UNIT – IV PROGRAMMING LOGIC CONTROLLERS

1. Sketch and explain the architecture of plc. (APRIL/MAY2019) (NOV / DEC 17 & 16)
Explain the architecture of a PLC and explain about its elements. (NOV / DEC 17 & 16)

Central Processing Unit: Control Unit:

 The CPU controls and processes all the  A control unit is used to control the timing of
operations within the PLC. operations.
 It is supplied with a clock with a frequency of  The processor functions under a permanent
typically between 1 to 8 MHz. supervisory operating system that directs the
 This frequency determines the operating overall operations from data input and
speed of the PLC and provides the timing output to execution of user programs.
and synchronization for all elements in the  The controller can perform only one
system. operation at a time. So, it scans each of the
 The information within the PLC is carried by inputs sequentially, evaluates the ladder
means of digital signals. diagram program, provide each output(s),
 The processor is a microprocessor that and then repeat the whole process.
executes a program to perform the  Hence, the timing control's necessary for a
operations specified in a ladder diagram or a PLC system.
set of Boolean equations. Memory Unit:
 The CPU consists of the following units  The sequence of instructions to be executed,
Arithmetic and Logic Unit (ALU): programs are stored in the memory unit.
 This unit performs data manipulation and  During entering and editing including
arithmetic and logical operations on input I Debugging, the program is stored in the
variable data and determines the proper state of temporary storages called RAM (Random
the output variables. Access memory).
 The arithmetic operation includes addition,  Once the program is completely finished (free
subtraction etc., and logic operations include & from errors).
AND, OR, AND, EXCLUSIVE - OR.  It may be 'burned' into ROM
Memory Unit:  When the ROM is plugged into the PLC, the
 Memory termed registers located within device is ready to be placed into service in
the microprocessor and used to store the industrial environment.
information involved in a program  For network programmed PLCs, the final
execution. PLCs program is downloaded into a special
 These programs contain control actions to re- programmable ROM (EPROM, PROM,
be executed by the microprocessor for the and EEPROM) in the PLC.
given input. There are several memory  Memory may be either volatile type or Non-
elements in a PLC system. volatile type.

 2. How data handling can be used for data handling operation. (APRIL/MAY2019)
Write short notes on plc for the following: (NOV/ DEC 2016)
(i) Data movement.
(ii) Data comparison.
Data Movement:
Instruction : MOV
Function : To copy a value from one address to another
 When there is an input to X400,
 The data moves from the designated source address to the
designated destination address.
 The data transfer might move a constant into a data register
Data Comparison:
 The data comparison instruction gets the PLC to compare two data values.
 It compare a pre – set value (1) to the input value (2)
 For data comparison the typical instruction will contain the data transfer instruction to

compare the data from source address and designation address

 It is required to sound an alarm if a sensor indicates a temperature above 90˚C and remain
sounding until the temperature falls below 75˚C.
 For this, the ladder diagram is shown above.
 The input temperature data is inputted to the source address and the destination address contains the
set value.
 When the temperature rises 90˚C or higher, the data value in the source address becomes
>the destination address value and there is an output to the alarm which latches the input
 When the temperature falls to 75˚C or lower, the data value in the source address becomes <
the destination address value and there is an output to the relay which then opens the contacts and so
switches the alarm off

Explain how the timer and counter operations are carried out in PLC. (APRIL/MAY2019)
3.
TIMER:
 A timer is a special counter ladder function that allows the PLC to perform timing
operations based on a precise internal clock.
Types of Timers:
 Delay ON Timers
or ON delay timers
 Delay OFF Timers
or OFF delaytimers
 Pulse Timers
 Cascaded Timers
 ON-OFF Cycle
Timers
 One Shot Timers
Delay ON Timers:
 The term delay is used to indicate that this timer burns on, after waiting for a fixed time
delay period.
 When there is an input, the timer is energised and starts timing, after some pre-set value, the
 timer contacts are closed to output.
 TON is used to denote ON-delay.
Delay OFF Timers:
 OFF delay timers are maintained as ON for a fixed time of delay period before turning
off.
 TOF is used to denote OFF-delay.

4. ELABRATE THE CONSTRUCTION I/O DETAILS OF PLC. (NOV/DEC 2018)

INPUT / OUTPUT PROCESSING:
Sourcing:
 If a switch is connected to the positive of the battery and current flows from positive to negative,
it is said to be the sourcing the current. So, the input device receives current from the input module.
 For the PLC, input unit, hence input module is the source of the current. For the PLC output unit,
output module is the source of current as it supplies current to the output devices. Sourcing output
units for interfacing with solenoids.

 Here, the input device supplies current to the input module. For the PLC input unit, hence
the input module is the sink for the current. Sinking input units are used for interfacing with
electronic equipment.
 So, if a switch is connected to the negative of the battery and current flows from positive to
negative, by conventional current flow direction, it is said to be the sinking for Current. For
the PLC output unit, the current flows from output device to the output module then the output module
is the sink for current.

5. Explain the components of a PLC with a suitable block diagram. (APR / MAY 2018)
A programmable logic controller (PLC)
Program is a specially designed digital operating
Microprocessor-based controller that uses a
programmable memory for internal storage of
instructing and for internal storage of instructing
and for implementing function such as logic,
sequencing, timing, counting and arithmetic in order
to control machines and processes.
BASIC COMPONENTS OF PLC: The PLC
hardware system consists of the basic components
are
 Processor
 Memory
 Power Supply
 Input I Output modules
 Programming device
 Monitor
 6. Draw The Ladder Diagram Of Or,Nor ,Nand, Xor Logic (NOV/DEC 2018) (APRIL / MAY 2018)
a) AND b) OR

c)NAND e)XOR

7. Discuss PLC timer system with diagrams. (NOV/ DEC 17) (APR / MAY 2017)
TIMER:
 A timer is a special counter ladder function that allows the PLC to perform timing operations
based on a precise internal clock.
Types of Timers:
 Delay ON Timers or ON delay
timers
 Delay OFF Timers or OFF delay
timers
 Pulse Timers
 Cascaded Timers
 ON-OFF Cycle Timers
 One Shot Timers
Delay ON Timers:
 The term delay is used to indicate that this timer burns on, after waiting for a fixed time delay period.
 When there is an input, the timer is energised and starts timing, after some pre-set value, the timer
contacts are closed to output.
 TON is used to denote ON-delay.
Delay OFF Timers:
 OFF delay timers are maintained as ON for a fixed time of delay period before turning off.
 TOF is used to denote OFF-delay.

8. How is an internal relay used to start multiple outputs? Discuss this with a ladder diagram. (NOV/
DEC 17)
INTERNAL RELAY:
 An internal relay behaves like relays with their associated
contacts, buy they are not actual relays whose simulations are
controlled by the PLC software.
 Internal relays can be very useful in the implementation of switching
sequences.
 They are often used when there are programs with multiple input
conditions.
 They are also known as Auxiliary relays or markers.
 In using an internal relays, it has to be activated on one rung of a
 program and then its output used to operate switching contacts on another rung of a program.

9. What are the factors considered in the selection of a PLC system? Give examples.(NOV/ DEC 17)
SELECTION OF PLCS

The selection process of PLC for a particular task depends on the following factors.
 Capacity of Input and Output
 No. of Inputs and Outputs
 Types of Inputs and Outputs
 Size of memory required I,
 Speed and Power required of the CPU

10. Write a short note on Jump Control used in PLC. (APR / MAY 2017)
 The jump control is an output instruction enabling part of s ladder program to be jumped over.
 With the jump instruction, the processor scan time can be reduced by jumping over instruction not
pertinent to the machine operation.
 Jump to subroutine (JSR), Instruction format
 Jump To Label (JMP), instruction format:

A Jump to Subroutine instruction, which is a controlled instruction, must have a corresponding

subroutine program file. When the rung of a Jump to Subroutine instruction is false, the PLC does not jump
to the subroutine; the next rung scanned will be the one following the Jump to Subroutine instruction.
However, when the rung of a Jump to Subroutine instruction is true, the PLC jumps to the Subroutine
instruction at the beginning of the target subroutine file and resumes execution at that point. Movement is
always to the first instruction of the subroutine file. A Jump to Subroutine instruction can be used in both a
main application program and subroutine programs to “call” (execute) another subroutine program.

11. Discuss how AND, OR, NOR, and NAND systems can be formed with ladder diagram. (APR /
MAY 2017)
AND GATE OR GATE

1. Define PLC. What are the basic components of PLC?

DEFINITION OF PLC:
A programmable logic controller (PLC)
Program is a specially designed digital operating
Microprocessor-based controller that uses a
programmable memory for internal storage of
instructing and for internal storage of instructing
and for implementing function such as logic,
sequencing, timing, counting and arithmetic in order
to control machines and processes. BASIC
COMPONENTS OF PLC: The PLC hardware
system consists of the basic components are
 Processor
 Memory
 Power Supply
 Input I Output modules
 Programming device
 Monitor

12. Define bus used in PLC System.

 A set of parallel lines that provides communication between various devices of a system is termed as a
Bus.
 The bus system carries information and data’s to and from the CPU, Memory and I/O units.
 The information is transmitted in binary form as 0 or 1
 Digital signals or electrical signals are flowing inside the bus.
 It might be tracks on a printed circuit board (PCB) or wires in a ribbon cable.
 The PLC system contains four buses.
 They are namely Data Bus, Address Bus, Control bus and system bus.

13. Describe the different types of buses in PLC System.

Data Bus:
 The data bus contains 8, 16 or 32 parallel signal lines for sending data between the various
devices of a system.
 An 8-bit microprocessor has an internal data bus which can handle 8-bit numbers.
 The double ended arrows on the bus line show that they are bidirectional.
 This means that CPU can read data in from memory or from I/O unit on these lines or it can send
data out to memory or to I/O unit on these lines.
 Many devices in a system will have their outputs connected to the data bus, but only one device will
have its output enabled at a time.
Address Bus:
 The Address bus contains 16, 20, 24 or 32 parallel signal lines to carry the Address of the memory
locations for accessing stored data.
 Every memory location is given a distinct unique address to locate easily and accessed by the CPU
either to read or write data.
Control Bus:
 The Control bus contains 4 to 10 parallel signal lines to carry the signals used by the CPU that
are related to internal Control actions. Typical control bus signals are Memory read Memory write, I/O
Read and I/O write.
I/O System Bus:
 The I/O system bus provide the communication between the I/O ports and I/O units

14. What are the Different types of ROM used in PLC?

  Mask programmed ROM
 PROM
 EPROM
 EEPROM
Mask Programmed ROM:
 It is a special type of ROM which is programmed during manufacturing.
 The programmed content stored by this type of ROM memory cannot be altered.
PROM:
 PROM stands for programmable Read only memory.
 It is a special type of ROM usually programed by manufacturer during manufacturing.
 It has the disadvantage of requiring special programming device and once programmed cannot be
erased or altered.
EPROM:
 EPROM stands for electrically programmable Read only Memory.
 Here, the user programs electrically.
 One can erase the program completely by shining UV light source or quartz window in package.
15. Explain in detail Input / Output processing of PLC with help of diagram.
INPUT / OUTPUT PROCESSING:
Sourcing:
 If a switch is connected to the positive of the battery and current flows from positive to negative, it is
said to be the sourcing the current. So, the input device receives current from the input module.
 For the PLC, input unit, hence input module is the source of the current. For the PLC output unit,
output module is the source of current as it supplies current to the output devices. Sourcing output
units for interfacing with solenoids.

 Here, the input device supplies current to the input module. For the PLC input unit, hence the
input module is the sink for the current. Sinking input units are used for interfacing with
electronic equipment.
 So, if a switch is connected to the negative of the battery and current flows from positive to negative,
by conventional current flow direction, it is said to be the sinking for Current. For the PLC
output unit, the current flows from output device to the output module then the output module is the
sink for current.

16. State that the steps followed in Input / Output processing of PLC.
The sequence followed by a PLC when carrying out a program can be as follows:
 Scan the inputs associated with one rung of the ladder program
 Solve the logic operation involving those inputs.
 Set / Reset the outputs for that rung
 Move on the next rung and repeat the operations 1, 2, 3

The two methods of Input/ Output processing operations are

  Continuous updating  Mass Input / Output copying
Continuous Updating:
The sequence followed thus in continuous updating is as follows:
 Fetch and decode the first program instruction
 Scan there relevant inputs
 Fetch and decode the second program instruction
 Scan the relevant inputs etc. For the remaining program instructions
 Update outputs
 Report the entire sequence.
Mass Input / Output Copying:
The sequence followed in Mass I/O copying is thus:
 Scan all the inputs and copy into RAM
 Fetch and decode and execute all the program instructions in sequence
 Copy all the output instructions to RAM
 Update all outputs.
 Repeat the sequence
17. List down the various mnemonics used in PLC.

18. Explain in detail AND logic function of PLC with its LADDER Diagram.
AND Logic Function:
 AND logic circuit represents series circuit
 AND gate is composed with two inputs and one output.
 AND gate produce output when both the inputs are HIGH state.

Explain OR logic function with help of

PLC Ladder diagram.
OR Logic Function:
 OR logic circuit represents the parallel circuit.
 OR Gate is composed of two or more inputs and one output.
 OR operation is like addition of binary numbers.
 OR gate produce output when any one input are HIGH state.
 19. Explain how can make PLC ladder logic diagram for NOT logic function.
NOT Logic Function:

 NOT function is also known as Inverter.

 NOT gate is composed of single input and a single output.
 The bubble, or circle, at the output is the standard symbol used to represent inversion.
 In NOT gate, there is an output, when there is no input and no output when there is an input

20. Explain NAND Logic function with necessary PLC ladder diagram.
NAND Logic Function:
 NAND is a combination of AND and NOT gates.
 Arrangement shows AND gate is followed by NOT gate. Hence it is called NOT AND gate.
 Both the inputs A and B have to be at LOW state to get the output at HIGH state.
 NAND Gate is composed of two or more input with a single output.
 Any one input is in LOW state also output will be HIGH state

UNEXPECTED QUESTIONS
1. What is latching? explain with necessary PLC ladder diagram.
Latching:
 It is necessary to hold an output coil energized, even when the input ceases
 The term latch is used for the circuit used to carry out such an operation.
 Latch circuit is a self – maintaining circuit that maintains its output in an energized state until the next
input is updated

2. Define Timer. Explain in detail of Delay ON & OFF Timer with neat sketch.

TIMER:
 A timer is a special counter ladder function that allows the PLC to perform timing operations
based on a precise internal clock.
Types of Timers:
 Delay ON Timers or ON delay timers
 Delay OFF Timers or OFF delay timers
 Pulse Timers
  Cascaded Timers
 ON-OFF Cycle Timers
 One Shot Timers
Delay ON Timers:
 The term delay is used to indicate that this timer burns on, after waiting for a fixed time delay period.
 When there is an input, the timer is energised and starts timing, after some pre-set value, the timer
contacts are closed to output.
 TON is used to denote ON-delay.

Delay OFF Timers:

 OFF delay timers are maintained as ON for a fixed time of delay period before turning off.
 TOF is used to denote OFF-delay.

3. Explain the following 1.Pulse Timers, 2.Cascade Timers, 3.ON-OFF Cycle

timer, & 4.One shot Timers.
1.Pulse Timers:
 Pulse timer switches is another type of Timer
which comes either ON or OFF for a fixed
period of time as a function of pulses.
 TP is used to denote Pulse Timers
2. Cascaded Timers:
 Cascading means more elements are linked together to form a
system.
 The cascading timers are linked together to give longer
delay times which is easily achieved than just one timer.
3. ON – OFF Cycle Timer:
 Timers producing an output for some
period and no output for some period
and an output for some period.
 Tzhe timer is designed to switch an
output for T sec and off for another T
second
4. One Shot Timers:
 One shot timers produces an output for a
fixed length of some initiation input.
 4. Explain Internal Relay with help of neat sketch.
INTERNAL RELAY:
 An internal relay behaves like relays with their associated contacts, buy they are not actual
relays whose simulations are controlled by the PLC software.
 Internal relays can be very useful in the implementation of switching
sequences.
 They are often used when there are programs with multiple input
conditions.
 They are also known as Auxiliary relays or markers.
 In using an internal relays, it has to be activated on one rung of a
program and then its output used to operate switching contacts on
another rung of a program.
02. Briefly explain about Counters. And its types.
COUNTERS:
 Counters are used to count a specified number of contact
operations.
Types of Counters:
 Up Counters
 Down Counters
Up Counters:
 Up counters count up from the zero to pre – set value
 The events are added until the pre – set value is reached
 When the counter reaches the set value, its contacts change
state
Down Counters:
 Down counters count down from the pre – set value to zero
 The events are subtracted until the pre – set value is reached
 When the counter reaches the Zero value, its contacts change state

5. Explain the following 1.Shift Register, 2.Data handling.

SHIFT REGISTER:
 A shift register is an electronic storage device that allows the stored bits of one relay to get shifted into
another relay.
DATA HANDLING:
The steps involved in data handling with a PLC system are
 Moving data from one memory location to another
 Comparison of Magnitudes of data
 Arithmetic operations
 Data conversion
Data Movement:
Instruction : MOV
Function : To copy a value from one address
to another
 When there is an input to X400,
 The data moves from the designated source address
to the designated destination address.
 The data transfer might move a constant into a data
register

6. Explain in detail following 1.Data comparison, 2. Data Arithmatic operation.

Data Comparison:
 The data comparison instruction gets
the PLC to compare two data values.
 It compare a pre – set value (1) to
the input value (2)
 For data comparison the typical
instruction will contain the data transfer
instruction to compare the data from source
address and designation address

 It is required to sound an alarm if a sensor indicates a temperature above 90˚C and remain
sounding until the temperature falls below 75˚C.
 For this, the ladder diagram is shown above.
 The input temperature data is inputted to the source address and the destination address contains the
set value.
 When the temperature rises 90˚C or higher, the data value in the source address becomes > the destination
address value and there is an output to the alarm which latches the input
 When the temperature falls to 75˚C or lower, the data value in the source address becomes <
the destination address value and there is an output to the relay which then opens the contacts and so
switches the alarm off.
Data Arithmetic Operations:
 PLCs are offered with the ability to carry out the arithmetic operations such as addition, subtraction,
multiplication and division only.
 They cannot carry out exponential functions.
 Addition and subtraction operations are used to alter the value of data held in data registers.
 Multiplications are used to multiply some input before adding to or subtracting it from another.
Code Conversions:
 All the internal operations in the CPU of a PLC are
carried out through binary numbers.
 Most PLCs provide BCD-to-binary and binary-to-
BCD conversion for use.
 When a decimal (input) signal is given, BCD conversion is used.
 Similarly, when a decimal output is required, Decimal conversion is used.
 The data at the source address is in BCD and converted to binary and placed at the destination
address.

7. 05. Explain selection of PLC.

SELECTION OF PLCS

The selection process of PLC for a particular task depends on the following factors.
 Capacity of Input and Output
 No. of Inputs and Outputs
 Types of Inputs and Outputs
 Size of memory required I,
 Speed and Power required of the CPU