Objectives

:
At the end of the Session we will be able to:

●Describe the major components of a common

PLC.
●Interpret PLC specifications.
●Apply troubleshooting techniques.
●Convert conventional relay logic to a PLC
language.
●Operate and program a PLC for a given
application.
Contents :

●History of Programmable
Controllers
●Relay Ladder Logic
●Central Processing Unit
●Input/Output System
●Programming and Peripheral
Devices
●Programming Concepts
●Applications
●Troubleshooting and
Maintenance
Process Control &
Automation
Process
control
Recognizing Process the Actuate the
the status Information control elements

Rules &
guidelines
 Why
Automation ?
Higher productivity

Superior quality of end product

Efficient usage of energy and raw materials

Improved safety in working condition

etc
…
History of Process Control &
Automation

PLC Control

Electronics Control

Hard-Wire Control

Manual Control
 1. PLC -
Introduction
What does PLC stand for?

• PLC - Programmable Logic Controller

•PLC implements logic control functions by means

of a program
 Programmable Logic Controllers
( Definition according to NEMA standard ICS3-1978)

A digitally electron
apparatus
operating uses a ic
which memory the programming
internal storage
for
instructions of
for specifi
implementing
functions as logic, c
such
timing, countingsequencing,
and arithmetic to
control through digital or analog
modules, various types of machines
or process.
 1. PLC -
Introduction
How does a PLC differ from a computer?

• A computer is optimized for calculation and

display tasks

• A computer is programmed by specialists

• A PLC is designed for (logic) control and

regulation tasks

• A PLC is programmed by non-specialists

• A PLC is well adapted to industrial environment

PLC Origin

• Developed to replace relays in the late

1960s

• Costs dropped and became popular by

1980s

• Now used in many industrial designs

Historical Background

•The Hydramatic Division of the General Motors

Corporation specified the design criteria for the
first programmable controller in 1968

Their primary goal :

•To eliminate the high costs associated with

inflexible, relay-controlled systems.
Historical Background
•The controller had to be designed in modular
form, so that sub-assemblies could be removed
easily for replacement or repair.

•The control system needed the capability to pass

data collection to a central system.

• The system had to be reusable.

•The method used to program the controller had

to be simple, so that it could be easily
understood by plant personnel.
Programmable Controller Development
1968 □ Programmable concept
developed 1969 □ Hardware CPU
controller, with logic
instructions, 1 K of memory and
1974 □ 128 I/O points
Use of several (multi) processors
within a PLC - timers and counters;
arithmetic operations; 12 K of
1976 □ memory and 1024 I/O points
1977 □ Remote input/output systems
introduced Microprocessors -
Programmable Controller Development

1980 □ Intelligent I/O modules

developed Enhanced
communications facilities
Enhanced software features
(e.g. documentation) Use of personal
1983 □ microcomputers as programming aids
1985 □ Low - cost small PLC’s introduced
onward Networking of all levels of PLC,
s
computer and machine using SCADA
software.
INTRODUCTION TO PLCS
Advantages of PLCs :

• Less wiring.

• Wiring between devices and relay contacts are

done in the PLC program.

• Easier and faster to make changes.

• Trouble shooting aids make programming

easier and reduce downtime.

• Reliable components make these likely to

operate for years before failure.
INTRODUCTION TO PLCS
Advantages of PLCs :

• They are cost-effective

• They are flexible, reliable and compact

• They have significant

advantages over traditional control
systems based on relay or pneumatics
 1. PLC -
Introduction
What tasks do PLC perform ?

• The logic control tasks as

such
interlocking, sequencing, timing and
undertaken
counting
with relays (previously
or pneumatics)

• In addition, PLCs can perform a

variety of calculation, communication and
monitoring tasks
Leading Brands Of PLC

AMERICAN: 1. Allen Bradley

2. Gould Modicon
3. Texas
Instruments
4. General Electric
5. Westinghouse
6. Cutter
Hammer
7. Square D
EUROPEAN: 1. Siemens
2. Klockner & Mouller
3. Festo
4. Telemechanique
Leading Brands Of PLC

JAPANESE: 1. Toshiba
2. Omron
3. Fanuc
4. Mitsubis
hi
Areas of Application :

• Manufacturing /
Machining

• Food / Beverage

• Metals

• Power

• Mining

• Petrochemical /
Chemical
PLC Size :
Small: • It covers units with up to 128 I/O’s and
memories up to 2 Kbytes.

• These PLC’s are capable of providing

simple to advance levels or machine
controls.
Medium • Have up to 2048 I/O’s and memories
: up to 32 Kbytes.

Large: • The most sophisticated units of the PLC

family.
• They have up to 8192 I/O’s and memories up
to 750 Kbytes.
• Can control individual production
processes or entire plant.
Major Components of a Common PLC

POWER

SUPPL
Y

I M O M
N O U O
P D T D
U U PROCESSOR P U
T U L
From T E
L
To
SENSORS OUTPUT
Pushbutto E Solenoi
ns, contacts, ds,
limit contactors,
PROGRAMMING
switches, etc. DEVICE alarms.
Mot
ors
etc.
 Major Components of a Common PLC

Power Supply:

• Provides the voltage needed to run the primary PLC

components

I/O Modules:

• Provides signal conversion and isolation between

the internal logic- level signals inside the PLC and
the field’s high level signal.
 Major Components of a Common PLC

Processor :

• Provides intelligence to command and govern the

activities of the entire PLC systems.

Programming Device :

• Used to enter the desired program that will

determine the sequence of operation and control of
process equipment or driven machine.
I/O Module

• The I/O interface section of a PLC connects it to

external field devices.

• The main purpose of the I/O interface is to

condition the various signals received from or sent to
the external input and output devices.

• Input modules converts signals from discrete or

analog input devices to logic levels acceptable to
PLC’s processor.

• Output modules converts signal from the

processor to levels capable of driving the connected
discrete or analog output devices.
I/O Module
DC Input
Module IS NEEDED TO:
USE TO Prevent voltage
DROP transients from
THE damaging the
VOLTAGE processor.
Helps reduce the
TO LOGIC
effects of electrical
LEVEL noise

Current Buffer,
FROM Limiting OPTO- Filter, TO
INPUT ISOLA hysteresi PROCESSOR
DEVICE Resistor T OR s
Circuits
I/O Module
AC Input
Module
IS NEEDED TO:
CONVERTS THE Prevent voltage
AC INPUT TO DC transients from
AND DROPS damaging the
THE VOLTAGE processor.
Helps reduce the
TO LOGIC
effects of electrical
LEVEL
noise

Rectifier Buffer,
FROM Filter,
, OPTO- TO
INPUT Hysteresis
Resistor ISOLA PROCESSOR
Circuits
DEVICE T OR
Network
2
9
 I/O Module
DC/AC Output IS NEEDED TO:
Module Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise

Amplifier
FROM RELAY
TTL OPTO TO
PROCESSOR TRIAC
Circuits - OUTPUT
X’SISTO
ISOLA DEVICE
R
TOR
I/O Circuits
DIFFERENT TYPES OF I/O CIRCUITS

1. Pilot Duty Outputs :

• Outputs of this type typically are used to drive high-

current electromagnetic loads such as solenoids,
relays, valves, and motor starters.

• These loads are highly inductive and exhibit a large

inrush current.

• Pilot duty outputs should be capable of withstanding

an inrush current of 10 times the rated load for a
short period of time without failure.
I/O Circuits

2. General Purpose Outputs :

• These are usually low- voltage and low-current and are

used to drive indicating lights and other non-inductive
loads. Noise suppression may or may not be included
on this types of modules.

3. Discrete Inputs :

• Circuits of this type are used to sense the status of

limit switches, push buttons, and other discrete
sensors. Noise suppression is of great importance in
preventing false indication of inputs turning on or off
because of noise.
I/O Circuits
4. Analog I/O :

• Circuits of this type sense or drive analog signals.

• Analog inputs come from devices, such as

thermocouples, strain gages, or pressure sensors, that
provide a signal voltage or current that is derived
from the process variable.

• Standard Analog Input signals: 4-20 mA; 0-10V

• Analog outputs can be used to drive devices such as

voltmeters, X-Y recorders, servomotor drives, and
valves through the use of transducers.

• Standard Analog Output signals: 4-20 mA; 0-5V; 0-10V

I/O Circuits

5. Special Purpose I/O :

• Circuits of this type are used to interface PLCs to very

specific types of circuits such as servomotors,
stepping motors PID (proportional plus integral plus
derivative) loops, high-speed pulse counting, resolver
and decoder inputs, multiplexed displays, and
keyboards.

• This module allows for limited access to timer and

counter presets and other PLC variables without
requiring a program loader.
 OUTPUTS

INPUTS
MOTOR

CONTACTOR
LAMP

PUSH BUTTONS

PLC
INPUT DEVICES:

Push Button

Limit Switch

Thumbwheel SW

Level SW

Flow SW
OUTPUT DEVICES:
Motor

Solenoid

LED Display

Heater Coil

Lamp
 Allen-Bradley 1746-
1A16
L I= Input
L
1 2 Modul
I: slot # in
e
2 rack

0
P. B SWITCH Module
Terminal
# I:2.0/0
Address
LADDER PROGRAM

INPUT MODULE

WIRING
DIAGRAM
 CONTACTOR
L N
L 1 .
2 O
MOTOR
L
C •SOLENOI
2 D
FIELD L1 •VALVES
•LAMP
WIRIN
•BUZZER
G
OUTPUT
MODULE
WIRING
L
1 O:4
L2

CONTACTOR 0

LADDER PROGRAM
Discrete Input

A discrete input also referred as digital input is an input that is either

ON or OFF are connected to the PLC digital input. In the ON condition
it is referred to as logic 1 or a logic high and in the OFF condition
maybe referred to as logic o or logic low.

Normally Open

Pushbutton Normally

Closed Pushbutton

Normally Open

switch Normally

Closed switch

Normally Open
 IN

OFF PLC
Logic 0
Input
Module
24 V dc

IN

OFF PLC
Logic 1
Input
Module
24 V dc
Analog Input

An analog input is an input signal that has a continuous

signal. Typical inputs may vary from 0 to 20mA, 4 to 20mA
or 0 to10V. Below, a level transmitter monitors the level of
liquid in the tank. Depending on the level Tx, the signal to the
PLC can either increase or decrease as the level increases
or decreases.

Level Transmitter IN

PLC
Analog
Tan Input
k Module
Digital Output

A discrete output is either in an ON or OFF condition. Solenoids,

contactors coils, lamps are example of devices connected to the
Discrete or digital outputs. Below, the lamp can be turned ON or OFF by
the PLC output it is connected to.

OUT
PLC
Lamp
Digital
Output

Module
Analog Output

An analog output is an output signal that has a continuous

signal. Typical outputs may vary from 0 to 20mA, 4 to 20mA
or 0 to10V.

Electric to
pneumatic
transducer
E
P
Supply air
PLC 0 to 10V
OUT

Analog

Output
Pneumatic control valve
Module
Processor
The processor module contains the PLC’s microprocessor, its supporting
circuitry, and its memory system.

The main function of the microprocessor is to analyze data coming from

field sensors through input modules, make decisions based on the user’s
defined control program and return signal back through output modules to
the field devices. Field sensors: switches, flow, level, pressure, temp.
transmitters, etc. Field output devices: motors, valves, solenoids, lamps, or
audible devices.

The memory system in the processor module has two parts: a system
memory and an application memory.
Memory Map Organization
•System memory includes an area called the EXECUTIVE,
composed of permanently-stored programs that direct all
system activities, such as execution of the users control
program, communication with peripheral devices, and other
SYSTEM system activities.
•The system memory also contains the routines that
implement the PLC’s instruction set, which is composed of
specific control functions such as logic, sequencing,
timing, counting, and arithmetic.
•System memory is generally built from read-only memory
devices.

APPLICATION
•The application memory is divided into the data table area
•Data Table and user program area.
•The data table stores any data associated with the user’s
•User Program control program, such as system input and output status
data, and any stored constants, variables, or preset values.
The data table is where data is monitored, manipulated, and
changed for control purposes.
•The user program area is where the programmed
instructions entered by the user are stored as an
application control program.
Memory Designs
VOLATILE.
A volatile memory is one that loses its stored information when power is
removed.

Even momentary losses of power will erase any information stored or

programmed on a volatile memory chip.

Common Type of Volatile Memory

RAM. Random Access Memory(Read/Write)

Read/write indicates that the information stored in the memory can be
retrieved or read, while write indicates that the user can program or write
information into the memory.
Memory Designs
The words random access refer to the ability of any location (address) in
the memory to be accessed or used. Ram memory is used for both the
user memory (ladder diagrams) and storage memory in many PLC’s.

RAM memory must have battery backup to retain or protect the stored
program.
Memory Designs
Several Types of RAM Memory:

1. MOS
2. HMOS
3. CMOS

The CMOS-RAM (Complimentary Metal Oxide Semiconductor) is probably

one of the most popular. CMOS-RAM is popular because it has a very low
current drain when not being accessed (15microamps.), and the information
stored in memory can be retained by as little as 2Vdc.
Memory Designs
NON-VOLATILE
Has the ability to retain stored information when power is removed,
accidentally or intentionally. These memories do not require battery back-up.

Common Type of Non-Volatile Memory

ROM, Read Only Memory

Read only indicates that the information stored in memory can be read only
and cannot be changed. Information in ROM is placed there by the
manufacturer for the internal use and operation of the PLC.
Memory Designs
Other Types of Non-Volatile Memory

PROM, Programmable Read Only Memory

Allows initial and/or additional information to be written into the chip.

PROM may be written into only once after being received from the PLC
manufacturer; programming is accomplish by pulses of current.

The current melts the fusible links in the device, preventing it from being
reprogrammed. This type of memory is used to prevent unauthorized
program changes.
Memory Designs
EPROM, Erasable Programmable Read Only Memory

Ideally suited when program storage is to be semi-permanent or additional

security is needed to prevent unauthorized program changes.

The EPROM chip has a quartz window over a silicon material that contains
the electronic integrated circuits. This window normally is covered by an
opaque material, but when the opaque material is removed and the
circuitry exposed to ultra violet light, the memory content can be erased.

The EPROM chip is also referred to as UVPROM.

Memory Designs
EEPROM, Electrically Erasable Programmable Read Only
Memory

Also referred to as E2PROM, is a chip that can be programmed using a

standard programming device and can be erased by the proper signal being
applied to the erase pin.

EEPROM is used primarily as a non-volatile backup for the normal RAM

memory. If the program in RAM is lost or erased, a copy of the program
stored on an EEPROM chip can be down loaded into the RAM.
Programmable Logic
Controller
Power

supply

Input CPU Output

module Program memory
module

Field
Control
Input
Elements
Process / Machine
PLC Operating
Principle
In-put
scan

Self test
Star
t

Communication

Out-put scan
PLC Operation
Basic Function of a Typical PLC

Read all field input devices via the input interfaces, execute the user
program stored in application memory, then, based on whatever control
scheme has been programmed by the user, turn the field output devices on
or off, or perform whatever control is necessary for the process application.

This process of sequentially reading the inputs, executing the program in

memory, and updating the outputs is known as scanning.
While the PLC is running, the scanning process includes the following four
phases, which are repeated continuously as individual cycles of operation:

PHASE 1
Read Inputs
Scan
PHASE 2
Program
Execution
PHASE 3
Diagnostic
s/ Comm
PHASE 4
Outpu
t Scan
PHASE 1 – Input Status scan
 A PLC scan cycle begins with the CPU reading the status of its inputs.

PHASE 2– Logic Solve/Program Execution

 The application program is executed using the status of the inputs

PHASE 3– Logic Solve/Program Execution

 Once the program is executed, the CPU performs diagnostics and
communication tasks
PHASE 4 - Output Status Scan
•An output status scan is then performed, whereby the stored output
values are sent to actuators and other field output devices. The cycle
ends by updating the outputs.
As soon as Phase 4 are completed, the entire cycle begins again with
Phase 1 input scan.

The time it takes to implement a scan cycle is called SCAN TIME. The scan
time composed of the program scan time, which is the time required for
solving the control program, and the I/O update time, or time required to
read inputs and update outputs. The program scan time generally depends
on the amount of memory taken by the control program and type of
instructions used in the program. The time to make a single scan can vary
from 1 ms to 100 ms.
PLC Communications
Common Uses of PLC Communications Ports

Changing resident PLC programs - uploading/downloading from a

supervisory controller (Laptop or desktop computer).

 Forcing I/O points and memory elements from a remote terminal.

Linking a PLC into a control hierarchy containing several sizes of PLC

and computer.

Monitoring data and alarms, etc. via printers

 or Operator Interface Units
(OIUs).
PLC Communications
Serial Communications

PLC communications facilities normally provides serial transmission of

information.

Common Standards

RS 232

 Used in short-distance computer communications, with the majority of

computer hardware and peripherals.
 Has a maximum effective distance of approx. 30 m at 9600 baud.
PLC Communications
Local Area Network (LAN)

Local Area Network provides a physical link between all devices plus
providing overall data exchange management or protocol, ensuring that each
device can “talk” to other machines and understand data received from them.

LANs provide the common, high-speed data communications bus which

interconnects any or all devices within the local area.

LANs are commonly used in business applications to allow several users to

share costly software packages and peripheral equipment such as printers
and hard disk storage.
PLC Communications
RS 422 / RS 485

Used for longer-distance links, often between several PCs in a

distributed system. RS 485 can have a maximum distance of about 1000
meters.
PLC Communications
Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET

Square D SY/NET
Texas Instruments TIWAY
Specifications
Several factors are used for evaluating the quality and performance of
programmable controllers when selecting a unit for a particular application.
These are listed below.

NUMBER OF I /O PORTS

This specifies the number of I/O devices that can be connected to the
controller. There should be sufficient I/O ports to meet present requirements
with enough spares to provide for moderate future expansion.
 Working of
PLC II

CPU
•User Program memory IV

Input I/O Bus •Internal timers

I/O Bus Output
Module •Internal counters
Module
I PII PIQ III

Field Field
signals Controls
 PLC
Programming
PLC is software driven equipment like computer

Working of PLC (process) is decided by user through

program.

Depending on process requirement program (set of

instruction) is prepared.

CPU sequentially read these instruction and

operates control elements based on input signals
and program instruction.

Programming can be done On-line or Off-line.

Normally programming / change in program is done in

memory of programming unit and then simply this change
is loaded in CPU memory of PLC
Addressing Inputs &
Outputs
Slot
01 2 numbers
3 4 30 31
0 ----------------
1
2
CPU 3
CPU
5
6
7

Channel
Nos.
PROGRAMMING

Normally Open Normally Closed

(NO) (NC)

Power flows through these contacts when they are closed. The
normally open (NO) is true when the input or output status bit
controlling the contact is 1. The normally closed (NC) is true
when the input or output status bit controlling the contact is 0.
Coil
s

Coils represent relays that are energized when power flows to

them. When a coil is energized it causes a corresponding
output to turn on by changing the state of the status bit controlling
the output to 1. That same output status bit maybe used to control
normally open or normally closed contact anywhere in the program.
Boxes

Boxes represent various instructions or functions that are

Executed when power flows to the box. Some of these
Functions are timers, counters and math operations.
 AND OPERATION

A B C

Rung

Each rung or network on a ladder program represents

a logic operation. In the rung above, both inputs A and B
must be true (1) in order for the output C to be true (1).
 OR OPERATION

A C

Rung

In the rung above, it can be seen that either input A or B

is be true (1), or both are true, then the output C is true (1).
 NOT OPERATION

A C

Rung

In the rung above, it can be seen that if input A is be true (1),

then the output C is true (0) or when A is (0), output C is 1.
 Writing
•
–
Program
Ladder Diagram (LAD)
Use relay logic symbols to
formulate the control task

• Control System Flowchart (CSF)

– Use digital graphical symbols to
formulate the control task
&

• Statement List (STL)

– Use mnemonic
abbreviation in
programming.
 1. PLC -
Introduction
Data Flow in the PLC
1. PLC -
Introduction
n One of the advantages of PLC is that it can be
programmed by non-specialists

n Program can be written either in the form of a

statement list: a set of mnemonic instructions

representing a function of the CPU
or a
ladder diagram: a graphical language resembling the
electrical relay diagrams
1. PLC -
Introduction
statement
list
1. PLC -
Introduction
Ladder
diagram
 Writing
•
Program
Circuit Diagram • Ladder Diagram
(LAD)
I I I I Q
1.0 1.2 1.0 1.1 4.1

I I
1.1 1.3
I I
1.2 1.3

Q
4.1
 Writing
Program
• Circuit • Control System Flowchart
Diagram (CSF)
I
I I 1.0
1.0 1.2 &
I
I 1.1
I
1.1 1.3

>=1
I
Q
1.2
Q I & 4.1
=
4.1 1.3
 Writing
•
Program
Circuit Diagram • Statement List
(STL)
I
1.0
I A I
1.2
1.0
I I
1.1 1.3 A I
1.1
O
Q AI
4.1
1.2
AI
1.3
 (Kontaktplansprache, langage à contacts)

Ladder logic (1)

The ladder logic is the oldest programming language
for PLC it bases directly on the relay intuition of the
electricians.
it is widely in use outside Europe.
It is described here but not recommended for new
projects.
 Ladder Logic (2)
make
origin: (contact
contact
electric 0 relay
travail)02
al 1 coil
circuit (bobine
50 )
break
03 contact repos)
(contact

0 0
1 2 5
correspondin run
0 0 g
g ladder
3
diagram
5 0 "coil" 50 is used to
0 5 4 move other
4 contact(s)
Ladder logic (3)
The contact plan or "ladder logic" language allows an easy transition
from the traditional relay logic diagrams to the programming of
binary functions.

It is well suited to express combinational logic

It is not suited for process control programming (there are

no analog elements).

The main ladder logic symbols represent the elements:

make contact contact travail

Arbeitskontakt
break contact repos
Ruhekontakt
contact bobin Spule
e
relay coil
Ladder logic (4)
Binary combinations are expressed by series and parallel relay contact:

ladder logic representation “logic" equivalent

Series
+ 01 02 01

50 50
02

Coil 50 is active (current flows) when 01 is active and 02 is not.

Parallel + 01
40 01

02 40
02

Coil 40 is active (current flows) when 01 is active or 02 is not.

Ladder logic (5)
The ladder logic is more intuitive for complex binary expressions than literal languages

textual expression
1 2 3 4
50 !N 1 & 2 STR 3 & N 4 STR N 5
5 6 & 6 / STR & STR = 50

0 1 4 5 12
50 !0 & 1 STR 2 & 3 / STR STR 4
2 3 6 7 & 5 STR N 6 & 7

/ STR & STR STR 10

10 11 & 11 / STR & 12 =
50
Ladder logic (6)
Ladder logic stems from the time of the relay technology.
As PLCs replaced relays, their new possibilities could not be expressed any
more in relay terms.
The contact plan language was extended to express functions:

00 01
literal expression:
FUN 02 200
!00 & 01 FUN 02 = 200

The intuition of contacts and coil gets lost.

The introduction of «functions» that influence the control flow itself, is problematic.
The contact plan is - mathematically - a functional representation.
The introduction of a more or less hidden control of the flow destroys the
freedom of side effects and makes programs difficult to read.
Ladder logic (7)
Ladder logic provides neither:
• sub-programs (blocks), nor
• data encapsulation nor
• structured data types.

It is not suited to make reusable modules.

IEC 61131 does not prescribe the minimum requirements for a compiler /
interpreter such as number of rungs per page nor does it specifies the minimum
subset to be implemented.

Therefore, it should not be used for large programs made by different persons

It is very limited when considering analog values (it has only counters)

→ used in manufacturing, not process control

 Criteria for selecting a
• PLC
How many control inputs to be processed – Nos. of
Input
• How many outputdevices or controlling
elements are controlled – Nos. of Output.
• What memory capacity is needed to store the
`user program’ ?
• What speed of processing and
operational capabilities desire?
• What are the communication requirements ?
• Are thereany specialor specificrequirements
including that of safety, reliability, expandability
etc.
• System voltage available for auxiliary supply of
PLC.

On getting this information check

for the specification of the available
Selecting a
PLC
Criteria

• Number of logical inputs and outputs.

• Memory
• Number of special I/O modules
• Scan Time
• Communications
• Software
A Detailed Design Process

1. Understand the process

2. Hardware/software selection
3. Develop ladder logic
4. Determine scan times and memory requirements
Specifications
Several factors are used for evaluating the quality and performance of
programmable controllers when selecting a unit for a particular application.
These are listed below.

NUMBER OF I /O PORTS

This specifies the number of I/O devices that can be connected to the
controller. There should be sufficient I/O ports to meet present requirements
with enough spares to provide for moderate future expansion.
Specifications
OUTPUT-PORT POWER RATINGS

Each output port should be capable of supplying sufficient voltage and

current to drive the output peripheral connected to it.

SCAN TIME

This is the speed at which the controller executes the relay-ladder logic
program. This variable is usually specified as the scan time per 1000 logic
nodes and typically ranges from 1 to 200 milliseconds.
Specifications
MEMORY CAPACITY

The amount of memory required for a particular application is related to the

length of the program and the complexity of the control system. Simple
applications having just a few relays do not require significant amount of
memory. Program length tend to expand after the system have been used
for a while. It is advantageous to a acquire a controller that has more
memory than is presently needed.
PLC Status Indicators
•Power On
•Run Mode
•Programming Mode
•Fault
Troubleshooting

1. Look at the process

2. PLC status lights
HALT - something has stopped the CPU
RUN - the PLC thinks it is OK (and probably is)
ERROR - a physical problem has occurred with the PLC
3. Indicator lights on I/O cards and sensors
4. Consult the manuals, or use software if available.
5. Use programming terminal / laptop.
List of items required when working with PLCs:

1. Programming Terminal - laptop or desktop PC.

2. PLC Software. PLC manufacturers have
their own specific software and license key.
3. Communication cable for connection from Laptop
to PLC.
4. Backup copy of the ladder program (on diskette, CDROM,
hard disk, flash memory). If none, upload it from the PLC.
5. Documentation- (PLC manual, Software manual,
drawings, ladder program printout, and Seq. of
Operations manual.)
Examples of PLC Programming Software:

1. Allen-Bradley – Rockwell Software RSLogix500

2. Modicon - Modsoft
3. Omron - Syswin
4. GE-Fanuc Series 6 – LogicMaster6
5. Square D- PowerLogic
6. Texas Instruments – Simatic
6. Telemecanique – Modicon TSX Micro
 Summar
y– A dedicated computer for rapid processing of
• Overview

simple logic instructions in a defined time

– Used in automated processes (rollercoaster)
– Used a lot in automated industry
– Logic control and sequencing approaches
– Cost: $60-$400
– Machine vision commonly used as supporting
technology
– Dr. Red = Good reference
• Use in Industry
– Applications include simple and, or, not
diagrams/programs
– Few limitations for its function
– Main known vendors: Honeywell, Rockwell, Sharp,
Unitronics
– Standards: IEC 61131. Trying to standardize PLC
programs
• Application examples
– Modeling Programs and Diagnosable functions for
PLCs
– Useful in planning and determining structure and