PLC Introduction

Good morning all, this is a virtual labouratory on ‘Programmable Logic Controllers’ recorded under the
Automation Labouratory, Department of Production Engineering, PSG College of Technology.

A Programmable Logic Controller which is abbreviated as PLC is a device that was invented to replace
the necessary sequential relay circuits for machine control. The PLC works by looking at its inputs and
depending upon their state, turning on/off its outputs. The user enters a program, usually via software,
that gives the desired results. PLC acts as a controller in automated systems which are responsible for
automatic controlling of various devices associated with the system. Usually PLCs have low voltage at
their outputs about 24 volts which are unable to operate devices of higher voltage ratings, in such cases
the relays are used which are energized using PLC’s outputs and relays themselves connect or disconnect
devices from higher power sources. There are five basic components in a PLC system: The PLC
processor or controller, I/O (Input /Output) modules, Chassis or backplane, Power supply, Programming
software that runs in a PC.

The PLC used here is Siemens LOGO. Since it is a modular PLC, expansion module is provided here to
increase the number of I/O ports and it has 12 inputs and 8 outputs. A modular PLC system is made in
parts that can be swapped out, upgraded individually, removed or replaced with different parts while a
fixed PLC system would be one that’s supplied complete and cannot be changed/upgraded. The inputs are
specified with the letter I and a number. When you look at LOGO from the front, you can see the
connectors for the inputs at the top. The outputs are specified with the letter Q and a number. This PLC is
a closed architecture type, whose design makes it more difficult to connect devices and programs made by
other manufactures. If we are working with open architecture PLC, it is easy to connect devices and
programs made by other manufacturers.

As any PLC, this is also basically a microprocessor based control system. Microprocessor communicates
with the outside world with input/output devives via a circuitry. This circuitry protects the microprocessor
and other elements of PLC from the high voltages and currents coming to the PLC. Microprocessor does
its basic functions of taking decisions according to the instructions written in the programs which are
stored in the memory. PLC scans a set of sensor inputs rapidly and repeatedly. Then it evaluates their
logic relationships to defined outputs according to a logic program. At last it sets the outputs according to
the programmed logic

PLCs are programmed through concept of ladder logic. In general there exists a graphical user interface
(GUI) to program a PLC that makes it different from other processers. Ladder logic program will be
written in between two columns in general. Left column shows input devices like switches, sensors while
in output column is at right side which shows actuators like cylinders, motors.
 PROGRAMMING PART

Few basic instructions used in PLC programming are:

Input Instructions:

-- [ ] -- 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 i.e.; 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.

Addressing Sample:

I: 3/1 This indicates address of a sample. I indicates input image table, 3 indicates slot no. 3 of input
port and 1 indicates bit three of 3rd slot of input port.

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.

Addressing Example

O:3/1, O -- output image table, 3 -- slot three, 1 -- bit one of slot three

There are three fundamental types of timers.

1. TON – On delay timer

2. TOF – Off delay timer
3. RTO – Retentive on delay

• An on-delay timer will wait for a set time after a line of ladder logic has been true before turning on,
but it will turn off immediately.

• An off-delay timer will turn on immediately when a line of ladder logic is true, but it will delay
before turning off.

• An RTO function the same as a TON with the exception that once it has begun timing, it holds its
count of time even if the rung goes false, a fault occurs or power is lost.
There are two types of counters used:

1. CTU – count up
2. CTD – count down.

• CTU - This output instruction counts up for each false-to-true transition of conditions preceding it in
the rung and produces an output when the accumulated value reaches the preset value.

• CTD - This output instruction counts down for each false-to-true transition of conditions preceding
it in the rung and produces an output when the accumulated value reaches the preset value.

OTL -(L)- This is called as ‘output latch’. This instruction functions similar to output energize except
that once a bit is set with OTL, it is latched on. Once an OTL bit has been set ON (1 on the memory)
it will remain ON even if the rung condition goes false. The bit must be reset. (U) This is called as
‘output unlatch’. This is used to unlatch (reset) a latched bit. Its address must be same as latched one.