LECTURE 01

INTRODUCTION TO PROGRAMMABLE
LOGIC CONTROLLER-PLC
 LERNING OBJECTIVES
• Upon successful completion of this lecture
trainees should be able to;
➢Define the term Programmable logic
Controller-PLC
➢ Explain evolution of PLC
➢ List parts of PLC
➢ Identify Components of PLC
➢ Distinguish PLC Vs PC
➢Explain the working principle of PLC
 INTRODUCTION
• A programmable logic circuit (PLC) is a digital
computer used for automation of
electromechanical processes such as control
of machinery on factory assembly lines,
control of lighting fixtures etc
• Programmable Logic Controllers are the most
widely used electronic devices in the factories
due to its simplicity and versatility.
 Introduction cont…..
• PLCs are used in many industries and
machines. Unlike general-purpose computers,
the PLC is designed for multiple inputs and
output arrangements, extended temperature
ranges, immunity to electrical noise, and
resistance to vibration and impact.
• Programs to control machine operation are
typically stored in battery-backed or non-
volatile memory.
 What is a PLC?
Definition
•A programmable logic controller (PLC) is an
industrial solid-state computer that monitors
inputs and outputs, and makes logic-based
decisions for automated processes or machines
OR
•Programmable Logic Controllers (or PLC) are
solid-state devices designed to perform logical
decision making for control applications in the
industrial environment
 Define PLC terminologies:

• Several different terms used to described

programmable controllers:
(i) PLC –Programmable Logic Controller (UK
origin)
ii. PC – Programmable controller (US origin)
• Most referring to the functional operation of the
machine.
• PLC has been used in this text to avoid
confusion with the personal computer.
Samples of PLCs
 History of the PLC
• PLC invention was in response to the needs of
the American automotive manufacturing
industry where software revision replaced the
re-wiring of hard-wired relay based control
panels when production models changed.
Before the PLC; controlling, sequencing, and
safety interlocking logic for manufacturing
automobiles relied on thousands of relays,
cam timers, and drum sequencers and
dedicated closed-loop controllers
 History of PLC cont…
• The process for updating such facilities for the
yearly model change-over was very time
consuming and expensive, as electricians
needed to individually and manually rewire
each and every relay.
• Therefore dealing with a thousands of relays
became a tedious work, thus a need for PLC
arises.
 History of the PLC

In 1968, a group of engineers from General

Motors developed the concept of PLC with an
initial specification. The PLC must be:
i. Easy to program.
ii. Not need rewiring the control system if
change the program.
iii. Smaller in size, cheaper and high reliability.
iv. simple construction and low maintenance
v. Cost- competitive
 The history of PLC cont..
• Bedford Associates started a new company
dedicated to developing, manufacturing,
selling, and servicing this new product:
MODICON, which stood for MOdular DIgital
CONtroller. One of the people who worked on
that project was Dick Morley, the "father" of
the PLC.
 The history of PLC cont..
• In other industries, PLCs replaced relay
systems used in manufacturing applications.
This eliminated the high cost of maintaining
these inflexible systems. In 1970, with the
innovation of the microprocessor, the machine
that was originally used as a relay
replacement device only, evolved into the
advanced PLC of today.
 History of PLC cont…..
• The PLC was immediately accepted in the
automotive industry and are commonly found
in applications in many different industries.
The PLC performs functions that formerly
required relays, solid-state electronics, or mini
computers. PLC's are lightweight, rugged
devices that operate without fans, air
conditioning or electrical filtering.
 Parts of PLC
• The PLC has three major parts which are;
✓The input
✓Central Processing Unit and
✓The output
• The PLC Input/output (I/O)
Electrical noise, such as spikes in the power
lines or load kick-back would have serious
impact on a PLC's internal circuits since its
CPU operates at very low voltages levels.
 The Input/output of PLC
• This is where the (I/O) portion of a PLC plays a
critical role. The I/O, both inputs and outputs,
protects the CPU from electrical noise.
• The I/O section is where status signals are
filtered to remove noise, validate voltage
levels, and CPU decisions are made and put
into operation.
• The PLC Inputs provide their status to a
storage area within the CPU and outputs are
driven from similar stored status in the CPU.
 Examples of I/O Signals
• Inputs:
– Pushbutton (Energizing an Input)
– Relay Contact Output
– DC Voltage Level
– Digital Logic Signal (+5V or 0 V, etc)
• Outputs:
– 24 V ac
– 120 V ac
– 120 V dc etc.

16
 The Central Processing Unit (CPU)
• The function of the CPU is to store and run
the PLC software programs. It also interfaces
with the Co-Processor Modules, the I/O
Modules, the peripheral device, and runs
diagnostics. It is essentially the "brains" of the
PLC.
Central Processing Unit
 Main components
• Programmable Logic Controllers have three
components. These three PLC components are:
(i) processor,
(ii) power supply, and
(iii) an input/output (I/O) section. The
processor, or the brain of the PLC system, is
a solid-state device designed to perform a
wide variety of production, machine tool,
and process-control functions.
 PLC sections
A basic PLC system consists of the following
sections:
• Input/ Output Section: The input section or
input module consists of devices like sensors,
switches and many other real world input
sources. The input from the sources is
connected to the PLC through the input
connector rails. The output section or output
module can be a motor or a solenoid or a
lamp or a heater, whose functioning is
controlled by varying the input signals.
The I/O system
 PLC sections cont…
• CPU or Central Processing Unit:
It is the brain of the PLC. It can be a hexagonal
or an octal microprocessor. It carries out all the
processing related to the input signals in order
to control the output signals based on the
control program.
The CPU
 Programming device and power
supply
• Programming Device: It is the platform where
the program or the control logic is written. It
can be a hand-held device or a laptop or a
computer itself.
• Power Supply: It generally works on a power
supply of about 24 V, used to power input and
output devices.
The power supply
 The rack
• The rack is the component that holds
everything together. Depending on the needs
of the control system it can be ordered in
different sizes to hold more modules. It has a
backplane at the rear which allows the cards
to communicate with the CPU.
• The power supply plugs into the rack as well
and supplies a regulated DC power to other
modules that plug into the rack.
 Memory
The memory is divided into two parts- The
data memory and the program memory. The
program information or the control logic is
stored in the user memory or the program
memory from where the CPU fetches the
program instructions. The input and output
signals and the timer and counter signals are
stored in the input and output external image
memory respectively.
Components
 PLC Vs PC
• Processor speed: This was the reason that a
PLC designed for instead of just using a
computer. A PLC uses one dedicated
microprocessor instead of using a full
processor like computers, or using dual
processors that computers today use.
• The PLC microprocessor has a very small and
limited operating system dedicated to only
one task, scanning in sequential order one
rung of ladder logic (programming language)
at a time.
 PLC Vs PC cont….
• A computer is a multi-task, capable of
scanning and acting on multiple code
simultaneously. So the computer’s operating
systems is much larger and slower.
• PLCs result in real world actions or decisions in
milliseconds and sometime microseconds.
 PLC Vs PC cont…
• Programming language: When PLC were
designed, the secondary goal was to make it
easy for Electrician and electrical engineers to
write codes, to troubleshoot, and modify
existing programs.
• So the Ladder Logic was picked as the primary
programming language. Ladder Logic is a
symbolic graphical programming language
that is basically an adaptation of electricians
electrical ladder diagram.
 PLC Vs PC cont..
• On other hand computers were designed for
the IT and computer programmers to work
with, using mostly structured text type
programming language which is more difficult
for electricians to work with.
 PLV Vs PC cont…
• Reliability: PLCs are more reliable than PCs in
case a problem occurs.
• Computers are just software potentially
failing, PLCs are real-world actions and
physical failures.
• Also, to increase reliability, the electronics for
a PLC are industrial grade design.
 PLV Vs PC cont…
• Network security: PLCs use proprietary
microprocessors and programming software
while computers uses standard processors and
programming languages among many
computer vendors, so they are more known
by hackers and more easily accessible.
 PLV Vs PC cont…
• Physical inputs and outputs: The more
obvious and less significant difference is the
PLC gets inputs from sensors and switches
outside the PLC device, and outputs voltages
and currents to devices outside the PLC
device. Computers do not for the most part
 Why using PLC?
• PLCs are robust and can survive harsh
conditions including severe heat, cold, dust,
and extreme moisture. Their programming
language is easily understood, so they can be
programmed without much difficulty. PLCs are
modular so they can be plugged into various
setups.
 Why using PLC? Cont….
• Relays switching under load can cause
undesired arcing between contacts. Arcing
generates high temperatures that weld
contacts shut and cause degradation of the
contacts in the relays, resulting in device
failure. Replacing relays with PLCs helps
prevent overheating of contacts.
• PLC are user friendly microprocessor based
specialized computer carrying out control
functions and many types and levels of
complexity in industrial application
 Working principle of PLC
• The PLC program is executed as part of a
repetitive process referred to as a ‘’scan’’.
• A PLC starts with the CPU reading the status of
inputs. The application program is executed
using the status of the input. Once the
program is completed, the CPU perform
internal diagnostics and communication tasks.
 Working principle cont….
• The scan cycle ends by updating the outputs,
then starts over again.
• The cycle time depends on the size of the
program, the number of I/O and the amount
of communication required.
Cycle of operation
The PLC operating cycle
 How it works
• The input sources convert the real time analog
electric signals to suitable digital electric
signals and these signals are applied to the
PLC through the connector rails.
• These input signals are stored in the PLC
external image memory in locations known as
bits. This is done by the CPU
 How it works cont….
• The control logic or the program instructions
are written onto the programming device
through symbols or through numeric and
stored in the user memory.
• The CPU fetches these instructions from the
user memory and executes the input signals
by manipulating, computing, processing them
to control the output devices
 How it works cont….
• The execution results are then stored in the
external image memory which controls the
output drives.
• The CPU also keeps a check on the output
signals and keeps updating the contents of the
input image memory according to the changes
in the output memory. The CPU also performs
internal programming functioning like setting
and resetting of the timer, checking the user
memory.
THE END