PLC PROGRAMMING

Information subject: 3 credits (45h)

Midterm Exam : Practice exercises
Final Exam : Projects
Lecturer : Msc. Pham Hai Yen
Phone number : 0946336688

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 1

 What are some common examples
of control?
Washing machine, sump pump, microwave, ….
Others?

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 2

 I. Defining Control Systems

1. Control System
2. Reference Input
3. Controlled Variable
4. Disturbance
5. Feedback Element

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 3

 1. Control System is..
Components that connected to system or
process that want to be controlled.
5 basic element of control system:
i. Reference signal generator
ii. Measurement element
iii. Comparator
iv. Controller
v. Actuator

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 4

 1.1 OPEN LOOP CONTROL SYSTEM:

• Output does not affect the function of the entire system.

Reference Controller Actuator System Output signal

input

Fig. 1: Block diagram of Open loop control system

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 5

 1.1 EXAMPLE : Street Lighting System

• Commonly a system that using timer.

• ON and OFF at specific time

( Night = ON and Day = OFF)

• Duration within ON and OFF is set up bytimer.

System
Time Controller Actuator (street Street Lamp
set up (timer) (Relay) lighting ON @ OFF
system)

Fig. 2: Block diagram of Street Lighting System using Open loop control system

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 6

 1.2 CLOSED LOOP CONTROL SYSTEM

•Also known as Feedback Control System

• System Output affect the control function of the entire system.

comparator
System
Reference input controller Actuator Output
signal

Measurement element

Fig. 3: Block Diagram of Closed Loop System

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 7

 1.2 EXAMPLE : STREET LIGHTING SYSTEM

• Commonly a system that using sensor as input element.

• ON and OFF automatically as the light sensor detect the light

regardless of the particular time.

• Dark =comparator
ON and Bright = OFF)
System
Reference input controller Actuator Output
(Light intensity) (relay) (street signal
lighting (lamp
system) ON@OFF)

Measurement element
(light sensor)

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 8

 1.3 COMPUTERISED CONTROL SYSTEM
• A control system that use a computer as a controller.

• This system can be represented by the block diagram

as in figure 5.

COMPUTER
Reference system
controller Actuator Output
signal
signal

Measurement element

Fig. 5: Block Diagram of Closed Loop System

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 9

 2. REFERENCE INPUT:
• Is a signal to start a system.
• Ex: such as temperature, pressure and level.
• Fix value.
3. CONTROLLED VARIABLE:
• Is a signal or variable that is controlled at its output.
• Ex: Temperature, pressure and level.
• Fix value.
4. DISTURBANCE:
• Element that disturb a control signal in control system.
• Can be from within the system itself or external.
5. FEEDBACK ELEMENT
• Element that use to send output signal to be compared with
input signal by comparator in closed loop system.
PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 10
 6. COMPARISON

Open Loop System (OLS) Close Loop System (CLS)

Easy to design The design is complicated or
Complex.
The accuracy depends on the The system is very accurate.
calibration elements

less instability problem. problems of instability.

Unable to reduce the impact of Non-linearity effects can be

non-linearity. minimized.

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 11

 INTRODUCTION TO PLC
II. Explain PLC
II.1.1 Define PLC terminologies
II.1.2 Explain PLC background
II.1.3 Explain PLC functions
II.1.4 List and explain the types and advantages of PLC.

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 12

 II.1.1 Define PLC

What is Programmable Logic Controller (PLC) ?

Definition: National Electrical Manufacturers Association

US (NEMA)

A PLC is a digital operating electronic apparatus

which uses a programmable memory for internal storage of
instruction for implementing specific function such as
logic, sequencing, timing, counting and arithmetic to control
through analog or digital input/output modules various
types of machines or process.

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 13

 Define PLC terminologies:

• Several different terms used to described

programmable controllers:

i. PLC –Programmable Logic Controller (UK origin)

ii. PC – Programmable controller (US origin)

• Most referring to the functional operation of the machine.

• PLC has been used in this text to avoid confusion with the personal
computer.

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 14

 II.1.2 Explain PLC background

PLC Development factors:

i. needs for low-cost
ii. Flexible
iii. Easily commissioned/ smart usage

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 15

 Historical Background:

In 1968, a group of engineers from General Motors

developed the concept of PLC with an initial
specification. The PLC must be:

i. Easy to program.
ii. Not need rewiring the control system if
change the program.
iii. Smaller in size, cheaper and high reliability.
iv. simple construction and low maintenance
v. Cost- competitive

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 16

 2.1.3 PLC functions

CONTROL TYPE: FUNCTIONS

i. Conventional Relay Control Logic replacer

Sequence Control ii. Timers/ Counter
iii. PCB Card controller replacer
iv. Auto/Semi-auto/Manual control of machine
and process.

i. Arithmetic operation (+, -, × , ÷)

Advanced/ Sophisticated ii. Information Handling
Control iii. Analog Control (Temperature, Pressure )
iv. P.I.D (Proportional Integral Derivation)
v. Servo Motor Control
vi. Stepper Motor control

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 17

 PLC functions:

CONTROL TYPE: FUNCTIONS

i. Process monitoring and alarm.

Supervisory Control ii. Fault Diagnostic and monitoring
iii. Interfacing with Computer (RS-232C/RS 422)
iv. Printer/ ASCII Interfacing
v. Factory Automation Networking
vi. Local Area Network (LAN)
vii. Wide Area Network (WAN)
viii. Factory Automation (F.A), Flexible
Manufacturing System (F.M.S) & Computer
Integrated Manufacturing (C.I.M).

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 18

 PLC Size:
• Small :
- it covers units with up to 128 I/O’s and memories up to 2
Kbytes.
- 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 and memories up to 750 Kbytes.
- Can control individual production processes or entire plant.
PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 19
 2.1.4 Types of PLC Construction:

i. Compact PLC
ii. Modular PLC
iii. PLC Plug-in Card

Manufacturer: OMRON, Allen Bradley,

Mitsubishi, NAIS, Siemens, Toshiba, Festo etc.

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 20

 2.1.4 Types of PLC Construction:

i. Compact PLC:

Compact PLC – MELSEC FX3U

PLC Programming Figure 1: CompactLOGIC

1. AN INTRODUCTION TO PROGRAMABLE PLC CONTROLLERS 21
 i. Modular PLC

PLC Programming Figure 2: ModularLOGIC

1. AN INTRODUCTION TO PROGRAMABLE PLC CONTROLLERS 22
 iii. PLC Plug-in Card

PLC Programming Figure 3: Plug-in Card

1. AN INTRODUCTION TO PROGRAMABLE PLC CONTROLLERS
LOGIC 23
 ADVANTAGES OF USING PLC:
• Shorter project implementation time.
• Easier modification
• Project cost can be accurately calculated.
• Shorter training time required.
• Design easily changed using software ( changes and addition
to specifications can be processed by software.
• A wide range of control application
• Easy maintenance.
• High Reliability
• Standardization of Controller hardware.
• Able to withstand Harsh plant/process environments (Operate
normally under severe conditions of temperature, humidity,
voltage fluctuations and noises).
PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 24
 PLC HARDWARE DESIGN

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 25

 3.0 PLC HARDWARE DESIGN

3.1 Processor Architecture for PLC:

Data BUS

ROM RAM Output

Input
Microproces
sor/ CPU

Address Bus

Control Bus

Figure 4: Design of Basic Microcomputer

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 26

 3.1.1 FUNCTION OF EACH BLOCK:

a. Central Processing Unit (CPU)

• The CPU controls, monitors and supervises all operations

within PLC.

• It is also caries out programmed instructions stored in the

memory.

• An internal communications highway also known as a bus

system, carries information to and from the CPU, memory
and I/O units under the control of the CPU.

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 27

 3.1.1 FUNCTION OF EACH BLOCK:

b. Memory Unit

• For storage of programs.

• The user’s ladder logic program, the state of I/O in the memory of PLC.

• The main program and the other programs necessary for the operation of
PLC.

• The organization of the data and information in the memory is called

memory map.

2 types of Memory

ROM RA
M

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 28

 3.1.1 FUNCTION OF EACH BLOCK:

TYPES OF MEMORY:

RAM ROM
Random Access Memory Read Only Memory (read)

This memory can be read from This memory can be read only
and written to.

Storing all user’s programs Storing all system’s program

Entire contents will be lost if power Memory content remain when the
is switched off. power is switched off.

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 29

 3.1.1 FUNCTION OF EACH BLOCK:

c. Input/ Output (I/O) Unit

• Input Unit:
Function as a medium that connects the external input
devices
(Switch, sensor & timer)

• Output Unit:
Function as a medium that connects the external output
devices to the CPU within PLC.
( Lamp, motor & solenoid )

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 30

 INPUT DEVICES:

Push Button

Limit Switch

Thumbwheel
SW

Level SW

Flow SW

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 31

 INPUT DEVICES:
Motor

Solenoid

LED Display

Heater Coil

Lamp

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 32

 d. Display and Indicator Unit

Referring to PLC standard display Internal Relay:

• Console’s LCD Display
if user use Mnemonic Code Programming.
• Monitor Screen
LCD Display
if user use software programming method.

Monitor Screen

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 33

 e. Housing Unit
Protect PLC circuit and internal component

f. Programming Unit
Consist of 2 devices:
i. Programming Console

ii. Computer

g. Secondary Storage Unit

This unit related to CPU where all program
and information were kept.

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 34

h. Power Supply Unit:

Supplies DC power to the Central Processing Unit, Input Unit and

Output Unit.

i. Printing Unit
Used to print control system programming that controlled by PLC
wether graphically or text.
 PLC Programming Languages

The standard IEC (International Electro technical Commission) was established to

standardize the multiple languages associated with PLC programming by defining the
following five standard languages:
• Ladder Diagram (LD) —a graphical depiction of a process with rungs of logic, similar to
the relay ladder logic schemes that were replaced by PLCs
• Function Block Diagram (FBD) —a graphical depiction of process flow using simple and
complex interconnecting blocks.
• Sequential Function Chart (SFC) —a graphical depiction of interconnecting steps, actions,
and transitions.
• Instruction List (IL) —a low-level, text-based language that uses mnemonic instructions.
• Structured Text (ST) —a high-level, text-based language such as BASIC, C, or PASCAL
specifically developed for industrial control applications
PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 36
 Ladder Diagram and Programming

PLC Programming 1. AN INTRODUCTION TO PROGRAMABLE LOGIC CONTROLLERS 37