PLC (Programmable Logic Controller)

Introduction, Use, Example with Block diagrams

Brief introduction of PLC

We all know full form of PLC is PROGRAMMABLE LOGIC CONTROLLER. PLC is a device that
is used for automation such as industrial processes, machine automation, and controlling various types
of equipment. A PLC is a user-friendly, microprocessor-based computer that controls many types of
functions and levels of complexity.
Why do we use PLC?
Before PLC we used the microcontroller and Relay logic for controlling and automation. If
we use a microcontroller, it has high breakdown and high failure due to shorting and atmospheric
conditions. But PLC is safe from shorting and all atmospheric conditions. Ladder programming uses
for PLC programming. Ladder programming contains a readymade block for any execution. But in
the microcontroller, we have to create logic for every block. Ladder programming is very easy and
easily understood able as compared to microcontroller programming. It can also be programmed,
controlled, and operated by an UNSKILLED person
Flexibility
 Before PLC, each production machine required its own electronic controller for example 5
machines might require 5 different controllers.
 Now using PLC, we can control all 5 machines by a single PLC.
Modification and correction errors
 With a wired relay-type panel, if we want modification or correction in the machine, it
requires more time to rewire of the panel.
 But by using PLC, we can modify the program easily within minute time without wiring
changes.
Simulation
 We can check programs or logic in the lab using a simulator facility.
Visual observation
 We can check input and output easily whether it is coming or not.
Reliability and Maintainability
 PLC contains a solid state device. That’s why maintenance cost is very low or reliable as
compared to mechanical timer, relay, and contactor.

Block diagram of PLC.

PLC contains mainly three units CPU, INPUT, and OUTPUT.

Block diagram of PLC- Programmable logic controller

CPU:-CPU contains a processor. CPU reads and executes programming instruction which is
programmed by the programmer. CPU controls all activity by receiving input, and as per the program
control all output. Using communication devices we can communicate CPU with other devices like
personal computers and others. Using communication devices we can download programs in memory
and the CPU can also read other devices’ memory.

Also Check: 9 Tips to Learn Programming Faster

INPUT:-PLC can read both type of input (digital and analog input). Digital input means on/off or
discrete signal. Analog input means variable voltage/current or data input. Digital input connected to
CPU with optocoupler device as per following figure:-
 input block diagram of PLC

Here photo coupler is used for safety purposes. If any abnormality comes from the input section, the
photo coupler shut off and no signal goes to the CPU unit.
DIGITAL INPUT– Push buttons, selector switches, joysticks, relay contacts, pressure switches and
proximity switches, sensors, etc.
ANALOG INPUT– Potentiometers, temperature transducers, level transducers, pressure transducers,
humidity transducers, etc.
We show input as X0, X1, X2,….. I0, I1, I2,…..
OUTPUT:- Output is not directly connected to cp. Between CPU and output section there is a relay
or transistor. We show output as Y0, Y1, Y2,….. Q0, Q1, Q2,……

Output block diagram of PLC

How to connect input to plc

There are several types of input like a push button, limit switch, pressure switch, and sensor. Here we
connect one push button to PLC.
Sink and source concept:-
There is a common point (S/S) in PLC for several input points. We connect the input to PLC in two
types PNP and NPN. PNP and NPN connection is also called SINK & SOURCE connection. The
sink and source connection depend on the current flow between the common point and the input point.
If current flows from the common point to the input point, this is called a SOURCE or NPN
connection. If current flows from the input section to a common point, this is called a SINK or PNP
connection.
SOURCE CONNECTION:- In this type of connection +VDC supply connects to S/S point and -
VDC supply is used for input connection. Whether we give input to plc then we use –VDC supply for
input supply. In this connection current flow from s/s point to input point in plc. But on the field side
current flows from the input point to s/s point.

PLC source block diagram – Programmable logic controller

SINK CONNECTION:-In this type of connection -VDC supply connects to S/S point and +VDC
supply is used for the input connection. Whether we give input to PLC then we use +VDC supply for
input supply. In this connection, current flows from the input point to S/S point in PLC. But on the
field side current flows from the S/S point to the input point.
 PLC sink block diagram – Programmable logic controller

How to connect output with PLC:-

There is a com point in the output section. This point is common to point of all output. Whatever
supply is given to the com point when output is high then that supply (com supply) comes out from
the output point.
Let’s take an example to understand the output circuit deeply.

PLC Output circuit block diagram

Here we connect one relay with the output section. We connect +24V dc power supply to the com
point. When output Y0 is high +24v supply comes out from the Y0 point. That Yo point connects to a
24V-operated relay.

PLC Output circuit with relay block diagram

Relay Logic Circuit (RLC) (Relay, Contactor, Switch and Timer)

https://er.yuvayana.org/relay-logic-circuit-rlc-relay-contactor-switch-and-timer/
What is relay logic circuit? Relay logic is a method of OPERATING industrial electrical circuits
with the help of relay and contacts. In RLC, we use relay contactor mechanical timer counter etc.
These are basic element for RLC. To understand and create RLC, we must have to know about the
basic element.
First we understand what is NO and NC point. RLC depend on both point NO and NC.

NO point: -NO point is normally open. It means that point is normally open in ideal state. To
understand about NO point see figure:-

Normally Open switch diagram

In this figure when this point is in ideal state no output comes from it , but when we activate this point
it close and output comes.

NC POINT:- Full form of NC is Normally Close. It means NC point is close in ideal state. See
figure to understand this point

normally close switch diagram

In this figure when this point is in ideal state output comes from it, but when we activate this point, it
opens and no output comes. Now we discuss about relay

RELAY:- Relay is most important function in RLC. Without relay we can not assumes to create
RLC. Relay is a electrical operated switch. first relay is invented in 1835 for telegraphy by JOSEPH
HENRY. After few year relay become use for different purpose and application.

Relay with base

Relay is an Electromechanical device which operates by current. Relay consists one coil, armature,
spring and contact as shown in images.
 basic diagram of relay images

In above block diagram, there is coil which consist two terminal A1 and A2. When we give supply on
these terminal (A1, A2), coil generate magnetic field which attract or repel armature which is in coil.
That Armature end terminal connects with contact. When coil operate armature, operating contact
became change and when supply cut off, contact goes to ideal state with the help of spring.
Mainly use of relay is switch electric supply. Suppose your controlling voltage is 12V. But we want to
control 24V equipment. Here we use 12V operating Relay and 24v Bulb. See image to understand this
example.

working diagram of relay

CONTACTOR:- working principle of contactor is same as relay, but it mainly uses for heavy duty
work. Contactor Switching time is higher than relay.

Electrical contactor

Switch: - This element uses for interface between machine and human or operator. There are many
type of button as Momentary switch, Selector switch, toggle switch and latch switch. Switch is
operated by human. Using switch, Human give signal or command and control to machine or circuit.
Switch has two states ON and OFF.
 Type of switches

Momentary switch: - In this type of switch, when we press this switch, it gives signal and when
release signal off.

Momentary switch working

Selector switch:- This switch use for multiple selection from one switch. It is use for select one
circuit in many circuit.

Selector switch working diagram

Toggle switch: – In this type of switch , normally it is ON or OFF. When we press or operate this
switch, it will latch this state again we operated this switch than it goes to ideal state.

Toggle switch images

Timer:- As per name it is timer, a particular time we set in this device, after completing time, it’s
relay on. Timer has two element, timer and relay. Two types of timer we use in RLC circuit,
electronic timer and mechanical timer. With help of following timing diagram we can easily
understand working of timer.
 Timer
When we give supply to timer, timer run and after completing set time (T) timer’s relay on.

Timimng diagram of timer

We can use timer as ON delay and OFF delay. In ON-delay timer, relay ON after completing time.
But in OFF delay timer, relay OFF after completing time

Timing diagram of timer-2

Ladder Logic Diagram

Device notations, Programming & Example
This Tutorial will cover the Ladder Logic Diagram basics like how to read LAD program, Device
notations, Programming with example & Diagram.
https://er.yuvayana.org/ladder-logic-diagram-device-notations-programming-example/

Ladder Logic Diagram (LAD) Programming:

Ladder logic Diagram (LAD programming) is very commonly used method for the PLC
Programming. In Ladder programming language writing a program is equivalent to drawing a
switching circuit in electronic. The ladder diagram consists of two vertical lines; these are as left most
vertical line and right most vertical line. The left most vertical line representing the power rails named
as hot rail while the right most vertical line representing the neutral rail. The complete circuits in
ladder logic are connected with horizontal lines, i.e. the rungs of the ladder, between these two
verticals lines i.e. hot and neutral rails.
How to read Ladder Logic Diagram:
To understand the ladder logic diagram, we need to know the about how does it works and perform
operation. For this purpose some of the conventions are adopted, when a programmer drawing a
ladder diagram and these conventions are as follows;
  At the both (left and right ends) the vertical lines of the diagram represent the power rails
between which circuits are connected. The left and right lines are known as hot and neutral
rail respectively. The power flow is taken to be from hot rail across a rung to neutral rail.
 In the ladder diagram each rung defines the operations in the control process.
 To understand the ladder logic the diagram is read from left to right and from top to bottom,
Figure 6.1 showing the scanning motion employed by the PLC. The top rung is read from left
to right i.e hot rail to neutral rail. Then the second rung down is read from left to right and so
on.
 Scanning of Ladder diagram

Figure 6.1: Scanning of Ladder diagram

 When the PLC is in its run mode, it goes through the entire ladder program to the end, the end
rung of the program being clearly denoted, and then promptly resumes at the start. This
procedure of going through all the rungs of the program is termed a cycle. The end rung
might be indicated by a block with the word END or RET for return, since the program
promptly returns to its beginning.
 In ladder logic diagram every rung must have an input or set of inputs and rung must end with
at least one output. The term input is used for a control action, such as closing the contacts of
a switch and output of the sensors, used as an input to the PLC. The term output is used for a
device connected to the output of a PLC, e.g. a motor, solenoid valves.
 The inputs and outputs are all identified by their addresses, the notation used depending on
the PLC manufacturer. This is the address of the input or output in the memory of the PLC.
 A particular device can appear in more than one rung of a ladder. For example, we might have
a relay which switches on one or more devices. The same letters and/or numbers are used to
label the device in each situation.
 Electrical devices are shown in their normal condition. Thus a switch which is normally open
until some object closes it, is shown as open on the ladder diagram. A switch that is normally
closed is shown closed.
Basic Device notations used in PLC LAD Programming:
When a PLC programmer using the LAD programming, in each rang programmer have to represent
the required devices. So as per the most required devices in the PLC a standard notation is used to
represent the required devices. Mostly in PLC programming, there are six basic programming devices
are required and each device has its own unique use. To enable quick and easy identification each
device is assigned a single reference letter or say this single latter defines the particular existence of
the available device;
 X: This is used to identify all direct, physical inputs to the PLC.
 Y: This is used to identify all direct, physical outputs from the PLC.
 T: This is used to identify a timing device which is contained within the PLC.
 C: This is used to identify a counting device which is contained within the PLC.
 M and S: These are used as internal operation flags within the PLC.
All of the devices mentioned above are known as ‘bit devices’. This is a descriptive title telling the
user that these devices only have two states; ON or OFF, 1 or 0.

A Simple Example of PLC System: simple example of ladder logic diagram

 Figure 6.2: A simple example of ladder logic diagram

In the Figure 6.2, shown the control a motor by the toggle switch and input limit is monitor by the
limit switch. This motor control by the two switches is programmed by the Ladder diagram shown in
the center part of the Figure 6.2. Let us consider X0 (Toggle switch), X1 (Limit switch) and Y0
represent the output of the logic or Y0 connected with the motor.
In this logic X0 is NO (Normally Open) i.e. when toggle switch is on/pressed; the logic X0 becomes
NC (Normally Closed), its means power comes from hot rail follow the path of X0. The logic X1 is
NC i.e. when the limit is crossed then the limit switch is ON and the logic X1 becomes OFF and the
power flow path brake, result is no output.
Hence, to run the motor pressed the switch X0 under the limit X1. The output is gathered from Y0 i.e.
motor is attached with Y0.