8) Programmable Logic Controllers

Programmable Logic Controllers

Sequential Control (Discrete-State Process Control or On/Off Control): Process has
to follow a predefined sequence by turning On or turning Off the actuators. Sequential
control can be solved by Boolean logic [Combinational Boolean Logic + Sequential
Boolean Logic].

Relay Logic
− Conventional method of implementing Sequential Control using array of relays
and switches
− Special kind of relays/switches e.g. timer relay (for delays), Limit switches, Level
switch (to detect level), thermal switch (to detect temperature)

Relays /Switches

Relay Logic: OR
 Using two switches, a logical “OR” operation can be constructed. An example is
given below:
 Switch 1 “OR” Switch 2 = Coil

 Switch 1 off “OR” Switch 2 off = Coil off

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 8) Programmable Logic Controllers

• Switch 1 on “OR” Switch 2 off = Coil on

• Switch 1 off “OR” Switch 2 on = Coil on

• Switch 1 on “OR” Switch 2 on = Coil on

Example 1: On/Off push button of a motor

Motor OFF

Relay OFF

Stop pressed Start pressed

Motor ON

Relay ON

State Diagram of On/Off push button

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 8) Programmable Logic Controllers

Relay Contact a1
(Normally Open)
+VCC

Start Push Button Relay Contact a2

(Normally Open) (Normally Open)

Stop Push Button

(Normally Closed)
Motor
M M
Relay Coil
A

PLC System
Software solution to Relay Logic.
1. CPU: Central Processing Unit, generally consists of
i) Microprocessor: mathematical and logical operation
ii) Memory: stores data and program. Generally basic PLC programming in
ROM and user program and data in EEPROM (Electrically Erasable
Programmable Read–Only Memory)
iii) Power Supply: DC supply to CPU and modules
2. Programmer/Monitor: device to program and monitor PLC. PC also used.
3. I/O Modules: Interface with process to be controlled. E.g. Digital I/O, Analog I/O,
Encoder interface, PWM output etc.
4. Special Modules: for special purpose. E.g. PID controller module, Interrupt handling
module
5. Racks and Chassis: to enclose CPU and different modules. The CPU and modules
are attached by a bus system within the racks.
Programmer/
Monitor

CPU
Microprocessor
Input Memory Output
Module Module

Power
Supply

Rack and Chasis

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 8) Programmable Logic Controllers

Power Supply CPU I/O Modules

Power to PLC Communicating Ports

to PM or PC

Ladder Diagram
− Graphical Programming Language for PLC
− Based on Relay Logic

Basic Components of Ladder Diagram

Normally Open (NO) Contact

Coil/Output
Normally Closed (NC) Contact

ISO Standards for Logic Gates Symbols [Combinational Logic]

Commonly used logical gate symbols (page 247, Olsson and Piani)

1
NOT Y=A

&
AND Y= A × B

OR Y= A + B
≥1

Y = A× B = A + B
&
NAND

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 8) Programmable Logic Controllers

NOR Y = A + B = A× B
≥1

=1
XOR Y = A× B + A× B

RS Flip flops [Sequential Logic]

S R Yn Yn+1
0 0 0 0
0 0 1 1
0 1 0 0
0 1 1 0
1 0 0 1
1 0 1 1
1 1 0 X Y=
n +1 R ( S + Yn )
1 1 1 X

Yn SR 00 01 11 10
0 0 0 X 1
1 1 0 X 1 Reset

Y=0

S = 0; R=1 S = 1; R = 0

Set

Y=1

State Diagram of RS-Flip Flop

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 8) Programmable Logic Controllers

Example 1: On/Off push button of a motor

Input Connection
Start Push Button

Stop Push Button

Program
Connection

Motor
M
Output

Connections to Input Module

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 8) Programmable Logic Controllers

Connections to Output Module

Basic Instruction Set
Ladder Diagram is compiled into Assembly Code (Instruction Set) and then into Machine
Code.

LD, LDI Load (LD)/Inverted Load (LDI) to accumulator

AND, ANI AND/ANI between accumulator and input
OR, ORI OR/ORI between accumulator and input
OUT Stores accumulator to memory
Value remains in accumulator

LD X1
OR Y1
AND X2
AND X3
OUT Y1
OUT Y2

LDI X2
OUT Y3

ANB Operates on last element in the stack and accumulator and stores result in
ORB accumulator

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 8) Programmable Logic Controllers

LD X1
OR X2
LD X3
OR X4
ANB
OUT Y1

LDI X2
AND X4
LD X3
AND X5
ORB
OUT Y2

Process Scan of Programmable Logic Controllers

OUTPUT SCAN

INPUT SCAN

PROGRAM SCAN

INPUT INPUT USER OUTPUT OUTPUT

T STATUS PROGRAM STATUS T
E TABLE TABLE E
R R
M M
I I
N N
A A
L L
S S

INPUT OUTPUT
PROGRAM SCAN
SCAN SCAN

Example 2: Water Tank

Simple water tank
• Level sensors, wires.
• If water level is less than LDown, NO contact of LDown is opened
• If water level is less than LUp, NO contact LUp is opened

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 8) Programmable Logic Controllers

P1 (Pump) Lup

LDown

Timers and Counters in PLC

• Timers: used to time an event for desire length of time
1. Timer Status Bits
2. Timer Current Values
3. Types of Timers in DL230/ DL240

• Counters: used to count the events

1. Counter Status Bits
2. Counter Current Values

Timers:
1. Timer Status Bits
• Timer status bit will be on when current value is equal or greater than the preset
value i.e. 3 sec.
• When input X0 turn on, timer T1 will start and when timer reaches the preset
value of 3 sec. (K of 30) timer status contact T1 turns on.
• When T1 is ON o/p Y0 turns on.

2. Timer Current Values

• Current value associated with timer is automatically stored in variable memory.
e.g. V1 hold current value of T1.

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 8) Programmable Logic Controllers

3. Types of Timers in DL230/ DL240

i. single input timer :
• will time as long as the input is on.
• i/p change from on – off timer is reset to 0.

ii. Accumulating timer

• two inputs required
• start/stop i/p start or stop timer.
• when timer is stops elapsed time is maintained.
• When timer starts again the timing continues from elapsed time
• when reset s turn on the elapsed time is cleared and the timer will start at 0 when
restarted.

Counters:
1. Counter Status Bits
• counter status bit will be on when current value is equal or greater than the preset
value i.e. 10 counts.
• Each time X0 transitions from off to on, the counter increments by one. If X1 is
on counter is reset to 0.
• when counter reaches the preset value of 10 sec. (K of 10) counter status contact
CT3 turns on and o/p Y12 turns on.

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 8) Programmable Logic Controllers

2. Counter Current Values

• Current value associated with counter is automatically stored in variable memory.
e.g. V1003 hold current value of CT3.

3. Types of Counters in DL230/ DL240

i. up counters

ii. 2. up/down counters

Example 3: Automation of Product Packaging

• System consists of two conveyer belts, one for feeding apples and one for feeding
packaging boxes.
• Sensors:
• Apple Sense: detects apple
• Box Sense: detects box

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 8) Programmable Logic Controllers

• Actuators:
• Apple Convey: Moves the conveyer belt of apples
• Box Convey: Moves the conveyer belt of boxes

Apple Convey

Apple Sense
Box Convey

Box Sense

When apple is not present When apple is present

Opens Closes

Closes Opens

When box is not positioned When box is positioned

Opens Closes

Closes Opens

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 8) Programmable Logic Controllers

Grafcet Diagram (Sequential Function Chart/ IEC 848 Standard)

– Graphical technique for writing concurrent control programs.

Basic Elements of Grafcet

Initial step: the first step
Initial Step

Step: basically a state of operation. A state often has an associated action

Step Action

Macrostep: a collection of steps (basically a subroutine)

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 8) Programmable Logic Controllers

Transition: causes a shift between steps, acts as a point of coordination

Flowlines: connects steps and transitions (these basically indicate sequence)

Step I
Transitions

Flowlines
Step II

Selection branch: an OR - only one path is followed

Step I

Step II Step III

Simultaneous branch: an AND - both (or more) paths are followed

Step I

Step II Step III

Example 2: Water Tank

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 8) Programmable Logic Controllers

Tank filling
do/Pump On

tank filled tank empty

[Lup] [Ldown]

Idle
do/Pump Off

Statechart for Water Tank

Stage Programming for Water Tank

Initial
Step
Tank Filling
1 Action
Pump On
Transition LUp
Idle
2
Pump Off
LDown
Step
Grafcet Diagram Explained

Example 3: Automation of Product Packaging

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 8) Programmable Logic Controllers

System OFF

Stop Start

Position New Box

Stop do/Box Convey

Box Positioned [Box Sense]

Apple Counter ≥ 10
& NOT (Stop)
& not (Stop)
Fill Apple
do/Apple Convey;
Apple Count

Statechart for Automation of Product Packaging

1 System OFF

Start
Position New Box
2
Box Convey
Box Sense
Stop & NOT (Stop)
Fill Apple
3
Apple Convey;
Apple Count
Stop
Apple Counter ≥ 10
& NOT (Stop)

Grafcet diagram for Automation of Product Packaging

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 8) Programmable Logic Controllers

Stage Programming for Automation of Product Packaging

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 8) Programmable Logic Controllers

Example 4: Bottle Filling Plant

Buffer Tank

Valve Control (V)

Level Sensor
bottle_present (BP) bottle_filled (BF)
Motor (M)

Conveyer belt

Conveyer belt is moved by Motor (M), Bottle is filled from a buffer tank by opening
the valve (V). Bottle filled is detected by the level sensor, bottle_filled (BF). Correct
positioning of the bottle is detected by limit switch, bottle_present (BP).

Assume both Normally Open and Normally Closed contacts of the sensors BF and BP
are available.

Process cycle is described as follows

1) Move the conveyer belt until bottle is in correct position.
2) Open valve (V) and fill the bottle until bottle_filled is detected.
3) Move the conveyer belt until next bottle is in position.
4) Repeat from step 2.

Assuming the contacts BF and BP closes when bottle is filled and bottle is positioned
respectively i.e. the contacts BF and BP opens when bottle is not filled and bottle is
not positioned respectively.

Position New Bottle

do/Move Conveyer M ON

Bottle Present (BP) Bottle Filled (BF)

Fill Bottle

do/Open Valve V  ON

Statechart for Automation of Product Packaging

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 8) Programmable Logic Controllers

Position New Bottle

1
Move Conveyer M ON
BP
Fill Bottle
2
Open Valve V ON

BF
Grafcet diagram for Automation of Product Packaging

Stage Programming for Bottle Filling Plant

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 8) Programmable Logic Controllers

Example 5: Elevator System

Shown in the figure is an Elevator System. M1 (For Up Motion)
The elevator is operated by two motors.

M1 for Up Movement LS1 (Down)

M2 for Down Movement
Start Stop
Two Limit Switches, LS1 (for Down Limit)
and LS2 (for Up Limit) are Normally Closed X0 X1
contacts. The contacts open when the hatch Up Down
reaches corresponding position.
X2 X3
Four Controls buttons is also provided.
LS2 (Up)
STOP button is Normally Closed and
START, UP, DOWN buttons are Normally
Open. M2 (For Down Motion)

The required Sequence of Operation are given below

• When START button is pushed, the platform should be in the DOWN Position.
• When STOP button is pushed, the platform is halted at whatever position it occupies
at that time.
• When UP or DOWN push buttons are pushed the platform should move accordingly.
Note the platform should move when push button is pushed and halt when the button
is released.

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 8) Programmable Logic Controllers

Figure: Ladder Diagram for Elevator System

• Example 6: Garage Door Controller

The behavior of the garage door controller is as follows,
– There is a single button in the garage, and a single button remote control.
– When the button is pushed the door will move up or down.
– If the button is pushed once while moving, the door will stop, a second push will
start motion again in the opposite direction.
– There are top/bottom limit switches to stop the motion of the door.
– There is a light beam across the bottom of the door. If the beam is cut while the
door is closing the door will stop and reverse.
– There is a garage light that will be on for 5 minutes after the door opens or closes.

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