3.

Device Connection to Software

MUKURWE-INI TECHNICAL Books
1. Programmable Logic Controllers: Programming Methods and
TRAINING INSTITUTE Applications by John R. Hackworth and Frederick D. Hackworth,
ELECTRICAL AND ELECTRONICS ENGINEERING DEPARTMENT
Jr.
DIPLOMA IN ELECTRICAL & ELECTRONICS ENGINEERING
(POWER OPTION) - MODULE II Programmable Logic Controllers by W. Bolton 4" Edition
Programmable Controllers: Theory and Implementation by
INDUSTRIAL PROGRAMMABLE LOGIC CONTROLLER
L.A. Bryan and E.A. Bryan. 2nd Ed.
COURSE OUTLINE 4. Industrial Automation by Srinivas Medida Vol. 6
1, Introduction to Industrial PLC 8 hrs
5. Practical SCADA for Industry by David Bailey, Edwin Wright
• Need for Industrial PLC
• Types of Industrial PLC 6. Industrial Networks for Communication and Control by S.
2. PLC system
Djiev,
• Hardware Configuration
• Ladder Logic Programming
• External Peripherals
• PLC Maintenance

3. Supervisory Control and Data Acquisition (SCADA) 15 hrs

• Definition
• Human Machine Interface (HMI)
• Data Acquisition
• Sequence Control
• Data Storage and Activity
• Security (Access Control)
4. Industrial Communication Network 15 hrs
• Networks - LAN & WAN
• Industrial Network Topologies
• Industrial Network Protocol
• Network Construction
• Physical Network Address
• Network Device
5. Calibration Software 13 hrs
1. Types of Calibration Software
2. Operation of Calibration Software

1
 Devices that measure PV are transducers or sensors. In many cases,
the 'sensor consists of a direct measurement device called an
TOPIC f; INTRODUCTION TO INDUSTRIAL PLC element and a separate signal processor called a transmitter.
The set-point is the desired value pf the PV, normally preset into the
Process Control control system by an operator, or derived as an output of another
Process control consist of monitoring the state of a critical control calculation
parameter, detecting when it varies from desired state, and taking The error signal is the difference between the PV and the set-point,
action to restore it. lt involves the process variable,set points and andis the basis for control action
manipulated variable. l
The controller is the device that processes the error signal
Most basic process control systems consist of a control loop. This has »determines the required control action and provides a control output
four main components which are Manipulated Variable (V) to the process. The device that converts
A measurement of the state or 0onion 0fa process the control output into control action is the actuator,
A controller calculating an action based on this measured val ug
' Control Modes
again$a pre-set or desired value (set point)
In control, there are 0ontrol systems which can be discrete or a0al0g
An output signal resulting from the controller calculation weh is
manual or automated, periodic or continuous
used to manipulate the pro0e s action through some of of
actuator 6¥ There are five basic forms of control available in Pro00ss Control
1 On-Off control: The oldest strategy for control is to use a switch
The process itself reacting to this signal, and chapglhg its state o,
giving simple on-off control. This is a discontinuous form of control
condition [Link] action, and is also referred to as two-position control. A perfect on
off controller is 'e' when the measurement is below the set-point
I I (SP) and the manipulated variable (MV)is at its maximum value
Above the SP, the controller is 'off and the MV is at a minimum
2 Modulating control: If the output of a controller can move
through a range of values, this is modulating control. Modulation
J Control takes place within a defined operating range only. That is
it must have upper and lower limits. Modulating control is a
smoother form of control than step control. It can be used in both
open loop and closed loop control systems
3. Open loop control Open loop control is thus called because the
Twoof the most important signals used in process control are called
control action (Controller Output Signal) is not a function of the V
+ Process Variable or V
(Process Variable) or load changes. The open loop 0onrol does
+ Manipulated Vaniable or MV not self-correct wen these Vs drift
In industrial process control, the Process Variable (PV)is measured 4. Feed forward control: Feed forward 0control is a form of control
by an instrument in the field and acts as an input to an automatic based on anticipating the correct manipulated variables required
controller which takes action based on the value of it to deliver the required output variable. [tis seen as a form of open
The PVis the parameter that is to be controlled. To be controlled, the loop control as the Vis not used directly in the control action
pt must be capable of being measured and that measurement
converted into a signal that can be acted on by the controller

2
 5. Closed loop or feedback control: If the PV, the objective of and SCADA systems but they are primary/main components in
control, is used to determine the control action it is called closed smaller control configurations.
loop control system. Embedded Control: In this control system, small components are
attached to the industrial computer system with the help of a network
and control is exercised.
Industrial Control System (ICS) User Configuration Open System (UCOS) is a control system that
Industrial Automation is a discipline that includes knowledge and employs object-oriented technique at every level of its system
expertise from various branches of engineering including electrical, architecture, and includes a number of subsystems which segment
electronics, chemical, mechanical, communications and more recently P the functionality of UCOS. The subsystems include: an Engineering
computer and software engineering. � Workstation Subsystem, an Operator Workstation Subsystem, and a
ICS is a term that encompasses several types of control systems Field Control Unit (FCU) Controller Subsystem. The subsystems
used in industrial production. , communicate via a Control Network.
These include: Supervisory Control and Data Acquisition (SCADA)
systems, Distributed Control Systems (DCS) and other smaller co/trol
systems configuration such as Programmable Logic controllers(PLC).
The application for industrial process control systems are diverse
ranging from simple traffic control to complex electricabgrid, from
environmental control system to oil refinery process contfb[
The intelligence of these automated systems lies in their
measurement and control units. $''
SCADA is a combination of telemetry and data acquisition. It
encompasses the collecting of the information, transferring it back to
the central site, carrying out any necessary analysis and control and
then displaying that information on a number of operator screens or
displays. The SCADA is a centralized system and is composed of
various subsystems like Remote Telemetry Units, Human Machine
Interface, Programmable Logic Controller (PLC) and Communications
networks.
DCS is a process-oriented system and it treats the control of the
process as its main task, and it presents data to operators as part of
its job.
PLC is an industrial computer control system that continuously
monitors the state of input devices and makes decision based upon a
custom program, to control the state of devices connected as output.
They are based on the Boolean logic operations whereas some
models use timers and some have continuous control. These devices
are computer based and are used to control various process and
equipments within a facility. PLCs control the components in the DCS

3
TOPIC 2: PROGRAMMABLE LOGIC CONTROLLER (PLC) PLCs require shorter installation and commissioning times than do
Introduction hard-wired systems. To modify a control system and the rules that are
PLC is a unit of hardware used to control and automate industrial to be used, all that is necessary is for an operator to key in a different
processes. It is a micro-computer based controller that uses stored set of instructions. There is no need to rewire.
instructions in programmable memory to implement logic, sequencing, The result is a flexible, cost effective, system which can be used with
timing, counting and arithmetic functions through digital or analog control systems which vary quite widely in their nature and complexity.
input/output modules, for controlling machines and processes. PLCs are similar to computers but whereas computers are optimized
The term logic is used because programming is primarily concerned for calculation and display tasks, PLCs are optimized for control tasks
with implementing logic and switching operation. t>,,,t>,,, and the industrial environment.
The PLC is designed as replacement for the hard-wired relay and t),,,_
t>,,, Thus PLCs have specific features suited for industrial control :-
timer logic to be found in traditional control panels, where PLC, 1. Rugged and designed to withstand vibrations, temperature,
provides ease and flexibility of control based on programming and humidity and noise
executing logic instructions. 2. Modular plug-in construction, allowing easy replacement or
A PLC has three main aspects: the inputs and outputs and the gotrol addition of units (e.g. input/output);
program. In figure below, PLC has eight inputs and four outp&. 3. Standard input/output connections and signal levels
The input is arymg hat ca
sense the status of the
faeEEEEq 4. Have interacig tor iputs an outputs alreacy inside me
controller.
environment and then convert that 5. Easily understood programming language which is primarily
information in to a signal. Often the " concerned with logic and switching operations
signal can simply be a voltage that l___ 6. Ease of programming and reprogramming in-plant;
is either on or off. For example,
input devices can be proximity e
s"% 7. Capable of communicating with other PLCs, computers and
intelligent devices;
switches, photoelectric sensors, % am-rl 8. Competitive in both cost and space occupied with relay and solid-
temperature sensors, push state logic systems.
buttons, or pressure sensors. lieus• These features make programmable controllers highly desirable in a
The outputs are connected to the devices that need to be controlled wide variety of industrial-plant and process-control situations.
like motors, indicator lights, fans, warning sirens or heating elements.
Control processes need devices to monitor events or measure PLC Advantages
needed values. These devices are generically called inputs to the • Flexibility: One single PLC can easily run many machines.
PLC. • Correcting Errors: With PLC control, any change in circuit design
The program uses a set of logical instructions that drives the outputs or sequence is as simple as retyping the logic. Correcting errors in
based on the inputs. PLC is extremely short and cost effective.
• Space Efficient: Today's PLC memory is getting bigger and
The Need for PLCs bigger this means that we can generate more and more contacts,
Hardwired panels were very time consuming to wire, debug and coils, timers, sequencers, counters and so on. It is possible to
change. The PLCs eliminates much of the hard wiring that was have thousands of contact timers and counters in a single PLC.
associated with conventional relay control circuits. • Low Cost: Prices of PLC vary from few hundreds to few
PLCs have the great advantage that the same basic controller can be thousands.
used with a wide range of control systems.
4
 • Testing: A PLC program can be tested and evaluated in a lab. PLC Hardware
The program can be tested, validated and corrected saving very The structure of a PLC can be divided several parts/components. The
valuable time. main parts are input/output modules, central processing unit, memory and
• Visual observation: When running a PLC program a visual programming terminal.
operation can be seen on the screen. Hence troubleshooting a a) Processor unit or central processing unit (CPU) is the unit
circuit is really quick, easy and simple. containing the microprocessor and this interprets the input signals
and carries out the control actions, according to the program
Typical PLC Applications stored in its memory, communicating the decisions as action
signals to the outputs.
• PLCs are used to operate greenhouse irrigations systems. It can be •
used to control how often and the amount of water distributed to P b) Memory unit is where the program is stored that is to be used for
the control action to be exercised by the microprocessor and data
certain areas. It can control a large amount of valves to certain areas '?
and is flexible as the greenhouse's needs change.
stored from the input for processing and for the output for
outputting.
• PLCs are used for sorting packages on a conveyor by operating a
diverter. A sensor can detect a package type and a series of di/rters Programing
Terminal
can sort them at the end of the belt. But the PLC is flexible, Dcan be
reprogrammed if and when the sorting task changes or j(enhanced
operation is needed. p,%
.
t

• PLCs are implemented in a variety of control operations from large to

Po.. itr I
] Memory [
small. Carwashes are a popular use for PLCs b~Cause it involves l,Supply[ CPU

intricate use of sensors and motors, but also has the need for
relatively complex logic.
1
T I
• Lumber mills use PLCs to control the main saw and loading of wood
while various sensors ensure safe operation so that people and
� ln1mt
Module
Out1mt
Module I
equipment are not harmed PLC
• PLCs can withstand the harsh condition desert conditions while
Outpulll
controlling an oil recovery process. Temperatures can get higher than
120 degrees Fahrenheit in the desert, yet a PLC can read sensors
and control the motors necessary for oil extraction.
Input
Deviees I I Devices

PROCESS I
PLC Architecture c) Input and output modules -- are where the processor receives
There are two types: information from external devices and communicates information
1. Open architecture design allows the system to be connected to external devices. The I/O unit provides the interface between
easily to devices and programs made by other manufacturers. the system and the outside world, allowing for connections to be
2. Closed architecture or proprietary system is one whose design made through 1/0 channels to input devices such as sensors and
makes it more difficult to connect devices and programs made by output devices such as motors and solenoids. It is also through
other manufacturers. the 1/0 unit that programs are entered from a program panel.
NOTE: When working with PLC systems that are proprietary in nature you Every I/O point has a unique address which can be used
must be sure that any generic hardware or software you use is
compatible with your particular PLC.
5
 d) Input and output (/O) devices - is collection of physical 1, Arithmetic and Logic Unit (ALU) Which is responsible for data
elements of the control system that either provide or use [/O data. manipulation and carrying out arithmetic operations of addition and
e) Programming device / terminal are used to enter the required subtraction and logic operations of AND, OR, NOT and EXCLUSIVE --
program into the memory of the processor. The program is OR([Link]) it receives control signals from the control unit telling it to
developed in the device and then transferred to the memory unit carry out these operations
of the PLC. 2. Control Unit This controls the movement of instruction in and out of
f) power supply unit is needed to convert the mains A.C voltage to the processor and also controls the operation of ALU. It consists of a
low d.c. voltages necessary for the processor and the circuits in decoder, controls logic circuit and a clock to ensure everything

sP ,_
the input end output interface modules. happens at the correct time. It is also responsible for performing the
g) Rack Assembly: Most medium to large PLC systems are instruction execution cycle.
assembled such that the individual components - CPU, 1/0, power
supply - are modules that are held together within a rack. Im,
smaller PLC systems - all of these components may be contain~d
in a single housing or "brick" - these smaller systems,are
#f �

''
- -i .
sometimes referred to as "bricks" or "shoebox" PLCs.
h) Communication interface is used to receive and transmit data
on communication network from or to other remotPLC. It is
'' we[jf Ula
cP St Dal hp/ Ls
Pou
''
concurred with such actions as device vest~tion, data
acquisition, synchronization between user applications and
connection management. $S
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PLC CPU architecture ('IPli,,_-1- ------------------------------ -
The CPU controls and supervises all operations within the PLC, r
carrying out programmed instructions stored in the memory.
' 3 «terr bus A¢
An internal communications highway, or bus system, carries
information to end from the CPU, memory and A/O units, under control '' J l 17
of the CPU.
The CPU controls and processes all the operation within the PLC. It is
'' I Output Dles
I I lpt Dedie
I
supplied with a clock with a frequency of between 1 and 8 MHz. This '' Programming
frequency determines the operating speed of the PLC and provides
the timing and synchronization for all elements in the systems.
'' lrmial
'
The information within the PLC is carried by means of digital signals. 3. Registers - located within the microprocessor and used to store
The internal paths along digital signal flow are called buses. A bus is information involved in program execution. It is a small amount of
just a number of conductors along which electrical signals can flow. internal memory that is used for the quick storage and retrieval of data
The internal structure of the CPU depends on the microprocessor and instructions. All processors include some common registers used
concerned for specific functions, namely the program counter, instruction
The simplified model consist of five parts ALU, CU, Registers, Buses, register, accumulator, memory address register and stack pointer.
and memory.

6
4. Bus - Buses are the paths used for communication within the PLC. • User program memory -- The final area of memory in a PLC is
The information is transmitted in binary form i.e. as a group of bits allocated to the storage of the user program. It is this memory
with a bit being a binary digit of O or 1. area that the executive program instructs the micro-processor to
• System bus is used for communication between the 1/0 ports and examine or 'scan' to find the user instructions.
1/0 unit. It is a cable which carries data communication between • 1/0 status memory or 1/0 image table. A portion of RAM is
the major components of the computer including the allocated for the storage of current 1/0 status. Every single 1/0
microprocessor. module has been assigned to a particular location within the 1/0
• Control bus carries the signals relating to the control and co-
ordination of the various activities across the computer which can
be sent from the control unit within the CPU. It informs memory •
s. image table. The location within the input and output image
table/map are identified by addresses, each location has its own
unique address.
devices whether they are to receive data from an input or output
data and to carry out timing signals used to synchronize actions.,05' Memory organization
• Data bus carries the data used in the process carried out by_the This refers to how certain areas of memory in a PLC are utilized.
CPU. It is used for the exchange of data between the processor, Physical addressing is the ability to read data from a specific module
memory and peripherals, and is bidirectional. A micro processor terminal or write information to a specific module terminal.
termed as being 8-bit has an internal data bus which gan handle During the execution of user program, the micro processor scans the
8-bit number. 5 user program and interprets the user command, when information is
read from a contact or input, it is stored in memory. This portion of
• Address bus is used to carry the addresses of m~mhory location.
It contains the connection between the mi@processor and memory is the input image table/map which is designated to store
memory that carry the signals relating to the<@ddresses which the this input information. Each input typically has at a minimum, a single
CPU is processing at that time, such as the locations that the CPU bit designated to store its information
is reading from or writing to. Every memory location is given a Data resulting from logical analysis by the CPU i.e. various output
unique address. device status generated during the execution of user program is
stored in memory labeled as the output image table/map
5. Memory: - There are several memory elements in a PLC system. From this point, the information is transferred to a designated output
• Executive memory or operating system memory which is read module and then to a particular field device.
only memory (ROM) to give permanent storage for operating
system and fixed data used by the CPU. It is the one that actually Basic PLC Operation
does the scanning in the PLC. • A PLC works by continuously running a Check Input Status
• System memory -- in order for the operating system to function, a program that checks the inputs and then
section of the memory is allotted for system administration. As the updates the outputs. The process of the PLC
executive program performs its duties, it often requires a place to running throughout its program is called
store intermediate results and information. A section of RAM scanning. Scanning speed depends on the Execute Program
(Random Access Memory) is installed for this purpose. program size and execution time.
• Data memory -- This is a RAM where information is stored on the •The total time for a PLC to check the inputs,
status of input and output devices and the values of timers and run the program and update the outputs is
Update Output Status
counters and other internal devices. Data RAM is sometimes called the cycle time. Typical cycle times are
referred to as data table or register table. 10 ms to 100 ms. Every cycle the inputs are
check and saved to memory.
7
• Then the program is run using the status of the saved inputs. After the 4. Housekeeping - these steps includes communication with
program is done the outputs are updated and the cycle starts again. programming, internal diagnostic activities etc.
- -------.
Scanning processes
The PLC's CPU monitors the status of all inputs. It takes these values
and energizes or de-energizes the outputs according to the ladder
diagram I user program. This is referred to as Scanning. The CPU of
the PLC executes the user program over and over again when it is in ""
the run mode. p" %
A scan does not consist of a PLC executing ladder diagram rung by
rung, but instead the PLC performs an I/O and program scan. The I/O ........ --- ......... ................... '
scans transfers data to and from the output and input modules
respectively.
• The information is transferred in the form of bits and stored in,image
tables (image maps) are block of memory designated to store the
y
2
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Input
Module

', ...................
., ..
'

.
CPU.

Meet¥
·,

...
.
'
Output
Module
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input and output bit state) •$ ''' ...................

Pe 0pf
Device
The input and output is the portion of the PLC that inter1gs with the
outside world. The actual bridge between the physical world and
internal world of the PLC is the optical isolation cir~u@try.
• $e

·- nest into[0 ,-

There are four basic steps in the operation of @pL_cs; input scan,
program scan, output scan, and house keeping. These steps
continually take place in a repeating loop.
1. Input scan· Dunng the input scan, the current status of every
input module is stored in the input image (memory) table, bringing
t up-to-date. Thus all the status of the input devices (which in turn
_
'2
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-·-·-----

Input
Module

' ...................
.. ·- .
CPU

Menory
tit ..
. ... ··-···-·--·--

.
. .....
... nc ............ :
Output vu
Module
·,

'-e

-'
Dev
is connected to the input module) is updated in the input memory
table.
2. Program scan; Following the input scan, the CPU enters its user
program execution, or program scan. The execution involves PLC input and output (110) devices
starting at the program's first instruction, then moving on to the Input/output (I/O) is information representing the data that is received
second instruction and carrying out its execution sequence. This from senses elements / devices and the commands that are sent to
continues to the last program instruction, Throughout the user- actuating and indicating devices. The I/O system is collection of
program execution, the CPU continualy keeps its output image physical elements of the control system that either provide or use [/O
(memory) table up-to-date. data.
3. Output scan: During program scan, the output modules The term sensor is used for an input device that provides a usable
themselves are not kept continually up to date. Instead, the entire output in response to a specified physical input. For example, a
output image table is transferred to the output modules during the thermocouple is a sensor which converts a temperature difference
output scan which comes after the program execution. Thus the into an electrical output.
output devices are activated accordingly during the output scan.
8
 The term transducer is generally used for a device that converts a numerical value by an AID converter. The process of sampling the
signal from one form to a different physical form. Thus sensors are data is not instantaneous, so each sample has a start and stop time.
often transducers, but also other devices can be transducers, e.g. a The time required to acquire the sample is called the sampling time.
motor which converts an electrical input into rotation. AID converters can only acquire a limited number of samples per
The number of 1/0 devices used within a control system is called its second. The time between samples is called the sampling period T,
point count. Thus the total number of digital and analog point is used and the inverse of the sampling period is the sampling frequency (also
to give an indication of the size of a control system. called sampling rate). The sampling time is often much smaller than
PLC has input and output lines through which is connected to a the sampling period
system it directs. Any electrical signal processing always requires a Analog output devices respond to a range of output values from the
voltage supply (an active part) and a load (passive part) or vice versa. � controller common analog output signals include motor speed, valve
1/0 modules connect "real world" field devices to the controller. They position, air pressure etc. An analog output card will convert a digital
convert the electrical signals used in the field devices into electronig number sent by the CPU to its real world voltage or current. Analog

world values to IO table values.

I/O modules communicate with PLC CPU in one of three ways'
a
signals that can be used by the control system, and translate real device data requires significantly more manipulation and processing
then digital device data.

1. Backplane - The I/O modules can be located in the same rack or 2. Digital input and output devices
station. Communications then takes place within_tb~ rack or Inputs come from sensors that translate physical phenomena into
across the backplane. a
2. Backplane extension - backplane extension modules allow I/O
digital signal. Thus digital input devices may be either on or off, they
may not hold any other value.
modules to be located in racks or stations @lch are separated Common digital field input devices include push buttons, unit switches
from the controller. and photo eyes.
3. Device network - modules can communicate with a controller Digital output devices are devices which give either on or off.
over a network. Industrial networks are used to interconnect field Common types are relays, motor starter, solenoid valves etc.
level devices with controllers. Common 10 networks are FieldBus,
Profibus, and DeviceNet. Examples of inputs and outputs
There are major types of 1/0 Inputs for a PLC come in a few basic varieties the simplest are AC
• Analog - continuous devices that sense and respond to a range and DC inputs. Examples of input devices are:
of values • Proximity switches - use inductance, capacitance or light to
• Digital - binary devices which must be in one of only two states detect an object logically
on or off. • Switches - mechanical mechanisms will open or close electrical
contacts for a logical signal
1. Analog input and output devices • Potentiometer - measures angular position continuously using
Analog input devices senses continuous parameters common analog resistance.
inputs are pressure, temperature, speed transducers etc. • LVDT (Linear variable differential transformer) - measures
An analog input card converts a voltage by current leg or signal that linear displacement continuously using magnetic coupling.
can be anywhere from O to 20mA) into digitally equivalent number that Outputs to actuators allow a PLC to cause something to happen in a
can be understood by the CPU. process. Outputs from PLC are often relays, but they can also be solid
To input an analog voltage (into a PLC or any other computer) the state electronics such as transistors for DC output or TRIACs for AC
continuous voltage value must be sampled and then converted to a

9
 outputs. Continuous output requires special output cards with digital to Sourcing and sinking
analog converters. Sourcing and sinking are used to describe the way in which d.c
Examples are devices are connected to a PLC and uses d.c currents and voltages.
• Solenoid valves -- logical output that can switch a hydraulic or
pneumatic flow 1. Sourcing - When active, current flows from supply, through the use a
• Lights - logical output that can often be powered directly from single supply voltage. With sourcing, using the conventional current
PLC output boards flow direction as from positive to negative, an input device receives
• Motor starters -- motors often draw a large amount of current current from the input module i.e. the input module is the source of the
when started, so they require motor starters which are basically P» current (Fig a)
large relays. Ifthe current flows from the output module to an output load then the
• Servo motors -- a continuous output from the PLC can command output module is referred as to sourcing (fig b)
,
a variable speed or position. ' r,

Active and passive inputs/outputs • Output

Active I/O are those inputs or outputs which have the power,source Module
and are referred to as having a current source or voltage source
(sourcing) Q
Passive 1/0 are those inputs or outputs which don@f'have power
source and acts as the load or current sink (sinking)@ (a) (b)
In order that an electrical circuit can function properly, current must
flow in a circuit even when an instrument is usually known as a load, 2. Sinking- when active the output allows current to flow to a common
the current is not consumed by tis rather it only flows from the current ground. This is best selected when different voltages are supplies.
or voltage source through the load and back to the current source. With sinking, using the conventional current flow direction from
pout cared positive to negative, our input device supplies current to the input
module i.e. the input module is the sink for the current (fig a)
If the current flows to the output module from an output load then the
output module is referred to as sinking (fig b)

•
Input Input
device module

(a (b)

av.
(current/voltage sour0e
g internal wotag$00ply
(battery, sol cell, )

IO
 Typical Connections of PLC Types of PLC system
• The PLC sizes are given in terms of program memory size and the
Sensor PLC
1
-------
+V I Input
r----------------, maximum number of 1/0 points the system can support.
I
]

I
L

I
(sinking) • However to evaluate properly any PLC, consideration is taken for
I I
]
Output g
cl
many additional features such as its processor, cycle time, language
]
I
(sorsing) E£ facilities, functions expansion capability etc.
I cg
_r_"D common j Sy
PLC size Max 1/0 point User memory size
� - - �- - - ; � - - - - - - - - - - - - - - - _1
�
� defined (No. of instructors)
Connecting sensors with a sourcing output to a PLC controller sinking input $.} Small 40/40 1k
Medium 128/128 4k
I - - - - - - -I
I
Output
sinking)
Input
(sorsing)
�
PLC
- - - - - - - - - - - - - - - - ; 53
I\ Large >128/>128 >4k
o
1 (

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1. Small PLC - small and mini PLCs are designed as robust, compact
units which can be mounted on or beside the equipment to be
controlled. They are mainly used to replace hard wired logic relays,

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t
Common

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timers, counters etc that control individual items of plant or
machinery, but can also be used to co-ordinate several machines
cont�sourci working in conjunction with each other. Programming is by way of
Connecting sensors with sinking output to a PLC ng input
logic instruction list (mnemonic) or relay ladder diagrams.
----------------------------
PLC 2. Medium-sized PLC: - In this range, modular construction
LED on the
top of PLC +24V predominates with plug-in modules on rack mounting system or
controller
Back plane system. This allows the simple upgrading or expansion
of the system by fitting additional 1/0 cards into the racks
CPU
3. Large PLC - where control is very large numbers of input and
Output � v •
24 output points is necessary or complex control functions are required,
tSofsl/lg)r a large PLC is selected. It is designed for use in large plants or
Output load
dewice machines requiring continuous control. They are also employed as
supervisory controllers to monitor and control several other PLCs or
Connecting output load device to a sourcing PLC controller output intelligent machines e.g. CNC tools.
PLC
---------------------------
LED on the
Output
top of PLC
controller (sinking)
PLC styles of construction
Output load
dewice • The main styles are unitary, modular and rack mounting.
1. Unitary PLC - is the smallest and least expensive. It contains every
CPU
24V
feature of a basic system in one box and is attached to the machine
being controlled. They are not expandable so the application is limited
GND
to on-board 1/0.
2. Modular - These are a range of modules that slot together to build up
Connecting output load device to a sinking PLC controller output a system. Basic modules are the power supply, the main module
11
 containing the CPU, the input module and the output module. Modular PLC programming process is to plan activities such as design and write
PLCs are used in applications where a higher 1/0 count is needed or a program to perform the required tasks. The parts that should be
when using specialty modules such as quadrature encoders. They there in a PLC program are shown.
may be designed to be fixed direct to a back panel. Usually they are
arranged on a rack or rail and mounted inside a large cabinet for Start Starting an operation

protection and security. The main advantage is that the number of Operating Mode Determining the origin of the device input / output and
input and output terminals can be expanded to cope with changes to also the starting point
the hardware system.
I»t>
3. Rack mounting -- are usually more expensive, expandable and The Reset Controlling the operation of start/ stop it manually or

powerful than modular PLC. The rack provides a power and D automatically in the program

communication backplane that greatly increases the communication I» Operations / Ordering Program design as required by the task
rate between the processor and the modules as well as allowing some
specialty modules to communicate with each other without the Process

processor. The number of available 1/0 points is also much higher in Signal Output Trigger output devices.

the rack systems. Status Output Display indicator light or alarm.

-�
End Stop the process./operation

While ladder logic is the most commonly used PLC programming

language, it is not the only one.
IEC 61131-3 (Formerly IEC 1131-3) is the international standard for
PLC languages. The following is a list of programming languages
specified by this standard.
PLC Programming i) Ladder diagram (LO)
Programming devices can be hand-held devices, a desktop console ii) Instruction list (IL)
or a computer. Only when the program has been designed on the iii) Function block diagram (FBD)
programming device is ready, it is transferred to the memory unit of iv) Structured text (ST)
the PLC v) Sequential function chart (SFC)
• Hand-held programming devices - will normally contain enough 1. Ladder diagram language (LD): It uses a standardized set of
memory to allow the unit to retain programs while being carried ladder programming symbols to implement control functions.
from one place to another. Initially programmed with simple contacts that simulated the
• Desktop consoles -- are likely to have a visual display unit with a opening and closing of relays, ladder logic, programming has
full keyboard and screen displays. extended to include such functions as counters, timers, shift
• Personal computers -- are widely configured as program registers and mathematical operations.
development work station. A major advantage of using a computer
is that the program can be stored on the hand disk or CD and
copies easily made. it 12