Industrial Technology Laboratory

23 February 2016
8.30am 4.30pm

1
Description
This training introduces the basic hardware and software
components of a Programmable Controller (PLC). It
details the architecture and basic instruction set common
to all PLCs. Basic programming techniques and logic
designs are covered. This training describes the
operating features of the PLC, the advantages of the
PLC over hard-wired control systems, practical
applications, troubleshooting and maintenance of PLCs.

2
Objectives
At the end of the training the participants should be able
to:

Describe the major components of a common PLC.

Interpret PLC specifications.

Apply troubleshooting techniques.

Convert conventional relay logic to a PLC language.

Operate and program a PLC for a given application.

3
Course Contents
History of Programmable Controllers
Relay Ladder Logic

Central Processing Unit

Input/Output System

Programming and Peripheral Devices

Programming Concepts

Applications

Troubleshooting and Maintenance

4
INTRODUCTION TO PLCS
Advantages of PLCs

Less wiring.
Wiring between devices and relay contacts are done in
the PLC program.
Easier and faster to make changes.
Trouble shooting aids make programming easier and
reduce downtime.
Reliable components make these likely to operate for
years before failure.
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.

7
Historical Background
The controller had to be designed in modular form, so that
sub-assemblies could be removed easily for replacement or
repair.

The control system needed the capability to pass data

collection to a central system.

The system had to be reusable.

The method used to program the controller had to be simple,

so that it could be easily understood by plant personnel.

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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

9
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 PLCs introduced
1985 on Networking of all levels of PLC, computer
and machine using SCADA software.

10
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.

11
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

12
Leading Brands Of PLC
JAPANESE 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubishi

13
Areas of Application
Manufacturing / Machining

Food / Beverage

Metals

Power

Mining

Petrochemical / Chemical

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PLC Size
1. SMALL - it covers units with up to 128 I/Os and
memories up to 2 Kbytes.
- these PLCs are capable of providing
simple to advance levels or machine
controls.
2. MEDIUM - have up to 2048 I/Os and memories up
to 32 Kbytes.
3. LARGE - the most sophisticated units of the PLC
family. They have up to 8192 I/Os and
memories up to 750 Kbytes.
- can control individual production
processes or entire plant.

15
Tank Used to Mix Two Liquids

MOTOR
A
FS FLOAT SWITCH

SOLENOIDS B

SOLENOID
C
TIMER

1 -MINUTE

16
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.

17
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.

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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
T E To
SENSORS OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, alarms
etc. etc.
PROGRAMMING
DEVICE

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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 fields
high level signal.

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Major Components of a Common PLC
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.

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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 )

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Programming Device
Types:

Hand held unit with LED / LCD display

Desktop type with a CRT display

Compatible computer terminal

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I/O 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 PLCs processor.

Output modules converts signal from the processor to

levels capable of driving the connected discrete or analog
output devices.

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

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

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

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

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27
28
29
I/O Module
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
XSISTOR
DEVICE

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31
I/O Circuits
DIFFERENT TYPES OF I/O CIRCUITS

1. Pilot Duty Outputs

Outputs of this type typically are used to drive high-current
electromagnetic loads such as solenoids, relays, valves, and
motor starters.

These loads are highly inductive and exhibit a large inrush

current.

Pilot duty outputs should be capable of withstanding an

inrush current of 10 times the rated load for a short period of
time without failure.

32
I/O Circuits
2. General - Purpose Outputs
These are usually low- voltage and low-current and are used
to drive indicating lights and other non-inductive loads. Noise
suppression may or may not be included on this types of
modules.

3. Discrete Inputs
Circuits of this type are used to sense the status of limit
switches, push buttons, and other discrete sensors. Noise
suppression is of great importance in preventing false
indication of inputs turning on or off because of noise.

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I/O Circuits
4. Analog I/O

Circuits of this type sense or drive analog signals.

Analog inputs come from devices, such as thermocouples,
strain gages, or pressure sensors, that provide a signal
voltage or current that is derived from the process variable.
Standard Analog Input signals: 4-20mA; 0-10V

Analog outputs can be used to drive devices such as

voltmeters, X-Y recorders, servomotor drives, and valves
through the use of transducers.
Standard Analog Output signals: 4-20mA; 0-5V; 0-10V

34
I/O Circuits
5. Special - Purpose I/O

Circuits of this type are used to interface PLCs to very specific

types of circuits such as servomotors, stepping motors PID
(proportional plus integral plus derivative) loops, high-speed
pulse counting, resolver and decoder inputs, multiplexed
displays, and keyboards.

This module allows for limited access to timer and counter

presets and other PLC variables without requiring a program
loader.

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 36

OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC
 37

Allen-Bradley 1746-1A16

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

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

LADDER PROGRAM
INPUT MODULE
WIRING DIAGRAM
 CONTACTOR 38
L2 L1 N.O

MOTOR
L2
C SOLENOID
L1 VALVES
FIELD WIRING LAMP
BUZZER

OUTPUT MODULE
WIRING
L1 O:4 L2

CONTACTOR 0
LADDER PROGRAM
 39
Discrete Input
A discrete input also referred as digital input is an input that is
either ON or OFF are connected to the PLC digital input. In the
ON condition it is referred to as logic 1 or a logic high and in the
OFF condition maybe referred to as logic o or logic low.

Normally Open Pushbutton

Normally Closed Pushbutton

Normally Open switch

Normally Closed switch

Normally Open contact

Normally closed contact

 40

IN

OFF PLC
Logic 0
Input
Module
24 V dc

IN

OFF PLC
Logic 1
Input
Module
24 V dc
 41
Analog Input
An analog input is an input signal that has a continuous
signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA
or 0 to10V. Below, a level transmitter monitors the level of
liquid in the tank. Depending on the level Tx, the signal to the
PLC can either increase or decrease as the level increases
or decreases.
Level Transmitter IN

PLC
Analog
Tank Input
Module
 42
Digital Output

A discrete output is either in an ON or OFF condition. Solenoids,

contactors coils, lamps are example of devices connected to the
Discrete or digital outputs. Below, the lamp can be turned ON or
OFF by the PLC output it is connected to.
OUT

PLC
Lamp
Digital
Output
Module
 43
Analog Output

An analog output is an output signal that has a continuous

signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA
or 0 to10V.
Electric to pneumatic transducer

OUT
E Supply air
PLC 0 to 10V P

Analog
Output
Module
Pneumatic control valve
Processor
The processor module contains the PLCs microprocessor,
its supporting circuitry, and its memory system.

The main function of the microprocessor is to analyze data

coming from field sensors through input modules, make
decisions based on the users defined control program and
return signal back through output modules to the field
devices. Field sensors: switches, flow, level, pressure, temp.
transmitters, etc. Field output devices: motors, valves,
solenoids, lamps, or audible devices.

The memory system in the processor module has two parts:

a system memory and an application memory.
44
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 PLCs 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 and
Data Table user program area.
The data table stores any data associated with the users control
User Program 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.

45
Memory Designs
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.

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Memory Designs

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 PLCs.

RAM memory must have battery backup to retain or protect

the stored program.

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Memory Designs
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.

48
Memory Designs
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.

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Memory Designs
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.

50
Memory Designs
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.

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Memory Designs
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.

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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.

53
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

54
PHASE 1 Input Status scan

A PLC scan cycle begins with the CPU reading the status
of its inputs.
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

55
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.

56
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.

57
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).
58
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.
59
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.
60
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.

61
PLC Communications
Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET
Square D SY/NET
Texas Instruments TIWAY

62
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.

63
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
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.

66
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 a acquire a controller that has more
memory than is presently needed.

67
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.
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
 72

PROGRAMMING

Normally Open Normally Closed

(NO) (NC)

Power flows through these contacts when they are closed. The
normally open (NO) is true when the input or output status bit
controlling the contact is 1. The normally closed (NC) is true
when the input or output status bit controlling the contact is 0.
 73

Coils

Coils represent relays that are energized when power flows to

them. When a coil is energized it causes a corresponding
output to turn on by changing the state of the status bit controlling
the output to 1. That same output status bit maybe used to control
normally open or normally closed contact anywhere in the program.
 74

Boxes

Boxes represent various instructions or functions that are

Executed when power flows to the box. Some of these
Functions are timers, counters and math operations.
 75
AND OPERATION

A B C
Rung

Each rung or network on a ladder program represents

a logic operation. In the rung above, both inputs A and B
must be true (1) in order for the output C to be true (1).
 76
OR OPERATION

A C
Rung

In the rung above, it can be seen that either input A or B

is be true (1), or both are true, then the output C is true (1).
 77
NOT OPERATION

A C
Rung

In the rung above, it can be seen that if input A is be true (1),

then the output C is true (0) or when A is (0), output C is 1.