Chapter 1

Programmable Logic
Controllers [PLCs]
An Overview
Section 1.1

Programmable Logic Controllers

 PLC
Most widely
used industrial
process control
technology.

➢Designed for machine process control.

➢A computer built to operate in
industrial environments.
➢Equipped with input/output interfaces
and a control programming language.
Initially used to replace relay
logic its ever-increasing
range of functions includes
timing, counting, calculating,
comparing, and the
processing of analog signals.
 PLC
control
panel

Relay
control
panel

Eliminates much of the hardwiring

associated with conventional relay
control circuits.
Increased Reliability - Since all the logic
is contained in the PLC’s memory, there
is no chance of making a logic wiring
error.
More Flexibility -
It is easier to
create and
change a
program in a PLC
than to wire and
rewire a circuit.
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.
Communications Capability
Can communicate with
other PLCs or computers.

Communications
Module
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

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

PLC
Monitor
Process
Easier to Test Field Devices –
A PLC control panel has the ability to
check field devices at a common point.
Section 1.2

Parts of a PLC
PLC Block Diagram
 PLC Architecture

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.
Fixed I/O comes in one
package with no separate
removable units.
Modular I/O is divided
by compartments
into which separate
modules can be
plugged.
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
The processor (CPU)
consists of a
microprocessor for
implementing the logic
and controlling the
communications among
the modules. Image Used with Permission of Rockwell Automation, Inc.

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.
The PLC program is executed as part of a
repetitive process referred to as a scan.

Starts with the

CPU reading the
status of all inputs.

Repeated
Continuously
The I/O (Input/Output) system forms the
interface by which field devices are connected
to the controller.
Input devices
such as
pushbuttons,
limit switches,
and sensors
are hardwired
to the input
module
terminals.
 The I/O (Input/Output) system forms the
interface by which field devices are
connected to the controller.
Output devices
such as motor
starters, solenoid
valves, and
Photo courtesy
ASCO Valve Inc.
indicator lights are
hardwired to the
output module
terminals.
This material and
associated copyrights are
proprietary to, and used
with permission of
Schneider Electric
A programming device is used to enter the desired
program into the memory of the processor.

PLC

Programming Device
A personal computer (PC) is the most commonly
used programming device.

The computer
monitor is able
to display more
logic on the
screen thus
simplifying
interpretation of
the program.

Image used with Permission of Rockwell Automation, Inc.

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.
Section 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.
 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.
 PLC method for control of motor
The same input field devices Field devices are
(pressure switch, hardwired to an
temperature switch, and input module.
pushbutton) are used.

Photo courtesy
Automation Direct
 PLC method for control of motor
Starter coil is The same output field
hardwired to an device (motor starter
output module. coil) is used.

Photo courtesy
Automation Direct
 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.
• 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.
LogicPro simulation of the PLC
program

Input Output Ladder Logic Program

Module Module
Typical wiring required to implement the process
control scheme using a fixed PLC controller.

Image used with Permission of Rockwell Automation, Inc.

Section 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.
➢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.
LogicPro simulation of the modified
PLC program
Section 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.
Unlike the personal computer, the PLC is
programmed in relay ladder logic or other
easily learned languages.

Photo courtesy Rogers Machinery Company, Inc.

The PLC comes with its program language built into

its memory and has no permanently attached
keyboard, CD drive, or monitor.
Computers are capable of executing several
programs simultaneously and in any
order.

PLCs execute a single

program in an
orderly and
sequential fashion
from first to last
instruction.
Troubleshooting is
simplified by the use of
fault indicators and
messaging displays.

Input/output
modules are easily
connected and Module
slides into
replaced.
the rack
 PLC Programming Software

RSLogix RSLinx

Is used to program and document the process

Ladder logic most popular

programming language
 PLC HMI Software
Human Machine Interface
(HMI) - software allows the
user to monitor and control
the process.

➢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
Programmable Automation Controllers (PACs)
combine PLC ruggedness with PC functionality.
Section 1.6

PLC Size and Application

The criteria used in categorizing PLCs include
functionality, number of inputs and outputs,
cost, and physical size.
Nano types have less
than 15 I/O points.

Micro types have 15 to

128 I/O points.

Medium types have

128 to 512 I/O points.

Large types have

over 512 I/O points.
A single ended application involves one PLC
controlling one process.
A multitask PLC application involves one PLC
controlling several processes.
A control management PLC application
involves one PLC controlling several others.
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.
The amount of memory required depends on:
➢Number of I/O points
➢Size of control program
➢Data-collecting requirements
• Supervisory functions required
• Future expansion
The instruction set for a particular PLC lists
the different types of instructions supported.