ENG/OS/MC/CR/06/5/A
Operating programmable Logic Controllers
JULY 1, 2021
BETT K. BENARD
OKAME TECHNICAL AND VOCATIONAL COLLEGE
Lecture Notes 1
INSTALL PLCS SYSTEM
Introduction to PLCs
PLC acronym stands for programmable Logic Controllers
A PLCs is basically a microprocessor based device that is used for controlling any machine
(electrical, mechanical, electronic). It is also used in controlling assembly lines in industries. The
first PLC was developed by a group of Engineers at General Motors in 1968, When the company
were looking for an Alternative to replace complex relay Control systems.
PLC is a digitally operating electronic system, Designed for use in an industrial environment,
Which uses a programmable memory for the Internal storage of user-oriented instructions for
Implementing specific functions such as logic, Sequencing, timing, counting and arithmetic, to
Control, through digital or analog inputs and Outputs, various types of machines or processes.
PLCs Evolution
The first PLC began being developed in 1968. General Motors designed a specification for a ‘Standard
Machine Controller’ and distributed it to vendors for a quote. Some of the major elements of the
specification included: use solid state components which should be modular and expandable, contain 16
units that can be expanded to 256, have 16 outputs that can be expanded to 128, offer easy
programming and reprogramming, not lose stored programs during power outages, therefore, have at
least 1k of memory that can be expanded to 4k
Following this success, Bedford Associates changed its name to Modicon PLC. They began producing the
Modicon 084, the first PLC. What differentiated the Modicon 084 from other products in the market was
its programming technique. The others were utilizing ‘Boolean Statements’ to manipulate their
equipment.
The engineers were used to relay control systems which employed ladder diagrams. This is because
whenever relay circuits are drawn between a hot and neutral common, they resemble the rungs of a
ladder. Morley’s genius idea was to incorporate ‘ladder logic’ into his system.
Need for PLC
Since Relay control systems or hard- wired panel were time consuming to time, debug or change, there
was a need for a control system which is solid state and not mechanical, easy to manipulate its inputs or
output, easily programmed and maintained by industrial electrician and able to function in an industrial
environment.
Differences between plc and hard-wired control systems
Hard wired control system Plc system
The function are determined by physical The function are determined by the
wiring program stored in the memory
Changing the function means changing Control function can be changed by
the wiring simply changing the program
Can be contact making type(relay Consist of control device for which all the
contactor) or electronic type (logic) sensors and actuators are connected to
PLC Architecture
PLC hardware components
1. Power supply
Most PLC controllers work either at 24 VDC or 220 VAC. However, PLC utilizes about 5v DC
Some PLC controllers have electrical supply as a separate module, while small and medium
series already contain the supply module.
• Supplies DC power to other Modules that plug into the rack.
• In large PLC systems, this Power supply does not Normally supply power to the Field
devices.
• In small and micro PLC systems, the power supply Is also used to power field devices.
2. Central Processing unit (CPU)
• Is the “brain” of the PLC.
• Consists of a microprocessor for implementing the logic, and controlling the
communications among the modules.
• Designed so the desired circuit can be Entered in relay ladder logic form.
• The processor accepts input data from various sensing devices, executes the Stored
user program, and sends appropriate output commands to Control devices.
• CPU makes a great number of check-ups of the PLC controller itself so eventual
errors would be discovered early.
3. Input Module
• Forms the interface by which input field devices are connected to the controller.
• The terms “field” and “real world” are used to distinguish actual external devices that
exist and must be physically wired into the system
4. Output Module
• Forms the interface by which output field devices are connected to the controller.
• PLCs employ an optical isolator which uses light to electrically isolate the internal
components from the input and output terminals.
• Output devices may include motors, pumps, control relay, alarms, horns, buzzer,
printers, fans,
Input and output modules respectively
5. System Buses
The internal paths along which the digital signals flow within the PLC are called busses.
The system has four busses:
• The data bus is used by the CPU for sending data between the different elements,
• The address bus to send the addresses of locations for accessing stored data,
• The control bus for signals relating to internal control actions,
• The system bus is used for communications between the I/O ports and the I/O unit.
6. Programming Devices
• A personal computer (PC) is the most commonly used programming device
• The software allows users to create, edit, document, store and troubleshoot programs
• The personal computer communicates with the PLC processor via a serial or parallel data
communications link
• Hand-held programming devices are sometimes used to program small PLCs. They are compact,
inexpensive, and easy to use, but are not able to display as much logic on screen as a computer
monitor
PLC NETWORKING
As control systems become more complex, they require more effective communication schemes
between the system components. Some machine and process control systems require that
programmable controllers be interconnected, so that data can be passed among them
Easily to accomplish the control task.
Other systems require a plantwide communication system that centralizes functions, such as data
acquisition, system monitoring, maintenance diagnostics, and management production reporting, thus
providing maximum efficiency and productivity.
Local Area Network
The term local area network (LAN) is used to describe a communication network designed To link
computers and their peripherals within the same building or site. A LAN is a high-speed, medium
distance communication system.
For most LANs, the maximum distance between two nodes in the network is at least one mile, and
the transmission speed ranges from 1 to 20 megabaud. Also, most local networks support
at least 100 stations, or nodes.
PLC PROGRAMMING
The term PLC programming language refers to the method by which the user communicates
information to the PLC. The three most programming languages are:
i. Ladder logic diagram
ii. Structured text (Boolean language)
iii. Block diagram
Among these, ladder logic diagram is the most used as whenever a personnel wants to change the PLC,
he does not have to learn entirely new programming language but only the knowledge of the circuitry is
enough.
This method includes the direct entry of logic diagram into the PLC memory. This method requires the
use of keyboard and a display screen with graphics capability to display the symbols of the components
and their relationships in the ladder logic diagram. Programming is accomplished by inserting
appropriate components in the rung of the ladder diagram.
Ladder diagram
• The ladder diagram language is basically a symbolic set of Instructions used to create the
controller program. These ladder Instructions symbols are arranged to obtain the desired
control .
• Ladder logic diagram uses graphic symbols similar to relay schematic circuit diagram.
• It consists of two vertical lines representing the power rails
• Circuits are connected as horizontal lines between these two vertical lines. Such horizontal lines
are called rungs
• Each rung contains at least one input and one output
• A particular input or output can appear in more than one rungof ladder
• Output is connected at right side and input is connected at the left side
• A ladder rung consists of a set of input conditions, represented by contact instructions, and an
output instruction at the end of the rung, represented by the coil symbol.
• For an output to be activated or energized, at least one left-to-right path of contacts must be
closed. A complete path is referred to as having logic continuity. When logic exists the rung
condition is said to be TRUE.
Example :
Examine If Closed (XIC) Instructions
Analogous to the normally open relay contact. For this instruction, we ask the processor to examine if
the contact is closed.
Typically represents any input. Can be a switch or pushbutton, a contact from a connected output, or a
contact from an internal Output. Has a bit-level address which is examined for an ON condition. The
status bit will be either 1 (ON) or 0 (OFF).
The symbol is
Examine If Open (XIO) Instructions
Analogous to the normally closed relay contact. For this instruction, we ask the processor to examine if
the contact is open.
Typically represents any input. Can be a switch or pushbutton, a contact from a connected output, or a
contact from an internal output. Has a bit-level address which is examined for an OFF condition. The
status bit will be either 1 (ON) or 0 (OFF).
State of the output is determined by changing the states of the input.
Features of a ladder diagram
• Power flows from left to right.
• Output on right side can not be connected directly with left side.
• Contact can not be placed on the right of output.
• Each rung contains one output at least.
• Each output can be used only once in the program.
• A particular input a/o output can appear in more than one rung of a ladder.
• The inputs a/o outputs are all identified by their addresses, the notation used depending on the
PLC manufacturer.
Examples of plc logic programs
Example one:
1. A lighting control system is to be developed. The system will be controlled by four switch :
SWITCH 1, SWITCH 2, SWITCH 3 AND SWITCH 4. The switches will control the lighting in a room
based on the following criteria.
i. Any of the three switches 1, 2 and 3 if turned ON can turn the light on
ii. All the three switches 1, 2 and 3 must be OFF before the light turn OFF
iii. Fourth switch is a master control switch. If this switch is in ON position, the light will be OFF and
none of the other three switches can turn on the light.
Draw a ladder diagram for the lighting control system above
Example two:
2. Star-Delta starters is one of the method used in starting large ac motors in an industrial
environment. Draw a ladder logic diagram for a Star-Delta starters
APPLY TUG OUT ON PLC SYSTEM
Process tag abbreviations
Devices might use designations like those listed below:
• Flow Transmitter: FT
• Valve: HV, FV
• Limit Switch: LSL (Low), LSH (High)
• Loop Control: FIC, PIC
• Pushbutton/Switch: HS, HIS
• Photoelectric, Proximity Switch: ZS
• Motor Starter: M
• Pressure Transmitter: PT, PIT.
The main consideration when creating tag names is to remember the technician or maintenance person
is the customer. The more the programmer can do to help someone find and understand the code, the
better.
Five tag and address naming tips
Naming conventions for device or unit tag names matter to aid understanding and speed
troubleshooting. Here are five important things to consider when deciding on tag names templates or
rules:
1. Make names as descriptive as possible as to the function of the tag. Use standardized terms and
abbreviations technicians will understand. Add descriptions if necessary.
2. Tags will appear in alphabetical and numeric order, so beginning tags with the same function or
area letters/numbers is important for organization.
3. Use underscores or capitalization wherever necessary to make the tag more readable.
4. If the software platform allows for local tags, assign all tags for a particular assembly or program
before copying it to duplicate programs. This can save a lot of time.
5. Use a spreadsheet to create tags. This is easier than typing tags manually into a database. Tags
can be incremented and duplicated more easily. PLC platforms allow for easy export/import of
tags. This also ensures programmers use the same names as electrical and mechanical
designers.
