Introduction

PLC plays very important role in automation. In fact, PLC is the tool that
provides the control for an automatic process. In many automatic processes,
PLC works as a central control system. PLC based systems use software
programming instead of hard wires to control the input and output devices.

Use of PLC offers the following advantages compared to electromechanical

relay based system:

 Ease of programming and reprogramming.

 Easy troubleshooting and diagnostics.
 In built software timers, counters, relays etc.
 Quickly change over from one product to another.
 Provides quick status of inputs, outputs, timers, counters etc.

PLC Building blocks

Generalised PLC Architecture is shown in Figure 2.1 .

Figure2.1 Generalised PLC Architecture

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 The basic building blocks of PLC are -

 Input Module
 Output Module
 Central Processing Unit (CPU)
 Power supply
 Programming Device (PC or Laptop)

The Function of each part is described in following sections:

INPUT and OUTPUT Modules:

Figure 2.2 shows the front panel appearance of typical input and
output module in a Modular PLC system.

Figure2.2 Front panel appearance of typical Input and Output module

Typical input or output modules have 8, 16, 24 or 32 input points. I/O modules are
available as INPUT only, OUTPUT only or COMBINATION of input and output.
In a modular PLC, input or output module are made up of the following features:
At the very top of the module is the identification indication whether this is Input, Output
or Combination Module.

Below the identification portion are the status indicator LEDs. There will be one status
indicator LED for each input or output point on the module. These LED alerts the
operator about the ON or OFF status of each input or output point of the Module.

Below the status LED’s there are actual input points or screw terminals for connection
of real input or output devices. Each screw terminal has a unique identification number
called an address.
 Input Module Input Module works as an interface between the CPU and Real world
input devices connected to input module. The devices connected to input module are
called as Input devices. The input module accepts the incoming signal (status of input
devices) and converts this signal in the form (usually 0 to 5v) which is compatible with
the CPU. The power required for operation of input module is supplied by internal
power supply.

Input module servers as the link between field input devices and the PLC?s CPU. The
main function of an input module is to take the input signal from field devices, convert it
to a signal level that the CPU can work with, electrically isolate it and send the signal to
the CPU.

Classification of Input Module: Figure 2.3 shows the general classification of Input
module.

Figure2.3 Classification of Input module

Digital input module deals with digital input signal coming from various digital input
devices. Digital input module is available in different types such as Sinking, Sourcing,
AC, DC or combination input module.

Typical digital signal comes from various digital input devices. Examples of such
devices are:
 Push button switches
 Limit switches
 Temperature Limit switches
 Pressure Limit switches
 Flow Limit switches
 Proximity sensors
 Inductive Proximity sensors
 Capacitive Proximity sensors
 Ultrasonic Proximity sensors
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Analog Input Module deals with analog input signal coming from various analog input
devices. Analog input module converts analog signal into digital words. Analog input
modules are selected to accept either a current or a voltage input signal.

Typical analog signals come from temperature, pressure, position, level, flow in-puts.
Following are the examples of analog input devices:

LVDT, Thermocouple, RTD, Potentiometer, Thermistor, Flow meters etc.

Output Modules:

Output module works as an interface or link between the CPU and the real world
devices attached to the output module. The devices connected to the output module
are called a Output devices.

The main function of output module is to take control signal from CPU (which is
generated by CPU after solving the Program Logic) and based on signal received from
CPU it changes the ON or OFF status of output devices. The power required for
operation of output module is supplied by Power supply.

Output modules serves as the link between the PLC?s CPU and Field output devices.
The main function of output module is to take the CPU?s control signal, electrically
isolate it and then based on control signal received, changing the ON or OFF status of
field output devices.

Classification of Output Modules

Figure 2.4 shows the general classification of Output modules.

Figure2.4 Classification of Output module

Digital output module deals with digital output devices. The main function of digital
output module is to accept control signal from PLC’s CPU and based on signal
received from CPU, it changes the ON or OFF status of digital output devices.

Digital output module is available in different types such as AC, DC, Sinking, Sourcing,
Relay output module.
 Following are the examples of digital output devices:

Solenoid valve, Motors, Lamps, Bells or Alarms, Heating devices etc.

Analog output module deals with the analog output devices. The main function of
analog output module is to accept control signal from PLC?s CPU in the form of 16 bit
word and then convert it to an analog value through a digital to analog convertor
(DAC). This analog signal is then given to analog output devices. This can be in the
form of voltages or current.

Following are the examples of analog output devices:

Pneumatic control valve, Hydraulic control valve, Light dimmer, Speed control of motor
etc.

Central Processing Unit (CPU):

The CPU is the main part of any PLC. The CPU solve the user program logic ,by using
real time input status from input module and updates the status of outputs through
Output Module. The CPU consists of two parts:

1. Processor

2. Memory

PROCESSOR:

The Processor is responsible for the complete program scan in a PLC. During program
scan processor communicates with memory for-

 Understanding the status of input devices stored in memory.

 To get certain numerical data, stored in data memory to execute an instruction.
 To write the status of certain output devices after solving program logic into
output status file.

The central Processing Unit (CPU) performs the tasks necessary to fulfil PLC
operation. The CPU solves the user program logic , by real time input status from input
module and updates the status of outputs through output module.
The PLC processor operates in following three operating mode:

1. Program Mode

2. RUN Mode

3. REM (Remote) Mode

Program Mode: In this mode, processor allows the user to make changes in
the ladder program including entry and editing before downloading the program
into PLC memory
 RUN Mode: After downloading the program into PLC memory, if all inputs and
outputs are wired to the correct screw terminals, then user can put processor in
RUN mode. In RUN mode processor starts scanning ladder program. The
scanning of ladder program is performed sequentially and repeatedly by the
processor which is called as ”SCAN Cycle”. The processor could be in RUN
mode for hours, days, weeks even months.

REM (Remote) mode: In this mode, the PLC’s processor is placed into remote
mode. i.e. in the network with several other PLC’s are connected. In this mode the
user is allowed to edit the program and make change in the program mode.

SCAN Cycle:

The SCAN cycle consists of the series of sequential operations that includes
the steps as shown in figure 2.5 .

Figure2.5 Classification of Output module

Input Scan: During the input scan, the processor scans the status of Input
point which is stored in Input status file by input module.

Program scan: After the inputs are read and stored in the input the
processor uses this information to solve user program. During program scan
processor scans the user program starting at rung 0, from left to right, and
evaluates one instruction at a time until output instruction is reached. When
scanning of rung 0 is completed the processor goes on to rung 1, rung 2 and
rung 3 and so on, sequentially to the last rung. The output status is the logical
result of solved input logic for any particular rung. The logic ’1’ or ’0’ output
states are then placed in the output status file.

Output scan: During output scan processor writes the ON or O of specific

output point to the associated output module. Each output status word is
consists of ON or OFF electrical signal. There is an ON or OFF signal for each
output point.

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 Communication and Memory management: After updated output data has
been written to the output module, the processor goes into communica-tion and
memory management cycle. Communication includes updating the handheld
programming device or PC monitor screen and sending signals to other PLC’s
in the network. Memory management includes updating timers, counters,
internal time base and other internal data files.

MEMORY:

The PLC’s CPU has 1000’s of memory location that stores information in the
form of binary data (0 and 1 or ON and OFF). These are known as words or
registers. The purpose of memory is to store system program, user program,
status of various inputs and outputs, timer data, counter data, alphanumeric
data related to user program.

All above information which is stored in memory must be stored in an orderly

manner, so that whenever processor requires fetching any specific information,
which can be easily available. Therefore, to achieve this, PLC memory is divided
into two parts (files) namely-

1. Data Memory (Also known as RAM)

2. Program memory (also known as ROM).

Data memory is a volatile or RAM memory used to store the data related to
input status, output status, timers, counters, internal bit relays, numerical values
( integer or floating point ) etc.

Program memory is a non-volatile or ROM memory used to store system pro-

gram and user program.

MEMORY Organisation in PLC:

To understand the organisation of memory in PLC, think of program files and
data files like a two drawer file cabinet, where, program files are in one drawer
and data files are in the other drawer as shown in figure.

Figure2.6 PLC memory as two drawer cabinet

 Program files: The PLC processor stores system information, configuration
information and user program in one group of files called program files. Figures
2.7 illustrates a grouping of program files.

Figure2.7 Program files folder

There are 256 program files available per project file. As shown in figure 2.7 all
256 files (i.e. file 0 to file 255) are orderly arranged in program file folder. Program
file consists of following information in individual files -

Power Supply
Power Supply is a part of PLC which is used to supply required amount of
power to CPU, Input module and Output module. PLC has two types of Power
supplies -
1. Internal power Supply: This powers the processor module.
2. External Power supply: This gives AC or DC power supply to I/O modules.

The processor requires low DC power. The AC power supply of 240V needs to
be converted into low DC power for the internal power requirements of I/O
modules.The PLC power supply has four sections as shown in figure 2.19 .

Figure2.19 Block diagram of Power Supply

 The first section is a step down transformer which reduces the AC power
voltage. The second section is the full wave rectifier that converts AC into
pulsating DC voltage. The third section is the filter network which DC pulsating
voltage that comes from rectifier section. The final section contains a voltage
regulator that maintains a constant DC output voltage even if the incoming AC
voltage fluctuates.

Classification Of PLC
Generally, PLC is available in variety of different ranges and sizes. But for
sim-plicity the PLC is classified into categories as shown in figure 2.20 .

Figure2.20 PLC Classification

Fixed PLC: A fixed PLC consists of a fixed, or inbuilt Input section, output
section, CPU and power supply unit. I.e. input section, output section, CPU and
power supply are included within the self-contained package. Figure 2.21 shows
the standard diagram for fixed PLC.

Figure2.21 Fixed PLC

 Fixed PLC is categorised into:
1. Pico PLC: It is called Pico because of very small number of I/O count. It
consists of maximum 12 I/O points.

2. Micro PLC: It is very popular type of fixed PLC. This type of PLC normally
consists of maximum of 32 number of I/O points.

Modular PLC: Modular PLC is a PLC which uses separate module (unit) for
input section, output section, CPU and Power supply. Every Modular PLC will
have only one CPU module and power supply module and there can be more
number of input and output modules. Figure 2.22 shows the diagram for Modular
PLC.

Figure2.22 Modular PLC

figure 2.22 the frame or cabinet in which the I/O modules are inserted is called
Rack or Chassis. The I/O modules are inserted inside a rack into a specified
space called as slot. The size of the rack depends on the number of slots such
as 4, 8, 12 and 16. Modular PLC is categorised into:

1. Small PLC: A PLC which consists of 32 to 128 I/O points is called Small
PLC.

2. Medium PLC: A PLC is called medium size PLC when it consists of 128 to
1024 I/O points.

3. Large PLC: A PLC with 1024 to 4096 number of points is called large size
PLC.

4. Very Large PLC: A PLC with more than 4096 I/O points is called very
large size PLC.
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Sourcing in PLC:

Sinking refers to the configuration where the device (such as a sensor or a

switch) provides a path for current to flow to ground (negative side) when it is
activated. In this setup, the current flows from the positive supply, through the
load (the PLC input), and then to ground when the device is active.

Sourcing in PLC:

Sourcing refers to a type of input or output configuration where the device

provides the power or current to the connected load. In a sourcing input, the
current flows from the positive terminal (source) to the negative terminal (sink).
This configuration is often used with NPN (negative-positive-negative) type
sensors or devices.