1.

CONCEPT OF PLC SYSTEMS:

Programmable Logic Controllers or PLC’s evolved as industries sought

economical ways to automate their production lines. The PLC’s took the
place of relay based control systems which were comparatively slower, less
reliable, and which required formidable wiring and maintenance
requirements.
PLC’s operate by monitoring input signals from the INPUT DEVICES.
When changes are detected in the signals, the PROGRAMMABLE
LOGIC CONTROLLER (PLC) SYSTEM reacts, through user
programmed internal logic, to produce output signals. These signals actuate
the OUTPUT DEVICES.

INPUT DEVICES:
A device connected to the PLC and sends a signal to the PLC is called an
Input device. The signal it sends is called an Input Signal. Signal enters the
PLC via interfacing relays through terminals or through pins on a connector
on a unit. The place where the signal enters the PLC is called an input point.
This input point is allocated a location in memory that reflects its status i.e.,
either ON or OFF. This memory location is called an input bit. The CPU, in
its normal processing cycle, monitors the status of all input points and turns
ON or OFF corresponding to input bits accordingly. PLC’S can receive
inputs from either automated or manual devices. Data can be received from
user via a push button switch, keyboard, or similar device. Automated inputs
can come from variety of devices: limit switches, timers, photoelectric,
proximity switches etc.

OUTPUT DEVICES:

Devices connected to the PLC and takes the output signals from PLC are
called output devices. There are also output bits in memory that are allocated
output points on unit through which output signals are sent to output
devices via interfacing relays, i.e., an output bit is turned ON to send a signal
to the output device through an output point. The CPU periodically turns the
output points ON or OFF according to the status of the output bits. A PLC
can output to wide variety of devices in automated control. Some of the most
common devices are motors, solenoid valves, relays, indicator lights,
buzzers, alarms, servomotors, stepper motors etc. Microprocessor based
CONTROLLER SYSTEM eliminates much of the wiring and rewiring that
was necessary with the conventional relay based system. Instead the
programmed logic provides the “wiring network” which can be changed as
required by simply reprogramming the PLC. PLC’s historically originated
from relay based control systems. Although the integrated circuits (IC’s) and
internal logic of the PLC have taken the place of the discrete relays, timers,
counters etc. actual PLC operation proceeds as if those discrete devices were
still in place. PLC control, however, also provides computer capabilities and
accuracy to achieve a great deal more flexibility and reliability than is
possible with relays. The symbols and other control concepts used to
describe PLC operation also come from relay based control and form the
basis of the ladder diagram programming method.

RELAY Vs. PLC TERMINOLOGY:

2. DIFFERENT GENERATION OF PLC SYSTEMS:

There are different makes of PLC systems namely OMRON, ALLEN

BRADELY, HIMA, GE FANUC,TATA HONEYWELL,SIEMENS etc
available in the market. We in IFFCO, have all the above makes of PLC’s in
use. However we widely use OMRON make PLC’s of different generations.
The same are being discussed below in detailed.

2.1 SYSMAC C-20 :

These are the first generation PLC’s. These are low cost, versatile industrial
control system that can be quickly installed and easily operated by
technicians with little or no experience with programmable controllers. All
functions for a small-scale control system are integrated in a single housing
suitable for applications, which require fewer I/O control points. The C 20
comes in two versions, a basic unit and an expandable unit.
The basic unit has the capacity of 1194 program statements, 28 I/O points
and 136 internal auxiliary relays. The expandable unit is functionally
identical to the base unit except that it can be expanded using expansion I/O
units to include up to 140 I/O points. Due to its compact design the C20
incorporates the detachable I/O terminals and microprocessor functions in a
single housing called the CPU. The detachable programming console
functions as the programming device. It is upwardly compatible with the full
line of SYSMAC C series programmable controllers. The same shall be
discussed in detail during the PLC programming.
2.2 SYSMAC C- 200, 500, 2000:

These can be called second generation PLC’s suitable for applications

requiring higher I/O count above 150. These are back plane versions with
rack mounted PLC, I/O, POWER SUPPLY CARDS. The system can be
expanded and expansion I/O racks can be connected through I/O connecting
cables. I/O units are available with 5, 8, 12, 16 or 32 points. The basic
configuration consists of a CPU RACK with Power supply and I/O cards.
C2000 PLC’s have both simplex and duplex mode of operations.

2.3 SIMPLEX PLC SYSTEM:

Simplex PLC system consists of single CPU unit that controls the
operations. Failure of the CPU unit will hamper the control operations in the
plant, reducing the reliability of the system. A simple schematic of such
systems can be shown as below:

SCHEMATIC DIAGRAM OF SIMPLEX PLC SYSTEMS

2.4 DUPLEX PLC SYSTEM:

To increase the reliability of the PLC system, duplex PLC systems have been
developed with double CPU units. They can be serviced easily without
shutting down operation in the rare event that one of these units should fail.
Duplex CPU units function on hot standby method. It is a method where the
two CPU units are simultaneously performing calculating functions. One
CPU unit performs the control functions (active CPU) and the other is
placed on standby while it is performing the calculation functions. If the
CPU unit performing control functions detects an error and stops, then
control functions switch immediately over to the CPU unit that is on
standby. The two CPU units are synchronized to ensure a smooth transition
between them.

A simple schematic of such systems can be shown as below:

SCHEMATIC DIAGRAM OF DUPLEX OLC SYSTEM

2.5 SYSMAC CVM1D DUPLEX :

These are considered the latest generation of PLC’s in the market. They
incorporate double systems for higher reliability. These PLC’S are available
as simplex systems with double power supply units or as a duplex systems
with double CPU and double POWER SUPPLY units.
Power supply units are connected in parallel. Even if one of the power
supply units breaks down, the PLC can continue to operate normally and the
faulty unit can be replaced without interruption. With double CPU units and
Power supply units, a CPU unit or a Power supply unit can be serviced
easily without shutting down operation in the rare event that one of these
units fail. I/O units on CPU, CPU exp. and I/O exp. racks can be replaced
from the programming console while the system is running. It has high
speed processing of 0.125 micro sec and I/O point capacity of 2048.

A typical schematic of such PLC’s is as shown below:

SCHEMATIC DIAGRAM OF SYSMAC CVM1D DUPLEX PLC SYSTEM

2.6 SYSMAC CPM2A, CPM2C:

These are the latest version of PLC’s in the micro PLC series. It is a compact
PLC having advanced functions having high speed processing. The
processing speed is 0.64 micro sec. I/O capacity is max 60 points with basic
unit and 120 points with the expansion unit Program capacity is 4096 words.
Supports programmable terminals or display screens via built in RS232 port
for visual confirmation of operating conditions and debugging. They have
provision for both DIN rail and surface mounting.

SYSMAC CPM2A, CPM2C PLC SYSTEM

The diagram above explains the different generation of PLC systems that are
used in industry. However the detailed hardware configurations and software
programming techniques varies from manufacturer to manufacturer and also
from one generation of PLC’s to the other generation. With the advancement
in technology, the new generation PLC’s can cater to analog control
applications in addition to basic concept of sequential logic control.
3. DIFFERENT COMPONENTS OF PLC SYSTEMS:

A simple schematic scheme of a PLC is shown below:

A TYPICAL PLC BLOCK

A typical PLC has three basic components. They are detailed as below.

3.1 INPUT/OUTPUT SECTION

This section consists of wiring and interfacing relays that connect the PLC to
the equipment being controlled (Input / Output devices). The detailed circuit
configuration is as below:
3.2 CENRAL PROCESSING UNIT ( CPU )

The CPU contains the control circuitry as well as the memory that stores the
control program that guides equipment operation. It is the heart of the PLC
and organizes all controller activity by scanning the control plan along with
the status of the inputs and executes specified commands to specified
outputs.

3.2.1 PROGRAMMING DEVICE

This device is used to enter the control program into the CPU memory.
Operation keys in the instructions used to sequentially control the
application process. Relay ladder diagram programming technique is
generally used. It can be a dedicated terminal compatible to a particular
brand of PLC or a PC terminal loaded with the proprietary programming
software communicating with the PLC.
There are three different types of memory chips are used in PLC’s for
storing the
program. These are EPROM, EEPROM and RAM. The size varies with the
no of
programming lines. In case of RAM, battery back up is provided in order to
retain the program when the power is off. Units with battery back up can
retain the data for approximately five years at room temperatures ( 25 0 c ).

Power supply shall be either 24 V DC or 110 / 220 AC used with the PLC.

3.2.2 SCAN TIME:

When a PLC operating, it executes the program to control the external
system. In the process a series of operations are performed inside the PLC.
These are common processes such as resetting the watchdog timer and
checking the user program memory, Data input and output, Instruction
execution, Peripheral device command servicing. The total time required for
a PLC to perform all of these internal operations is called scan time. It
primarily varies from the no of I/O units, no of program instructions and any
peripheral devices connected to the system. It is typically in the order of
milli seconds.

3.3.3 RESPONSE TIME:

Response time is the time from when the PLC receives an input signal until
it outputs the control signal. It is also in the order of milli seconds.
4. INTRODUCTION TO PROGRAMMING:

To understand the basic programming techniques, we select C20 OMRON

PLC systems as the learning kit and programs are developed and run on the
same. As already mentioned above, relay ladder diagram method is followed
in programming the PLC. However there are eight basic programming steps
to follow in creating the control program for the PLC.
Determine what the controlled system must do and in what order. Controlled
system is basically a part of the process, which is controlled by the PLC
system.
For example:
Let us consider the case of lube oil system where the lube oil supply header
is maintained at a desired set pressure by pumping through the main oil
pump. In case the main oil pump trips, oil pressure drops. When it reaches
the low set point, the stand by oil pump should take start to maintain the set
pressure and sustain the process. But Pump to stop only on manual. Also
there shall be a provision to start the pump manually in case of emergency.
Display lamps shall indicate the low-pressure alarm.
There shall be a logic bypass arrangement for on line maintenance of lube
oil pressure switch. Lamp test to check the display lamp. This is the logic to
be implemented in the PLC system. Based on above we have to assess the
Number of I / O’s required. The same is as below:

Assign identification nos. to input and output devices, that is, designate the
external devices that will send signals to and receive signals from the PLC
via interfacing relays.
PLC ’s use the concept of I / O channels to identify the I / O terminals or
points. Each channel consists of 16 points.
A four digit no is used to identify an I/O point. The left two digits indicate
the channel no. and the right two digits indicate the point within the channel.
For eg:
“0000” identifies the first point of the first channel and “0105” identifies the
sixth point of second channel. It may be noted that both channel and point
designations start from zero.
Part of the output points is not used to send the output signals directly to the
output devices but function as internal relays. These relays do not control
external devices directly but they are used to control other relays, timers and
counters. They are also assigned specific nos. These called internal auxiliary
relays. Timers and counters are also assigned specific nos. But the same
number cannot be assigned for both timer and a counter.
I / O assignment is proprietary detail of the PLC manufacturer with ref to the
nos.
assigned for I/P and O/P channels, I/P and O/P points, internal relays,
counters and timers.
The actual number of channels and the I/O points available depend upon the
hardware configuration of the system.

Draw a diagram, using relay ladder symbols. This represents in the correct
sequence, all of the required functions and their relationship.

A ladder diagram consists of two vertical lines running down the sides with
lines
branching in between them. The vertical lines are called bus bars. The
branching lines are the instruction lines called rungs. Along the instruction
line are placed the contacts/input conditions that lead to the output to the
right bus bar.
Code the ladder symbols into a form that can be input to the CPU by
programming console.
When finished writing the ladder diagram, the next step is to encode the
diagram into a language the PLC can understand. This language consists of
addresses, instructions and data. The addresses are locations in the memory
where instructions and data are stored. The instructions are used to tell the
PLC what to do using the data that follows each instruction.
For example let us consider the ladder diagram developed above.
To code this, we first need to specify the memory address from which this
program starts. In this example we will use “0000” as the starting address.
To this address, an instruction that indicates the beginning of the program
must be written. This is LD instruction or LOAD. The first contact in the
circuit must be stored as data of the LD instruction. Like wise rest of the
program follows as below:
When finished we always have to tell the PLC when a program is over. So
we assign the END statement to address 0012.
The number of instructions vary from a typical 27 to 275 which will be
listed out in the users manual of the PLC with symbols.
Transfer these written instructions to the CPU via the programming console.

Before we go any further, it is required to know how a programming console

looks like and the key sequence followed to enter the written instructions to
the CPU.
As already explained before a programming console can be a dedicated
terminal compatible to a particular brand of PLC or a PC terminal loaded
with the proprietary programming software communicating with the PLC.
Here we limit ourselves to the dedicated terminals used for programming the
PLC.
The keyboard consists of numeric keys 0 to 9:
These keys are used to input the numeric values used for program data. For
example these keys would be used to input the input / output numbers and
timer / counter numbers and values.
CLR key used to clear the display.
A typical programming console looks as below:

INSTRUCTION KEYS:

These keys are used to place the instructions in the program.

For example:
AND instruction is used for ANDing two contacts.
LD instruction used for loading a specified input.
OUT instruction used for outputting to a specified output point.
The detailed functions of the individual keys along with symbols and
mnemonic codes shall be obtained from list of instructions in the PLC users
manual.
OPERATION KEYS:

These sets of keys are used to edit the programs. Particularly the following
three keys
which are in variably used.
↑ Key is used to scroll through the program one step at a time
backward until you reach the beginning of the program. The displayed
memory address of the program will decrement once for each press.
↓ Key is used to scroll through the program one step at a time forward
till you reach the end of the program. The displayed memory address of the
program will increment once for each press.

WRITE Key:
During the programming when the instruction and its data are written, this
key used to register the instruction in the PLC memory at the address
desired.

MODE SWITCH:

It is a 3-position switch used to select the operating mode of the PLC.\

• Run mode: the run mode is used to begin the PLC operation. When turned
ON, the PLC begins controlling the equipment using the program written
into the PLC memory.
• Monitor mode: the monitor mode allows to visually monitors the operation
in progress. For instance if you want to check whether a particular relay is in
the
correct state or not, we can move to the address (or step) that refers to the
relay.
• Program mode: PLC is kept in program mode while programming.
CONSOLE DISPLAY:
It is an easy to read LCD display through which we interact with the PLC.
Now with the basic understanding of the programming console we can now
start entering the program developed in the previous step:

5. ERRORS:

There are basically two levels of errors- fatal and non-fatal.

A fatal error, such as a memory error, prevents the PC from operating.

A non fatal error, such as a battery failure, allows the operation to proceed
but still must be corrected. In case both types of errors have occurred, the
error messages for fatal errors take precedence over the other and must be
corrected first.
FORCED SET / RESET: During the execution of the program, this
operation is used to force set or reset (for one scan time) the operating status
of each i/o relay, internal auxiliary relay, holding relay, timer or counter. The
most common use of this function is during the trial run of the controlled
system.
Programs are saved in EPROM’S, CASSETE TAPES, FLOPPY DISKS
ETC.