PROGRAMMABLE

LOGIC
CONTROLLER

PLC Krushna Solanki

Academy
18-11-2024
 Flow…..

SCADA

Basic Of PLC iMCC Overview Of

iMCC

Hardware
and
Communicat
ion

2
▪ What is PLC
▪ PLC Basic
▪ Architecture
▪ PLC Application
▪ Siemens PLC
▪ Hardware
▪ Communication
▪ Software Overview

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 What is PLC?

▪ PLC is a digital computer designed for multiple input and output arrangements, extended temperature ranges, immunity to electrical
noise and resistance to vibration and impact.

▪ A PLC is an example of a real time system.

▪ They both have a power supply, a CPU (Central Processing Unit), inputs and outputs (I/O), memory, and operating software (although
it’s a different operating software).

▪ Automation – is basically the delegation of human control function to technical equipment aimed toward achieving.

▪ Higher productivity

▪ Superior quality of end product

▪ Efficient usage of energy and raw materials

▪ Improved safety in working condition.

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 PLC Basics

▪ PLCs, created by Dick Morley in 1964, have transformed the industrial and
manufacturing sectors with functions such as timing, counting, and signal
processing.

▪ The main advantage of a PLC over a “hard-wired” control system is that you can go
back and change a PLC after you’ve programmed it, at little cost (just the cost of the
programmer’s time). In a hard-wired control system, you’re essentially having to rip
out wires and start from scratch, (which is more expensive and takes longer).

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 Evolution of PLC

PLC Control

Electronic Control

Hard wire / Relay Control

Manual Control

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 Evolution of PLC

▪ First generation PLCs (1970s) were large, expensive, and used primarily to replace relay-based control systems.

▪ Second generation PLCs (1980s) added more memory and processing power, and began to use more standardized programming
languages. They also started to incorporate more advanced functions such as timers, counters, and data manipulation.

▪ Third generation PLCs (1990s) became more compact and efficient, and were able to control a wider range of industrial processes.
They also began to incorporate networking capabilities, allowing PLCs to communicate with other devices and systems.

▪ Fourth generation PLCs (2000s) They also began to incorporate advanced features such as Ethernet connectivity, support for
industrial protocols such as Modbus and Profinet, and the ability to handle large amounts of data.

▪ Fifth generation PLCs (2010s) built-in high-speed communication interfaces, support for IoT and cloud connectivity, and advanced
security mechanisms.

▪ Currently, sixth-generation PLCs More robust support for IoT, AI and Machine Learning, Cybersecurity, and can be accessed remotely,
offer more flexibility in terms of scalability.

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 PLC Manufacturer company

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 PLC Advantages

▪ High Reliability
▪ Small Space Requirements
▪ Computing Capabilities
▪ Reduced Costs
▪ Ability To Withstand Harsh Environments
▪ Expandability

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 PLC Setup

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 Physical Structure of PLC

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 Types of PLC

Compact :- I/O number fixed

Modular :- I/O can be as per selection

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 SIEMENS S7 – Within the system family

High range S7-1500 Mid-and low end

performance range
S7-300
High-end range /
medium range
S7-400

Micro PLCs
S7-200

❖ Programming devices
❖ STEP 7 software
❖ Communication
❖ Human-machine Interface
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 Siemens S7– Ranges

200 300 400

Series 212 to 226 312 to 318 412 to 418

Digital I/O 256 1024 16384

Analog I/O 38 256 4000

Programming Micro Win Simatic Manager

Software
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 Siemens S7 – PLC hardware

▪ PS - Power supply
▪ CPU - Central processing Unit
▪ IM - Interface Module
▪ SM - Signal Module (I/O modules)
▪ Bus connector Rack – Eleven Slot rail
▪ CP - Communication Processor
▪ FM -Functional Module

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 Basic components

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 CPU Overview

▪ Retrieves, decodes, stores, and processes information.

▪ The cost – effective entry into TIA.

▪ Special instructions and coding to perform its functions.

▪ The CPU has three parts:

▪ The Processor - codes, decodes, and computes data
▪ The memory System - Stores both the control program and data
▪ The power supply - Voltage and current

▪ The sophisticated solution for medium-range I/O configurations.

▪ CP the standard CPU for a wide range of application with integrated PROFIBUS DP interface.

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 The Compact CPUs - Highlights

▪ Integrated Functions
▪ Count/Measure, control, Positioning.
▪ Integrated I/O
▪ Digital, Analog
▪ Integrated Communication Interfaces
▪ In addition to MPI, also PROFIBUS DP and point-to-point

CPU 313C CPU 314C-2 PtP

CPU 312C CPU 313C-2 PtP CPU 314C-2 DP
CPU 313C-2 DP

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 Test and diagnostics functions

▪ System diagnostics
▪ Fault diagnostics from CPU to I/O
▪ Internal CPU services (e.g error message with time stamp)

▪ Process diagnostics
▪ Monitoring critical process signals at the program level.
▪ CPU generates messages automatically for S7 HMI
▪ So that your service personnel can diagnose the problem sooner.

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 The Input/Output System

▪ The input/output (I/O) system is the section of a PLC to

which all of the field devices are connected.

▪ If the CPU can be thought of as the brains of a PLC, then the

I/O system can be thought of as the arms and legs.

▪ The I/O system is what actually physically carries out the

control commands from the program stored in the PLC’s
memory.

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 Input and Output Devices

▪ Inputs are devices that supply a signal/data to a PLC.

▪ Typical examples of inputs are push buttons, switches, and measurement devices.

▪ Outputs are devices that await a signal/data from the PLC to perform their control functions.

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 Analog and Discrete Devices

▪ Discrete devices are inputs and outputs that have only two states: on and off.

▪ Analog devices are inputs and outputs that can have an infinite number of states. These devices can not only be on and off, but they
can also be barely on, almost totally on, not quite off, etc.

▪ These devices send/receive complex signals to/from a PLC. Their communications consist of a variety of signals, not just 1s and 0s.

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 CPU – Communication ports

▪ MPI is used for PLC programming, inter CPU communication, SCADA/HMI communication

▪ In addition to above profibus is also used for remote I/Os and Drives communication.

▪ Now a days profibus is implemented on industrial Ethernet as Profinet(RS-485).

▪ Profibus can also be implemented using fibre optic technology.

MPI Profibus

Baud rate max 1.5 Mb Ps Dafault 187.5 12 MbPs

KbPs

No. of max. nodes 32 126

Network Length 4000 Ft Without 4000 Ft Without

repeater repeater

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 Communications integrated: MPI, PROFIBUS-DP
interface
▪ Interfaces
▪ MPI intergraded into every CPU.
▪ DP in 314 2DP, 315-2 dp, 316-2DP, 318-2DP.
▪ Programming from any point in the network.
▪ HMI services for connection of OP/OS
▪ No additional programming
▪ Minimal CPU cycle load

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 Addressing Concepts

▪ All the addresses are based on byte numbers.

▪ The signal modules (I/O) can be put from slot no 4 onwards. When we do the I/O configuration byte numbers required for each
modules are defined by the system which we can use in the programming.

▪ In certain CPUs these Byte numbers can be changed by the user. Generally, system defined addressing is preferred as it avoids
memory holes.

▪ The typical addressing in PLCs is as follows.

▪ Digital input starts with I124.0 (Byte No 124)

▪ Digital output Starts with Q124.0 (Byte No 124)
▪ Analog input starts with PIW 256 or PIW 752
▪ Analog Output starts with PQW 256 or PQW 752

▪ Similar I/O mapping is followed for Profibus DP based remote I/Os.

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 I/O Addressing

Input / Output BYTE Address BIT Address

I 0 : 0 (0 to 7)
I 1 : 0 (0 to 7)
Q 0 : 0 (0 to 7)
Q 1 : 0 (0 to 7)

▪ Four Bytes are allotted for each slot

▪ 32 I/O are permitted in each slot
▪ One rail 8 slot are for SM, CP & FM
▪ 32 * 8 = 256 I/O in one rail
▪ Four rail configuration permitted
▪ 256 * 4 = 1024 I/O permitted in four rails

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 Block Type

▪ OB - Organization block (OB1- main block)

▪ FC – Functions (Subroutine-user defined)
▪ FB – Functional Block (Defining function with memory)
▪ DB – Data block (creating memory data)
▪ SFC – System Functions (Syst. Block)
▪ SFB – System Function block (Syst. Block)

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 CPU-Memory organization

▪ Load memory:- Users program stored, capacity can be changed by MMC up to 256k.

▪ Work memory :- Instructions required program execution.

▪ System memory:- Holds OS, Timer, Counter, Memory bits, Process Image Memory, Buffer diagnostics.

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 Memory addressing

▪ M – Marker memory
▪ MB - Memory byte
▪ MW – Memory word
▪ MD – Memory double word

▪ If total memory bits 1024 then 1024/8 = 128

▪ Memory byte no. – 0 to 127

▪ Bit Level Address :-

▪ M0.0..M0.7..M1.0….M1.7……………M127.7

▪ Byte Level Address:-

▪ MB0, MB1, MB2, MB3,……………....MB127

▪ 8BITS = 256 OR - 127 To 127

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 Memory addressing

▪ WORD level Address:-

▪ MW0,MW2,MW4,………………..MW126
▪ 16 BITS = 65536 OR -32767 to 32767

▪ Word address is used to display Timer & counter value and for integer function within above limit.

▪ DOUBLE WORD Level Address:-

▪ MD0,MD4,MD8,……………………MD124

▪ 32BITS = 42949697296 0R -2147483647 TO 2147483647

▪ Double word address is used for integer function value more than word limit.

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 PLC Programming

▪ A PLC program consists of a set of instructions either in textual or graphical form, which represents the logic that governs the process
the PLC is controlling. There are two main classifications of PLC programming languages, which are further divided into many sub-
classified types.

▪ Textual Language
▪ Instruction list
▪ Structured text

▪ Graphical Form
▪ Ladder Diagrams (LD) (i.e. Ladder Logic)
▪ Function Block Diagram (FBD)
▪ Sequential Function Chart (SFC)

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 Programming Language

I0.0 I0.1 Q0.0

▪ Ladder :- ----------| |----------| |---------( )------------

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 STL :- Structural Text Language

▪ Structured text, a programming language for PLCs, uses simple statements to dictate operations. It is similar to conventional
programming but isn’t case-sensitive, using operators to express logic and relationships.

▪ STL :- Structural Text Language

A
(
A I0.0
A I0.1
)
= Q0.0

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 Functional Block Diagram (FBD)

▪ Functional Block Diagram (FBD) is a simple and graphical method to program multiple functions in PLC. PLC Open has described using
FBD. A function block is a program instruction unit that, when executed, yields one or more output values.

▪ It is represented by a block, as shown below. It is represented as a rectangular block with inputs entering on the left and output lines
leaving on the right. It gives a relation between the state of input and output

▪ FBD :- Functional Block Diagram

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 Instructions

▪ ---------| |------------ NO
▪ ---------| \|------------NC
▪ ---------( )------------ O/P COIL
▪ ---------(S)----------- SET COIL
▪ ---------( R )---------- RESET COIL
▪ ----------( P )--------- POSITIVE EDGE
▪ ----------( N )---------- NEGATIVE EDGE

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 Instructions

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 PLC – LED Description

▪ SF
▪ 1. Hardware faults
▪ 2. Programming errors
▪ 3. Parameter assignment errors
▪ 4.Calculation error
▪ 5.faulty memory card
▪ 6. I/O fault / error
▪ 7. Communication error

▪ BATF
▪ The backup battery is missing, faulty or not charged.
It also is on when an accumulator is connected. The
reason for this is that the user program is not back
up by the accumulator.

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 PLC – LED Description

▪ STOP Flashes
▪ When CPU is not processing a user program. The CPU requests a
memory reset.

▪ 5 V DC – this must be ON. It shows CPU logic power (5V) available.

▪ FRCE – If any I/O force exist in CPU it will glow yellow.

▪ RUN – Solid green represents CPU in run mode.

▪ STOP solid yellow CPU in stop mode.

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 Logic Gates with ladder diagram

▪ OR Logic

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 AND Logic

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 NOT Logic

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 NAND Logic

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 NOR Logic

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 Ex- OR

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 Ex - NOR

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 Ladder diagram for Motor starter :

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 Motor Control Circuits

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 Thank you

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