PLC Selections:

1. Compatibility

One of the first things to consider when choosing a new PLC is how well it will integrate with
your existing systems. Compatibility with current hardware, software, and communication
protocols is essential to ensure smooth operation. Consider whether the new PLC can
communicate effectively with your existing equipment, such as HMIs (Human-Machine
Interfaces), VFDs (Variable Frequency Drives), and other control systems. It is also important to
think about future expansions or upgrades – choose a PLC that is scalable and can adapt to future
technological advancements.

2. Hardware Features

When choosing a new PLC, understanding the various hardware features is crucial. Each
component plays a significant role in the overall performance and suitability of the PLC for your
specific application. This section delves into the critical hardware features you need to consider:
CPU (Central Processing Unit), Memory, Communication Interface, I/O Ports, and their types
(digital, analog, HSC/PWM), and the difference between expandable and fixed Designs.

CPU (Central Processing Unit)

The CPU is the heart of the PLC, responsible for executing control instructions, processing data,
and managing the overall operation of the system. When evaluating the CPU, consider its speed
(measured in MHz or GHz), which affects how quickly it can process instructions. A faster CPU
is beneficial for complex and high-speed applications. Additionally, assess the architecture of the
CPU (such as 32-bit or 64-bit) as it impacts the efficiency and the amount of data it can handle at
once.

Memory

PLC memory falls into two categories: program memory and data memory. Program memory
stores the control program, while data memory holds the process variables. The size of the
memory (often measured in KB or MB) determines the complexity of the programs the PLC can
handle and the amount of data it can store. For larger systems with more complex operations,
choosing a PLC with more memory is preferable.

Communication Interface

The communication interface of a PLC is crucial for network connectivity and interaction with
other devices. This includes Ethernet ports for network communication, serial ports using RS-
232/RS-485 for device connection, and USB ports for programming and diagnostics. Evaluate
the types and number of communication interfaces available to ensure they meet your system’s
connectivity requirements.
I/O Ports

Input/Output (I/O) ports serve as the crucial connection points where a Programmable Logic
Controller (PLC) interacts with the external environment. These ports gather data from sensors
(inputs) and transmit control signals to actuators (outputs).

 Analog: Inputs that can read analog signals are used for sensors that provide a continuous
range of values, like temperature or pressure. Analog outputs control devices that require
variable signals.

 Digital: Digital inputs are for sensors with on/off states such as switches, while digital
outputs control devices like relays or contactors.

 HSC (High-Speed Count): HSC inputs are used for applications requiring precise
counting of high-speed processes as encoder signals.

 PWM (Pulse Width Modulation): PWM outputs could be used to control the speed and
position of devices like servo motors by varying pulse widths.

When selecting a PLC, it’s essential to carefully evaluate the quantity and variety of I/O ports
required, ensuring they align with the specific demands of your application.

Expandable vs. Fixed PLC Design

 Expandable PLCs: Thanks to their modular design, expandable PLCs offer a flexible,
scalable solution for a wide range of automation needs. They allow for easy integration
and customization by adding or removing input/output and specialty modules, catering to
specific process requirements. This adaptability makes them cost-effective and future-
proof, as they can evolve with changing needs without necessitating a complete system
overhaul. Additionally, their compact size and ease of maintenance make them ideal for
space-constrained environments and can simplify system upgrades.

 Fixed PLCs: Fixed PLCs integrate the CPU, I/O, and communication interfaces into a
single unit. They are typically more compact but offer less flexibility for future expansion
or customization. Fixed PLCs are suitable for smaller systems with defined and stable
requirements. The right combination of hardware components will ensure that the PLC
can efficiently handle your industrial processes and adapt to future changes or
expansions. Careful consideration of these aspects will lead to a more informed decision,
aligning the PLC capabilities with the specific needs of your application.

3. PLC Programming Languages

PLCs typically support multiple programming languages, each with their own unique features
and best use cases. Understanding the differences between these languages can impact the
efficiency and effectiveness of your PLC programming.

Ladder Logic Diagram (LD)

Ladder Logic Diagram is the most traditional and widely used PLC programming language. It
mimics electrical relay logic (on/off states) and is visually represented in a format resembling a
ladder, with rungs representing control logic. Ladder Logic is particularly user-friendly for those
with a background in electrical engineering or relay control systems. It is best suited for simple
control systems and applications where binary decisions are predominant.

Instruction List (IL)

Instruction List is a low-level programming language like assembly language. This text-based
language consists of a series of instructions, with each representing a different operation. Its
compact and efficient nature makes it suitable for applications with limited memory and
processing power. However, it requires a good understanding of programming concepts and is
less intuitive than graphical languages like Ladder Logic.

Function Block Diagram (FBD)

Function Block Diagram is a graphical language that uses blocks to represent functions, with
lines connecting them to define relationships. Each block can represent a simple function like a
timer or a more complex operation like a mathematical function. FBD is particularly effective for
process control and applications involving complex mathematical operations. It is user-friendly
for those with a background in control systems and process engineering.

Structured Text (ST)

Structured Text is a high-level textual programming language that uses statements like languages
like Pascal or C. It is suitable for complex applications that require algorithms, data processing,
or tasks that are difficult to represent graphically. ST is best used in applications requiring
complex control processes, calculations, and data manipulation.

Sequential Function Charts (SFC)

Sequential Function Charts are used to describe the sequence of control operations in a system.
SFCs are graphical and represent a process flow, making them ideal for sequential control
processes and tasks that require coordination of multiple operations or stages. They are
especially useful in batch processing and applications where the sequence of operations is a
critical aspect.
While all these programming languages offer similar functionality, your choice of programming
language can significantly impact the development time, ease of maintenance, and scalability of
your control systems. Selecting the right programming language depends on the specific
requirements of your application, the complexity of the tasks, and the background of the
personnel involved in programming and maintenance.

4. PLC Software Features

In addition to the hardware and programming languages, the software used to program and
manage PLCs is equally crucial. Modern PLC programming software offers a range of features
that can significantly enhance productivity, ease of use, and troubleshooting.

Online Editing

Online editing allows programmers to modify the PLC program while it is running. This feature
is invaluable for making real-time adjustments without stopping the entire process, thereby
minimizing downtime. It enables immediate testing and optimization of the control logic, but it
requires careful handling to avoid unintended disruptions to the operating process.

Simulation Modes

Simulation modes enable testing of PLC programs without the need for physical hardware. This
feature is crucial for validating logic, troubleshooting, and training purposes. It allows
programmers to simulate different scenarios and conditions, identify errors, and optimize
program performance before deployment.

Automatic Detection

Automatic detection in PLC software aids in identifying connected devices and configuring them
appropriately. This feature simplifies the setup process, especially in complex systems with
multiple devices, by automatically recognizing and integrating them into the PLC environment.

Find & Replace

Find and replace functionality is essential for efficient programming, particularly in large and
complex programs. It allows for quick modifications across the program, saving time and
reducing the potential for manual errors.

Cross Referencing

Cross-referencing is a feature that helps in tracing where and how certain variables or elements
are used throughout the program. This is particularly useful for debugging and understanding the
flow of the program, especially when working with large or complicated PLC programs.
Custom Function Block Libraries

Custom function block libraries allow users to create and store reusable blocks of code. This
feature enhances efficiency by enabling programmers to use these predefined blocks in various
parts of the program or in future projects, ensuring consistency and reducing repetitive coding
efforts.

Diagnostic Tools

PLC programming software may also provide users with diagnostic tools for effective
troubleshooting and system maintenance. These tools actively track PLC operations through real-
time monitoring and logging and can identify hardware and software issues using diagnostic
utilities. They ensure reliable PLC communications through network diagnostics and promptly
alert users to system irregularities. These tools play a crucial role in maintaining system
reliability and performance in PLC operations.

Documentation

Comprehensive documentation within the PLC software is invaluable for programming and
maintenance. It should include detailed help files, guides, and examples. Good documentation is
especially helpful for training inexperienced users and for reference during complex
programming tasks.

User Experience

The overall user-friendliness of the PLC software cannot be overstated. An intuitive interface,
easy navigation, clear labeling, and accessible help features make the software more
approachable for new users and efficient for experienced programmers. User-friendliness
enhances productivity and reduces the learning curve associated with new software.

The software features of a PLC play a crucial role in the efficiency and effectiveness of the entire
control system. Features like online editing and simulation modes bring flexibility and safety to
the programming process. Automatic detection and cross-referencing streamline setup and
troubleshooting. Custom function block libraries, comprehensive error codes, and thorough
documentation enhance the efficiency and ease of programming. Lastly, user-friendliness ensures
that the software is accessible to users of all skill levels, making it a critical factor in the overall
productivity of the PLC system. By considering these software features, users can significantly
optimize the programming, operation, and maintenance of their PLCs.

5. Power

The way a PLC is powered and the voltage levels used by its I/O interfaces can significantly
influence its compatibility and efficiency in various industrial applications.
Supply Voltage

PLCs are designed to operate on specific supply voltages, and it is crucial to ensure compatibility
with your facility’s power supply. Commonly, PLCs operate on:

 24/48V DC: This is the most prevalent voltage for PLC systems, especially in industrial
environments. 24V DC is preferred due to its safety and reliability. It is low enough to be
safe for operators and sensitive equipment, yet sufficient to ensure reliable signal
transmission.

 120V: Some PLCs are designed to operate on standard AC voltage levels. These are most
often used for large-scale control circuits and may be more cost-effective by reducing the
need for multiple separate power supplies.

I/O Voltage

The voltage levels used by the PLC’s Input/Output (I/O) interface are crucial since they must be
compatible with the sensors, actuators, and other devices connected to the PLC. Common I/O
voltage levels include:

 DC Voltage Levels: For digital inputs and outputs, common levels are 5V DC, 12V DC,
and 24V DC. The choice depends on the devices connected to the PLC. For example,
24V DC is widely used in industrial applications due to its robustness and noise
immunity.

 AC Voltage Levels: AC inputs and outputs might also operate at 120V AC. This is
typically used for applications involving higher power devices such as motors or large
heating elements and can reduce costs by centralizing the power supply for multiple
devices in one place.

Selecting the appropriate power supply and voltage levels for a PLC is vital for ensuring reliable
operation and minimizing the risk of equipment damage or operational inefficiencies in different
industrial environments.

6. PLC Scan Time

Understanding the concept of scan time is critical when selecting a PLC for any industrial
application. Scan time directly affects the perceived processing speed of a PLC and plays a
pivotal role in the controller’s ability to meet the demands of dynamic and time-sensitive
processes.

Scan Time and Processing Speed

The scan time of a PLC refers to the time it takes to complete one cycle of its operational
process, which includes reading inputs, executing the control program, and updating outputs.
This cycle is continuous and typically measured in milliseconds (MS). The faster the scan time,
the more responsive the PLC is to changes in input conditions, making it crucial for applications
requiring real-time control and rapid decision-making.

A shorter scan time means the PLC can process data and react to inputs more quickly, which is
perceived as a higher processing speed. This is particularly important in high-speed
manufacturing processes, precise control applications, and situations where rapid response to
input changes is critical.

Factors Contributing to Increased Scan Time

Several factors can contribute to increased scan time in a PLC, potentially affecting its
performance in time-sensitive applications:

 Control Program Complexity. More complex programs with numerous instructions,

intricate logic, or extensive mathematical calculations can increase scan time. Each
additional operation requires processing time, thus extending the overall cycle time.

 I/O Processing. The number of input/output points and the type of processing (analog vs.
digital) can impact scan time. For example, analog signal processing generally takes
longer than digital due to the need for signal conversion and scaling.

 Data Logging and Reporting Features. Advanced data logging and reporting can
increase scan time, particularly if the PLC is processing and storing large amounts of data
or generating complex reports.

 Specialized Functions and Modules. Special functions like PID control, high-speed
counters, or specialized modules (such as motion control) can lengthen the scan time, as
these tasks are typically more processor intensive.

 Processor Speed. Processor speed is a critical aspect of PLC performance, particularly in

environments requiring rapid response times and high-speed data processing. The speed
of the PLC’s processor determines how quickly it can execute the control program and
manage tasks like I/O processing and communication.

Optimizing Scan Time

To optimize the scan time, it is essential to balance the complexity of the control program with
the PLC’s processing capabilities. Simplifying control logic where possible, optimizing data
handling, and ensuring efficient communication can help reduce scan time. Additionally,
selecting a PLC with a faster processor and more memory can alleviate the effects of increased
scan time due to complex operations or extensive I/O processing.
By considering the complexity of the control program, the nature and quantity of I/O processing,
communication needs, and special functions, you can choose a PLC that provides the optimal
balance between functionality and responsive performance.

7. Environment

Environmental factors like temperature, vibration, humidity, dust, and corrosive atmospheres can
significantly impact the performance and longevity of a PLC. Understanding how these factors
affect PLCs is crucial in choosing a model that can withstand specific environmental challenges.

Operating Temperature

Temperature is one of the most critical environmental factors affecting PLCs. Each PLC is
designed to operate within a specified temperature range, usually provided in its technical
specifications.

 High Temperatures: Excessive heat can lead to malfunction or damage to the electronic
components of a PLC. High-temperature environments often require PLCs with enhanced
cooling systems or those designed with heat-resistant materials.

 Low Temperatures: Similarly, extremely low temperatures can affect the performance
and reliability of a PLC. In such conditions, PLCs with special provisions to combat cold,
like built-in heaters or insulation, are necessary.

Vibration

Vibration is another significant environmental factor, especially in industrial settings with heavy
machinery. Constant vibration can cause mechanical wear, loosening of connections, and
potential failure of electronic components. Choose PLCs designed to withstand the level of
vibration typical in your operational environment. These PLCs often have ruggedized
components and reinforced mounting systems to endure continuous vibration without
degradation of performance.

Humidity

High humidity can lead to condensation and corrosion in electronic circuits. PLCs operating in
humid environments should have adequate protection against moisture.

Dust and Corrosive Atmospheres

In environments with elevated levels of dust or corrosive substances, PLCs with higher ingress
protection ratings are necessary. These PLCs are designed to prevent the ingress of dust and
resist corrosive materials.

Electromagnetic Interference
PLCs should have proper shielding and grounding to prevent operational disruptions in areas
with high levels of EMI, such as near heavy electrical equipment or radio transmitters.

Explosive Atmospheres

In industries where explosive gases, vapors, or dust are present, it is vital to select PLCs certified
for use in such hazardous environments. These PLCs feature designs that actively prevent the
ignition of the surrounding atmosphere. They typically have seals to block the ingress of
explosive substances and are constructed to minimize the risk of generating sparks or excessive
heat.

A thorough evaluation of the operating environment in terms of temperature, vibration, humidity,

dust, and other factors is essential to ensure the chosen PLC can operate reliably under those
conditions. By considering these environmental factors, you can significantly reduce
maintenance issues and prolong the lifespan of the PLC.

8. Certifications

It is important to consider various certifications that indicate compliance with safety, quality, and
environmental standards for a new PLC. These certifications serve as benchmarks for reliability
and performance in different environments and applications. Understanding what each
certification represents can help in choosing a PLC that meets specific regulatory and operational
requirements.

UL (Underwriters Laboratories)

UL certification signifies that the PLC meets stringent safety standards, primarily for the North
American market. This certification indicates that experts have tested the PLC to ensure it
complies with safety-related requirements, including risks like fire, electric shock, and related
hazards.

Class I, Div 2

The UL organization issues this certification specifically for devices used in hazardous locations.
Class I, Div 2 certified PLCs are designed to operate safely in environments where flammable
gases or vapors may be present under abnormal conditions.

NEMA (National Electrical Manufacturers Association)

NEMA ratings define the types of environments in which an electrical enclosure can be used. A
PLC with a NEMA rating is certified for protection against factors like dust, water, and
corrosion, making it suitable for various industrial conditions.

CE (Conformité Européenne)
The CE mark indicates that the PLC complies with the necessary European Union regulatory
requirements, particularly in terms of health, safety, and environmental protection. It is
mandatory for products sold within the European Economic Area.

IP (Ingress Protection)

IP ratings, denoted as IP followed by two digits, indicate the level of protection a PLC offers
against solids and liquids. The first digit represents protection against solid objects, and the
second digit represents protection against liquids. Higher numbers mean better protection.

RoHS (Restriction of Hazardous Substances)

RoHS compliance means that the PLC does not contain specific hazardous materials banned by
the European Union, such as lead, mercury, and cadmium. This certification is important for
environmental protection and health safety.

ATEX (Atmosphères Explosibles)

ATEX certification applies to equipment intended for use in explosive atmospheres in the
European Union. It ensures that the PLC is designed to prevent ignition and can safely operate in
potentially explosive environments.

FCC (Federal Communications Commission)

The FCC certification is relevant in the United States and indicates that the electromagnetic
interference from the PLC is under limits approved by the Federal Communications
Commission. This is important for preventing undue interference with other electronic devices.

These certifications ensure that a PLC is suitable and safe for specific applications and
environments. This not only ensures compliance with legal standards but also guarantees that the
PLC will perform reliably and safely under the designated conditions.

9. Size

The physical size of a PLC is an often overlooked but crucial factor in the selection process. The
size of a PLC can have a significant impact on its installation, integration, and usability in
various industrial settings.

Space Constraints

In many industrial environments, space can be a premium commodity. Facilities with limited
space in control cabinets or on manufacturing floors require compact PLCs that can fit into small
areas without compromising functionality. A smaller PLC can be advantageous in such settings,
allowing for efficient use of space.

Scalability and Expansion

The size of a PLC can also influence its scalability and ability to expand. Modular PLCs, which
allow for the addition of extra modules such as I/O, communication, or special functions, tend to
occupy more space as they expand. Understanding the physical space available and future
expansion needs is crucial in selecting a PLC of appropriate size.

Heat Dissipation

PLC size can also affect its heat dissipation capabilities. Larger PLCs have more surface area,
which can aid in better heat dissipation, whereas compact PLCs might require additional cooling
mechanisms, especially when installed in confined spaces or in environments with high ambient
temperatures.

Installation and Maintenance

Larger PLCs might offer easier access for installation, wiring, and maintenance, as there is
typically more room to work around the unit. However, compact PLCs, while space-efficient,
may present challenges in terms of accessibility for maintenance and modifications.

When choosing a new PLC, consider the available space, the potential need for expansion, heat
management requirements, and ease of installation and maintenance. A well-chosen PLC in
terms of size can lead to smoother integration, better use of space, and overall operational
efficiency in your industrial processes.

10. Support Resources

In the world of industrial automation, choosing the right PLC involves more than just technical
specifications; the availability and quality of support resources play a pivotal role in the PLC’s
long-term performance and user satisfaction.

PLC Installation or Commissioning

 PLC Commissioning is a series of careful examinations done in a PLC control system to

ensure that the controller, program, input and output devices, and associated wiring
conform to the specifications of the design.
 Before you start PLC commissioning, it is important that you eliminate the possible
hazards in your workspace first.
 This means that actuators, especially ones that produce powerful movements such as
motors or valves must be disconnected from the programmable logic controller.
 With that out of the way, here are the steps to get you started with PLC Commissioning.

Steps in PLC Commissioning

1. Cable connections must meet standards

  All cable connections between the PLC, the input devices, the power supply, the output
devices, and the programming device must be checked thoroughly as they are the media
that the PLC uses to communicate between each of the devices.
 All cables must meet the required specifications according to the standards, it should
even meet the local standards set for the specific hardware.

2. Check the power supply

 The power supply of the PLC must match the voltage setting of the PLC.
 The voltage setting of the power supply must also conform to the voltage ratings of the
input and output devices, otherwise, one of the two must be replaced by another device.

3. Check indicator lights of the PLC

 The indicator lights on the PLC should determine if the PLC will work properly.
 If the power is properly applied, the power indicator of the PLC should turn on. Fault
indicators are usually installed on PLCs, so ensure that the fault light is not turned on at
this point.

4. Put PLC in a test mode.

 The PLC must be put in a mode that prevents it from sending an output voltage or current
to the output devices.
 This can either be called “Disable” or “Continuous test” mode depending on the PLC
manufacturer.
 In this mode of operation, the outputs will be de-energized, so you are assured of your
safety when testing.

5. Check protective devices

In this step, you must ensure that the protective devices of the PLC are set to their proper trip
settings.

6. Check emergency stop buttons

The emergency stop buttons, usually normally closed push buttons, must be checked thoroughly
because these buttons are the ones that will stop ALL PLC operations in an emergency event.

7. Check connection points of input and output devices

 In this step, the connection points of all input and output devices must be double-
checked.
 Make sure that each device is connected to the proper address according to the program
present in the PLC memory.
  If you fail to do this step, you may encounter issues such as the output being turned on at
inappropriate times (usually because of the wrong sensor being activated).
 So, pay extra attention to this step.

8. Test the software

 After all of the previous steps have been performed, it is now time to load the program
into the PLC and start testing the software.
 Testing the software is relatively easy as most PLCs contain software-checking programs
already.
 Even though this step checks the program for incorrect device addresses, it is always
important to do the preceding step (Checking connection) in order to save time.
 The PLC provides a printout of the input and output points that were used, along with the
counter presets, timer settings, with the errors that it has encountered.
 If you already did a great job in the preceding steps, doing this only serves as a
“proofread” for all the things that you have performed.

Testing the Input and Output Devices

 In testing the input and output devices during the PLC commissioning process, you must
check them one at a time to ensure that each device works properly according to
specifications.
 That may sound tedious, but it is actually worth the time.
 In project management, or in any step-oriented work, there is a rule of thumb that must be
followed, that is “The later you catch a mistake, the harder it is to correct”.
 Just imagine if you missed a tiny detail that caused several hours of downtime in your
system: More time would be spent troubleshooting the system, and you would have to
perform PLC Commissioning again, anyway.

Input Devices

 In testing the input devices, you should be able to manually check each device by using
pilot lights at the output side of the Programmable Logic Controller.
 Because input devices are usually in the form of switches, the pilot lights at the output
side of the PLC can suffice to represent the switching conditions of the input devices.
 You should obviously have to learn about the different input devices for the PLC before
you start testing them: just the knowledge of activating them and knowing what each
input device should be used for may already be enough, but that shouldn’t stop you from
learning more about it!
 Of course, because the devices are being tested one at a time, then you must connect each
device to the same input terminal at the I/O side of the PLC.

Output Devices
 Output Devices – Solenoid

 In testing the output devices, make sure that you disconnect every single device from the
PLC.
 Testing the output devices requires that you use the appropriate source for that output
device and make sure that it runs according to specifications.
 Similar to input devices, the testing must be done one device at a time.
 Simply put, testing output devices not only allows you to check whether each device is
working or not, but it also allows you to check if it still performs accordingly.