Title: Introduction to Industrial Automation & PLC Programming

1. Introduction to Industrial Automation System

Industrial automation uses PLCs, SCADA, DCS, and robotics to replace manual operations
with machines and computerized control. It increases efficiency, reduces errors, and
improves safety in industries like manufacturing, oil & gas, power plants, and
automotive.

2. PLC Components & Control Strategy

A Programmable Logic Controller (PLC) is a digital control system used in industrial

automation.

PLC Components:

 Power Supply – Converts AC to DC.

 CPU (Central Processing Unit) – Executes the program.

 Memory – Stores program instructions.

 Input Modules – Receives data from sensors and switches.

 Output Modules – Sends control signals to actuators and motors.

 Communication Modules – Interfaces with external devices.

Control Strategy:

A control strategy is designed using logic operations like AND, OR, timers, counters, and
interlocks to ensure system automation.

3. PLC Hardware Configuration & Architecture

PLCs come in different architectures:

 Modular PLC – Expandable with separate modules for I/O, CPU, power.

 Compact PLC – Integrated design with fixed I/O.

 Rack-mounted PLC – High-end systems with multiple slot configurations.

4. Types of PLCs & Communication Cables

 Fixed PLC – Limited I/O, used in small applications.

 Modular PLC – Expandable I/O, used in medium to large industries.

 Distributed PLC – Used in remote automation systems.

Common Communication Cables:

 RS-232, RS-485 – Serial communication.

 Ethernet – High-speed communication.

 PROFIBUS, Modbus – Industrial networking protocols.

5. Basics of Input/Output Devices & I/O Listing

Input Devices:

 Push Buttons, Switches – Manual control.

 Sensors – Proximity, Photoelectric, Temperature, Pressure.

Output Devices:

 Relays, Contactors – Control circuits.

 Motors, Valves – Actuation devices.

 Alarms, Indicators – Visual/audible alerts.

I/O Listing documents all input and output devices along with PLC addresses.

6. Selection Criteria for PLC Systems

Factors to consider when selecting a PLC:

✅ Number of I/O – Determines system size.
✅ Processing Speed – Important for real-time applications.
✅ Communication Capabilities – Ethernet, Modbus, Profibus, etc.
✅ Environmental Conditions – Temperature, humidity resistance.

7. Scan Cycle & Scan Time

A PLC executes a Scan Cycle in four steps:

1. Input Scan – Reads sensor data.

2. Program Execution – Processes logic.

3. Output Scan – Updates outputs.

4. Housekeeping – Handles diagnostics and communication.

Scan Time refers to the duration required to complete one full scan cycle.

8. Relay Based Logic Diagram (NO-NC Concept)

 NO (Normally Open) – Contact closes when activated.

  NC (Normally Closed) – Contact opens when activated.

9. Logic Diagram & Control Strategy

A logic diagram visually represents control flow using symbols like contacts, coils, timers,
and counters.

10. Basics of Programming Software

PLC programming is done using:

 RSLogix 5000 (Allen Bradley)

 TIA Portal (Siemens)

 GX Works (Mitsubishi)

11. Addressing Concept & Data Files / Function Blocks

Each PLC follows a specific addressing scheme for I/O, timers, and counters. Function
Blocks provide predefined logic functions.

12. Programming Languages & Basic Instructions

PLC programming is done in:

 Ladder Logic (LL) – Graphical representation of relay logic.

 Function Block Diagram (FBD) – Block-based programming.

 Structured Text (ST) – Text-based programming.

 Sequential Function Chart (SFC) – Used for process control.

13. Upload / Download / Monitoring of Programs

 Upload – Extracts the program from the PLC to a PC.

 Download – Transfers a new program to the PLC.

 Monitoring – Real-time debugging of PLC operations.

14. Read / Write Instructions, AND-OR Logic & Set/Reset Functions

 Read/Write Instructions – Handle data storage and retrieval.

 AND-OR Logic – Implements conditional operations.

 Set/Reset – Controls latching operations.

15. Logic Gates & Flip-Flop Programming

  Logic Gates: AND, OR, NOT, NAND, NOR, XOR, XNOR.

 Flip-Flops: SR, D, JK, T flip-flops for memory storage.

16. Latching/Holding & Interlocking Programming

 Latching keeps an output ON after activation.

 Interlocking prevents unsafe operations by ensuring specific conditions are met.

17. Compare / Move & Math Computing Instructions

 Compare Instructions – Used for decision-making (>, <, =).

 Move Instructions – Transfers data between registers.

 Math Blocks – Perform arithmetic operations.

18. Timer & Counter Function Programming

 Timers: ON-Delay, OFF-Delay, Retentive.

 Counters: Up Counter (CTU), Down Counter (CTD).

19. Digital & Analog Signal Interfacing

 Digital (0/1 signals): Pushbuttons, relays, proximity sensors.

 Analog (0-10V, 4-20mA): Temperature and pressure sensors.

20. Scaling & Calibration

Scaling converts raw input values into meaningful process variables,

while calibration ensures measurement accuracy.

21. Communication with SCADA Software

SCADA (Supervisory Control and Data Acquisition) allows remote monitoring and
control of industrial processes.

22. Control Wiring & Sourcing-Sinking Techniques

 Sourcing (PNP sensors): Supplies voltage to input.

 Sinking (NPN sensors): Ground connection to input.

23. System Installation & Configuration

Includes mounting PLC, wiring, power connections, and configuring I/O modules.

24. System Integration Techniques

Combining PLC with SCADA, HMI, and other control systems for full automation.

25. Fault Finding & Troubleshooting Techniques

 Checking power supply, wiring, I/O responses, and software errors.

 Using diagnostic tools like multimeters and oscilloscopes.

26. Hands-on Experience on Real-Time Applications

Practical implementation of PLC-controlled systems in manufacturing, water treatment,

HVAC, and industrial machinery.