Unit 5 Programmable Logic Controller

Instrumentation and Control

Prof. Praveen P. Rathod

[email protected]
Department of Mechanical Engineering

BRACT’S, Vishwakarma Institute of Information Technology, Pune-48

(An Autonomous Institute affiliated to Savitribai Phule Pune University)

(NBA and NAAC accredited, ISO 9001:2015 certified)
 Objective`

1. To understand the interdisciplinary applications of Electronics, Electrical, Mechanical and

Computer Systems for the Control of Mechanical and Electronic Systems.

Learning Outcome/Course Outcome

1. Apply Program Logic Controller for implementation on real time systems.

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Outline

• Basic structure of a PLC

• Input and output modules
• Power supply and CPU
• Sinking and sourcing inputs and outputs
• PLC programming
• Ladder logic programming
• Timers, Counters, Internal relays, Registers

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 What
WhatisisaPLC
PLC? ?
 Programmable logic controllers (PLCs) are specialized industrial devices
for interfacing to and controlling analog and digital devices.

 They are designed with a small instruction set suitable for industrial control
applications. They are usually programmed with ladder logic, which is a
graphical method of laying out the connectivity and logic between system
inputs and outputs.

 PLCs are being flexible and easy to program, they are robust and relatively
immune to external interference.

 A PLC is the natural replacement for the relay circuits, timers, counters and
analog controllers used in the past (and still used today) to control the
operation of machines.
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Department of Mechanical Engineering, VIIT , Pune-48
PLC Simulator for Marking Machine with Ejector
Step 1 :
If Upper Limit = ON And Switch Start =
ON Then Marking DOWN = ON.

Step 2 :
If Marking DOWN = ON And Lower Limit
= ON Then Marking UP = ON And
Marking DOWN = OFF.

Step 3 :
If Marking UP = ON And Upper Limit =
ON Then Marking UP = OFF And Ejector
Forward = ON And Marking DOWN =
OFF.

Step 4 :
If Ejector Forward = ON And Forward
Step 5 : Limit = ON Then Ejector Forward = OFF
If Ejector Reverse = ON And Reverse Limit = ON And Ejector Reverse = ON And Marking
Then Ejector Reverse = OFF And Ejector Forward DOWN = OFF And Marking UP = OFF.
= OFF And Marking DOWN = OFF And Marking
UP = OFF.
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Department of Mechanical Engineering, VIIT , Pune-48
What is PLC ?

Programmable Beverage Valve

Logic Controller –
the heart and soul Output signal
of every machine

Object
sensor

Sensor signal
Bottle
Bottle
Open
0.50
1.00
1.50
0.00 Kg
Present
valve
Full Analog input 1.50 Kg
0.50
0.00
1.00
PLC signal
Scale

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What is PLC ?

Programmable Beverage Valve

Logic Controller –
the heart and soul Output signal
of every machine

Object
sensor

Close
valve
0.00 Kg
1.50
PLC
Scale

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What is PLC ?

Programmable Beverage Valve

Logic Controller –
the heart and soul Output signal
of every machine

Object
sensor

Sensor signal
Bottle
Bottle
Open
0.50
1.00
1.50
0.00 Kg
Present
valve
Full Analog input 1.50 Kg
0.50
0.00
1.00
PLC signal
Scale

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 Inputs
What is PLC Inputs
?
Push button
• Push Buttons
• Proximity switches
• Photoelectric sensors
• Temperature sensors Photo Sensor
• Pressure sensors Program

Outputs
Pressure Sensor
• Motors
• Solenoids
• Indicator lamps
• Resistive loads
• Contactors
Motor Outputs
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 • Inputs
Components of PLC Device
• CPU
• Memory
• Outputs

Inputs

CPU Memory

Outputs

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Components of Ladder Diagram

Check Input Status

Execute Program

Update Output Status

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 Ladder Logic

• Ladder logic uses a Power rails

variety of programming
symbols Normally
Closed Contact
• Power always flows
from left to right
Normally
Open Contact
• Output devices are in
the ON state if power
Output Device
flows through them or Coil

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Contacts

Power flows when

Contact
programmed the input device is
normally open
on

Contact Power flows when the

programmed
normally closed
input device is off

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Ladder Logics for Logic Gates
AND Electric Circuit AND Truth Table AND Ladder Diagram

OR Electric Circuit OR Truth Table OR Ladder Diagram

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Ladder Logics for Logic Gates
NOT Electric Circuit NOT Truth Table NOT Ladder Diagram

NOR Truth Table NOR Ladder Diagram

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Ladder Logics for Logic Gates
NAND Truth Table NAND Ladder Diagram

XOR Truth Table XOR Ladder Diagram

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 There are often situations where it is necessary to hold an output
Latching energized, even when the input ceases. A simple example of such a
situation is a motor which is started by pressing a push button switch.
Though the switch contacts do not remain closed, the motor is
required to continue running until a stop push button switch is
pressed.
 When the input X400 contacts close, there is an
output at Y430.
 However, when there is an output, another set of
contacts | | Y430 associated with the output closes.
 These contacts form an OR logic gate system with
the input contacts.
 Thus, even if the input X400 opens, the circuit will
still maintain the output energized.
Latch Circuit  The only way to release the output is by operating
the normally closed contact X401.
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 Consider a motor controlled by stop and start push button
Latching switches and for which one signal light must be illuminated
when the power is applied to the motor and another when
Application it is not applied.

 When X400 is momentarily closed, Y430 is

energized and its contacts close.
 This results in latching and also the switching
off of Y431 and the switching on of Y432.
 To switch the motor off, X401 is pressed and
opens. Y430 contacts open in the top rung
and third rung, but close in the second rung.
Thus Y431 comes on and Y432 off.

Latch Circuit
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Timers and Counters
• Block type of timer

Timer Attributes
Time Base:
• Timers are typically programmed with several different time bases
• 1 second, 0.1 second, 0.01 second, 0.001 second
• Suppose time base is set to 0.1 and Delay increments is set to 50
• timer has 5 seconds delay (0.1 x 50)

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Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Department of Mechanical Engineering, VIIT , Pune-48
Counters

• Counting is critical in industrial applications

• Suppose 24 can go into a case
• Then the 24th can must be sensed by the PLC and the case is sealed
• Primary Counter Types
UP Counters - PLC sense how many finished products leaving the machine
Down Counters - PLC sense how many parts are left
Up/Down Counters - PLC monitors an automated storage system to track how many are coming
and how many are leaving to determine total number in stock
• Choice used depend on the task

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• Counters usually use low-to-high transition from an input to trigger the counting action
• Counters count the number of low-to-high transitions on the input line
• Similar to Timers, which count the number of time increments
• Counters also have a reset instruction to clear the accumulated count

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 Practical Examples

• Problem 1

• Programmable Logic Controller for Bottle Filling Machine

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 Problem Diagram

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 Problem Solution
Step 1 From the previous workstations bottle/jar will
come.
Step 2 Then the MOTOR starts and the conveyor moves
forward towards water filling machine.
Step 3 If the sensor detects the presence of bottle which
is in position with the solenoid valve, then the
conveyor will stop.
Step 4 When photocell detects the bottle/jar, the valve
turns ON and the bottle will get filled till the timer
gets off.
Step 5 After bottle gets filled, a delay is provided and
then after the delay the conveyor starts moving
Step 6 And the process respects itself repeats itself from
step3
Step7 After bottles/tumblers will get filled, will go to
other stations like packing, and moving to another
workstations.
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 PLC Program

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 Problem 2

One open tank is installed in the plant of which liquid level is to be controlled. When level
reaches the Level Low, Outlet flow is blocked and inlet flow is allowed until high level is
achieved. And when Level High is detected, outlet flow is allowed and inlet flow is blocked.

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 Problem Diagram

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 Problem Solution
To detect high and low level of liquid in the tank, two level switches are used which gives
output in digital terms, that is when corresponding levels are detected, it gives output high
otherwise remain low.
To control level of this system, Single Acting piston valve can be used which has two states,
either fully open or fully close.
Low Level Switch is mounted at the bottom of the tank and Level High switch mounted at the
side upper most position.
When this inputs are detected, output to Control Valve has to be latched in order to
continuously fill or empty the system.
Master start/stop is also provided to shut down or start the entire process.

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 PLC Program
Here is PLC program to Control Level of a Single Tank, along with program explanation
List of Inputs and Outputs
I:1/0 = Level High Switch (Input)
I:1/1 = Level Low Switch (Input)
O:2/0 = Inlet Valve (Output)
O:2/1 = Outlet Valve (Output)
I:1/14 = Start (Input)
I:1/15 = Stop (Input)

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 Program Description

•RUNG000 is simply for latching a coil and master start-stop buttons.

•RUNG001 is to control the outlet valve through O:2/1. This is done when Level High is detected.

•Latching of Output O:2/1 is done because when High Level is detected, input to RUNG001 is temporary,
like Push Button. So in order to keep outlet valve open until the Level Low I:1/1 is detected, latching is
done. XIO of Level Low Switch is connected in series so that when Level Low is detected, it goes true closing
the outlet valve.

•Similarly in RUNG002, it works exactly same. The only difference in RUNG002 is that extra I:1/14 contact in
parallel with LLS.

•Suppose when the system is started and the tank is partially filled, neither LHS nor LLS is detected, in this
case, outlet and inlet valves remain closed while inlet valve should open to start filling the tank because it’s
partially filled.

•To eliminate this error, I:1/14 (Start) is connected in parallel to LLS I:1/1 contact. This checks if LHS (I:1/0) is
detected or not. If LHS is not detected, then it opens the inlet valve until LHS is detected.

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 Practical Examples

• Problem 3

• Programmable Logic Controller for Traffic Light Controller

•Three on delay timers are used to turn ON and OFF traffic lights.
•The red light on for 30 seconds. The green light ON for 40 seconds and yellow light ON for 10
seconds.

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PLC Program

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 Problem
Draw Ladder diagram for cutting machine.

Press start button lubricant stars to flow

After 20 second of lubricant flow cutter should be switched ON. Process should continue untill
we press stop button

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 Solution

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 Practical Examples

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PLC Program

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 Problem on Counter

• When we press start counter should start counting when material passes through sensor.
• After counting 10 items packed inside the cartoon pump should start and push the package
and reset the counter.

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 Solution

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 PLC Architecture
Components

• Input Module

• Output Module

• CPU

• Memory

• Power Supply

• Programming Device

• Communication Channel
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  Figure shows the typical wiring to a PLC
input module.
 The input module examines the state of
the physical switches and other input
devices and puts their state into a form
suitable for the processor.
 It is able to accommodate a number of
inputs called channels.
 If the switch is closed, the input will be
24 V DC, and if open, 0 V DC. The input
module converts this into the 1 or 0
state needed by the processor.

Input Module
Ref: Process Control Instrumentation - C D
Johnson

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 Input Module
• Input Module: Convert real world voltage and currents to signals the PLC can understand. Since there
are different types of input devices, there is a wide variety of input modules available, including both
digital and analog modules.

• Discrete / Digital Module: Use 0 or 1 to depict state

• Analog Module: Use numbers to depict state e.g. 30 degree

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  Figure shows the typical wiring to the PLC
output module.
 The Output Module supplies ac power to the
external devices such as motors, lights,
solenoids, etc.
 Internally, the output module accepts a 0 or
1 from the processor, and uses it to turn ON
or OFF a device.
 An output module can have one or several
channels per unit. Each channel is usually
provided with an indicator light to show
whether the particular channel is being
driven ON/OFF.

Output Module
Ref: Process Control Instrumentation - C D
Johnson

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 Output Module

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 CPU & Memory
• CPU: The brain of PLC is the central processing unit (CPU).
• It executes the various logic and sequencing functions by operating on the PLC inputs (sensor
information) to determine the appropriate output signals for the actuator.
• The processor is microprocessor very similar in its construction to those used in personal computers and
other data-processing equipment.
• Memory: Tied to the CPU is the PLC memory, which contains the program of logic, sequencing, and
other input/output operations.
• The memory for a programmable logic controller is specified in the same way as for a computer, and may
range from 1k to over 48 k of storage capacity.
• Memory types are ROM, RAM, EPROM

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 Power Supply
• Power Supply: A power supply of 115 volts is used to provide power to the PLC and any other modules.
Power supplies come in various forms:

• Power supply modules that fit into one of the slots in a chassis

• External power supplies that mount to the outside of a chassis

• Stand alone power supplies that connect to the PLC or I/O through a power cable

• Embedded power supplies that come as part of the PLC block.

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 Programmable Device
• Programming Device: The PLC is programmed by means of a programming device.

• The programming device is usually detachable from the PLC cabinet so that it can be shared between

different controllers.

• Different PLC manufactures provide different devices:

• Simple teach pendant-type devices, similar to those used in robotics

• PLC programming keyboards and CRT displays.

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 Communication Channel
• The buses are the paths used for communication within the PLC.

• The information is transmitted in binary form, i.e. as a group of bits with a bit being a binary digit

of 1 or 0, i.e. on/off states.

• The term word is used for the group of bits constituting some information. Thus an 8-bit word might

be the binary number 00100110.

• Each of the bits is communicated simultaneously along its own parallel wire.

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 Communication Channel

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 A motor or a pump might need to be controlled to operate for a
Timers particular interval of time, or perhaps be switched on after some
To control time time interval. PLCs thus have timers as built-in devices. Timers
count fractions of seconds or seconds using the internal CPU clock.

Timers are to behave like relays with coils which when

energised result in the closure or opening of contacts
after some pre-set time. The timer is thus treated as an
output for a rung with control being exercised over pairs
of contacts elsewhere

The time duration for which a timer has been set is

termed the pre-set and is set in multiples of the time
base used. Typical time bases are 10 ms, 100 ms, 1 s, 10 s
and 100 s. Thus a pre-set value of 5 with a time base of
100 ms is a time of 500 ms.
On-delay timer
Timers  Ladder rung diagram involving a delay-on timer.
Application  The timer is like a relay with a coil which is
energised when the input X400 occurs (rung 1).
 It then closes, after some pre-set time delay, its
contacts on rung 2.
 Thus the output from Y430 occurs some pre-set
time after the input X400 occurs.

Ladder program
with a delay-on
timer
 Motor sequence
 Shows how timers can be used to start three
outputs, e.g. three motors, in sequence
following a single start button being pressed.
 When the start push button is pressed there is
an output from internal relay IRl.
 This latches the start input. It also starts both
the timers, Tl and T2, and motor 1.
 When the pre-set time for timer 1 has elapsed
then its contacts close and motor 2 starts.
 When the pre-set time for timer 2 has elapsed
then its contacts close and motor 3 starts.
 The three motors are all stopped by pressing
the stop push button.
 Counters
Application Figure shows a basic counting circuit. When there is a
pulse input to input 1, the counter is reset. When there
is an input to input 2, the counter starts counting, if the
counter is set for, say, 10 pulses, then when 10 pulse
inputs have been received at input 2, the counter's
contacts will close and there will be an output from
output 1.

if at any time during the counting

there is an input to input 1, the
counter will be reset and start all over
again and count for 10 pulses.
The Program Scan

Gradually the tank fills because 500(fill

motor) is on.
After 100 scans the oil level rises above the low
level sensor and it becomes open. (i.e. FALSE)

Initially the tank is empty. Therefore, input 0000 is

TRUE and input 0001 is also TRUE.
 Signal lamp to monitor operations
 Consider a basic situation where a
signal lamp is required to be
switched on if a pump is running and
the pressure is satisfactory, or if the
lamp test switch is closed.
 For the inputs from the pump and
the pressure sensors we have an
AND logic situation since both are
required if there is to be an output
from the lamp.

 We, however, have an OR logic situation with the test switch in

that it is required to give an output of lamp on regardless of
whether there is a signal from the AND system.
Pressure
emergency release Pressure
sensor Timer

PLC ladder
logic program Counter

Timer Solenoid

Pressure
sensor Solenoid
Wiring diagram - + + -

for PLC PLC

 Pressure
Sensor
- +
Actual Circuit
Safety Diagram
Sensor Solenoid
- + + -
PLC
Manual
shut off
- + Sensor Timer

Counter

Safety Manual
Timer sensor shut off Solenoid

Ladder Logic
 Button

Actual Circuit
Relay Diagram
24 V DC
Motor
Input

Button Motor

Ladder Logic
Power Rails
 Pressure Solenoid
sensor
Actual Circuit
- + PLC
+ - Diagram

Pressure
sensor Timer

Counter
Ladder Logic Timer Solenoid
 Pressure
Sensor
- + Actual Circuit
Safety Diagram
Sensor Solenoid
-
+
- + PLC
Manual
shut off
- +
Sensor Timer

Counter

Ladder Logic Safety Manual

Timer sensor shut off Solenoid
Cyclic movement of a piston
Consider the task of obtaining cyclic
movement of a piston in a cylinder. This
might be to periodically push workpieces into
position in a machine tool with another
similar, but out of phase, arrangement being
used to remove completed workpieces.

 Consider both timers set for 10 s. When

the start contacts X400 are closed, timer
T450 starts. Also there is an output from
Y431. The output Y431 is one of the
solenoids used to actuate the valve.
 When it is energised it causes the
pressure supply P to be applied to the
right-hand end of the cylinder and the
left-hand side to be connected to the vent
to the atmosphere.
 Consider both timers set for 10 s. When the start
contacts X400 are closed, timer T450 starts. Also
there is an output from Y431. The output Y431 is
one of the solenoids used to actuate the valve.
 When it is energised it causes the pressure supply
P to be applied to the right-hand end of the
cylinder and the left-hand side to be connected to
the vent to the atmosphere.
 The piston thus moves to the left. After 10 s, the
normally open T450 contacts close and the
normally closed T450 contacts open. This stops
the output Y431, starts the timer T451 and
energises the output Y430.
 As a result, the pressure supply P is applied to the
left-hand side of the piston and the right-hand
side connected to the vent to the atmosphere.
The piston now moves to the right.
 After 10 s, the T451 normally closed contacts are
opened. This causes the normally closed contacts
of T450 to close and so Y431 is energised. Thus
the sequence repeats itself
 Central heating system

Consider a domestic central heating system where the central heating boiler is to
be thermostatically controlled and supply hot water to the radiator system in the
house and also to the hot water tank to provide hot water from the taps in the
house. Pump motors have to be switched on to direct the hot water from the
boiler to either, or both the radiator and hot water systems according to whether
the temperature sensors for the room temperature and the hot water tank
indicate that the radiators or tank need heating. The entire system is to be
controlled by a clock so that it only operates for certain hours of the day.
 The boiler, output Y430, is switched on if X400 and X401 and either X402
or X403 are switched on.
 This means if the clock is switched on, the boiler temperature sensor
gives an on input, and either the room temperature sensor or the water
temperature sensor give on inputs.
 The motorised valve Ml, output Y431, is switched on if the boiler, Y430,
is on and if the room temperature sensor X402 gives an on input.
 The motorised valve M2, output Y432, is switched on if the boiler, Y430,
is on and if the water temperature sensor gives an on input.
Industrial Mixer

• Filled with liquid

• Heated

• Mix for 10 minutes.

Sequential Function Chart

Fill with
State 1
liquid Start
button Pump
Level full switch 1 1

Level full
State 2 Heat floater Heater

2 2

Temperature Switch
PLC Mixing
Temperature
sensor Motor
State 3 Rotate 3 3

Timer
Ladder Logic Start button
Level full
floater Pump

State 1 Pump

Level full Temperature Sensor

floater Heater

State 2

Temperature Sensor
10 minute
Timer

State 3
10 minute Mixing motor
Timer
 In a certain bank, each of three bank officers has a unique key to
the vault. The bank rules require that two out of the three officers
be present when the vault is opened. Draw the ladder diagram for
a relay logic circuit that will unlatch the door and turn on the light
when two of the three keys are inserted.

Three combinations of keys will open the vault:

A and B, A and C, and B and C.
Each of the three keys—A, B, and C—fits in its own key switch that has two sets
of NO contacts.

The top rung has three branches of switch contacts, one for each acceptable
possibility. At least one branch must have continuity so that the relay coil is
energized.

The bottom rung, activated when the relay contacts close, provides power to
the door-latch solenoid and the vault light.

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 Ladder Logic
Three combinations of keys will open the
vault:
 A and B,A and C, and B and C.
 Each of the three keys—A, B, and C—fits in
its own key switch that has two sets of NO
contacts.
 The top rung has three branches of switch
contacts, one for each acceptable
possibility. At least one branch must have
continuity so that the relay coil is
energized.
 The bottom rung, activated when the relay
contacts close, provides power to the door-
latch solenoid and the vault light.

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An automatic drilling machine
An automatic drilling machine (Figure) might be required to start lowering the drill
when the workpiece is in position, start drilling when the drill reaches the workpiece
and the workpiece is in position, stop drilling when the drill has produced the
required depth of hole, retract the drill and then switch off and wait for the next
workpiece to be put in position before repeating the operation.

Thus we might have a

program of the form:

If switch A closes
Output to motor circuit
If switch B and C closed
Output to valve circuit
 Sequential movement of pistons

Consider another task involving three pistons A, B and C that

have to be actuated in the sequence:
A to the right,
A to the left,
B to the right, (such a sequence is often
B to the left, written A+, A-, B+, B -, C+, C-).
C to the right,
C to the left
• A small house has three windows and two doors. Each window and door has a switch attached
such that the contacts close when a door or window opens. Draw a ladder logic diagram that
will turn on a light if one or more windows are open or if both doors are open.
• A process for washing parts requires the following sequence:
• 1. Spray water and detergent for 2 min (Wash cycle).
• 2. Rinse with water spray till cloths get completed clean (sensed by sensor) (Rinse cycle).
• 3. Water off, air blow dry for 3 min (Drying cycle).
• The sequence is started with a toggle switch. Draw the ladder diagram for this process (using
the Sequencer instruction).
This problem is essentially concerned with
part of the domestic washing machine
program. Devise a ladder program to switch
on a pump for 100 s. It is then to be
switched off and a heater switched on for
50 s. Then the heater is switched off and
another pump is used to empty the water.
Thank You

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