Programmable Logic

Controllers (PLCs)

Definition
According to National Electrical Manufacturers Association
a PLC is:
A digital electronic device using a programmable memory
to store instructions and to implement specific functions
such as logic, sequence, counting, timing and arithmetic to
control machines and processes through digital or analog
input/output modules.

What is a PLC?

A special computer for logic controls

PLC History
In the late 1960's PLCs were first introduced
Bedford Associates (Bedford, MA) proposed something called
a Modular Digital Controller (MODICON) to a major US car
manufacturer
In the mid70's the dominant PLC technologies were sequencer statemachines and the bit-slice based CPU. The AMD 2901 and 2903 were
quite popular in Modicon and A-B PLCs
Communications abilities began to appear in approximately 1973.
The first such system was Modicon's Modbus. The PLC could now
talk to other PLCs and they could be far away from the actual
machine they were controlling
The 80's saw an attempt to standardize communications with General
Motor's manufacturing automation protocol(MAP
The 90's have seen a gradual reduction in the introduction of new protocols

Basic PLC Operation

PLCs consist of input modules or

points, a Central Processing
Unit (CPU), and output modules
or points.

Pushbuttons (sensors), in this

simple example, connected to
PLC inputs, can be used to start
and stop a motor connected to
a PLC through a motor starter
(actuator).

PLC ARCHITECTURE
Programmable controllers replace most of the relay panel wiring
by software programming.

It is consists of the
following modules:
Power supply module
CPU module
Digital input module
Digital output module
Analog input module
Analog output

PLC
COMPONENTS
1. Processor Microprocessor based, may allow

arithmetic operations, logic operators,

block
memory, computer interface, local
area network,
functions, etc.

2. Memory
Measured in words.
ROM (Read Only Memory),
RAM (Random Access Memory),
PROM (Programmable Read Only Memory),
EEPROM (Electric Erasable Programmable
ROM),
EPROM (Erasable Programmable Read Only
Memory),

PLC COMPONENTS
3. I/O

Modular plug-in periphery

AC voltage input and output,
DC voltage input and output,
Low level analog input,
High level analog input and output,
Special purpose modules, e.g., high speed
timers,
Stepping motor controllers, etc. PID, Motion

4. Power supply AC power

5. Peripheral

hand-held programmer (HHP)

printer
simulator
EPROM loader
graphics processor
network communication interface
modular PC

Discrete I/O :
-AC Voltage I/O or
Discrete Input:
Selector switches,
Pushbuttons,
Photoelectric Eyes,
Limit switches,
Circuit breakers,
proximity switches,
Level switch,
Pressure switch,
Temperature switches,
Motor starter contacts,
Relays contacts and
Thumbwheel switch

-DC Voltage I/O

Non-locking

Normally
open

Multiple
through
SPDT

locking

Normally closed

Multiple
pole
DPST

RELAYS
A switch whose operation is activated by an electromagnet is called
a "relay" . Coil circuit controls many contact points
contact

Relay coil
R1

coil

input

Output contact normally

open
Output contact normally
closed

R1

R1

Relays and Schematic

Symbols

in p u t c o il

O R

n o r m a lly
c lo s e d

n o r m a lly
open

O R

Logical Control with Relays

115VA C
wall plug

relay logic

input B
(normally open)

input A
(normally closed)

output C
(normally open)

C
ladder logic

Relay Logic In a PLC

push buttons

power
supply
+24V
com.

PLC
inputs

ladder
logic

outputs

115Vac
AC power
neut.

light

Discrete Output
Alarms,
Control relays,
Fans, Lights, Horns,
Valves,
motor starters, and
Solenoids

Analog I/O
Analog inputs:
-Flow sensor,
Pressure sensors,
Potentiometers,

Humidity sensors,
Temperature sensors,
load cell transducers

Analog outputs:
Analog meters
Analog valves
Actuators
Chart recorders
DC and AC motor drives

Some Special
Thermocouple
I/O input

Low level analog signal, filtered, amplified, and digitized

before sending to the processor through I/O bus.
Fast input
50 to 100 microsecond pulse signal detection.
ASCII I/O
Communicates with ASCII devices.
Stepper motor output
Provide directly control of a stepper motor.
Servo interface
Control DC servo motor for point-to-point control and
axis positioning.
PID control
The Proportional Integral Derivative is used for closed
loop process control.
Network module

LADDER DIAGRAM
A ladder diagram (also called contact symbology) is a means
of graphically representing the logic required in a relay
logic system.

Rail
Rung

start
PB1

emergency stop
PB2

R1

R1

R1
A

LADDER DIAGRAM
The left vertical line of a ladder
logic diagram represents the
power or energized conductor.
The output element or instruction
represents the neutral or return
path of the circuit.
The right vertical line, which
represents the return path on a
hard-wired control line diagram,
is omitted. Ladder logic diagrams
are read from left-to-right, topto-bottom. Rungs are sometimes
referred to as networks.
A network may have several
control elements, but only one
output coil.

Reading Ladder Logic

HOT

NEUTRAL
A

INPUTS

OUTPUTS

Note: Power needs to flow through some combination of the inputs

(A,B,C,D,E,F,G,H) to turn on outputs (X,Y).

A Ladder Logic Example

Note: When A is pushed, the output B will turn on, and

the input B will also turn on and keep B on perma
nently - until power is removed.
Note: The line on the right is being left of f intentionally
and is implied in these diagrams.

Statement list
A statement list (STL) provides another view of a set of instructions. The
operation, what is to be done, is shown on the left. The operand, the
item to be operated on by the operation, is shown on the right. The set
of instructions in this statement list perform the same task as the ladder
diagram.

0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

0
0
0
0
0
0
0
0
0

0
1
2
3
4
5
6
7
8

LD N
LD
A N D
LD
LD
A N D
O R
ST
EN D

A
B

t h e m n e m o n ic c o d e is e q u iv a le n t t o
t h e la d d e r lo g ic b e lo w

C
D
X
A

EN D

N o t e : T h e n o t a t io n s h o w n a b o v e is
n o t s t a n d a r d A lle n - B r a d le y
n o t a t io n . T h e p r o g r a m t o t h e
r ig h t w o u ld b e t h e A - B e q u iv a
le n t .

SO R
BST
X IC A
X IO B
N X B
X IO C
X IO D
BN D
O TE X
EO R
EN D

Function Block Diagrams

Function Block Diagrams (FBD) provide another view of a set
of instructions. Each function has a name to designate its
specific task. Functions are indicated by a rectangle. Inputs
are shown on the left-hand side of the rectangle and outputs
are shown on the right-hand side.

Standard PLC scan cycle

PLC Scan
The PLC program is executed as part of a repetitive process referred
to as a scan. A PLC scan starts with the CPU reading the status of
inputs. The application program is executed using the status of the
inputs. Once the program is completed, the CPU performs internal
diagnostics and communication tasks.
The scan cycle ends by updating the outputs, then starts over. The
cycle time depends on the size of the program, the number of I/Os,
and the amount of communication required.

Software
Software is any information in a form that a
computer or PLC can use. Software includes the
instructions or programs that direct hardware.
Hardware
Hardware is the actual equipment. The PLC, the programming device,
and the connecting cable are examples of hardware.

Basic Requirements
In order to create or change a program, the following items are
needed:
PLC
Programming Device
Programming Software
Connector Cable

Programming Devices
The program is created in a programming device (PG) and then
transferred to the PLC. The program for the S7-200 can be
created using a dedicated Siemens SIMATIC S7 programming
device, such as a PG 720 (not shown) or PG 740, if STEP 7
Micro/WIN software is installed.

A personal computer (PC), with STEP 7 Micro/WIN installed,

can also be used as a programming device with the S7-200.

Software
A software program is required in order to tell the PLC what instructions it
must follow. Programming software is typically PLC specific. A software
package for one PLC, or one family of PLCs, such as the S7 family, would
not be useful on other PLCs. The S7-200 uses a Windows based software
program called STEP 7-Micro/WIN32. The PG 720 and PG 740 have STEP
7 software pre-installed. Micro/WIN32 is installed on a personal computer
in a similar manner to any other computer software.

Connector Cables PPI

(Point-to-Point Interface)
Connector cables are required to transfer data from the (Point-to-Point
Interface) programming device to the PLC. Communication can only take
place when the two devices speak the same language or protocol.
Communication between a Siemens programming device and the S7-200 is
referred to as PPI protocol (pointto- point interface). An appropriate cable is
required for a programming device such as a PG 720 or PG 740. The S7-200
uses a 9-pin, D-connector. This is a straight-through serial device that is
compatible with Siemens programming devices (MPI port) and is a standard
connector for other serial interfaces.

Connector Cables PPI

A special cable is needed when a personal computer is used as a
programming device. Two versions of this cable are available.
One version, called an RS-232/PPI Multi-Master Cable, connects a
personal computers RS-232 interface to the PLCs RS-485 connector.
The other version, called a USB/PPI Multi-Master Cable, connects a
personal computers USB interface to the PLCs RS-485 connector.

S7-200 Micro PLCs

The S7-200 Micro PLC is the smallest member of the SIMATIC S7 family
of programmable controllers.
The central processing unit (CPU) is internal to the PLC. Inputs and
outputs (I/O) are the system control points. Inputs monitor field devices,
such as switches and sensors. Outputs control other devices, such as
motors and pumps. The programming port is the connection to the
programming device.

S7-200 Models
There are five S7-200 CPU types: CPU 221, CPU 222, CPU 224,
CPU 224XP, and CPU 226 and two power supply configurations
for each type.

S7-200 Features
The S7-200 family includes a wide variety of CPUs and features. This
variety provides a range of features to aid in designing a cost-effective
automation solution. The following table provides a summary of the
major features, many of which will be covered in this course.

Mode Switch and

Analog Adjustment
When the mode switch is in the RUN position the CPU is in the run
mode and executing the program. When the mode switch is in the STOP
position the CPU is stopped. When the mode switch is in the TERM
position the programming device can select the operating mode.
The analog adjustment is used to increase or decrease values stored in
special memory. These values can be used to update the value of a timer
or counter, or can be used to set limits.

Optional Cartridge
The S7-200 supports an optional memory cartridge that provides a
portable EEPROM storage for your program. The cartridge can be
used to copy a program from one S7-200 PLC to a like S7-200 PLC.

Expansion Modules
The S7-200 PLCs are expandable. Expansion modules contain additional
inputs and outputs. These are connected to the base unit using a ribbon
connector.

The ribbon connector is protected by a cover on the base unit. Sideby-side mounting completely encloses and protects the ribbon
connector.

The ribbon connector is protected by a cover on the base unit. Sideby-side mounting completely encloses and protects the ribbon
connector.

External Power Supply

An S7-200 AC/DC/Relay would be connected to a 120 or

230 VAC power supply.

I/O Numbering
S7-200 inputs and outputs are labeled at the wiring terminations and
next to the status indicators. These alphanumeric symbols identify
the I/O address to which a device is connected. This address is used
by the CPU to determine which input is present and which output
needs to be turned on or off. I designates a discrete input and Q
designates a discrete output. The first number identifies the byte, the
second number identifies the bit. Input I0.0, for example, is byte 0,
bit 0.

Inputs

Outputs

Freeport Mode
The programming port has a mode
called freeport mode.
Freeport mode allows connectivity to
various intelligent sensing devices
such as a bar code reader.

Printer

Freeport mode can also be used to

connect to a non-SIMATIC printer.

Interconnection

It is possible to use one

programming device to address
multiple S7-200 devices on the
same communication cable. A total
of 31 units can be interconnected
without a repeater.

Symbols

Contacts

Coils
Coils represent relays that are energized when power flows to them.
When a coil is energized, it causes a corresponding output to turn on
by changing the state of the status bit controlling that output to 1.
That same output status bit may be used to control normally open and
normally closed contacts elsewhere in the program.
Boxes

Boxes represent various instructions or functions that are executed when

power flows to the box. Typical box functions are timers, counters, and
math operations.

Entering Elements

An AND Operation

PLC HARD WIRING

DIAGRAM
External switches with stored program ladder
diagram and output devices can be presented using
The shown PLC hard wired diagrams
A

Input
01

Output

PLC
01

02

20

11
12

02
20

03
20

11

External
switches

Stored program

PLC
Programming Device
Programming Software
Connector Cable

Input Card Example

n o r m a lly o p e n p u s h - b u t t o n
24 V A C
Pow er
S u p p ly

H ot

P L C In p u t C a rd
24V A C
00
01
02

N e u t.

03
04
n o r m a lly o p e n
t e m p e r a t u r e s w it c h

05
06
07
C O M

P u s h b u t t o n ( b o b :3 :I . D a t a . 1 )

it is in r a c k " b o b "
s lo t 3

T e m p s e n s o r ( b o b :3 :I . D a t a . 3 )

N o t e : in p u t s a r e n o r m a lly h ig h im p e d a n c e . T h is m e a n s t h a t t h e y w ill
u s e v e r y lit t le c u r r e n t .

Output Card Example (Transistors)

24 V D C
O u tp u t C a rd

120 V A C
P ow er
S u p p ly

00

N e u t.

01

R e la y

02
03
M o to r

04
05

24 V L am p

06
07
C O M
ra c k "s u e "
s lo t 2

+24 V D C
P ow er
S u p p ly
C O M
M o t o r ( s u e :2 . O . D a t a . 3 )

L a m p ( s u e :2 . O . D a t a . 3 )

Output Card Example (Relays)

1 2 0 V A C /D C
O u tp u t C a rd

24 V D C
P ow er
S u p p ly

00
01
02
03
R e la y

04
05
06
07
in r a c k 0 1
I/O g ro u p 2

M o to r
2 4 V la m p

120 V A C
P ow er
S u p p ly

Some Design Issues

DC voltages are usually lower, and therefore safer (e.g.,
24V).
DC inputs are very fast, AC inputs require a longer on-time.
DC voltages can be connected to more electrical systems.
AC signals are more immune to noise than DC.
AC power is easier and less expensive to supply to
equipment.
AC signals are very common.

Relays

Contactor - Special relays for switching large current loads.

Motor Starter - Basically a contactor in series with an overload relay
to cut off when too much current is drawn.
Arc Suppression - when any relay is opened or closed an arc will
jump. This becomes a major problem with large relays. On relays
switching AC this problem can be overcome by opening the relay
when the voltage goes to zero (while crossing between negative and
positive). When switching DC loads this problem can be minimized by
blowing pressurized gas across during opening to suppress the arc
formation.
AC coils - If a normal relay coil is driven by AC power the contacts will
vibrate open and close at the frequency of the AC power. This problem
is overcome by adding a shading pole to the relay.

Problem: You are planning a project that will be controlled by a PLC.

Before ordering parts you decide to plan the basic wiring and select
appropriate input and output cards. The devices that we will use for
inputs are 2 contact switches, a push button and a thermal switch. The
output will be for a 24Vdc solenoid valve, a 110Vac light bulb, and a
220Vac 50HP motor. Sketch the basic wiring below including PLC cards.
L1

010
s to p

s ta rt

C R1
M C R

020
C R1

030

040

L1
C R1

I :0 / 0

PB1

I :0 / 1

LS1

I :0 / 2

050
060

PB2

070

PLC

N
O :0 / 0

O :0 / 1

O :0 / 2

I :0 / 3
O :0 / 3

9 0 -1

1 0 0 -1

1 1 0 -1

090

100

S1
1 2 0 -1

120
C R2

C R1
090

9 0 -1

035

100

1 0 0 -1

050

110

1 1 0 -1

060

1 2 0 -1

070

120

130

C R2

L2
G

11 0

ac com

080

L1
R

D r ill S t a t io n
L1
N

Wiring Symbols

disconnect
(3 phase AC)

normally open
limit switch

normally open
push-button

circuit interrupter
(3 phase AC)

normally closed
limit switch

normally closed
push-button

double pole
push-button

breaker (3 phase AC)

mushroom head
push-button

Input
Connections

AC
AC input module allows
interfacing of input
devices which provide
AC output. Converter is
used to covert incoming
AC voltage to a DC logic
signal to be used by the
processor

DC
The Dc input module
allows interfacing of
input devices which
provide a DC output
voltage. The range of
input voltage for DC
input module varies
between 5 VDC and 30
VDC

TTL
TTL input interfaces allow the
controller to accept signals
from TTL compatible devices
including solid state controls
and sensing instrumentation.
TTL inputs are used for
interfacing with some 5 VDC
level control devices and
several types of photoelectric
sensors

Output Connections

AC
AC output module
allows interfacing of
output devices which
provide AC input.

DC
DC output module
interface is used to
control DC loads by
switching On and Off.

TTL
The TTL output
interface allows
the controller to
drive output
devices that are
TTL compatible
such as seven
segment LED
display

DC Inputs
The difference between the two types is whether the load (in our
case, the plc is the load) is switched to ground or positive voltage.
An NPN type sensor has the load switched to ground whereas a
PNP device has the load switched to positive voltage.

DC Inputs
Inside the sensor, the transistor is just acting as a switch. The sensors
internal circuit tells the output transistor to turn on when a target is
present. The transistor then closes the circuit between the 2 connections
shown above. (V+ and plc input).

AC Inputs
AC input modules are less common these days than dc input modules
sensors typically have transistor outputs

Relay Outputs

A relay is non-polarized and typically it can switch either AC or DC.

Here the common is connected to one end of our power supply and
the other end of the supply is connected to the load. The other half
of our load gets connected to the actual plc output you have
designated within your ladder program.

Transistor Outputs

Shown above is how we typically connect our output device to the

transistor output. Please note that this is an NPN type
transistor. If it were a PNP type, the common terminal would most
likely be connected to V+ and V- would connect to one end of our
load. Note that since this is a DC type output we must always
observe proper polarity for the output. One end of the load is
connected directly to V+ as shown above.

Typical I/O connections with PLC:

The shown
diagram is a
typical PLC
with input
and output
module to
control
pneumatic
actuator

Advantages of PLCs:

Increase flexibility,
Faster implementation of changes and
correction,
Lower cost,
Increased visual observations,
Increased operation speed,
Increased reliability and maintainability,
Increased security,
Reprogramming capability,
Elimination of wiring.

Summary
This sequence covered the following
topics
1-PLCS definition
2-PLCs Components
3-PLCS advantages
5-PLCS I/O connections