids to begin filling the tank.
2.When the tank is filled, the float switch trips. This de-
energizes solenoids A and B and starts the motor used to mix
the liquids together.
3.The motor is permitted to run for one minute. After one
minute has elapsed, the motor turns off and solenoid C
energizes to drain the tank.
41
Tank Used to Mix Two Liquids
4. When the tank is empty, the float switch de-energizes
solenoid C.
5. A stop button can be used to stop the process at any
point.
6. If the motor becomes overloaded, the action of the
entire circuit will stop.
7. Once the circuit has been energized it will continue to
operate until it is manually stopped.

42
 Building block of PLC system
• The PLC is basically a programmed interface
between the field input elements like limit
switches, sensors, transducers, push buttons etc
and the final control elements like actuators,
solenoids valves, damper, drivers, LEDs,
hooters etc
• This interface is called PLC consisting:
1. Input modules
2. CPU with processor and program memory
3. Output modules
4. Bus system 43

5. Power supply
Major Components of a Common PLC

POWER
SUPPLY

I M O M
N O
P D U O
U U PROCESSOR T D
T L P U
From E U L
To
SENSORS T E
OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE

44
Inside a PLC Communications

C C
I i O i
n r u r
p c Central t c
u u
i
Processor p u
i
t u
t t t CR
s s

High High
Voltag Isolation
Voltag
e Isolation MEMORY Barrie
r e
Barrie
r program data

Low Voltage
AC Power Supply External
85-264 or DC Power Supply
50/60Hz
VAC,
46
Major Components of a Common PLC
POWER SUPPLY
Provides the voltage needed to run the primary PLC
components
I/O MODULES
Provides signal conversion and isolation between the
internal logic- level signals inside the PLC and the field’s
high level signal.

47
 Contd.

PROCESSOR
Provides intelligence to command and govern the activities
of the entire PLC systems.
PROGRAMMING DEVICE
used to enter the desired program that will determine the
sequence of operation and control of process equipment or
driven machine.

48
PLC illustrated with relay

49
 Relay Logic vs. PLC & Ladder Logic
PB1 LS1 SOL2 Inputs Outputs

Programmable
Logic
Controller
LS1 PB2 CR3
C
R

LS3

I/4 I/6 O/0

|| || ()

CR3 LS4 M1 I/7 I/5 B/0

|| || ()
|/|
I/8
||
B/0 I/9 O/1
|/| || ()
Programming Device
Also known as:

Industrial Terminal ( Allen Bradley )
 Program Development Terminal ( General

Electric )
 Programming Panel ( Gould Modicon )

 Programmer ( Square D )

 Program Loader ( Idec-Izumi )

 Programming Console ( Keyence / Omron )

 MPI Adaptor(Siemens)
51
Programming Device
Types:

 Hand held unit with LED / LCD display

 Desktop type with a CRT/LCD display

 Compatible computer terminal

52
Input/output Module
• The I/O interface section of a PLC connects it to
external field devices.
• The main purpose of the I/O interface is to condition the
various signals received from or sent to the external input
and output devices.
• Input modules converts signals from discrete or analog
input devices to logic levels acceptable to PLC’s processor.
• Output modules converts signal from the processor to
levels capable of driving the connected discrete or analog
output devices.

53
Input Modules
• The input module acts as an interface between
the field control inputs and the CPU
• The voltage or the current signals generated by
the sensors, transducers, limit switches, push
buttons etc are applied to the terminals of the
input module
• It converts the field signal into a standard control
signal for processing by the PLC. The standard
control signal delivered by input module could be
5V or 9V whereas the field signal received by it, 54
could be 24V DC, 230V AC or 115V AC.
 Contd.
• If required, it isolates the field signal from the
CPU
• It sends one input at a time to CPU by
multiplexing action
• Depending upon the nature of the input signal
coming from the field the input module could be:
 Analog input module
 Digital input module
• The typical analog current input modules are 4 to
± 20mA, 0 to ± 20mA & analog voltage input
modules are 0 to ± 50mV, 0 to ± 500mV & 0 to
± 10V 55

• The typical digital input modules are 24V DC,

DC DIGITAL INPUT MODULE
IS NEEDED TO:
USE TO  Prevent voltage
DROP THE transients
VOLTAGE from damaging
TO LOGIC the processor.
LEVEL Helps reduce
the effects of
electrical noise

Current Buffer,
FROM Limiting Filter,
OPTO- TO
INPUT Resistor ISOLATOR hysteresis
PROCESSOR
DEVICE Circuits

56
AC DIGITAL INPUT MODULE
IS NEEDED TO:
CONVERTS THE AC  Prevent voltage
INPUT TO DC AND transients
DROPS THE from damaging
VOLTAGE TO LOGIC the processor.
LEVEL Helps reduce
the effects of
electrical noise

Rectifier, Buffer,
FROM Resistor Filter,
OPTO- TO
INPUT Network ISOLATOR Hysteresi
PROCESSOR
DEVICE s Circuits

57
58
59
PLC input circuit

60
Some of the input devices

61
Contd. • Pushbuttons
• Selector
Switches
• Limit Switches
• Level Switches
• Photoelectric
Sensors
• Proximity
Sensors
• Motor Starter
Contacts
• Relay Contacts 62

• Thumbwheel
63
Input Wiring: PLC input is the load in the circuit,
sensing if voltage is present
Terminal Isolation
Blo Barrie
ck r
Input Devices
1
2
3
L1 4
5
P
L1 6 L
7
8 C
9
10
L2 COM
WIRING OF POWER SUPPLY WITH INPUT CARD

65
Central Processing Unit
• CPU consists of the following blocks:
 Arithmetic Logic Unit(ALU)
 Program Memory
 Internal timers and counters
 Flags
 The heart of CPU is microprocessor chip
 The working of CP is fully controlled by the
instructions/program stored in “user program memory”
 The user program directs and controls the CPU’s
working
 The program is prepared by the user based on the 66
control logic required for the control and automation task
Arithmetic Logic Unit(ALU)
• It organizes the input of external signals and data
• It performs logical operation with the data
• It performs calculations
• It takes account of the value of internal timers and
counters
• It takes account of the signal states stored in the
flags
• It stores the signal states of the input in the
“process input image”(internal memory of CPU)
during the program scan
67
• It organizes the output of the result
OUTPUT MODULES

• The output module acts as a link between the

CPU and the output devices located in the field
• The field devices could be relays, contactors,
lamps, motorized potentiometers, actuators,
solenoid valves, control valves, dampers etc
• The output module converts the output signal
delivered by CPU into an appropriate voltage
level suitable for the output field devices.
• Like input module the output module could be
analog or digital
68
 Contd.
• The selection is based on the voltage rating of
the field output devices. If the output device is
analog, then the analog output module is
required. If it is digital like contactor coil or a
lamp, then digital output module is required.
• Typical analog output modules have the rating
of 4 to ± 20mA or 0 to ± 10V and the digital
output modules have 24V DC, 115V AC, and
230V AC
69
DC / AC OUTPUT MODULE
IS NEEDED TO:
 Prevent voltage
transients
from damaging
the processor.
Helps reduce
the effects of
electrical noise

Amplifier
FROM RELAY
TTL OPTO- TO
PROCESSOR ISOLATOR TRIAC
Circuits OUTPUT
X’SISTOR
DEVICE

70
Output circuitry of a PLC

71
72
Output Wiring: PLC output is the switch,
controlling current flow to load
Isolation Terminal
Barrie Blo
r ck Output Devices
OUT 1 L1
CR
OUT 1 L
OUT 2 2
OUT 2
P OUT 3 L1
L2
L OUT 3
OUT 4
C OUT 4
OUT 5
OUT 5
OUT 6
OUT 6
Wiring of Output field devices with output card

74
Some of the output devices

75
 Contd.

• Valves
• Motor
Starters
• Solenoid
s
• Control
Relays
• Alarms 76
• Lights
• Fans
Bus system
• Bus system is a path for the transmission of
signals. In PLC it is responsible for the signal
exchange between processor and I/O modules

77
PLC Hardware Types
 Most Basic of PLC Systems
In the most basic of PLC systems, a self contained
(shoe box) PLC has 2 terminal blocks, one for
Inputs and one for Outputs
Today, most PLC’s in this category are know as
Micros. Typically they provide front panel
LED status indication of I/O and Processor
states
Inputs Outputs

Programmable Controller

C
R
 Modular Chassis Based PLC’s
The vast majority of PLC’s installed today are
modular chassis based systems
consisting of:

1. Processor
Module (CPU)
2. Input & Output
Modules
3. Chassis
4. Power Supply
 Modular Chassis-less PLC Systems
Also available from many vendors are “Chassis less”
but still Modular PLC systems. These
systems still require a Processor, I/O
Modules, and Power Supply, but in place of a
chassis these components mount directly
onto a panel, din rail, and many use a tongue
and grove system to allow easy insertion and
removal
The configuration of PLC refers to the packaging of the
components.

 Typical configurations are listed below from largest to

smallest.
 Rack Type: A rack is often large and these use a range
of modules that use together to build up a system.
 Shoebox: A compact, all-in-one unit that has limited
expansion capabilities. Lower cost and compactness
make these ideal for small applications.
 Micro: These units can be as small as a deck of cards.
They tend to have fixed quantities of I/O and limited
abilities, but costs will be lowest 82
PLC Configuration

RACK

MICRO
SHOE BOX (UNITARY)
PLC Application Considerations
• Inputs/Outputs
– Type,
• Functions required
• AC, DC, sourcing, • Instruction set
sinking, etc. • Messaging
– Number of • PID
• PTO, PWM
• 10, 16, 20, 32, 156
• Arithmetic
• Memory
– Type • Communications
• DeviceNet, Ethernet
• Flash or Battery backed
• Remote I/O, DH+
– Size
• Report generation
• 1k, 6k, 12k, 16k, 64k
 SOURCING vs. SINKING

SOURCING Pushbutton SINKING Pushbutton

( (
P N
N P
P +VDC N
) + )
+ DC
Power
DC
Supply
Power
Supply
-
- DC COM
 SOURCING vs. SINKING DC Inputs

SOURCING SINKING
(PNP) (NPN)

+VDC
Field
Device IN1 +
DC DC
+ DC Power
Input
DC Input Supply
Power Modul
Modul
Supply
e
- e
Field
- DC COM Device IN1
 RULES

•Field devices on the positive side (+VDC) of the field power

supply are sourcing field devices.
•Field devices on the negative side (DC COM) of the field
power supply are sinking field devices.
•Sourcing field devices must be connected to sinking I/O cards
and vice versa.
•Sinking field devices must be connected to sourcing I/O cards
and vice versa.
 Memory Map Organization
•System memory includes an area called the EXECUTIVE,
composed of permanently-stored programs that direct all
system activities, such as execution of the users control
program, communication with peripheral devices, and other
SYSTEM system activities.
•The system memory also contains the routines that
implement the PLC’s instruction set, which is composed of
specific control functions such as logic, sequencing, timing,
counting, and arithmetic.
•System memory is generally built from read-only memory
devices.

APPLICATION
•The application memory is divided into the data table area
•Data Table and user program area.
•The data table stores any data associated with the user’s
•User Program control program, such as system input and output status
data, and any stored constants, variables, or preset values.
The data table is where data is monitored, manipulated, and
changed for control purposes.
•The user program area is where the programmed
instructions entered by the user are stored as an application
control program.

88
Memory
VOLATILE.
A volatile memory is one that loses its stored
information when power is removed.

Even momentary losses of power will erase any

information stored or programmed on a volatile memory
chip.

Common Type of Volatile Memory

RAM. Random Access Memory(Read/Write)

Read/write indicates that the information stored in the
memory can be retrieved or read, while write indicates
that the user can program or write information into the
memory. 89
Memory

The words random access refer to the ability of any

location (address) in the memory to be accessed or
used. Ram memory is used for both the user memory
(ladder diagrams) and storage memory in many PLC’s.

RAM memory must have battery backup to retain or

protect the stored program.

90
Memory
Several Types of RAM Memory:

1.MOS
2.HMOS
3.CMOS

The CMOS-RAM (Complimentary Metal Oxide

Semiconductor) is probably one of the most popular.
CMOS-RAM is popular because it has a very low current
drain when not being accessed (15microamps.), and the
information stored in memory can be retained by as little
as 2Vdc

91
 Contd.

4. NOVRAM(Non-Volatile Random Access Memory)

-it is a combination of an EEPROM and a RAM.
-When the power is about to go off, the contents of the R
AM memory are quickly stored in EEPROM. The stored dat
a can then be read into the RAM memory when the power
is again restored.

92
Memory
NON-VOLATILE
Has the ability to retain stored information when power is
removed, accidentally or intentionally. These memories
do not require battery back-up.

Common Type of Non-Volatile Memory

ROM, Read Only Memory

Read only indicates that the information stored in
memory can be read only and cannot be changed.
Information in ROM is placed there by the manufacturer
for the internal use and operation of the PLC.

93
Memory
Other Types of Non-Volatile Memory

PROM, Programmable Read Only Memory

Allows initial and/or additional information to be written
into the chip.

PROM may be written into only once after being

received from the PLC manufacturer; programming is
accomplish by pulses of current.

The current melts the fusible links in the device,

preventing it from being reprogrammed. This type of
memory is used to prevent unauthorized program
changes.
94
Memory
EPROM, Erasable Programmable Read Only Memory

Ideally suited when program storage is to be semi-

permanent or additional security is needed to prevent
unauthorized program changes.

The EPROM chip has a quartz window over a silicon

material that contains the electronic integrated circuits.
This window normally is covered by an opaque material,
but when the opaque material is removed and the
circuitry exposed to ultra violet light, the memory
content can be erased.

The EPROM chip is also referred to as UVPROM.

95
Memory
EEPROM, Electrically Erasable Programmable Read
Only Memory

Also referred to as E2PROM, is a chip that can be

programmed using a standard programming device and
can be erased by the proper signal being applied to the
erase pin.

EEPROM is used primarily as a non-volatile backup for

the normal RAM memory. If the program in RAM is lost
or erased, a copy of the program stored on an EEPROM
chip can be down loaded into the RAM.

96
 PLC Operation

Basic Function of a Typical PLC

Read all field input devices via the input interfaces, execute
the user program stored in application memory, then, based
on whatever control scheme has been programmed by the
user, turn the field output devices on or off, or perform
whatever control is necessary for the process application.

This process of sequentially reading the inputs, executing the

program in memory, and updating the outputs is known as
scanning.

97
While the PLC is running, the scanning process
includes the following four phases, which are repeated
continuously as individual cycles of operation:

PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostics/
Comm
PHASE 4
Output
Scan

98
The scan time is the total time the PLC takes to
complete the program and I/O update scans
99
100
PHASE 1 – Input Status scan
 A PLC scan cycle begins with the CPU reading the
status of its inputs(from sensors).
PHASE 2– Logic Solve/Program Execution
 The application program is executed using the status
of the inputs
PHASE 3– Logic Solve/Program Execution
 Once the program is executed, the CPU performs
diagnostics and communication tasks

101
PHASE 4 - Output Status Scan
•An output status scan is then performed, whereby the
stored output values are sent to actuators and other field
output devices. The cycle ends by updating the outputs.

102
As soon as Phase 4 are completed, the entire cycle begins
again with Phase 1 input scan.

The time it takes to implement a scan cycle is called SCAN

TIME. The scan time composed of the program scan time,
which is the time required for solving the control program,
and the I/O update time, or time required to read inputs and
update outputs. The program scan time generally depends
on the amount of memory taken by the control program and
type of instructions used in the program. The time to make a
single scan can vary from 1 ms to 100 ms.

103
The program scan time generally depends on two
factors:
1. the amount of memory taken by the control
program
2. the type of instructions used in the program
(which affects the time needed to execute the
instructions)
The time required to make a single scan can vary
from a few tenths of a millisecond to 100 104

milliseconds.
 PLC Communications
Common Uses of PLC Communications Ports
Changing resident PLC programs -
uploading/downloading from a supervisory
controller (Laptop or desktop computer).
Forcing I/O points and memory elements from a

remote terminal.
Linking a PLC into a control hierarchy containing

several sizes of PLC and computer.

Monitoring data and alarms, etc. via printers or
Operator Interface Units (OIUs).

105
PLC Communications
Serial Communications

PLC communications facilities normally provides serial

transmission of information.

Common Standards

RS 232

 Used in short-distance computer communications, with

the majority of computer hardware and peripherals.
 Has a maximum effective distance of approx. 30 m at

9600 baud. 106

 PLC Communications
Local Area Network (LAN)

Local Area Network provides a physical link between all

devices plus providing overall data exchange management
or protocol, ensuring that each device can “talk” to other
machines and understand data received from them.

LANs provide the common, high-speed data

communications bus which interconnects any or all devices
within the local area.

LANs are commonly used in business applications to allow

several users to share costly software packages and
peripheral equipment such as printers and hard disk
storage. 107
 PLC Communications

RS 422 / RS 485

Used for longer-distance links, often between several

PCs in a distributed system. RS 485 can have a
maximum distance of about 1000 meters.

108
Specifications
Several factors are used for evaluating the quality and
performance of programmable controllers when selecting
a unit for a particular application. These are listed below.

NUMBER OF I /O PORTS

This specifies the number of I/O devices that can be

connected to the controller. There should be sufficient
I/O ports to meet present requirements with enough
spares to provide for moderate future expansion.

109
 Specifications
OUTPUT-PORT POWER RATINGS

Each output port should be capable of supplying sufficient

voltage and current to drive the output peripheral
connected to it.

SCAN TIME

This is the speed at which the controller executes the relay-

ladder logic program. This variable is usually specified as
the scan time per 1000 logic nodes and typically ranges
from 1 to 200 milliseconds.

110
Specifications
MEMORY CAPACITY

The amount of memory required for a particular application

is related to the length of the program and the complexity of
the control system. Simple applications having just a few
relays do not require significant amount of memory.
Program length tend to expand after the system have been
used for a while. It is advantageous to acquire a controller
that has more memory than is presently needed.

111
Selecting a PLC
Criteria

• Number of logical inputs and outputs.

• Memory
• Number of special I/O modules
• Scan Time
• Communications
• Software
A Detailed Design Process

1. Understand the process

2. Hardware/software selection
3. Develop ladder logic
4. Determine scan times and memory requirements
A systematic approach control system design using a
PLC

1. Determine the machine sequence of operation

2. Assignment of inputs and outputs
3. Writing of a program
4. Programming in to memory
5. Running the systems
114
Contd.

115
PLC Status Indicators
•Power On
•Run Mode
•Programming Mode
•Fault
Troubleshooting

1. Look at the process

2. PLC status lights
HALT - something has stopped the CPU
RUN - the PLC thinks it is OK (and probably is)
ERROR - a physical problem has occurred with the
PLC
3. Indicator lights on I/O cards and sensors
4. Consult the manuals, or use software if
available.
5. Use programming terminal / laptop.
PLC MAINTENANCE
1. Periodically check the tightness of I/O module termin
al screw. They can become loose over a period of tim
e.
2. Periodically check for corrosion of connecting termin
als. Moisture and corrosive atmosphere can cause po
or electrical connection.
3. Make sure that components are free of dust.
4. Stoke commonly needed spare parts. Input and outp
ut modules are the PLC components that fail most o
ften.
118
5. Put a duplicate record of operating programs being u
sed.
 Contd.

6. Replace the PLC backup batteries more often than

their useable life would indicate.(Eg. Lithium battery
will stay between 3 to 5 yrs but better replace it
every year )
7. Have a written checklist control sheet for each PLC.

119
List of items required when working with PLCs:

1.Programming Terminal - laptop or desktop PC.

2.PLC Software. PLC manufacturers have their
own specific software and license key.
3.Communication cable for connection from Laptop
to PLC.
4.Backup copy of the ladder program (on diskette,
CDROM, hard disk, flash memory). If none, upload
it from the PLC.
5.Documentation- (PLC manual, Software manual,
drawings, ladder program printout, and Seq. of
Operations manual.)
Examples of PLC Programming Software:

1. Allen-Bradley – Rockwell Software RSLogix500

2. Modicon - Modsoft
3. Omron - Syswin
4. GE-Fanuc Series 6 – LogicMaster6
5. Square D- PowerLogic
6. Texas Instruments – Simatic
6. Telemecanique – Modicon TSX Micro
PLC PROGRAMMING
122
The purpose of a PLC Program is to control the
state of PLC outputs based on the current

123
condition of PLC Inputs.
Different PLC’s support different languages, but
the most popular PLC language is know as
“Ladder Logic”.
PLC Ladder Logic purposely resembles Relay
Logic
 OUTPUTS

INPUTS MOTOR

CONTACTOR

124
LAMP

PUSHBUTTONS
PLC
 Allen-Bradley 1746-1A16

L1 L2 I= Input
Module
I:2 slot # in rack

125
P. B SWITCH 0 Module
Terminal #
Address I:2.0/0

LADDER PROGRAM
INPUT
MODULE
WIRING DIAGRAM
 CONTACTOR
L2 L1 N.
O

MOTOR
L2
C •SOLENOID
L1 •VALVES
FIELD •LAMP
•BUZZER

126
WIRING

OUTPUT MODULE
WIRING
L1 O:4 L2

CONTACTOR 0
LADDER PROGRAM
TYPES OF PLC PROGRAMMING

-LADDER PROGRAMMING

127
-FBD PROGRAMMING

-STL PROGRAMMING
LADDER AND FBD
-A very commonly used method of programming
PLCs is based on the use of ladder diagram.
-Write a program is then equivalent to drawing a

128
control circ
uit
Ways of drawing the same electric circuits
 Contd.

129
-Each rung on the ladder defines one operation in the control
process
-A ladder diagram is read from left to right and from top to
bottom
-each rung must start from input or inputs and must end with at
least one output
- a particular device can appear in more than one rung of a ladder
-The input and outputs are all identified by their address, the
notation used depending on the PLC manufacturer.
1. Bit logic instruction
a. Normally open contact
b. Normally closed contact
c. Output coil

130
Logic function
1. AND

131
Ladder for AND
Contd.
AND using FBD language

132
Contd.
2. OR

133
Ladder for OR
Contd.
• OR using FBD

134
Contd.

Example

135
Change FBD to ladder
Contd.
3. NOT

136
Not using ladder
Contd.
4. NAND

137
Ladder fro NAND
Contd.
5. NOR

138
Ladder for NOR
Contd.
6. XOR

139
Ladder for XOR
Contd.
7. Latching circuit

140