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INTRODUCTION TO PLC
Programmable logic controllers (PLCs) are members of the computer family capable of storing
instructions to control functions such as sequencing, timing, and counting, which control a
machine or a process. The PLC is composed of two basic sections, the Central Processing Unit
(CPU) and the Input/output (I/O) interface system. The PLC measures input signals coming
from a machine and through the internal program provides output or control back to the
machine.
Ladder logic is the programming language used to represent electrical sequences of operation.
In hardwired circuits the electrical wiring is connected from one device to another according to
logic of operation. In a PLC the devices are connected to the input interface, the outputs are
connected to the output interface and the actual wiring of the components is done electronically
inside the PLC using ladder logic. This is known as soft wired.
PLC is a device that is capable of being programmed to perform a controlling function. Before
the advent of PLC, the problem of industrial control was usually solved by relays or hardwired
solid-state logic blocks. These are very flexible in design and easy for maintenance personal to
understand. However, they involved a vast amount of interconnection. For the wiring cost to be
minimized, relays and logic blocks had to be kept together. This led to development of control
panel concept for larger and more complex logic control system.
The PLC was first conceived by group of engineers from hydromantic division of GM in
1968.This was designed to provide flexibility in control based on programming and executing
logic instruction. Adopting the ladder diagram programming language, simplifying
maintenance and reducing the cost of spare parts inventories realized major advantages.

History of PLCs

The first Programmable Logic Controllers were designed and developed by Modicon as a
relay replacer for GM and Landis.

The primary reason for designing such a device was eliminating the large cost involved in
replacing the complicated relay based machine control systems for major U.S. car
manufacturers.

These controllers eliminated the need of rewiring and adding additional hardware for every
new configuration of logic.

The first PLC, model 084, was invented by Dick Morley in 1969.

The first commercial successful PLC, the 184, was introduced in 1973 and was designed by
Michel Greenberg.

Communications abilities began to appear in approximately 1973. The first such system was
Modicon's Modbus. The PLC could now talk to other PLCs and they could be far away from
the actual machine they were controlling.
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PLC Basic Block Diagram

A Programmable Controller is a specialized computer. Since it is a computer, it has all the basic
component parts that any other computer has; a Central Processing Unit, Memory, Input
Interfacing and Output Interfacing. A typical programmable controller block diagram is shown
below,

Figure 1. PLC Basic Block Diagram

The Central Processing Unit (CPU) is the control portion of the PLC.
1. It interprets the program commands retrieved from memory and acts
on those
commands.
2. In present day PLC's this unit is a microprocessor based system.
3. The CPU is housed in the processor module of modularized systems.
Memory in the system is generally of two types; ROM and RAM.
1. The ROM memory contains the program information that allows the CPU to interpret
and act on the Ladder Logic program stored in the RAM memory.
2. RAM memory is generally kept alive with an on-board battery so that ladder
programming is not lost when the system power is removed.
3. This battery can be a standard dry cell or rechargeable nickel-cadmium type.
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4. Newer PLC units are now available with Electrically Erasable Programmable ReadOnly
Memory (EEPROM) which does not require a battery.
5. Memory is also housed in the processor module in modular systems.
Input units can be any of several different types depending on input signals expected as
described above.
1. The input section can accept discrete or analog signals of various voltage and current levels.
2. Present day controllers offer discrete signal inputs of both AC and DC voltages from TTL to
250 VDC and from 5 to 250 VAC.
3. Analog input units can accept input levels such as 10 VDC, 5 VDC and 4-20 ma. current
loop values.
4. Discrete input units present each input to the CPU as a single 1 or 0 while analog input units
contain analog to digital conversion circuitry and present the input voltage to the CPU as
binary number normalized to the maximum count available from the unit.
5. The number of bits representing the input voltage or current depends upon the resolution of
the unit.
6. This number generally contains a defined number of magnitude bits and a sign bit.
7. Register input units present the word input to the CPU as it is received (Binary or BCD).
Output units operate much the same as the input units with the exception that the unit is
either sinking (supplying a ground) or sourcing (providing a voltage) discrete voltages or
sourcing analog voltage or current.
1. These output signals are presented as directed by the CPU. The output circuit of discrete
units can be transistors for TTL and higher DC voltage or Triacs for AC voltage outputs.
2. For higher current applications and situations where a physical contact closure is required,
mechanical relay contacts are available.
3. These higher currents, however, are generally limited to about 2-3 amperes.
4. The analog output units have internal circuitry which performs the digital to analog
conversion and generates the variable voltage or current output.
Extending PLC:
1. Every PLC controller has a limited number of input/output lines.
2. If needed this number can be increased through certain additional modules by system
extension through extension lines.
3. Each module can contain extension both of input and output lines.
4. Also, extension modules can have inputs and outputs of a different nature from those on
the PLC controller (ex. in case relay outputs are on a controller, transistor outputs can be
on an extension module).

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PLC ARCHITECTURE

Figure 2. PLC Architeture

Input pins :- It gets signal from real world input devices (switch or sensors) and provides the
signal to the controller.

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Output Pins :- It gets signal from controller and provide it to real world output devices ( motor
, lamp, valve ).

Communication Port :- It acts as data source.

Communication Cable :- It acts as medium.

Indicator or Monitor :- With the help of these monitor or indicator we come to know about
the status of input and output and also the different modes of PLC.

Controller :- It is a combination of processor and memory.

Processor :- Which let a programme run.

Memory :- Data storage is known as memory .

Pin Diagram of PLC

Figure 3. Pin Diagram Of PLC

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WORKING OF PLC
Bringing input signal status to the internal memory of CPU
The field signals are connected to the I/P module. At the output of I/P module the field status
converted into the voltage level required by the CPU is always available.
At the beginning of each cycle the CPU brings in all the field I/P signals from I/P module &
stores into its internal memory called as PII, meaning process image input.
The programmable controller operates cyclically meaning when complete program has been
scanned; it starts again at the beginning of the program.

I/O BUS
CPU

FIELD

SIGNAL
S

INPUT

MODULE

A PLC works by continually scanning a program. We can think of this scan cycle as consisting
of 3 important steps. There are typically more than 3 but we can focus on the important parts
and not worry about the others. Typically the others are checking the system and updating the
current internal counter and timer values.

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Figure 4. Working Of Block Diagram Of PLC

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Step 1-Check Input Status-First the PLC takes a look at each input to determine if it is on or
off. In other words, is the sensor connected to the first input on? How about the second input?
How about the third... It records this data into its memory to be used during the next step.
Step 2-Execute Program-Next the PLC executes your program one instruction at a time. Maybe
your program said that if the first input was on then it should turn on the first output. Since it
already knows which inputs are on/off from the previous step it will be able to decide whether
the first output should be turned on based on the state of the first input. It will store the
execution results for use later during the next step.
Step 3-Update Output Status-Finally the PLC updates the status of the outputs. It updates the
outputs based on which inputs were on during the first step and the results of executing your
program during the second step. Based on the example in step 2 it would now turn on the first
output because the first input was on and your program said to turn on the first output when this
condition is true.

Figure 5. Wiring Diagram Of PLC

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Basics About Conventional Ladder And PLC Ladder Logic


Electrical sequence of operation in hardwired relay circuits can be represented by electrical
ladder diagram. Ladder diagram shows the interconnection of field devices. In the ladder
diagram, each rung shows how a field device is turned on and also shows how it interacts with
next field devices.
The difference between a PLC ladder program and relay ladder rungs is the continuity. In an
electrical rung diagram, there is an electrical continuity only when the current flows from
left power rail to right power rail.

Fig (a), shows electrical continuity when SW1 is closed, as the current flows from L-1 to L-2
energizing the load.
Even though PLC ladder logic was modelled after the conventional relay ladder, there is no
electrical continuity in PLC ladder logic. PLC ladder rungs should have logical continuity in
order for the output to energize. PLC ladder program uses familiar terms like "rungs" and
"normally open" and "normally closed" contacts, but the relay ladder logic has no
electrical continuity between an input and the controlled output.
Note: - There is no physical conductor that carries the input signal through to the output.
Each rung in a ladder diagram is a program statement. This program statement consists of a
condition or sometimes conditions, along with some type of action. Inputs are the conditions,
and the action, or output, is the result of the conditions.
As in case of physical wiring hardware devices connected in series or parallel, PLC also
combines ladder program instructions in series or parallel. However, rather than working in
series or parallel, the PLC combines instructions logically using logic operators. Logical
operations performed by PLC are nothing but fundamental logic operation, using fundamental
logic operators like: AND, OR, and NOT. These operators are used to combine the instructions
on a PLC rung so as to make the outcome of each rung either true or false.

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The AND-logic function


The series circuit of 2 switches can be looked as an AND logic function. In fig (b) and fig (c),

both switch1 and switch2, must be closed to have electrical continuity. When there is electrical
continuity, output (light1) will energize. Hence the keyword here is AND.
The circuit in fig (b) is represented as a schematic diagram ladder rung in fig (c).When the
switch1 and switch2 is closed, electrical continuity is established to L-2. This is shown in fig
(d).
The various possible switch combinations are shown in the truth table below.
Table 1: Truth table for AND logic
Fig (d) can be written in PLC ladder format as shown in the figure below
Here is the program listing for a typical PLC, if you are entering the program with a handheld
programmer.

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LOAD I1
AND I2
OUT O5
The above instruction tell the processor to load input 1 (I1) into memory,
AND it with input 2 (I2) and then output the result to output 5 (O5). The resulting output will
be based on the truth table fig (e).
The OR-logic function
In an OR - LOGIC function, the output is true if any input is true. The OR logic also states that
if all inputs are true, the output will be true.
In the above figure, if switch1 OR switch2 is energized then light1 will energize. Also, if both
SW1 and SW2 are true, the output will also be true.
Fig (g) is converted to PLC ladder rung and it looks like fig (h)

A PLC rung of logic will have normally open or normally closed contacts instead of normally
open or normally closed switch symbols. Addresses and instructions are included. Here, in
additions to each contact and its address, text information such as SW1, SW2 and L-1 is used
and they are referred to as instruction comments. These instruction comments can be added
from programming software.

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The NOT-logic function


A normally closed relay contact passes power any time when the relay coil is not energized. In
the same manner, the normally closed PLC ladder logic instruction will pass power any time
when the input status file bit associated is not a 1. In this condition, the physical hardware input
is not sending an input signal into the PLC's input module. The opposite of normally open PLC
instruction or contact is the NOT logic. NOT logic can be used in conjunction with AND or OR
logic, when a logical 0 in the status file is expected to activate some output device. In other
words, NOT logic is used when an input is not energized i.e., 0 in the associated status bit, the
output should be energized. Also, when the input is energized i.e., 1 in the associated status bit,
the output should not be energized.
Truth table for NOT function

Analysis of rung 1
When I1 is true i.e. the input status file bit regarding I1 is true (1), the instruction I1 will
energize the output. The instruction I1 is considered true when it passes logical continuity. If
there is no valid input signal from the field input devices attached to I1's screw terminal on the
input module, a logical 0 will be placed in the associated input status file bit. A logical 0 in the
input status file will make the normally open input instruction to become false .When normally
open instruction is false, it will not pass logical continuity.
Analysis of rung 2
The normally closed instruction works much like normally closed contacts on a hardware
relay. In the fig (k), when the normally closed instruction I2 is true, i.e. the associated status file
bit has a valid zero (0), logical continuity is established to energize the output. When the
associated status file bit has valid 1, the NC instruction goes false and there is no logical
continuity and the output is not energized.

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The EXCLUSIVE OR-logic function


Truth Table for Input and output relation of an exclusive OR function.

Ladder rung of EXOR GATE would look like this

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Case 1
When I1 = 0 and I2 = 0:

Let us analyse main rung. When I1 = 0, the normally open instruction is false and, normally
closed instruction is true, but since normally open instruction is false, there is no logical
continuity and output cannot be energized. Similar analysis can be done in parallel rung,
normally closed instruction will be true and normally open instruction will be false and output
is not energized.
Case 2
When I1= 0 and I2 = 1:
In main rung, normally open instruction will be false and, normally closed instruction will be
true, but since there is no logical continuity this rung logic cannot energize the output. But, in
parallel rung, normally closed instruction will be true, as well as normally open instruction will
also be true, hence there is logical continuity, and output is energized.
Case 3
When I1 = 1 and I2 = 0:
This case is similar to case 2, only the role of inputs are interchanged i.e. here main rung is true
and energizes the output and parallel rung is false .
Case 4
When both inputs are true, the main ladder rung as well as the parallel ladder rung goes false.
In main rung, normally open instruction is true but normally closed instruction is false. Hence,
there is no logical continuity. In parallel ladder rung, normally closed instruction is false and
normally open instruction is true, and here also there is no logical continuity. Hence, the output
is not energized.

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Generally Used Instructions & symbol For PLC Programming


Input Instruction
--[ ]-- This Instruction is Called IXC or Examine If Closed.
ie; If a NO switch is actuated then only this instruction will be true. If a NC switch is
actuated then this instruction will not be true and hence output will not be generated.
--[\]-- This Instruction is Called IXO or Examine If Open.
ie; If a NC switch is actuated then only this instruction will be true. If a NC switch is
actuated then this instruction will not be true and hence output will not be generated.
Output Instruction
--( )-- This Instruction Shows the States of Output.
ie; If any instruction either XIO or XIC is true then output will be high. Due to high
output a 24 volt signal is generated from PLC processor.
Rung
Rung is a simple line on which instruction are placed and logics are created
E.g.; --------------------------------------------Here is an example of what one rung in a ladder logic program might look like. In real
life, there may be hundreds or thousands of rungs.

Practical Examples
Example-1
------[ ]--------------[ ]----------------O--Key Switch 1
Key Switch 2 Door Motor
This circuit shows two key switches that security guards might use to activate an electric motor
on a bank vault door. When the normally open contacts of both switches close, electricity is
able to flow to the motor which opens the door. This is a logical AND.

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Example-2
Switching on/off the Lamp whether they are at the bottom or the top of the staircase

Figure 6. Example Switching on/off the


Lamp

Topics Covered in
is using Contacts in

this example
parallel.

Number of PLC Inputs Required


X0 Switch at the bottom of Staircase i.e. X0 turns ON when the bottom switch is turned to
the right.
X1 Switch at the top of Staircase i.e. X1 turns ON when the top switch is turned to the right.
Number of PLC Outputs Required
Y0 Lamp

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PLC Ladder Programming:

PLC Ladder Program Description:


If the states of the bottom switch and the top switch are the same, both ON or OFF, the light
will be ON. If different, one is ON and the other is OFF, the light will be OFF
When the light is OFF, users can turn on the light by changing the state of either top switch
at the bottom switch of the stairs. Likewise, when the light is ON, users can turn off the light
by changing the state of one of the two switches.
Example-3 .Programming For Start/Stop of Motor by PLC
Often we have a little green "start" button to turn on a motor, and we want to turn it off with a big red
"Stop" button

--+----[ ]--+----[\]----( )--| start | stop run


|
|
+----[ ]--+
run

Figure 7. Pin Diagram For Start/Stop of Motor by PLC

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The pushbutton switch connected to input X1 serves as the "Start" switch, while the switch
connected to input X2 serves as the "Stop." Another contact in the program, named Y1, uses the
output coil status as a seal-in contact, directly, so that the motor contactor will continue to be
energized after the "Start" pushbutton switch is released. You can see the normally-closed
contact X2 appear in a colored block, showing that it is in a closed ("electrically conducting")
state.

Starting of Motor

If we were to press the "Start" button, input X1 would energize, thus "closing" the X1 contact
in the program, sending "power" to the Y1 "coil," energizing the Y1 output and applying 120
volt AC power to the real motor contactor coil. The parallel Y1 contact will also "close," thus
latching the "circuit" in an energized state:

Figure 8. Starting Condition of Motor.

Logic for Continous Running of motor When Start Button is Released


Now, if we release the "Start" pushbutton, the normally-open X1 "contact" will return to its
"open" state, but the motor will continue to run because the Y1 seal-in "contact" continues to
provide "continuity" to "power" coil Y1, thus keeping the Y1 output energized:

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Figure 9. Condition Of Continuous Run of Motor

To Stop the Motor

To stop the motor, we must momentarily press the "Stop" pushbutton, which will energize the
X2 input and "open" the normally-closed "contact," breaking continuity to the Y1 "coil:"

Figure 10. Condition Of Stop Moto

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When the "Stop" pushbutton is released, input X2 will de-energize, returning "contact" X2 to
its normal, "closed" state. The motor, however, will not start again until the "Start" pushbutton
is actuated, because the "seal-in" of Y1 has been lost.

Counters
Counters count rung transitions. The CTU runs the accumulated value of the counter up
on the false to true rung transition, and the CTD instruction runs the accumulated value
down. The CTU and CTD can be used in conjunction with each other.
Counters consist of the following components:
ACC Accumulated Value
PRE Preset Value
CD Count Down Bit
CU Count Up bit
OV Overflow Bit
UN Underflow bit
By default, data file C5 stores counters, however, other counter files can be added as well.
Below is how the C5 Data file would appear:

Figure 11. Counter Input In Plc

For the CTU instruction: The CU bit is high when the CTU instruction is true. The
ACC value increments by the value of 1 each time the CU bit goes high. When the ACC
reaches the PRE, the DN bit will be set. The CTU will continue to increment the
accumulated value until it reaches the maximum possible value for a 16 bit signed
integer(32767). If the CU bit goes high one more time, the OV bit will be set, and the ACC
value will go to -32768. Each time the CU bit goes high, the ACC value will still
continue to increment (become less negative).
For the CTD instruction: The CD bit is high when the CTD instruction is true. The ACC
value decrements by the value of 1 each time the CD bit goes high. Any time the
ACC is above or equal to the PRE, the DN bit will remain set. The DN bit is reset if the
ACC falls below the PRE at any time. The CTD will continue to decrement the accumulated
value until it reaches the minimum possible value for a 16 bit signed integer (-32768). If the
CD bit goes high one more time, the UN bit will be set, and the ACC value will go to 32767.
Each time the CD bit goes high, the ACC value will still continueto decrement (become less
positive)

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Example for counter in plc programming


The production line may be powered off accidentally or turned off for noon break. The program
is to control the counter to retain the counted number and resume counting after the power is
turned ON again. When the daily production reaches 500, the target completed indicator will be
ON to remind the operator for keeping a record. Press the Clear button to clear the history
records. The counter will start counting from 0 again.

Figure 12. Counting Process

Topics Covered in this example is Latched 16 bit UP counter.


Number of PLC Inputs Required
X0 Product Detecting Sensor.
X1 Production Counter RESET/Clear
Number of PLC Outputs Required
Y0 Production Counter Target Completed.
Number of PLC Counter Required
C120 16 Bit Latched Counter. (Max Count =32,768)

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PLC Ladder Programming:

PLC Ladder Programming Practice Problem 5


PLC Ladder Programming Description:
The latching counter is demanded for the situation of retaining data when power-off.
When a product is completed, C120 will count for one time. When the number reaches
500, target completed indicator Y0 will be ON.
For different series of PLC, the setup range of 16-bit latching counter is different.

Timers
Timers are generally used for delaying an event from taking place, or to delay a device
from shutting off either on an on transition or an off transition. There are three types of
timers: The Timer ON delay (TON), Timer Off delay (TOF), and the Retentative Timer
On delay (RTO).
By default, timers are stored in the T4 Data file, however other time files can be created..
A timer consists of the following components: Preset word (PRE), Accumulate word
(ACC), Done bit (DN), Timer Timing bit (TT), and Enable bit (EN). For Timers, the
Enable bit follows the rung condition.

Figure 13.Input for Timer

The entire timer is addressed by it's element (example: T4:0) Pieces of the timer can be
used in logic however such as the DN bit on an XIC (T4:0/DN), or the Accumulated
value in a MOV statement (T4:0.ACC)

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Timer On Delay (TON)


The Timer On delay delays an event from taking place. Once the timer becomes true, the enable
bit becomes true instantly. The timer will also start timing instantly, so the TT bit becomes
high. Since the timer is timing, the accumulated value will increment. Once the Accumulated
value reaches the preset, the done bit (DN) will go high, and the timer will stop timing. The
accumulated value remains at (or near) the preset until the rung goes false again. Here is what a
typical timer might look like in logic:

Figure 14. TON Delay

When the switch is energized, the timer will begin timing. When the ACC value reaches
the PRE value, the DN bit goes high, and the main motor will start. Since the Time Base
is .01, therefore 500 (preset) times .01 (timebase) = 5 second delay.
Timer Off Delay (TOF)
The Off Delay Timer is generally used to delay an event from shutting off. Image a lube system
on a large motor. As long as the main motor is turning, the lube pump should be running. When
the main motor shuts off, you wouldn't want to shut off the lube pump immediately because the
main motor needs time to coast down to zero RPM's. The Main motor could run off the EN bit,
and the Lube motor could run off the DN bit.
On the Off delay timer, as soon as the rung goes true, The EN bit goes true as it does for all
timers. Since the Off delay timer does not delay the DN bit from shutting off, the DN bit goes
high immediately. Remember, the TOF instruction delays the DN bit from shutting off, not
turning on. (Plus if we are delaying the DN bit from shutting off, it needs to be high to begin
with). While the rung is true, the timer is not timing, and the ACC value is at zero. When the
rung is shut off, the EN bit shuts off immediately. The ACC value will start timing until it
reaches PRE then the DN bit will shut off.
Here is what the TOF instruction might look like in logic:

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Figure 15. TOFF Delay

When the motor switch is energized, both the main motor and the lube motor will energize
immediately. When the main motor switch is shut off, the main motor shuts off immediately,
but since the TOF delays the DN bit from shutting off, the Lube motor will shut off 30 seconds
later. Warning: Using the RES instruction on a TOF instruction could cause unpredictable
operation.
Retentative On Delay Timer (RTO)
The RTO instruction works a lot like the TON instruction with one main exception: When the
rung goes false on the RTO instruction, it will retain the ACC value. When the rung becomes
true again, the ACC value will pick up from where it left off. One good application for the RTO
would be an hour meter to indicate total runtime for machinery. Since the RTO does not reset
itself when the rung goes false, the RES instruction must be used to reset a timer. Here is a
practical application:

Figure 16. RTO Delay

In this example, once the machine accumulates 1 hour of run time, a light might come on
indicating that a lubrication needs to be engaged. Once the operator lubricates the machine, he
can reset the hour meter.

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Example for Timer in PLC


Enabling the indicator to be ON immediately when switch pressed and OFF after a 5 sec delay
by the switch.

Topics Covered in this example is PLC Timer (OFF Delay).


Number of PLC Inputs Required
X1 Start Switch.
Number of PLC Outputs Required
Y1 Output Indicator
Number of PLC Timer Required
T0 5 second Timer, 100 ms Time Base. (See K50 Preset Value for Timer)
PLC Ladder Programming:

Figure 17. Program for timer

PLC Ladder Program Description:


When X1 = ON, TMR instruction will be executed. Timer T1 will be ON and start counting for
3 sec. When T1 reaches its set value, the NO (Normally Open) contact T1 will be activated and
indicator YI will be ON.
When X1 = OFF, TMR instruction will not be executed. Timer T1 will be OFF and so will NO
contact T1. Therefore, the indicator Y1 will be OFF.
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PLC Program For Filling Of Bottle In Industries

Figure 18. Program for bottle filling

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ADVANTAGES OF PLC
1.
2.
3.
4.
5.
6.
7.
8.
9.

Reduced space.
Energy saving.
Ease of maintenance.
Economical.
Greater life and reliability.
Tremendous flexibility.
Shorter project time.
Easier storage, archiving and documentation.
PLCs are armored for severe conditions (such as dust, moisture, heat, cold) and have the
facility for extensive input/output (I/O) arrangements.
10. PLCs read limit switches, analog process variables (such as temperature and pressure), and
the positions of complex positioning systems.
11. PLCs are used in many "real world" applications. If there is industry present, chances are
good that there is a plc present. If you are involved in machining, packaging, material
handling, automated assembly or countless other industries you are probably already using
them. If you are not, you are wasting money and time. Almost any application that needs
some type of electrical control has a need for a plc.

PLC DISADVANTAGES
1. There's too much work required in connecting wires.

2.

There's difficulty with changes or replacements.

3.

It's always difficult to find errors; and require skillful work force.

4.

When a problem occurs, hold-up time is indefinite, usually long.

5.

In contrast to microcontroller systems that have what is called an open architecture, most
PLCs manufacturers offer only closed architectures for their products.

6.

PLC devices are proprietary, which means that parts and software from One manufacturer
cant easily be used in combination with parts of another manufacturer, which limits the
design and cost options.

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APPLICATIONS OF PLC SYSTEM


In industry, there are many production tasks, which are of highly repetitive nature. Although
repetitive & monotonous, each stage needs careful attention of operator to ensure good quality
of final product.
Many times, a close supervision of the processes cause high fatigue on operator resulting in
loss of track of process control.
Sometimes its hazardous also as in the case of potentially explosive chemical processes.
Under all such conditions we can use PLCs effectively in totally eliminating the possibilities of
human error.
Some capabilities of PLCs are as follows:
Logic control
PID control
Coordination & automation
Operator control
Signaling and listing etc.
In short, wherever sequential logic control & automation is desired the PLCs are the best suited
to meet the task. It includes simple interlocking functions to complicated analog signal
processing to PID control action in closed loop control etc.
Few examples of industries where PLCs are used for control & automation purpose are
listed below: 1. Tyre industry.
2. Blender reclaimer.
3. Bulk material handling system at ports.
4. Ship unloader.
5. Wagon loaders.
6. Steel plants.
7. Blast furnace charging.
8. Brick-molding press in refectories.
9. Galvanizing plant.
10. Dairy automation.
11. Pulp factory.
12. Printing industry etc.
Today the PLCs are used for control and automation job in a single machine and it increases up
to full automation of manufacturing or testing process in a factory.
In robotics:
PLC is used for two tasks in robotics:
1) As the controller or un-programmable part of robot.
2) As an overall system controller.

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In flexible manufacturing system:


The logical development from linking machines in this manner is to group programmable
machines into flexible manufacturing cells, each capable of machining a variety of products
under fully automatic control.
In factory automation:
The plant produces multi style car body from individual body panels .The process consists of
following activities:
Pass tagged bodies to a main jig for automatic alignment & framing.
Conduct material transfer in which sub-assemblies are selected, transported &
distributed to workstation by conveyor system Maintain quality control by automatic
monitoring & manual inspection of each process.
The PLC tracks each component as it moves through the production area,
communicating this information to each appropriate robot as necessary. Data send
between PLC & robot includes handshaking signals to indicate robot busy parked,
action complete etc. Data in binary coded decimal form is used to send component
information & weld sequences from the PLC to root, which must acknowledge receipt
of the correct data before the PLC will allow it to commence operation.

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CONCLUSION
PLC is a device that is capable of being programmed to perform a controlling function. The
PLC was designed to provide flexibility in control based programming and executing logic
instruction. PLC allowed for shorter installation time and faster commissioning through
programming rather than wiring.
The PLC have in recent years experienced an unprecedented growth as universal element in
industrial automation .It can be effectively used in applications ranging from simple control
like replacing a small number of relays to complex automation problems.
Today the PLCs are used for control & automation job in a single machine & it increases up to
full automation of manufacturing / testing process in a factory.

30

INDEX
Contents.Page No.
Certificate...... i
Acknowledgement.... ii
Preface......iii
Introduction To PLC......................................................................................................................1
History Of PLCs...........................................................................................................................1
PLC Basic Block Diagram............................................................................................................2
PLC Architecture...........................................................................................................................4
Pin Diagram of PLC......................................................................................................................5
WORKING OF PLC.....................................................................................................................6
Basics About Conventional Ladder And PLC Ladder Logic........................................................8
The AND-logic function................................................................................................................9
The OR-logic function.................................................................................................................10
The NOT-logic function...............................................................................................................11

Generally Used Instructions & symbol For PLC Programming.................................................14


Practical Examples......................................................................................................................14
Counters......................................................................................................................................19
Example for counter in plc programming....................................................................................20

Timers..........................................................................................................................................21
Timer On Delay (TON).......................................................................................................................22
Timer Off Delay (TOF).......................................................................................................................22
Retentative On Delay Timer (RTO)....................................................................................................23
Example for Timer in PLC..................................................................................................................24

PLC Program For Filling Of Bottle In Industries.......................................................................25


Advantages Of PLC....................................................................................................................26
PLC Disadvantages.....................................................................................................................26
Applications Of PLC System......................................................................................................27
Conclusion...................................................................................................................................29

Table Of Figures
Figure Contents .Page No.
Figure 1. PLC Basic Block Diagram.............................................................................................2
Figure 2. PLC Architeture.............................................................................................................4
Figure 3. Pin Diagram Of PLC......................................................................................................5
Figure 4. Working Of Block Diagram Of PLC.............................................................................6
Figure 5. Wiring Diagram Of PLC................................................................................................7
Figure 6. Example Switching on/off the Lamp...........................................................................15
Figure 7. Pin Diagram For Start/Stop of Motor by PLC.............................................................16
Figure 8. Starting Condition of Motor.........................................................................................17
Figure 9. Condition Of Continuous Run of Motor......................................................................18
Figure 10. Condition Of Stop Moto............................................................................................18
Figure 11. Counter Input In Plc...................................................................................................19
Figure 12. Counting Process.......................................................................................................20
Figure 13.Input for Timer............................................................................................................21
Figure 14. TON Delay.................................................................................................................22
Figure 15. TOFF Delay...............................................................................................................23
Figure 16. RTO Delay.................................................................................................................23
Figure 17. Program for timer.......................................................................................................24
Figure 18. Program for bottle filling...........................................................................................25

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