T.C.

Chang

Chapter 7. PROGRAMMABLE
LOGIC CONTROLLER

Dr. T.C. Chang

School of Industrial Engineering
Purdue University

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FUNCTIONS OF CONTROLLERS
1) on-off control,
2) sequential control,

3) feedback control, and

4) motion control.

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CONTROL DEVICES
1) mechanical control - cam, governor,
etc.,
2) pneumatic control - compressed air,
valves,etc.
3) electromechanical control - switches,
relays, a timer, counters, etc,
4) electronics control - similar to
electromechanical control, except uses
electronic switches.
5) computer control.

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PROGRAMMABLE LOGIC
CONTROLLER
Invented in 1968 as a substitute for hardwired relay panels.
"A digitally operating electronic apparatus which uses a
programmable memory for the internal storage of instructions
by implementing specific functions such as logic sequencing,
timing, counting, and arithmetic to control, through digital or
analog input/output modules, various types of machines or
processes. The digital computer which is used to perform the
functions of a programmable controller is considered to be
within this scope.
Excluded are drum and other similar
mechanical sequencing controllers."
National Electrical Manufacturing Association (NEMA)

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VENDORS
MODICOM - GOULD
ALLEN-BRADLEY
GE
SQUARE-D
etc.

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PLC
CPU

Input

Input
Module

Flag
System
Output

Output
Module

User Ladder
Diagram

Working
memory
registers

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An Large Size PLC

The main module
measures 19 x 20 x 14.5.
have upto 10,000 I/O points
supports all functions
expansion slots to
accommodate PC and
other communication
devices.

Allen-Bradley PLC-3

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A Small Size PLC

Measures 4.72x 3.15 x
1.57.
32 I/O points
Standard RS 232 serial
communication port

Allen-Bradley MicroLogix 1000

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SWITCHES
No n-lo c king

Lo c king

No rma lly Ope n

No rma lly Clo s e d

DPST

P1

SPDT

P2

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Multiple Thro w

Multiple P o le

Bre a k-be fo re -ma ke

Ma ke -be fo re -bre a k

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TERMS
Throw - number of states

Pole - number of connecting moving parts (number of individual

circuits).
SPDT

A serial switch box (A-B box) has

two 25 pin serial ports to switch from.
A

B
Output

DPST

Input

Knob
How is this switch classified?
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TYPES OF SWITCHES

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Selector switches
Pushbutton switches
Photoelectric switches
Limit Switches
Proximity switches
Level switches
Thumbwheel switches
Slide switches

RATING:

24 Volts AC/DC
48 Volts AC/DC
120 Volts AC/DC
230 Volts AC/DC
TTL level
(Transistor-to-transistor
5V)
Isolated Input

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RELAYS
A switch whose operation is activated by an electromagnet is called a "relay"
contact

coil

input

Relay coil
R1

Output contact

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R1

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COUNTER
Digital counters output in the form of a relay contact when a preassigned
count value is reached.
input
Re giste r

Accumulator
re se t
conta ct
output

Input
Re se t
Output
Count
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TIMER
A timer consists of an internal clock, a count value register, and an
accumulator. It is used for or some timing purpose.
Clock

Accumulator
re se t
Re giste r

conta
Contact
ct
output

Clock
Reset
Output
Count

Time 5 seconds.
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AN EXAMPLE OF RELAY LOGIC

For a process control, it is desired to have the process start (by turning
on a motor) five seconds after a part touched a limit switch. The
process is terminated automatically when the finished part touches a
second limit switch. An emergency switch will stop the process any
time when it is pushed.
L1
LS1

PB1

LS2

R1

R1

R1

TIMER

R2

PB1
LS1

LS2

PR=5

TIMER
5

Motor
R2

R1

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

Progr am
Loade r

PC
Switche s

Printe r
Proce ssor

I/O
M odule s

M emory

Powe r
Supply

M achine s

Casse tte
Loade r
EPROM
Loade r

Exte r nal De v ice s

Pe riphe rals

A typical PLC
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PLC COMPONENTS
1. Processor

Microprocessor based, may allow arithmetic

operations, logic operators, block memory moves,
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),
EAPROM (Electronically Alterable Programmable
Read Only Memory), and
Bubble Memory.

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3. I/O

PLC
COMPONENTS
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)

CRT programmer
operator console

printer
simulator
EPROM loader
graphics processor

network communication interface

modular PC
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Discrete I/O
AC Voltage I/O
DC Voltage I/O
numerical input and output
special-purpose modules, for example, highspeed timers, and stepping motor controllers

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Analog I/O
Analog inputs:
Flow sensors
Humidity sensors
Potentiometers
Pressure sensors
Temperature sensors
Analog outputs:
Analog meters
Analog valves and actuators
DC and AC motor drives
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Some Special I/O

Thermocouple 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
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A Hand Held Programmer

An Allen-Bradley hand-held programmer for MicroLogix 1000

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

Rail
start
PB1

emergency stop
PB2
R1

Rung

R1

R1
A

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PLC WIRING DIAGRAM

Input
01

02

Output

PLC
01

02

20

11

12
20

03
20

11

External
switches

Stored program

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Input Connections

AC

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DC

TTL

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Output Connections

AC

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DC

TTL

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SCAN
A PLC resolves the logic of a ladder diagram (program) rung by rung,
from the top to the bottom. Usually, all the outputs are updated based on
the status of the internal registers. Then the input states are checked
and the corresponding input registers are updated. Only after the I/Os
have been resolved, is the program then executed. This process is run
in a endless cycle. The time it takes to finish one cycle is called the
scan time. In some controllers the idle state is eliminated. In this case,
the scan time varies depends on the program length.
Output
Input
begin
Idle
Scan cycle

Resolve
logic
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PLC Programming

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Ladder Diagram - most common

Structure Text Programming (ST)
Functional Block Programming (FB)
Instruction List (IL)
Sequential Function Chart (SFC)

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PLC Ladder Diagram

INSTRUCTIONS
1) Relay,
2) Timer and counter,
3) Program control,
4) Arithmetic,
5) Data manipulation,

6) Data transfer, and

7) Others, such as sequencers.

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LOGIC STATES
ON : TRUE, contact closure, energize, etc.
OFF: FALSE, contact open , de-energize, etc.

Do not confuse the internal relay and program with the external
switch and relay. Internal symbols are used for programming.
External devices provide actual interface.

(In the notes we use the symbol "~" to represent

negation. AND and OR are logic operators. )

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AND and OR LOGIC

PB1

PB2

R1

R1 = PB1.AND.PB2

AND

PB3

PB4

R2
R2 = PB2.AND.~PB4

PB1

R1
R1 = PB1 .OR. PB2

OR

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PB2

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COMBINED AND & OR

R1 = PB1 .OR. (PB2 .AND. PB3)

R1

PB1

PB2

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pb3

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RELAY
A Relay consists of two parts, the coil and the contact(s).
Contacts:
a. Normally open

-| |-

b. Normally closed

-|/|-

c. Positive transition sensing

-|P|-

d. Negative transition sensing

-|N|()

Coil:

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a. Coil

-( )-

b. negative coil

-(/)-

c. Set Coil

-(S)-

d. Reset Coil

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Relay (continue)
Coil:
e. Retentive memory Coil

-(M)-

f. Set retentive memory Coil

-(SM)-

g. Reset retentive memory Coil

-(RM)-

h. Positive Transition-sensing Coil

-(P)-

h. Negative Transition-sensing Coil

-(N)-

(set coil latches the state, reset coil deenergize the set coil.
retentive coil retain the state after power failure.)

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TIMERS AND COUNTERS

Input
Timers:

True

a. Retentive on delay

-(RTO)-

b. Retentive off delay

-(RTF)-

c. Reset

-(RST)-

RTO counting stop

RTF

stop

True
counting
resume

counting stop

RTO reach PR value, output ON

RTF reach PR value, output OFF

Counter:

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False

a. Counter up

-(CTU)-

b. Counter down

-(CTD)-

c. Counter reset

-(CTR)-

PR value in 0.1 second

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SEQUENCER
Sequencers are used with machines or processes involving
repeating operating cycles which can be segmented into
steps.
Output
Step

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Dwell time

ON

OFF OFF

5 sec.

ON

ON OFF

10 sec.

OFF

OFF ON

3 sec.

OFF

ON OFF

9 sec.

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A-B PLC
I/O points are numbered, they correspond to the I/O slot on the
PLC.

For A-B controller used in our lab

I/O uses 1-32
Internal relays use 033 - 098
Internal timers/counters/sequencers use 901-932
Status 951-982

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PROGRAMMING EXAMPLE 1
Bar code re ader
microswitch

Stopper
Conveyor

Part

Robot

id
MSI
R1
C1
R2
R3
C2
R4
C3
C4
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Machine

description
microswitch
output to bar code reader
input from bar code reader
output robot
output robot
input from robot
output to stopper
input from machine
input from machine

state
1
1
1
1
1
1
1
1
1

explanation
part arrive
scan the part
right part
loading cycle
unloading cycle
robot busy
stopper up
machine busy
task complete
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SOLUTION
Input
MS1

Outpu t

01

11

C1
C2

02

12

03

13

C3

04

14

C4

05

01

Pro grammable
Controlle r
PLC

11

14

14

02

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14

04

05

03

03

12

13

R1
R2
R3
R4

15

Rung 1. If part arrives and no

part is stopped, trigger the
bar code reader.
Rung 2. If it is a right part,
activate the stopper.
Rung 3. If the stopper is up,
the machine is not busy
and the robot is not busy,
load the part onto the
machine.
Rung 4. If the task is
completed and the robot is
not busy, unload the
machine.
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Structured Text Programming

a high level language
used to express the behavior of functions,
function blocks and programs
In IEC 1131-3 standard, it has a syntax very similar
to PASCAL
strongly typed language
Functions:

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assignments
expressions
statements
operators
function calls
flow control
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Data Types
SINT
INT
DINT
LINT
USINT
UINT
UDINT
ULINT
REAL
LREAL

short integer
integer
double integer
long integer
unsigned short integer
unsigned integer
unsigned double integer
unsigned long integer
real
long real

1 byte
2 bytes
4 bytes
8 bytes
1 byte
2 bytes
4 bytes
8 bytes
4 bytes
8 bytes

BOOL
BYTE
WORD
DWORD
LWORD

boolean
byte
16 bit bit string
32 bit bit string
64 bit bit string

1 bit
1 byte
16 bits
32 bits
64 bits

TIME time duration

DATE calendar date
TOD
time of day
DT
date and time of day
STRING character strings

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Derived Data Types

TYPE

(* user defined data types, this is a comment*)

pressure
:
REAL;
temp
:
REAL;
part_count
:
INT;
END_TYPE;

Structure:
TYPE data_packet:
STRUCT
input
:
t
:
out
:
count
:
END_STRUCT;
END_TYPE;
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BOOL;
TIME;
BOOL;
INT;

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Variable Declarations

Local variable:
VAR

I,j,k :
v
:
END_VAR

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INT;
REAL;

Use VAR, VAR_INPUT,

VAR_OUTPUT, VAR_IN_OUT,
VAR_GLOBAL,
VAR_EXTERNAL for different
variable types.

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Operators and Expressions

( )

parenthesized expression

function( )

function

**

exponentiation

negation

NOT

Boolean complement

+-*/

math operators

MOD

modulus operation

< > <= >=

comparison operators

equal

<>

not equal

AND, &

Boolean AND

XOR

Boolean XOR

OR

Boolean OR

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Y := X+1.0;
y := a AND b;

v := (v1 + v2 + v3)/3
output := (light = open) OR
(door = shut);

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Condition Statements
IF a > 100 THEN
redlight := on;
ELSEIF a > 50 THEN

yellowlight := on;
ELSE
greenlight := on;

END_IF;

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CASE dial_setting OF
1:
x := 10;
2:
x := 15;
3:
x := 18;
4,5: x := 20; (* 4 or 5 *)
ELSE
x := 30;
END_CASE

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Iteration Statements
FOR I:= 0 to 100 BY 1 DO
light[I] := ON;
END_FOR

I := 0;
WHILE I < 100 DO

I := 0;
REPEAT
I := I + 1;
light[I] := on;
UNTIL I > 100;
END_REPEAT

I := I + 1;
light[I] := on;
END_WHILE

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Functions
FUNCTION add_num : REAL
VAR_INPUT
I,J :

REAL

END_VAR
add_num := I + J;
END_FUNCTION
Call a function:
x:= add_num(1.2, 5.6);
Built-in Functions:

ABS, SQRT, LN, LOG, EXP, SIN, COS, TAN, ASIn, ACOS,
ATAN, ADD, MUL, SUB, DIV, MOD, EXPT, MOVE), logic
functions (AND, OR, XOR, NOT), bit string functions (SHL,
SHR shift bit string left and right , ROR, ROL rotate bit
string), etc.
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Programs
PROGRAM example7.1
R1 := MS1 AND (NOT R4);

VAR_INPUT

MSI :

BOOL;

R2 := R4 AND (NOT C3) AND (NOT C2);

C1

BOOL;

R3 := C4 AND (NOT C3);

C2

BOOL;

R4 := C1;

C3

BOOL;

END_PROGRAM

C4

BOOL;

END_VAR
VAR_OUTPUT
R1

BOOL : FALSE;

R2

BOOL : FALSE;

R3

BOOL : FALSE;

R4

BOOL : FALSE;

END_VAR

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Functional Block Programming

Functional block (FB) is a well packaged element of
software that can be re-used in different parts of an
application or even in different projects. Functional
blocks are the basic building blocks of a control system
and can have algorithms written in any of the IEC
languages.

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An Up Counter Function Block

The algorithm in Structured Text:

FUNCTION BLOCK CTU

VAR_INPUT
CU : BOOL;
R : BOOL;
PV : INT;

END_VAR
VAR_OUTPUT
Q : BOOL;

CU
R
PV
Q
CV

: input to be counted
: reset
: preset value
: contact output
: counter value.

CV : INT;
END_VAR

IF R THEN
CV := 0;
ELSEIF CU
AND (CV < PV) THEN
CV := CV + 1;
END_IF;
Q := (CV >= PV);
END_FUNCTION_BLOCK

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A PID Control Function Block

block diagram
SP

set point

PV

sensor feedback

KP

proportional error gain

TR

integral gain

TD

derivative gain

AUTO

calculate

XOUT

output to process

XO

manual output adjustment

cycle

time between execution

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Vout K p E Tr Edt Td

dE
dt

control algorithm

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Instruction List Programming

A low level language which has a structure similar to an
assembly language. Since it is simple, it is easy to learn
and ideally for small hand-held programming devices.
Each line of code can be divided into four fields: label,
operator, operand, and comment.
e.g.

loop

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LD
ST
ANDN

MS1
R1
C3

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Operators
Operator Modifiers Description

GT

greater than

LD

load operand into

register

GE

greater than and equal

to

ST

store register
value into operand

EQ

equal

NE

not equal

set operand true

LE

less than and equal to

reset operand
false

LT

less than

JMP C, N

jump to label

AND

N, (

Boolean AND

CAL C, N

call function block

&

N, (

Boolean AND

RET C, N

OR

N, (

Boolean OR

return from function or

function block

XOR

N, (

Boolean XOR

ADD

addition

execute last deferred

operator

SUB

subtraction

MUL

multiplication

DIV

division

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Modifier N means negate. ( defers the

operator. C is a condition modifier, the
operation is executed if the register value is true.
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Instruction List for Example 1

PROGRAM example7.1
VAR_INPUT

MS1

ANDN

R4

MSI

BOOL;

ST

R1

C1

BOOL;

LD

R4

C2

BOOL;

ANDN

C3

C3

BOOL;

ANDN

C2

C4

BOOL;

ST

R2

END_VAR

LD

C4

VAR_OUTPUT

ANDN

C3

R1

BOOL : FALSE;

ST

R3

R2

BOOL : FALSE;

LD

C1

R3

BOOL : FALSE;

ST

R4

R4

BOOL : FALSE;

END_VAR

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LD

END_PROGRAM

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Sequential Function Chart

(SFC)
A graphics language used for depicting sequential
behavior. The IEC standard grew out of the French
standard Grafcet which in turn is based on Petri-net. A
SFC is depicted as a series of steps shown as rectangular
boxes connected by vertical lines. Each step represent a
state of the system being controlled. The horizontal bar
indicates a condition. It can be a switch state, a timer, etc.
A condition statement is associated with each condition
bar. Each step can also have a set of actions. Action
qualifier causes the action to behave in certain ways. The
indicator variable is optional. It is for annotation
purposes.
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SFC
Action Qualifiers:
N

non-stored, executes while the

step is active

resets a store action

sets an action active

time limited action, terminates

after a given period

time delayed action.

a pulse action, executes once in

a step

SD stored and time delayed

DS time delayed and stored
SL stored and time limited
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SFC for Example 1

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