Lecture 1’s sequence

1.1 Programmable Logic Controllers

1.2 Parts of a PLC

1.3 Principles of Operation

1.4 Modifying the Operation

1.5 PLCs versus Computers

1.6 PLC Size and Application

1.1. Programmable Logic Controllers

▪ Programmable logic
controllers are now
the most widely used
industrial process
control technology.

▪ A PLC is basically a digital computer designed for use in machine control.

It has been designed to operate in the industrial environment and is
equipped with special input/output interfaces and a control
programming language.
1.1. Programmable Logic Controllers

▪ A PLC is designed to withstand the industrial environment, operating in

❑ Wide range of ambient temperatures

❑ Vibration

❑ Humidity

❑ Relatively resistant to electrical noise inherent in industrial facilities

1.1. Programmable Logic Controllers

▪ Initially the PLC was used to replace relay logic, but its ever-increasing
range of functions includes timing, counting, calculating, comparing, and
the processing of analog signals.

▪ The structure of a PLC is based on the same principles as those

employed in computer architecture.
1.1. Programmable Logic Controllers

▪ Programmable Logic Controller Advantages

PLC
Elimination of much control
of the hardwiring panel

associated with
Relay
conventional relay control
control circuits. panel
1.1. Programmable Logic Controllers

▪ Programmable Logic Controller Advantages

Increased Reliability - Since

all the logic is contained in
the PLC’s memory, there is
no chance of making a logic
wiring error.
1.1. Programmable Logic Controllers

▪ Programmable Logic Controller Advantages

More Flexibility - It is
easier to create and
change a program in
a PLC than to wire
and rewire a circuit.
1.1. Programmable Logic Controllers

▪ Programmable Logic Controller Advantages

Lower Cost - Generally, if an

application has more than
about a half-dozen control
relays, it will probably be less
expensive to install a PLC.
1.1. Programmable Logic Controllers

▪ Programmable Logic Controller Advantages

Communications Capability - A PLC can

communicate with other controllers or
computer equipment to perform such
functions as supervisory control, data
gathering, monitoring devices and
process parameters, and download
and upload of programs.
PLC
Communications
Module
1.1. Programmable Logic Controllers

▪ Programmable Logic Controller Advantages

Sensor
Faster Response Time - Machines
that process thousands of items
per second and objects that
spend only a fraction of a second
in front of a sensor require the
PLC’s quick-response capability.

Sensor
1.1. Programmable Logic Controllers

▪ Programmable Logic Controller Advantages

Easier to Troubleshoot - To find
and fix problems, users can
display the control program on a
monitor and watch it in real time PLC

as it executes. Process
Monitor
Lecture 1’s sequence

1.1 Programmable Logic Controllers

1.2 Parts of a PLC

1.3 Principles of Operation

1.4 Modifying the Operation

1.5 PLCs versus Computers

1.6 PLC Size and Application

1.2. Parts of a PLC

▪ The major parts of a PLC

system are the Central
Processing Unit (CPU),
the Input/Output (I/O)
section, the Power
Supply, and the
Programming Device.
1.2. Parts of a PLC

▪ The term architecture can refer to PLC hardware, to PLC software, or to a

combination of both.

❑ An open architecture design allows the system to be connected easily

to devices and programs made by other manufacturers.

❑ A system with a closed architecture is one whose design is

proprietary, making it more difficult to connect to other systems.
1.2. Parts of a PLC

▪ Fixed I/O is typical of

small PLCs that come in
one package with no
separate, removable
units. The processor
and I/O are packaged
together.
1.2. Parts of a PLC

▪ Modular I/O is divided by compartments

into which separate modules can be
plugged. This feature greatly increases
your options and the unit’s flexibility.
1.2. Parts of a PLC

▪ The power supply provides DC

power to all modules that plug
into the rack. For large PLC
systems, this power supply does
not normally supply power to
the field devices.

Power Supply
1.2. Parts of a PLC

▪ The processor (CPU) consists of a

microprocessor for implementing
the logic and controlling the
communications among the
modules.

The processor requires memory

for storing the results of the
logical operations performed by
the microprocessor as well as the
operating system and the PLC
program.
1.2. Parts of a PLC

▪ The PLC program is

executed as part of a
repetitive process Starts with the CPU
reading the status
referred to as a scan. of all inputs.

Repeated
Continuously
Concludes with
the updating of
all outputs.
1.2. Parts of a PLC

▪ The I/O (Input/Output)

system forms the
Input devices such
interface by which as pushbuttons,
field devices are limit switches, and
sensors are
connected to the hardwired to the
controller. input module
terminals.
1.2. Parts of a PLC

▪ The I/O (Input/Output)

system forms the
interface by which
Output devices
field devices are such as motor
connected to the starters, solenoid
valves, and
controller. indicator lights
are hardwired to
the output
module
terminals.
1.2. Parts of a PLC

▪ A programming device
is used to enter the
desired program into
the memory of the
processor.

Hand-held
The program is entered using the relay
programming device.
ladder logic programming language.
1.2. Parts of a PLC

▪ A personal computer
(PC) is the most used
programming device.

The computer monitor can

display more logic on the
screen thus simplifying
interpretation of the
program.
1.2. Parts of a PLC

▪ A program is a series of
instructions that directs
the PLC to execute actions.

Relay ladder logic, the

standard programming
language, is based on
electromagnetic relay
control.
Lecture 1’s sequence

1.1 Programmable Logic Controllers

1.2 Parts of a PLC

1.3 Principles of Operation

1.4 Modifying the Operation

1.5 PLCs versus Computers

1.6 PLC Size and Application

1.3. Principles of Operation

▪ Mixer Process Control Problem

➢ A mixer motor is to be used to
automatically stir the liquid in a
vat when the temperature and
pressure reach preset values.

➢ Manual operation of the motor is

provided by means of a separate
pushbutton station.
1.3. Principles of Operation

▪ Hardwired relay method for control of motor

The motor starter coil (M) is energized when both the pressure and temperature
switches are closed or when the manual pushbutton is pressed.
1.3. Principles of Operation

▪ PLC method for control of motor

Field devices are
The same input field hardwired to an
devices (pressure switch, input module.
temperature switch, and
pushbutton) are used.
1.3. Principles of Operation

▪ PLC method for control of motor

The same output field device Starter coil is hardwired
(motor starter coil) is used. to an output module.
1.3. Principles of Operation

▪ Enter the PLC ladder logic program into the memory of the CPU
➢ The symbols represent
instructions, and the
numbers represent the
instruction’s addresses.

➢ Each input and output

device is given an address,
which lets the PLC know
where it is connected.
1.3. Principles of Operation

▪ Enter the PLC ladder logic program into the memory of the CPU
➢ For the program to operate, the
controller is placed in the RUN mode.

➢ During each scan, the controller

examines the status of input devices,
executes the user program, and
changes outputs accordingly.

➢ The coil O/1 is energized when contacts I/1 and

I/2 are closed or when contact I/3 is closed.

➢ Either of these conditions provides a continuous

logic path across the rung that includes the coil.
1.3. Principles of Operation

▪ Typical wiring required to

implement the process control
scheme using a fixed PLC
controller.
Lecture 1’s sequence

1.1 Programmable Logic Controllers

1.2 Parts of a PLC

1.3 Principles of Operation

1.4 Modifying the Operation

1.5 PLCs versus Computers

1.6 PLC Size and Application

1.4. Modifying the Operation

▪ One of the important features of

a PLC is the ease with which the
program can be changed.
❑ Original hardwired process control
circuit modified.

❑ Change requires that the manual

pushbutton control be permitted
to operate at any pressure, but not
unless the specified temperature
setting has been reached.
1.4. Modifying the Operation

❑ If a relay system were used, it would

require some rewiring of the circuit

❑ If a PLC system were used, no

rewiring would be necessary.

❑ The inputs and outputs are still the

same.

❑ All that is required is to change the

PLC ladder logic program.
Lecture 1’s sequence

1.1 Programmable Logic Controllers

1.2 Parts of a PLC

1.3 Principles of Operation

1.4 Modifying the Operation

1.5 PLCs versus Computers

1.6 PLC Size and Application

1.5. PLCs versus Computers

▪ The architecture of a PLC is

basically the same as that of
a personal computer.

Unlike PCs, the PLC is

designed to operate in the
industrial environment
with wide ranges of
ambient temperature and
humidity.
1.5. PLCs versus Computers

▪ A properly designed PLC

installation is not as
affected by the electrical
noise inherent in most
industrial locations.
1.5. PLCs versus Computers

▪ Unlike the personal

computer, the PLC
is programmed in
relay ladder logic or
other easily learned
languages.

The PLC comes with its program language built into its
memory and has no permanently attached keyboard, CD
drive, or monitor.
1.5. PLCs versus Computers

▪ Computers are
complex computing
machines capable
of executing several
programs or tasks
simultaneously and
in any order.

▪ PLCs execute a single

program in an orderly and
sequential fashion from
first to last instruction.
1.5. PLCs versus Computers

▪ PLC control systems have been designed

to be easily installed and maintained.

Input/output modules for

Troubleshooting is simplified using fault connecting the field devices
indicators and messaging displayed on are easily connected and
the programmer screen. replaced.
1.5. PLCs versus Computers

▪ Software associated with a PLC but written and run on a personal

computer falls into the following two broad categories:
❑ PLC software that allows the
user to program and document
gives the user the tools to write
a PLC program—using ladder
logic or another programming
language—and document or
explain the program in as much
detail as is necessary.
1.5. PLCs versus Computers

▪ PLC software that allows the

user to monitor and control the
process is also called a human
machine interface (HMI).
▪ It enables the user to:
❑ view a process - or a graphical
representation of a process on a
monitor.
❑ determine how the system is
running, trend values, and receive
alarm conditions.
1.5. PLCs versus Computers

▪ Programmable Automation Controllers (PACs) combine PLC ruggedness

with PC functionality.
❑ Using PACs, you can build advanced
systems incorporating software
capabilities such as advanced control,
communication, data logging, and
signal processing with rugged
hardware performing logic, motion,
process control, and vision.
Lecture 1’s sequence

1.1 Programmable Logic Controllers

1.2 Parts of a PLC

1.3 Principles of Operation

1.4 Modifying the Operation

1.5 PLCs versus Computers

1.6 PLC Size and Application

1.6. PLC Size and Application

▪ The criteria used in

categorizing PLCs include
functionality, number of
inputs and outputs, cost,
and physical size
1.6. PLC Size and Application

▪ The I/O count is the most important size factor. In

general, the nano is the smallest size with less than
15 I/O points. This is followed by micro types (15 to
128 I/O points), medium types (128 to 512 I/O
points), and large types (over 512 I/O points).

Matching the PLC with

the application is a key
factor in the selection
process.
1.6. PLC Size and Application

▪ There are three major

types of PLC applications:
single ended, multitask,
and control management.

A single ended application

involves one PLC controlling
one process.
1.6. PLC Size and Application

▪ A multitask PLC application involves one

PLC controlling several processes.

Adequate I/O capacity

is a significant factor in
this type of installation.
1.6. PLC Size and Application

▪ A control management
PLC application involves
one PLC controlling
several others.

❑ This kind of application requires a large PLC processor designed to

communicate with other PLCs and computers
❑ The control management PLC supervises several PLCs by downloading
programs that tell the other PLCs what must be done.
1.6. PLC Size and Application

▪ Memory is the part of a PLC

controller that stores data,
instructions, and the control
program.
❑ Memory size is usually expressed in K values: 1 K, 6 K, 12 K, and so on.

❑ The measurement kilo, abbreviated K, normally refers to 1000 units.

❑ When dealing with computer or PLC memory, however, 1 K means 1024, because
this measurement is based on the binary number system (210 = 1024).

❑ Depending on memory type, 1 K can mean 1024 bits, 1024 bytes, or 1024 words.
1.6. PLC Size and Application

▪ The amount of memory required

depends on:
❑ Number of I/O points used

❑ Size of control program

❑ Data-collecting requirements

❑ Supervisory functions required

❑ Future expansion