G.A.

Rathy, Sr Lecturer/Electrical, NITTTR, Chennai

Relay is an electrically operated device that

mechanically switches electric circuits.
It consists of a coil and an internal switch.

One relay coil may be used to actuate more than

one set of contacts.

Those contacts may be normally-open, normallyclosed, or any combination of the two.

Allow a relatively small electric signal to switch a

relatively large electric signal,
Relays also offer electrical isolation between coil
and contact circuits. This means that the control and
power circuit(s) are electrically insulated from one
another.
One circuit may be DC and the other AC

PLC
PLC is a solid state equipment to perform
logical,decision making for industrial control
applications.
Used for Counting, Calculating, Comparing
and Processing of analog signals.
Mainly designed to replace the relay logic.

 It is similar to a PC to operate in the industrial

environment
It is equipped with inputs, outputs and a control
programming language

Advantages of PLC over relay control

panel
Wires
Real elements software
Process changes changeable

Advantages of PLC
Small
Inexpensive
Low power consumption
Ease of expandability

PLC BASED CONTROL PANEL

Definition of PLC
PLC - solid state device
- event driven device
(event taking place in the
field will result in a output)

Parts of PLC
The processor
The memory
The power supply
I/Os

Parts of PLC
CPU

Processor

8K

Memory
RAM
- Provides an excellent means for easily creating and
altering a program
ROM
- Information found in ROM is placed by the
manufacturer for the internal use and the
operation of PLC
EEPROM
- It provides permanent storage of the program.
Easily changed using Standard programming device.

Memory Map of PLC

Data
Table

Timers, Counters, Inputs,

Outputs

User
Program

User program

House
Keeping

(For processor)

Power Supply

Two types of power supplies.

These are 24 VDC and 120/240 VAC.

I/Os
Inputs
Limit switch
Push button
Sensors
Selector
Switches
Digital
or Analog

Motor
Motor starters
Solenoids
Indicator device

Digital
or Analog

PLC consists of input modules, a central processing unit

and output modules

An input accepts a variety of digital or analog signals from

various field devices(sensors) and converts them into a
logical signal that can be used by the CPU

The CPU makes decision and executes control instructions

based on the program instructions in memory.

Output modules convert the control instructions from the

CPU in to digital or analog signal that can be used to
control field devices

PLC uses three types of outputs:

Relay
Transistor
Triac

THE INPUT/OUTPUT SYSTEM

1. Types of input/output devices

2. Input interfaces
3. Output interfaces
4. I/O power distribution wiring

Analog or Digital Input Modules

Temperature
Light
Speed
Pressure
Small motors, Valves

INPUT INTERFACING

Communication

The PLC can be programmed using PC or hand held

Programmer. The communication between the PLC and
the PC is carried out using the RS 232 C Serial port.
The operating mode can be controlled from a computer
running the programming software.

Two Modes of Operation

Stop Mode
Run Mode
Programming and Downloading- STOP OR
OFFLINE

Verifying the program RUN OR ONLINE

will execute the application program residing in the
memory

Power on
Power up
Perform diagnostic checks

Fault

Scan Inputs
Scan Logic
Scan Outputs
Communication

Power fail

Fault

Power Failure

Set outputs to safe state

Turn Outputs off

Wait for fault

to clear

Prepare for
power up

Power up

Stop

Programming
Ladder
Statement List
Functional Block diagram

Ladder
Understood by workers
Fast
Graphic display and shows how power
flows

PLC Scan
In RUN mode, the PLC executes the user program.
It repeats the program continuously.
Execution of the program once is called PLC Scan
time

The PLC scan consists of

Input processing

Program processing

Output processing

I/P Image
Memory
in
Processor

Program
processing

O/P Image
memory in
Processor

Thank you

Memory System
The memory system consists of four units
File sections
Files
Words
Bits

Files 0 and 1
1000.

executive software of the Micro Logix

Keeping track of what is happening while the PLC is

operating.
Data about the processor, including type, configuration,
and passwords access

 File 2 holds the main ladder program that is entered into

the PLCs memory.
This ladder program controls the machine or process.

 File 3 stores an error fault routine

It is executed when a recoverable, or fixable, fault occurs
in the PLCs control program.
When this routine is executed, the Micro Logix corrects
the problem to get the system up and running again.

 File 4 stores the high-speed counter interrupt program

It is executed when a high-speed counter instruction
causes an interruption in the control program.

 File 5 contains the selectable timed interrupt program

Used to interrupt the normal program scan so that a
subroutine can be executed immediately.

Files 615 store the subroutine ladder programs that are called
by the main ladder control program.
This area can store up to ten subroutines

Data File Section

File 0 is the output file.
It stores data about the status of each output device connected to the
output terminals.
Each of the PLCs outputs is mapped to an address bit in this file.
File 0 is also known as the output image table. The output file
contains one word.

File 1 is the input file.

It stores data about the status of each input device.
The input file is also known as the input image table.
inputs is mapped to a specific bit in the input file.
The input file contains two words to account for all of the
possible input devices that can be connected

File 2 is the status file. It stores information about how the

PLC is operating and how it is set up.

File 3 is the binary, or bit file.

It stores data about the status of internal coils and contacts.
The binary file contains 32 words.
Because the binary file stores data about internal instructions, its
bits do not map real field devices, as the bits in the input and output
files do.

File 4 is the timer file.

It contains data about the timers used in the control program.
It includes data about each timers status, preset value, and
accumulated value.
The Micro Logix can use up to 40 timers in its control program,
and it dedicates three words for each timer.
The timer file has 120 words, three for each of its 40 timers.

File 5 is the counter file.

It stores data about the 32 counters available in the Micro Logix
1000.
It has three control words for each counter: the counters status,
preset value, and accumulated value.
Each piece of counter data is stored in its own word.
The counter file has 96 words, three words for each of the 32
counters.

File 6 is the control file.

It stores information used by specialized PLC instructions, like
shift and sequencer instructions.
This file can hold data for 16 instructions. It uses three words for
each instruction.
Therefore, this file can contain up to 48 words.

File 7 is the integer file.

This file stores miscellaneous numerical data, such as constant and
variable data, binary codes, and mask patterns.
The integer file uses 105 words to store all of this information.

I :0/0
The file label
The word label
The bit label