WHAT IS A PLC????

•PLC- Programmable Logic Controller

•It is a digital electronic device that uses a
programmable memory to store instructions and to
implement functions such as logic, sequencing,
timing, counting and arithmetic in order to control
machines.
•Used for logical and switching operations.
CONTROL
PROGRAM

PLC
INPUTS FROM OUTPUTS TO
DEVICES DEVICES
SPECIFIC FEATURES OF A PLC
• Rugged and designed to withstand vibrations,
temperature, humidity and noise.

• Interfacing for inputs and outputs is inside the

controller - Possible to modify a control system
without having to rewire the connections to the
input and output devices

• Easily programmable.
ARCHITECTURE OF A PLC..
BASIC STRUCTURE
• CPU- controls and processes all the operations within the PLC.

• Clock( 1 to 8 MHz ) – determines operating speed and provides timing

and synchronization for all elements.

• Bus – carries information to and from the CPU, memory and i/o units.

• Memory :
* ROM- permanent storage of operating system and fixed
data
* RAM- memory for user’s program( battery is used to
prevent loss of data when power goes off)
* Temporary Buffer- stores for i/o channels
Some important terms
• PROGRAM STEP:
It is an instruction for some event to occur.
(ex) examine the state of A

• PROGRAM TASK:
Consists of a number of steps.
(ex) examine the state of A, examine state of B, if
both A and B are closed energize solenoid P.
INPUT/OUTPUT
• provides interface between the
system and the outside world.

•i/o units can vary from small

keyboards with LCDs to those using a
visual display unit (VDU) with
keyboard and screen display.

•i/o channels provide signal

conditioning and isolation functions
so that sensors and actuators can be
directly connected to them.

•Common input voltages- 5V and

24V.
INPUT CHANNEL
•Common output voltages – 24V and
240V
TYPES OF OUTPUT
Three types:

1.Relay type of output

2.Transistor type of output
3.Triac type of output
RELAY TYPE OF OUTPUT
•Signal from the PLC output is
used to operate a relay.

•So, it is able to switch currents

of the order of a few amperes in
an external circuit.

•Relay isolates the PLC from the

external circuit .

•Advantage: Can be used for

both d.c. and a.c. switching.

•Disadvantage: relatively slow.

TRANSISTOR TYPE OF OUTPUT
•Uses a transistor to switch
current through the external
circuit.

•In fig (a), using the conventional

flow of currents from +ve to –ve,
an output device receives current
from output module – called
Sinking.
•In fig (b), the current flows from
SINKING
output module to an output load-
called sourcing.

•Optoisolators provide isolation

between the external circuit and
the PLC.

•Advantage: faster switching

action.
SOURCING •Disadvantage: only for d.c.
TRIAC TYPE OF OUTPUT

• Used to control external loads which are

connected to the a.c. power supply.

• Optoisolators are used to provide isolation.

INPUT/OUTPUT PROCESSING
The sequence followed by a PLC when carrying out a program is as
follows:

1. Scan the inputs associated with one rung of the ladder program.
2. Solve the logic operation involving those inputs.
3. Set/reset the outputs for that rung.
4. Move on to the next rung and repeat the operations 1,2 and3.
5. Move on to the next rung and repeat the operations 1,2 and3.
6. Move on to the next rung and repeat the operations 1,2 and3.
and so on until the end of the program.

Note: Each rung of the ladder program is thus scanned in turn.

TYPES OF I/O PROCESSING

Two types:

1.Continuous updating
2.Mass input/output copying
CONTINUOUS UPDATING
• CPU scans the input channels in order.
• Each input point is examined individually and its effect in the
program is determined.
• built-in delay (3ms)- ensures only valid input signals are read
by the microprocessor( avoids reading the same input twice).
• A number of inputs may have to be scanned, each with a 3ms
delay, before the program has the instruction for a logic
operation to be executed and an output to occur.
• Outputs are latched- so they retain their status until the next
updating.
• Disadvantage: longer time.
MASS I/O COPYING
• To allow more rapid execution – a specific area of RAM is used as a
buffer store between the control logic and the i/o unit.
• Each i/o unit has an address in the memory.

1. At the start of a program cycle- CPU scans all inputs and copies their
status into the i/o address in RAM.
2. During execution - the stored input data is read from the RAM.
3. After execution - the outputs are stored in the reserved i/o section of
RAM.
4. At the end of a program – outputs are transferred from RAM to output
channels.

• The outputs are latched so that they retain their status until the next
updating.
PROGRAMMING
Ladder diagrams-
• writing a program in a similar manner to drawing a
switching circuit.
• Two vertical lines- power rails.
• Horizontal rungs of the ladder between the 2 lines-
circuit connections.
• Inputs must always precede outputs.
• There must be atleast one output on each line.
• Each rung should start with an input(s) and end with
an output.
• The inputs and outputs are numbered- notations as
given by the manufacturer.
Contd…..

LADDER SYMBOLS LADDER DIAGRAM

EXAMPLES OF LADDER DIAGRAMS
EXAMPLE-1:
Output from the PLC is to energize a solenoid when a
normally open start switch is connected to the input is
activated by being closed.

QUESTION: SOLUTION:
• EXAMPLE-2:
On-off temperature control in which the input goes
from low to high when the temperature sensor
reaches the set temperature.

QUESTION: SOLUTION:
LOGIC FUNCTIONS

• The logic functions can obtained by a

combination of switches.

• The following few slides shows how ladder

programs can be written for such
combinations.
AND Logic

RELAY LADDER DIAGRAM LOGIC LADDER DIAGRAM

OR Logic

RELAY LADDER DIAGRAM LOGIC LADDER DIAGRAM

NOR Logic

RELAY LADDER DIAGRAM LOGIC LADDER DIAGRAM

NAND Logic

RELAY LADDER DIAGRAM LOGIC LADDER DIAGRAM

XOR Logic…

LOGIC LADDER DIAGRAM

COMBINATION OF AND & OR
• Situation:
A normally open switch A must be activated and either of two
other, normally open, switches B and C must be activated for
a coil to be energized.

RELAY LADDER DIAGRAM LOGIC LADDER DIAGRAM

SAMPLE APPLICATION OF LOGIC GATES…..
Consider the requirement for there to be an output to the
solenoid controlling the valve that will open a shop door
when the shopkeeper has closed a switch to open shop and a
customer approaches the door and is detected by a sensor
which then gives a high signal.
SHOP OPEN CUSTOMER SOLENOID
SWITCH APPROACHING OUTPUT
SENSOR
Off Off Off
Off On Off
On Off Off
On On On

SHOP DOOR SYSTEM TRUTH TABLE

It is seen that it is an application of an AND gate

LATCHING
• Used in situations where it is necessary to hold a coil
energized, even when the input which energized it ceases.
• Latch circuit- a self maintaining circuit which, after being
energized remains in that state until another input is
received.
•When input 1 is energized and closes,
there is an output.
•However, when there is an output, a set of
contacts associated with the output is
energized and closes.
•These contacts OR the input 1 contacts.
•Thus, even if input 1 contacts open the
circuit will still maintain the output
energized.
•The only way to release the output is by
LATCHING CIRCUIT operating the normally closed contact
input2.
EXAMPLE OF LATCHING CIRCUIT
The requirement for a PLC to control a motor so that when the
start signal button is momentarily pressed the motor starts and
when the stop switch is used the motor switches off, signal lamps
indicating when the motor is off and when on.
UNSAFE SYSTEM SAFE SYSTEM

NC switch in output and then the PLC

program being programmed as NO and being
If there is a PLC failure then the
switched as it finds the contacts closed.
motor cannot be stopped.
SEQUENCING
Consider the requirement for a ladder program for a pneumatic system
with double solenoid valves controlling two double-acting cylinders A and
B if limit switches a-, a+, b-, b+ are used to detect the limits of the piston
rod movements in the cylinders and the cylinder activation sequence
A+B+A-B- is required.
MNEMONICS
• It is an alternate way of entering a program.

• Consists of codes corresponding to each ladder element.

• Enter these into the programming panel.

• It is then translated into machine language.

• The mnemonics used in Mitsubishi F series PLCs is as shown in

the following slide.
MITSUBISHI MNEMONICS
FUNCTION
MNEMONICS
LD Start a rung with an open contact
OUT An output
AND A series element and so an AND logic instruction
OR Parallel elements and so an OR logic instruction
I A NOT logic instruction
…I Used in conjunction with other instructions to indicate the inverse
ORI An OR NOT logic function
ANI An AND NOT logic function
LDI Start a rung with a closed contact
ANB AND used with two subcircuits
ORB OR used with two subcircuits
RST Reset shift register/counter
SHF Shift
K Insert a constant
END End ladder
AND system

Step Instruction Notation

0 LD X400

1 AND X401

2 OUT Y430
OR system

Step Instruction Notation

0 LD X400

1 OR X401

2 OUT Y430
NOR system

Step Instruction Notation

0 LDI X400

1 ANI X401

2 OUT Y430
NAND system

Step Instruction Notation

0 LDI X400

1 ORI X401

2 OUT Y430
XOR system
Step Instruction Notation

0 LD X400

1 ANI X401

2 LDI X400

3 AND X401

4 ORB

5 OUT Y430
TIMERS
• Used to carry out tasks which involve time delay
and time counting.

• A timer circuit is specified by stating the interval

to be timed and the conditions or the events that
are to start and/or stop the timer.

• They are commonly regarded as relays with coils

which, when energized, result in the closing or
opening of input contacts after some preset time.
DELAY-ON TIMERS
• This timer waits for a fixed delay period before turning on.
• When there is an input, the timer is energized and starts
timing. After some preset time the contacts associated with
the timer close and the output occurs.

Part of program involving

delay-on timer

Delay-on timer
DELAY-OFF TIMERS
• A timer which switches off an output after a time delay.
• When the input contacts are momentarily closed the
output is energized and the timer started.
• The output contacts latch the input and keep the output
on.
• After a preset time of the timer, the timer comes on and
breaks the latch circuit, so switching the output off.
CASCADED TIMERS
• To give larger delay times that which is not possible
by just one timer – timers are linked together.
• They are called cascaded timers.
ON-0FF CYCLIC TIMER
• Used to cause an output to go on for a certain time
and then off for a certain period and repeat this
cycle.
INTERNAL RELAYS
• Also called as auxiliary relay or marker.

• They behave like relays with their associated

contacts, but in reality are not actual relays but
simulations by the software of the PLC.

• Some have battery back-up – to ensure a safe

shut-down of plant in the event of a power
failure.

• Useful in implementation of switching sequences.

INTERNAL RELAYS FOR MULTIPLE
INPUT CONDITIONS
• Excitation of output
depends on two
different input
arrangements.

• First rung- one input

arrangement to control
the cool IR1.

• Second rung- other

input arrangement to
control coil IR2.

• The contacts of the two

relays are then put in
an OR situation to
control the output.
Contd…..
• Using Mitsubishi code:
Step Instruction notation
0 LD X400
1 OR X401
2 OUT M100
3 LD X402
4 AND X403
5 OUT M101
6 LD M100
7 OR M101
8 OUT Y430
9 END
INTERNAL RELAYS FOR MULTIPLE
OUTPUTS
• When the start
contacts are
closed, the
internal relay is
activated and
latches the input.

• It also starts
output 1 and
makes it possible
for outputs 2 and
3 to be activated.
APPLICATION OF INTERNAL RELAYS-1
• To automate a pneumatic circuit (2 cylinders)
in which double solenoid valves are used in
the sequence A+B+B-A-.
APPLICATION OF INTERNAL RELAYS-2
• Used for resetting a latch.
•When the contacts of input 1
are momentarily pressed then
the output is energized.

•The contacts of the output

are then closed and so the
latch the output.

•The output can be unlatched

by the internal relay contacts
opening.

•This will occur if input2 is

closed and energizes the coil
of the internal relay.
BATTERY BACKED INTERNAL RELAY
• When the contacts of input1
close, the coil of battery
backed internal relay is
energized.

• This closes the relay contacts

and so even if contacts of the
input open as a result of
power failure the relay
contacts remain closed.

• (i.e) the output controlled by

the internal relay remains
energized, even when there is
a power failure.
COUNTERS
• Used when there is a need to count a specified number
of contact operations.

• Two types:
* Down- counter: the counter counts from
present value to zero(events are subtracted from the
set value) and when zero is reached its contact state
changes.
* Up-counter: counts up to the preset value
(events are added until the number reaches the set
value) and when this is reached its contact changes
state.
SAMPLE COUNTING PROGRAM
• K10 indicates that the contact state changes
on the 10th pulse.
• When input1 closes momentarily, the
counter is reset to set value.
• Then the number of pulses resulting from
the contacts of input2 closing and opening
are counted.
• When it reaches the set value(10), the
counter contact closes.
• The output is thus switched on after 10
pulses.
• If the contacts of input1 are momentarily
closed during the count, the counter will
reset to 10.
Contd…
• In Mitsubishi code:
Step Instruction Notation

0 LD X400

1 RST C460

2 LD X401

3 OUT C460

4 K 10

5 LD C460

6 OUT Y430
SAMPLE APPLICATION OF COUNTERS
• Consider the problem of the control for a machine which is
required to direct 6 items along one path for packaging in a box,
and then 12 items along another path for packaging in another box.
SHIFT REGISTERS
• A number of internal relays are grouped together to form a
register.
• Provides storage area for a series sequence of individual bits.
• A 4-bit register can be formed using 4 internal relays, an 8-bit
using 8.
• The bits can be shifted along by one bit when there is a
suitable input to the register.
• (ex) initially an 8- bit register might have:
1 0 1 1 0 1 0 1
then there is an input of a 0 shift pulse:
0 0 1 0 1 1 0 1 0 1
with the result that all the bits shift along one place and the
last bit overflows.
INPUTS TO SHIFT REGISTERS
• Three inputs
1. To load data into the first element of the register
(OUT) - a logic level 0 or 1 is loaded into the first
element of the shift register.

2. As the shift command(SFT) – a pulse moves the

contents of the register along one bit at a time, the
final bit overflowing and being lost.

3. For resetting(RST) – a pulse of a closure of a contact

resets the register contents to all 0s.
SAMPLE PROGRAM - SHIFT REGISTER
Step Instruction Notation
0 LD X400
1 OUT M140
2 LD X401
3 SFT M140
4 LD X402
5 RST M140
6 LD M140
7 OUT Y430
8 LD M141
9 OUT Y431
10 LD M142
Initially 11 OUT Y432
10000000 then etc.
11000000
20 LD M147
21 OUT Y437
MASTER CONTROLS
• A whole block of outputs can be
simultaneously turned off or on by using the
same internal relay contacts in each output
rung so that switching it on or off affects every
one of the rungs.

• An alternate way of programming to achieve

the same effect is to use a master relay.
SAMPLE PROGRAM – MASTER RELAY
• When there is an input to close
input1 contacts, then master
relay MC1 is activated and then
the block program rungs
controlled by the relay follows.
• MCR - The end of a master relay
controlled section.
• If there is an input to input2 ,
then master relay MC2 is
activated and the rungs
controlled by that master relay
follow.
• If there are no inputs to both 1
and 2 then the rung that follows
in the program is that for input9
controlled output Out6.
JUMPS
• Used in conditional situations.
• Enables program to be designed so that if a certain
condition exists then a section of the program is jumped.
• An example is as follows.
DATA HANDLING
• Some situations arise where a group of bits have to be handled.

• (ex) a sensor supplies an analogue signal which is converted to, say,

an 8-bit word before becoming an input to a PLC.

• The operations that may be carries out with a PLC on data words
normally include:
1. Moving data.
2. Comparison of magnitudes of data, (i.e.)greater then, equal to or
less than.
3. Arithmetic operations such as addition and subtraction.
4. Conversions between binary coded decimal (BCD), binary and octal.
DATA REGISTERS
• Data instructions also require memory addresses.

• The locations in the PLC memory allocated for data are termed as
data registers.

• Each data register can store a binary word of usually, 8 or 16 bits.

• Addresses are given as D0,D1,D2 and so on.

• A 8-bit word means that a quantity is specified to a precision of 1 in

256, a 16-bit a precision of 1 in 65536.

• Each instruction has to specify

1. the form of the operation
2. the source of the data used in terms of its data register
3. the destination data register of the data.
DATA MOVEMENT
• For data movement, the instruction will contain
1. Move data instruction
2. The source address of the data
3. The destination address of the data

• The following is the ladder rung to transfer data from D1 to

D2.
Step Instruction Notation
0 LD X300
1 MOV
2 D1
3 D2
DATA COMPARISON
COMPARISON SYMBOL CODE
Less than < LES
Equal to = EQU
Less than or equal to <= LEQ
Greater than > GRT
Greater than or equal to >= GEQ
Not equal to <> NEQ

The comparison instruction consists of: (ex) to see if D1 is greater than D2

1.Comparison instruction
2.The source address of the data Step Instruction Notation
3.Destination address
0 LD X300
1 >
2 D1
3 D2
SAMPLE APPLICATION OF DATA COMPARISON

• Comparison might be used when signals from two sensors are

to be compared by the PLC before action is taken.
• (ex) an alarm might be required to be sounded if a sensor
indicates a temperature above 80oc and remain sounding
until temperature falls below 70oc
ARITHMETIC OPERATIONS
• The instruction to add or subtract consists of:
1. The instruction.
2. The register containing the address of the value to be added or
subtracted.
3. The address of the value to which the addition or from which the
subtraction is to be made.
4. The register where the result is to be stored.
• It may be used to alter the value of some sensor input value,
perhaps a correction or offset term or alter the preset values of
timers or counters.
• The following shows the form used for the ladder symbol for
addition with OMRON.
CODE CONVERSIONS
• All internal operations in the CPU of a PLC are carried out
using binary numbers.

• So when input is a decimal, conversion to binary required.

• Also when a decimal output is required, conversion from

Binary to decimal is needed.

• (ex) following is the rung employed in conversion from

BCD to binary.
ANALOG INPUT/OUTPUT
• Many sensors generate analog signals and many actuators require
analog signals.

• Thus, some PLCs have A-D converter fitted to input channels and D-
A converter fitted to output channels.

• (ex) speed control of a motor so that its speed moves up to its

steady value at a steady rate. The program is as shown below:
Contd…
• A PLC equipped with analog input channels can be used to
carry out a continuous control function, (i.e) PID control.

• To carry out proportional control on an analog input the

following set of operations can be used:
1. Convert the sensor output to a digital signal.
2. Compare the converted actual sensor output with the
required sensor value (i.e) the set point and obtain the
difference(error).
3. Multiply the error by the proportional constant Kp.
4. Move this result to the D-A converter output and use the
result as the correction signal to the converter.
SAMPLE APPLCATION OF ANALOG I/O
• Temperature controller.

• The input could be from a thermocouple, which after

amplification is fed through an A-D converter into the PLC.

• The PLC is programmed to give an output proportional to

the error between the input from the sensor and the
required temperature.

• The output word is then fed through a D-A converter to the

actuator, a heater, in order to reduce the error. (program
in next slide).
TEMPERATURE CONTROL
SELECTION OF A PLC
• Criteria to be considered are as follows:
1. What i/o capacity is required, (i.e) the number of i/o, capability of
expansion for future needs.

2. What types of i/o are required, (i.e) isolation, onboard power

supply for i/o, signal conditioning.

3. What size of memory is required? This is linked to the number of

i/o and the complexity of program used.

4. What speed and power is required for the CPU? This is linked to
the number of types of instruction that can be handled by a PLC. As
the number of types increases , a faster CPU is required. Likewise,
the greater the number of i/o to be handled the faster the CPU
required.
PROBLEMS…..
1. What are the logic functions used for switches (a) in
series (b) in parallel?

2. Draw the ladder rungs to represent

(a). Two switches are NO and both have to be closed for a
motor to operate.
(b). Either of two NO switches have to be closed for a coil
to be energized and operate an actuator.
(c). A motor is switched on by pressing a spring-return
push-button start switch, and the motor remains on
until another spring-return push-button stop switch is
pressed.
3. Write the program instructions corresponding
to the latch program shown below.

4. Write the program instructions corresponding

to the program shown below and state how
the output varies with time.
5. Write the program instructions corresponding to
the program shown below and state the results
of inputs to the PLC.

6. Devise a timing circuit that will switch an output

on for 1s then off for 20s, then on for 1s, then off
for 20s and so on.

7. Devise a timing circuit that will switch an output

on for 10s and then switch it off.
8. Devise a circuit that can be used to start a motor
and then after a delay of 100s start a pump.
When the motor is switched off there should be a
delay of 10s before the pump is switched off.

9.Devise a circuit that could be used to start with a

domestic washing machine to switch on a pump
to pump water for 100s into the machine, then
switch off and switch on a heater for 50s to heat
the water. The heater is then switched off and
another pump is to empty the water from the
machine for 100s.
10. Devise a circuit that could be used with a
conveyor belt which is used to move an item
to a work station. The presence of the item at
the work station is detected by means of
breaking a contact activated by a beam of
light to a photo sensor. There it stops for 100s
for an operation to be carried out before
moving on and off the conveyor. The motor
for the belt is started by a normally open start
switch and stopped by a normally closed
switch.
11. How would the timing pattern for the shift
register in the figure (a) change if the data
output X400 was of the form as shown in fig
(b)?

Fig (b)

Fig (a)
12. Explain how a PLC can be used to handle an
analog input.

13. Devise a system, using a PLC, which can be

used to control the movement of a piston in a
cylinder so that when a switch is momentarily
pressed, the piston moves in one direction
and when a second switch is momentarily
pressed the piston moves in the other
direction. ( hint: you might consider using a
4/2 solenoid controlled valve).
14. Devise a system, using a PLC, which can be
used to control the movement of a piston in a
cylinder using a 4/2 solenoid operated pilot
valve. The piston is to move in one direction
when a proximity sensor at one end of the
stroke closes contacts and in the other
direction when a proximity sensor at the other
end of the stroke indicates the arrival there.