Competency Training and Certification Program in Electric Power System Engineering

Distribution System Control and Automation

Introduction to Programmable
Logic Controllers

U. P. NATIONAL ENGINEERING CENTER

NATIONAL ELECTRIFICATION ADMINISTRATION
Introduction to Programmable Logic Controllers 2

Outline

Hardwired Relay Control Logic

Programmable Logic Controllers
 What is a PLC?
 PLC modules
 PLC Programming Instructions
 Examples

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Switches and the Power Bus

Push Button

Vcc
+ Pilot
_ Lamp
GND

Vcc or
Power GND BUS
Bus
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The Mechanics of Relays

VSOURCE
+ - VSOURCE
+ -
NC 1 2 NC NC 1 2 NC
3 4 3 4
NO NO NO NO
5 6 5 6
7 8 NO 7 8 NO
NO NO

NO NO NO NO

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Sample Relays

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Relays as Switches
VSOURCE
Switch
+ -
1 2
3 4
5 6 7 8
7 8

Power GND

Note: The Power Source of

the Relay and the bulb may
Power GND be different.

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Relay Terminologies:

Relay/Contactor/Contactor Relay - is an electromechanical

device whose normally open contacts close (and normally
closed contacts open) when its input terminals are energized.

Energizing Element - refers to the input terminals of a relay.

Contacts / Contactors - refers to the outputs of the relay.

Timer Relay / Time Delay Relay - a special kind of relay
whose normally open contacts close (and normally closed
contacts open) only at a time t after its input is energized.
The contacts return to their normal state immediately after
its input is de-energized.

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Relays in Sequential Control

Illustration 1:
Momentary Switch RLY A

Illustration 2:
RLY A
Latch

RLY A

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Illustration 3: Illustration 4:
Latch and Automatic ON Auto Shutdown Sequence
Sequence

RLY A RLY A

RLY B
RLY A
RLY A

TIM 1
TIM 1
RLY A
RLY A

RLY B
RLY B
TIM 1; TC 2 secs.
TIM 1; TC 2 secs.

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Relays in Motor Control

A B C

+ RUN Ra Rb Rc

Vt
Field
Armature
M
Winding

RUN

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Start PB

RUN

RUN
TIM 1
RUN

A
TIM 1; TC 2 secs.

A Relay-Based TIM 2
A
Motor Control Circuit
B
TIM 2; TC 2 secs.

TIM 3
B

C
TIM 3; TC 2 secs.
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Internal Relays
Inputs
Start Start PB
RUNi Start

RUNi

TIM 1 Output Relays

RUNi

Ai RUN
RUNi
TIM 1; TC 2 secs.
TIM 2 A
Ai Ai

Bi
TIM 2; TC 2 secs. B
Bi
TIM 3
Bi

Ci C
Ci
TIM 3; TC 2 secs.

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Sample PLCs

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Programmable Logic Controllers

(PLCs)

also referred to as
Programmable
Controllers (PLCs or PCs)

used in commercial and
industrial applications.

monitors inputs, makes
decisions based on its
program, and controls
outputs to automate a
process or machine.
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PLC Application Example

Pushbuttons (sensors)
connected to PLC
inputs can be used to
start and stop a motor
connected to a PLC
through a motor
starter (actuator).

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Before PLCs

Hard-Wired Control
• Prior to PLCs, many of these control
tasks were solved with contactor or
relay controls. This is often referred to
as hardwired control.
• Circuit diagrams had to be designed,
electrical components specified and
installed, and wiring lists created.
• Electricians would then wire the
components necessary to perform a
specific task.
• If an error was made the wires had to be
reconnected correctly.
• A change in function or system
expansion required extensive
component changes and rewiring.
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Advantages of PLCs

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Why use PLCs?

The same, as well as more
complex tasks, can be done with a
PLC.

Wiring between devices and relay
contacts is done in the PLC
program.

Hard-wiring, though still required
to connect field devices, is less
intensive.

Modifying the application and
correcting errors are easier to
handle.

It is easier to create and change a
program in a PLC than it is to wire
and rewire a circuit.

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Parts of the PLC

Central
Input Output
Processing Unit
Modules Modules
(CPU)

Operator Programming
Interface Device

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Parts of the PLC

Input Modules receive a variety of digital or analog signals from various
field devices (sensors) and converts them into logic signals that can be
used by the CPU.

A Central Processing Unit (CPU) makes decisions and executes control
instructions based on program instructions in memory.

Output Modules convert control instructions from the CPU into digital or
analog signals that can be used to control various field devices (actuators).

A Programming Device is used to input the desired instructions. These
instructions determine what the PLC will do for a specific input.

An operator Interface device allows process information to be displayed and
new control parameters to be entered.

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Discrete Inputs

Pushbuttons, and Switches

Relay Contacts

Comparator/Binary
Outputs

Standard Discrete Levels:
 5, 12, 24, and 48 Volts (DC)
12, 24 48 Volts (AC)

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Discrete Inputs

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Analog Inputs

Continuous values
of input signals

Standard Analog
Input Levels:
 0 to 20 mA
 4 to 20 mA
 0 to 10 volts
 -10 to +10V
 -5v to +5v

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PLC DC Type Input Modules

http://www.plcs.net/

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PLC AC Input Module

http://www.plcs.net/

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Discrete Outputs

ON/OFF Controls

Actuators such as
motor starters, lamps,
electromechanical
relays

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PLC Relay Type Outputs

Can be used for both AC and DC outputs

http://www.plcs.net/
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PLC Transistor Type Output

(NPN)

Can accommodate DC Outputs only

http://www.plcs.net/
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Analog Outputs

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Analog Outputs

Analog outputs may be used as a variable reference for control valves,
chart recorders, electric motor drives, analog meters, and pressure
transducers.

Like analog inputs, analog outputs are generally connected to a
controlling device through a transducer. The transducer takes the voltage
signal and, depending on the requirement, amplifies, reduces, or changes
it into another signal which controls the device.

In the following example a 0 - 10 VDC signal controls a 0 - 500 Lbs. scale
analog meter.

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Function of the CPU

A microprocessor system
that contains the system
memory and is the PLC’s
decision-making unit.

The CPU monitors the
inputs and makes decisions
based on instructions held
in the program memory.

The CPU performs relay,
counting, timing, data
comparison, and sequential
operations.

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Programming Device

Used to input
program instructions
to the PLC.

Uses either a
 Personal Computer
with a programming
software, or a
 specialized Programming
Console

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PLC Scan Cycle

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The IEC 61131-3 Standard

IEC 61131-3 is the only global standard for industrial
control programming. It harmonizes the way people
design and operate industrial controls by standardizing
the programming interface.

The standard includes the definition of the Sequential

Function Chart (SFC) language, used to structure the
internal organization of a program, and four inter-
operable languages: Instruction List (IL), Ladder Diagram
(LD), Function Block Diagram (FBD) and Structured Text
(ST).

http://www.plcopen.org

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PLCopen
Standardization in Industrial Control programming

The IEC 61131-3 Programming Languages

Instruction List Structured Text
LD A
ANDN B C:= A AND NOT B
ST C

Function Block Diagram Ladder Diagram

AND A B C
A C -| |--|/|----------------( )
B

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Program Instructions

Instructions
 Standard Instructions – those that are found in most PLC
programs. Examples include timer, counter, math, logical,
increment/decrement, move, and block functions.
 Special Instructions – are used to manipulate data. They
include shirt, table, find, conversion, for/next, and real-time
instructions.
 High-speed instructions allow for events and interrupts to
occur independently of the PLC scan time. These include
high-speed counters, interrupts, output, and transmit
instructions.

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Logical AND

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Logical OR

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Timers

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On-Delay Timer

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Retentive On-Delay

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Off-Delay Timer

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Timer Example

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Counters

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UP Counters

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Down Counters

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UP/DOWN Counters

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LOAD INSTRUCTIONS:

A
Address Instruction Operands
X
00000 LD A
00001 OUT X

B
Address Instruction Operands
Y
00000 LD A
00001 OUT NOT Y

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AND OPERATIONS

A B C
X

Address Instruction Operands

00000 LD A
00001 AND NOT B
00002 AND C
00003 OUT X

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OR OPERATIONS

A
X
B

Address Instruction Operands

00000 LD NOT A
00001 OR NOT B
00002 OR C
00003 OUT X

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COMBINATION BLOCKS

A B C D

X
E

Address Instruction Operands

00000 LD A
00001 AND B
00002 OR E
00003 AND C
00004 AND NOT D
00005 OUT X

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COMBINATION BLOCKS

A C
X
B D Address Instruction Operands
00000 LD A
00001 OR B
00002 LD C
00003 OR NOT D
00004 AND LD --

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COMBINATION BLOCKS

A B
X

C D
Address Instruction Operands
00000 LD A
00001 AND NOT B
00002 LD C
00003 AND D
00004 OR LD --

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COMBINATION BLOCKS
A C E
X

B D F
Address Instruction Operands Address Instruction Operands
00000 LD A 00000 LD A
00001 OR NOT B 00001 OR NOT B
00002 LD NOT C 00002 LD NOT C
00003 OR D 00003 OR D
00004 AND LD -- 00004 LD E
00005 LD E 00005 OR F
00006 OR F 00006 AND LD --
00007 AND LD -- 00007 AND LD --
00008 OUT X 00008 OUT X

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COMBINATION BLOCKS

X
A B

C D

E F
Address Instruction Operands Address Instruction Operands
00000 LD A 00000 LD A
00001 AND NOT B 00001 AND NOT B
00002 LD NOT C 00002 LD NOT C
00003 AND NOT D 00003 AND NOT D
00004 OR LD -- 00004 LD E
00005 LD E 00005 AND F
00006 AND F 00006 OR LD --
00007 OR LD -- 00007 OR LD --
00008 OUT X 00008 OUT X

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COMBINATION BLOCKS
A B C D
X
E
F

Block a Block b

Address Instruction Operands

00000 LD A
00001 AND NOT B
00002 LD C
00003 AND D
00004 OR E
00005 OR F
00006 AND LD --
00007 OUT X

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COMBINATION BLOCKS
Block b1
A B C D
X

E F

Block b2
Block a Block b
Address Instruction Operands
00000 LD NOT A
00001 AND B
00002 LD C
00003 AND NOT D
00004 LD NOT E
00005 AND F
00006 OR LD --
00007 AND LD --
00008 OUT X

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COMBINATION BLOCKS

Block a1 Block b1

A B E F
X

C D G H
Address Instruction Operands
00000 LD A
Block a2 Block b2 00001 AND NOT B
00002 LD NOT C
Block a Block b 00003 AND D
00004 OR LD --
00005 LD E
00006 AND F
00007 LD G
00008 AND H
00009 OR LD --
00010 AND LD --
00011 OUT X

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Counters:
Address Instruction Operands
Count Pulse (CP)
CNT N 00000 LD A
00001 AND B
Reset (R) 00002 LD NOT C
SV 00003 CNT 001
00004 # 0700
00005 LD CNT 001
00006 OUT D
CP CNT 001
A B
Reversible Counters:
R #0700 II CNT N

D DI

C SV
R

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Timers:
TIM N

SV

Address Instruction Operands

00500 LD A

TIM 001 00501 AND NOT B

A B
00502 OUT TIM 001

# 050 00503 #050

00504 LD TIM 001
00500 OUT C
TIM 001 C

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PLC Program Simulations using the

TRi-LOGI PLC Emulator

Sample Problem1: MotorSta.pc4

Start PB runs a DC motor with a three-stage 9-second
starting procedure. Stop PB stops the motor at once.
Sample Problem2: Autostop.pc4
Start PB runs the motor with the same starting procedure
above. The motor does an N-second automatic shutdown sequence
after running for M seconds. Stop PB provided to stop motor at once.

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Simulation Exercise

A Motor Control Problem
 The motor runs CW for 10 seconds, stops, waits for
3 seconds then runs again for another 5 seconds,
this time in the CCW direction. Time transitions
above are exclusive of starting procedure.
 An E-Stop PB stops the motor at once.
 an external variable, when OFF, automatically stops
the motor after running for 5 seconds. Call this
variable Autostop.

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PLCs in an Industrial Setup

Actuators PLC
HMI,
Management,
Business
Sensors PC-Based Monitoring
Systems
Systems and Data

Other Field Acquisition

Other Systems
Devices
Controllers

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[Taken from Siemens catalogs]

[Taken from Siemens catalogs]

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http://Globalspec.com
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PLCopen
Standardization in Industrial Control programming

Fermentation Process
Agitator

Feed valve
Acidic reagent

Alkali reagent
Temperature
sensor
pH sensor

Heater band

Harvest valve

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[Taken from Siemens catalogs]

[Taken from Siemens catalogs]

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[Taken from Siemens catalogs]

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Examples: Parking Attendant

0
24V M1
manual open/close

1
24V M2
reset count INPUT

24V
2 MODULE +L
3.9K
LDR
24V

3
24V -M
3.9K LDR

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Examples: Parking Attendant

R
0
C (MSB)

1
B

2 A (LSB)

OUTPUT
MOTOR

3 1

MODULE RELAY
24V
4 2
A1
W 4
+L 5
A2
24V
B 5
-M M

R 6

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Examples: Process Control

Start
0
24V
Stop
1
24V
reset count

RT
2
INPUT
24V
R

MODULE
level 1 3
24V
(low)

level 2 4
-M
24V
(high)

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Examples:Process Control
220V
0
A1
Pump 1
A2
220V
1
A1
Pump 2
OUTPUT A2
220V
2
A1
Heater
MODULE A2
220V
3
A1
Bubbler
A2
24V
4
A1
Agitator
M- A2

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Examples: DC Motor Control Circuit

PR1 PR2

DCM CW2 DBRK

SR1 SR2

CCW2
BR
CCW2

DCM CW2 DBRK

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