Programmable Logic Controller & its

applications
UNIT 1
Definition: A PLC is a user friendly, microprocessor based specialized computer that
carries out control functions of many types and levels of complexity. Its purpose is to
monitor crucial process parameters and adjust process operation accordingly.

“Process” means, a step-by-step procedure whereby a product is manufactured and

assembled.
PLC SYSTEM LAYOUT
1. CENTRAL PROCESSING UNIT (CPU):
“brain”- has three sub-parts
a. Microprocessor: carries out mathematic and logical
operations.
b. Memory: data and information is stored and retrieved. Holds
the system software and user program
c. Power supply: converts AC line voltage to various
operational DC voltages.
2. Programmer/Monitor (PM): Device used to communicate with the circuit of the
PLC.
Hand-Held terminals, industrial terminals and Personal computer exist
as PM devices
In hand-held- input takes place through membrane keypad and display is
usually a LCD.
Industrial terminals or Personal Computers, type-writer type keyboard and
CRT are employed.
3. I/O Modules:
Input- terminals into which outside process electrical signals generated by sensors or
transducers enter.
Output – terminals to which output signals are sent to activate relays, solenoids, various
solid-state devices, motors and displays

4. Racks and Chassis: the racks on which the PLC parts are mounted and the
enclosure on which the CPU, PM, I/O modules are mounted.

Baud Rate: different computer operational rates a PLC parts require for proper
operation. Baud is a unit of signalling speed and refers to the number of times
the state (or condition) of data communication line changes per second.
ADVANTAGES AND DISADVANTAGES OF PLC
1. FLEXIBILITY
2. IMPLEMENTING CHANGES AND CORRECTING ERRORS
3. LARGE QUANTITIES OF CONTACTS
4. LOWER COST
5. PILOT RUNNING
6. VISUAL OBSERVATION
7. SPEED OF OPERATION
8. LADDER OR BOOLEAN PROGRAMMING METHODS
9. RELAIBILITY
10.DOCUMENTATION
11.SECURITY
12.EASE OF CHANGE BY REPROGRAMMING
13.NEWER TECHNOLOGY
14.FIXED PROGRAM APPLICATION
15.ENVIRONMENTAL CONSIDERATIONS
16.FAIL-SAFE OPERATION
Solid State Memory:
ROM and RAM IC chips
1. PROM (Programmable read-only memory): can be programmed only once.
2. EPROM (erasable programmable read-only memory): can be erased by subjecting a
window to UV light. Thus sometimes called as UVPROM
3. EEPROM (electrically erasable programmable read-only memory): can be erased by
giving Electrical signal.
4. NOVRAM (non-volatile random access memory): combination of EEPROM and RAM.
When power is about to go off, the content of RAM is quickly stored in EEPROM. The
stored data can then be read into the RAM when power is again restored.
NOVRAM chip combines the flexibility of RAM with non-volatility of EEPROM.
THE PROCESSOR
- ROM with the fixed operating system is attached to the
control section. This unalterable program manages the
operation of PLC.
- The Control Section, heart of the microprocessor, consists
of control unit with a clock, an ALU, and few temporary
storage registers.
- The input scan block scans the input and the places the
individual input statuses in RAM memory.
- After analysis, the logic scan (user ladder logic) updates the
output scan block to the appropriate state.
- Outputs are then scanned and updated.
- An optional interfacing section on extreme right is required
if PLC is a part of large system; to carry out communication
with other PLC CPUs and master computer.
 I/O MODULES
Input module performs four tasks
electronically:
First, it senses the presence or absence of
an input signal at each of its input
terminals. I/P signal tells if switch, sensor or
other signal is ON or OFF at the terminal.
Second, it converts the input signal for
high(ON) to a DC level usable by the
module’s electronic circuit. For a low(OFF),
no signal is converted, indicating OFF Fig. INPUT MODULE
Third, the I/P modules carries out
electronic isolation by electronically
isolating the input module output from its
input.
Fourth, it should produce an output via
output logic, to be sensed by the PLC CPU.
Typical I/P module has 4, 6, 8 ,12, 16, 32 terminals, along with safety and ground
terminals.
- First block receives I/P signal from switch, sensor..
- For AC input, DC converter consists of rectifiers and means to step a voltage down to
desired level, with a Zener diode
- For DC input, DC-to-DC converter is used.
- To protect the device from input surge or circuit malfunction, isolation block is
connected.
- Most CPUs work on 5V.

When input is ON, isolator sends signal to CPU.

Each terminal number of the module is assigned a number in consecutive order.
On-OFF status for each number is checked for each sweep of the input scan.
The result is then placed in RAM memory.
The output module operates in the opposite
manner from its input module
- DC signal from the CPU is converted to a
usable output voltage (AC or DC)
- A signal from CPU is received by the
output module logic, once for each scan.
- If the CPU signal code matches the
assigned number of the module, module
section is turned ON. Fig. OUTPUT MODULE

- There are 4, 6, 8, 12, 16, 32 terminals for

Output module.
 POWER SUPPLIES
Most PLCs operate on +5 and -5 Volts
- First block on the left: AC conditioning
block, it purifies the AC waveform, as
input waveform (pure sinusoidal) can be
distorted at times by two external factors:
- Power company’s generating system
sine wave might be distorted during
system switching by generation
problems
- Second, equipment form plant may
cause electrical back surges, affecting
the purity of the electrical sine wave.
- Second block is the Converter/Rectifier: changes the bidirectional AC to a pulsating,
unidirectional DC waveform. Internally a transformer steps the voltage down to an
appropriate level.
- Third block is the Filter section: accomplishes the required smoothening. It consists of
capacitors, resistors, and inductors.
- Fourth block is the Regulator, to keep the voltage at or near the desired level regardless of
load (CPU) demand.
Construction of PLC Ladder Diagram
1. A contact must always be inserted in slot 1 in the upper left.
2. A coil must be inserted at the end of a rung.
3. All contacts must run horizontally. No vertically oriented contacts are allowed.
4. The number of contacts per matrix is limited. i.e. 11 across by 7 down.
5. Only one output may be connected to a group of contacts.
6. Contacts must be nested( a branch circuit programmed within a branch circuit.)
properly.
7. Flow must be from left to right.
8. Contact progression should be straight across.
PROCESS SCANING CONSIDERATION
- During input scan, input terminals are read and the input status table is updated
accordingly.
- During the program scan, data in the input status table is applied to the user
program, the program is executed and the output status table is updated accordingly.
- During output scan, data associated with the output status table is transferred to the
output terminals.

Note: INPUT SCAN, PROGRAM SCAN and OUTPUT SCAN are separate independent
functions.
Thus any change in the status of the input devices during the program or output
scan are not recognized until the next input scan.
Also, the data changes in the output table are not transferred to the output terminal
during the input and program scans. The transfer affects the output device only
during the output scan.
A complete ladder scan time is usually a few milliseconds..
Proper operational sequencing of events:
DEVICES CONNECTED TO PLC I/O MODULES:

INPUT ON/OFF SWITCHING DEVICES:

- Toggle switches
- Push buttons (have momentary action while depressed)
- Limit switch ( changes the state from NO to NC, NC to NO; when its mechanical actuator
is contacted physically and displaced by some part.)
- Pressure switches
- Float switches
- Hall devices
- Magnetic sensitive switches
- Level switches
- Photoelectric systems
- Inductive sensitive switches
Electrical Switches and
Pushbutton Switches
configuration:
INPUT ANALOG DEVICES:

- Potentiometer
- LVDT (Linear Variable Differential Transformer): AC output of the LVDT varies as the
movable magnetic coil is moved linearly. As the coil is moved linearly, output
voltage varies accordingly. Voltage variation of LVDT output is used to indicate the
position of the device by appropriate linkage.
- Thermocouples: to indicate temperature value.
- Electrical input transducers and sensors are classified according to the physical
variable to which they are sensitive; Thermal, Optical, Magnetic and
Electromechanical (refer figure 4-8, textbook John Webb)
OUTPUT ON/OFF DEVICES:

- Electrical Solenoid: (its actuating plunger is held in a position (up-down) by a

spring. When current is applied to its coil, plunger goes down. Plunger is
connected to various types of mechanical devices. Common use is for ON/OFF
control of flow valves.. Eg. Gas control valve in furnaces; directional control valve
- Electromechanical Relay:

OUTPUT ANALOG DEVICES:

SERVOMOTOR
STEPPER MOTOR
PROGRAMING ON/OFF INPUTS TO PRODUCE ON/OFF OUTPUTS

1. Normally Open contact

2. Normally closed contact
3. Latch/Unlatch system
4. Differentiation up, or rising-edge actuation
5. Differentiation down, or falling-edge actuation

OUTPUTS: COILS, INDICATORS, AND OTHERS

- Coils in an internal PLC program are related to output signals that are sent to
external devices.
- An output is energized through the output module when its corresponding coil
number is turned ON in the PLC ladder diagram
- Not all coils in a program have a corresponding output, many coils are used for
internal logic only.
Operational Procedure

1. First step is to assign individual PLC identification numbers to the inputs and outputs.
- Input have prefix I or IN normally
- Output have prefix O or CR (control relay)
2. Sketch a ladder logic diagram to represent the operational circuit.
3. Figure out how many inputs and outputs will be connected to the input and output
modules.
4. Finally, the ladder program must be entered into the CPU by means of the keyboard.
Programming Examples:
I. SIMPLE ONE-CONTACT, ONE-COIL CIRCUIT
II. STANDARD START-STOP-SEAL CIRCUIT; ALTERNATE LATCH-UNLATCH CIRCUIT
III. FORWARD-REVERSE-STOP WITH MUTUAL INTERLOCKS
IV. FORWARD-REVERSE-STOP WITH DIRECT REVERSAL
V. START-STOP-JOG
VI. ALARM SYSTEM
A LOOK AT FAIL-SAFE CIRCUITS
FAIL SAFE CIRCUIT:
The latch/unlatch function requires an unlatch signal to turn the coil or output OFF.
So if you lose the control power, pushing the stop button has no effect and the coil
remains ON, since control power is needed for system turn-off.
INDUSTRIAL PROCESS EXAMPLE

DRILL PRESS OPERATION LAYOUT

- The initial position of the drill press spindle is
set at top, as shown.
- A part to be drilled is placed under the spindle.
- The drill is to then come done after two start
buttons are depressed (two push buttons are
recommended to assure that both hands are
out of the way).
- The drill spindle rotates as it is brought
downward.
- Downward spindle force is furnished by a
pneumatic air cylinder pushing against an
upward return spring.
- When the spindle is completely down and drill
bit goes through the part to be drilled, a down
sensor is actuated.
- Solenoid is then de-energised, drill returns
up by means of return-up spring.
- When the spindle is completely back up, the
system is to be reset to the off condition.
- If no part is in place initially, the drill spindle
cannot descend.
- For extra safety, a screen shield is included,
which comes down before the drill can start
down.
- Shield returns up at the same time as the
drill, by its own spring return.
- When the stop button is pushed at any time,
the drill and shield returns up
Procedural steps to arrive at a solution:
1. Define the process operation and list the step-by-step sequence of
operation.
2. Define and list the input and output devices and sensors required for
proper operation.
3. Assign corresponding PLC numbers to the input and output devices.
4. Draw up the PLC scheme
5. Enter the program into the PLC.
6. Wire the PLC system to a simulator and check its operation.
7. Check the actual process operation. Try various out-of-sequence
operations to check for hidden safety defects or sequencing problems.
8. Make modifications as required.
Procedural steps to arrive at a solution:
1. Define the process operation and list the step-by-step sequence of operation.
2. Define and list the input and output devices and sensors required for proper operation.
3. Assign corresponding PLC numbers to the input and output devices.
4. Draw up the PLC scheme
5. Enter the program into the PLC.
6. Wire the PLC system to a simulator and check its operation.
7. Check the actual process operation. Try various out-of-sequence operations to check for hidden safety defects
or sequencing problems.
8. Make modifications as required.

List the sequence:

1. Push system start switch.
2. Put part in place to actuate LSPP(part in place limit switch)
3. Push the two start buttons simultaneously.
4. Safety shield comes down, actuating LSSD(Shield down limit switch)
5. Drill starts rotating and descends.
6. Drill at bottom actuates LSDD(drill down limit switch).
7. System shuts down. Drill and shield return up by springs
8. System is reset.
Procedural steps to arrive at a solution:
1. Define the process operation and list the step-by-step sequence of operation.
2. Define and list the input and output devices and sensors required for proper operation.
3. Assign corresponding PLC numbers to the input and output devices.
4. Draw up the PLC scheme
5. Enter the program into the PLC.
6. Wire the PLC system to a simulator and check its operation.
7. Check the actual process operation. Try various out-of-sequence operations to check for hidden safety defects
or sequencing problems.
8. Make modifications as required.
List the input and output devices:
1. System start switch
2. System stop switch → stops everything
3. System pilot light
4. Shield and drill start → left-hand switch
5. Shield and drill start → right-hand switch
6. Shield and drill stop → left-hand switch
7. Shield and drill stop → right-hand switch
8. Position indicator → part in place
9. Position indicator → shield down
10.Position indicator → drill down
Procedural steps to arrive at a solution:
1. Define the process operation and list the step-by-step sequence of operation.
2. Define and list the input and output devices and sensors required for proper operation.
3. Assign corresponding PLC numbers to the input and output devices.
4. Draw up the PLC scheme
5. Enter the program into the PLC.
6. Wire the PLC system to a simulator and check its operation.
7. Check the actual process operation. Try various out-of-sequence operations to check for hidden safety defects
or sequencing problems.
8. Make modifications as required.
Assign input and output numbers to all components(including switches and sensors)
INPUTS OUTPUTS
IN001 system start OUT017 system pilot light
IN002 system stop OUT018 shield down solenoid
IN003 LSPP-part in place OUT019 drill rotate motor
IN004 Left start OUT020 air solenoid to drill down
IN005 Right start cylinder
IN006 Left stop
IN007 Right stop
IN008 LSSD-shield down
IN009 LSDD-drill down
Step 4: to sketch the PLC system
Step 5: to load the sketch into the CPU

Sequence:
Line A. push System Start.
Line B. CR017 seals on. PLI goes ON.
Line C. Put part in place. IN003/LSPP closes. CR017 contact is closed and
IN009/LSDD is closed. Pushing the two start buttons, IN004 and IN005
causes CR018, the shield air solenoid, to go on- lowering the shield.
Line D. CR018 seals through CR018 and IN008/LSSD as the shield goes
into place. The two start buttons must be held in the depressed position
until the shield is down.
Line E. CR019 goes on through CR018 and IN008/LSSD, starting drill motor
rotation.
Line F. Drill goes down, CR020, by another air solenoid, and drills the hole. When
the drill reaches the bottom of the hole, IN009/LSDD is actuated, opening the
circuit on line C.
Reset/off. CR018 is turned off by the opening of the NC contact , causing the
shield to go up back, drill machine turned off.
Conversion examples:
1. Convert a word description into ladder and gate diagrams.
2. Convert from ladder diagram to a gate diagram.
3. Convert from gate diagram to a ladder diagram.
 LARGE PROCESS LADDER DIAGRAM CONSTRUCTION
Steps in planning a program for a large process:
1. Define the process to be controlled.
2. Make a sketch of the process operation
3. Create a written step sequence listing for the process.
4. Add sensors on the sketch as needed to carry out the control sequence.
5. Add manual controls as needed for process setup or operational checking.
6. Consider the safety of the operating personnel and make additions and
adjustments as needed.
7. Add master stop switches as required for safe shutdown.
8. Create the ladder logic diagram.
9. Consider the “what if’s” where the process sequence may go astray
Step 2: Make a sketch of the process.
Step 3: Step sequence for this process

1. Turn on the paint pump and pneumatic air supply.

2. Turn the sequence on. Using push buttons.
3. Put the part on the mandrel. A sensor indicates that the part is in place.
4. Push the master start button and the two system start buttons.
5. The mandrel is raised by a pneumatic cylinder energised by the opening of an
electrically actuated air valve when the system start buttons are pressed. (down
action is by gravity and spring action.)
6. When the part reaches the top and is under the hood, it is held against a stop by
air pressure. Sensor indicates that the part has reached the top.
7. A timer starts and run for 6 seconds.
8. During the timing period of 6 seconds, paint is applied by the sprayer.
9. At the end of 6 seconds, painting stops and the mandrel with the part on it,
lowers.
10. Up sensor is de-energised when the mandrel with the part on it descends.
11. The part arrives at the bottom, reenergising the part-in-place sensor.
12. The part is removed from the mandrel.
13. The system resets. We can start at step 3 again.
Step 4:
Add sensors as required.
- Sensor to show that the part has been placed on the mandrel initially. LSP
- Sensor to indicate when the mandrel is fully extended upward. LSU
Step 5:
Add manual controls as needed
May need a manual pushbutton to raise the mandrel to the top (PBU)
Step 6:

Consider the safety of the operating personnel

- Add two start buttons to keep hands of operator out of a process.

Step 7:
Add master stop switches as required for safe shutdown.
Step 8:
Create the ladder diagram
Flowchart
FLOW CHART FOR
SPRAY PROCESS
SYSTEM
Thank you