Programmable Logic Controllers (PLCs): Basics, Types & Applications

What is a PLC?
PLC stands for “Programmable Logic Controller”. A PLC is a computer specially designed to
operate reliably under harsh industrial environments – such as extreme temperatures, wet,
dry, and/or dusty conditions. PLCs are used to automate industrial processes such as a
manufacturing plant’s assembly line, an ore processing plant, or a wastewater treatment plant.

PLCs share many features of the personal computer you have at home. They both have a
power supply, a CPU (Central Processing Unit), inputs and outputs (I/O), memory, and
operating software (although it’s a different operating software).

The biggest differences are that a PLC can perform discrete and continuous functions that a
PC cannot do, and a PLC is much better suited to rough industrial environments. A PLC can
be thought of as a ‘ruggedized’ digital computer that manages the electromechanical
processes of an industrial environment.

PLCs play a crucial role in the field of automation, using forming part of a larger SCADA
system. A PLC can be programmed according to the operational requirement of the process.
In the manufacturing industry, there will be a need for reprogramming due to the change in
the nature of production. To overcome this difficulty, PLC-based control systems were
introduced.

PLC Basics
PLCs were invented by Dick Morley in 1964. Since then, PLC has revolutionized the
industrial and manufacturing sectors. There is a wide range of PLC functions like timing,
counting, calculating, comparing, and processing various analog signals.

The main advantage of PLC over a “hard-wired” control system is that you can go back and
change a PLC after you’ve programmed it, at little cost (just the cost of the programmer’s
time). In a hard-wired control system, you’re essentially having to rip out wires and start from
scratch (which is more expensive and takes longer). Let’s look at an example to better
understand this advantage.
Imagine you have a light connected to a switch. In general, the light operates under two
conditions – ON and OFF. Now you are given a task that when you turn ON the switch, the
light should glow only after 30 seconds. With this hard-wired setup – we’re stuck. The only
way to achieve this is to completely rewire our circuit to add a timing relay. That’s a lot of
hassle for a minor change.
 Light Switch
This is where a programmable logic controller comes into the picture, which doesn’t require
any additional wiring and hardware to make sure of a change. Rather it requires a simple
change in code, programming the PLC to only turn on the light 30 seconds after the switch is
turned ON. So, by using a PLC, it is easy to incorporate multiple inputs and outputs.

This is just a simple example – a PLC has the ability to control much larger and more
complex processes. A PLC can be customized depending on the application and needs of the
user.

Light operated by a PLC

How Does a PLC work?
The working of a programmable logic controller can be easily understood as a cyclic
scanning method known as the scan cycle.
 Block Diagram of How A PLC Works
A PLC Scan Process includes the following steps

 The operating system starts cycling and monitoring of time.

 The CPU starts reading the data from the input module and checks the status
of all the inputs.
 The CPU starts executing the user or application program written in relay-
ladder logic or any other PLC-programming language.
 Next, the CPU performs all the internal diagnosis and communication tasks.
 According to the program results, it writes the data into the output module so
that all outputs are updated.
 This process continues as long as the PLC is in run mode.

Physical Structure of PLC

The structure of a PLC is almost similar to a computer’s architecture.

PLC Block Diagram

Programmable Logic Controllers continuously monitors the input values from various input
sensing devices (e.g. accelerometer, weight scale, hardwired signals, etc.) and produces
corresponding output depending on the nature of production and industry. A typical block
diagram of PLC consists of five parts namely:

 Rack or chassis
 Power Supply Module
 Central Processing Unit (CPU)
 Input & Output Module
 Communication Interface Module
Rack or Chassis
In all PLC systems, the PLC rack or chassis forms the most important module and acts as a
backbone to the system. PLCs are available in different shapes and sizes. When more
complex control systems are involved, it requires larger PLC racks.

Small-sized PLC is equipped with a fixed I/O pin configuration. So, they have gone for
modular type rack PLC, which accepts different types of I/O modules with sliding and fit in
concept. All I/O modules will be residing inside this rack/chassis.

Breakdown of PLC Rack

Power Supply Module
This module is used to provide the required power to the whole PLC system. It converts the
available AC power to DC power which is required by the CPU and I/O module. PLC
generally works on a 24V DC supply. Few PLC uses an isolated power supply.
CPU Module and Memory
CPU module has a central processor, ROM & RAM memory. ROM memory includes an
operating system, drivers, and application programs. RAM memory is used to store programs
and data. CPU is the brain of PLC with an octal or hexagonal microprocessor.

Being a microprocessor-based CPU, it replaces timers, relays, and counters. Two types of
processors as a single bit or word processor can be incorporated with a PLC. One bit
processor is used to perform logic functions. Whereas word processors are used for
processing text, numerical data, controlling, and recording data.

CPU reads the input data from sensors, processes it, and finally sends the command to
controlling devices. DC power source, as mentioned in the previous discussion is required
voltage signals. CPU also contains other electrical parts to connect cables used by other units.

Input and Output Module

Have you ever thought about how to sense physical parameters like temperature, pressure,
flow, etc? using PLC? Of course, PLC has an exclusive module for interfacing inputs and
output, which is called an input & output module.

Input devices can be either start and stop pushbuttons, switches, etc and output devices can be
an electric heater, valves, relays, etc. I/O module helps to interface input and output devices
with a microprocessor. The input module of PLC is explained in the below figure.

PLC Input Module

Circuit Diagram of PLC Input Module

The input module of PLC does four main functions.

1. Input module interface receives the signal from process devices at 220 V AC
2. Converts the input signal to 5 V DC that can be used by PLC
3. Isolator block is used to isolate/prevent PLC from undergoing fluctuation
4. After which the signal is sent to the output end i.e the PLC

There are two main sections in the input module namely the power section and the logical
section. Both sections are electrically isolated from each other. Initially push button is closed.
So, 220 V AC supply is given to the bridge circuit through the resistors R1 and R2.

A bridge rectifier (such as a diode bridge rectifier) is used to convert the AC signal into DC
and Zener diode is used to provide a low voltage supply to LED. When the light from LED
falls on the phototransistor, it works in the conduction region. Finally, a 5V DC supply is
given to the processor.
The output module of PLC works similarly to the input module but in the reverse process. It
interfaces the output load and processor. So here the first section would be logic session and
the power section come next. The working of the output module is shown in the below figure

PLC Output Module

So, here when the program logic high signal is generated from the processor, the LED will
turn ON and allow the light to fall on a phototransistor. When the transistor goes to the
conduction region, it generates a pulse to the gate of the Triac. The isolator block is used to
isolate the logic section and control section.

Communication Interface Module

To transfer information between CPU and communication networks, intelligent I/O modules
are used. These communication modules help to connect with other PLCs and computers
which are placed at a remote location.

Types of PLCs
The two main types of PLC are fixed / compact PLC and modular PLC.
Compact PLC
Within a single case, there would be many modules. It has a fixed number of I/O modules
and external I/O cards. So, it does not have the capability to expand the modules. Every input
and output would be decided by the manufacturer.

Modular PLC
This type of PLC permits multiple expansion through “modules”, hence referred to as
Modular PLC. I/O components can be increased. It is easier to use because each component
is independent of each other.

A Modular Type PLC

PLC are divided into three types based on output namely Relay output, Transistor output, and
Triac Output PLC. The relay output type is best suited for both AC and DC output devices.
Transistor output type PLC uses switching operations and used inside microprocessors.

According to the physical size, a PLC is divided into Mini, Micro, and Nano PLC.

Some of the manufacturers of PLCs include:

 Allen Bradley
 ABB
 Siemens
 Mitsubishi PLC
 Hitachi PLC
 Delta PLC
 General Electric (GE) PLC
 Honeywell PLC

PLC Applications
PLCs have a variety of applications and uses, including:

1. Process Automation Plants (e.g. mining, oil &gas)

2. Glass Industry
3. Paper Industry
4. Cement Manufacturing
5. In boilers – Thermal Power Plants
PLC Programming
When using a PLC, it’s important to design and implement concepts depending on your
particular use case. To do this we first need to know more about the specifics of PLC
programming.

A PLC program consists of a set of instructions either in textual or graphical form, which
represents the logic that governs the process the PLC is controlling. There are two main
classifications of PLC programming languages, which are further divided into many sub-
classified types.

1. Textual Language
 Instruction list
 Structured text
2. Graphical Form
 Ladder Diagrams (LD) (i.e., Ladder Logic)
 Function Block Diagram (FBD)
 Sequential Function Chart (SFC)
Although all of these PLC programming languages can be used to program a PLC, graphical
languages (like ladder logic) are typically preferred to textual languages (like structured text
programming).

Ladder Logic
Ladder logic is the simplest form of PLC programming. It is also known as “relay logic”. The
relay contacts used in relay-controlled systems are represented using ladder logic.
The below figure shows a simple example of a ladder diagram.

PLC Ladder Logic

In the above-mentioned example, two pushbuttons are used to control the same lamp load.
When any one of the switches is closed, the lamp will glow.

The two horizontal lines are called rungs and the two vertical lines are called rails. Every
rung form the electrical connectivity between Positive rail (P) and Negative rail (N). This
allows the current to flow between input and output devices.
Functional Block Diagrams
Functional Block Diagram (FBD) is a simple and graphical method to program multiple
functions in PLC. PLCOpen has described using FBD in the standard IEC 61131-3. A
function block is a program instruction unit that, when executed, yields one or more output
values.

It is represented by a block as shown below. It is represented as a rectangular block with

inputs entering on left and output lines leaving at the right. It gives a relation between the
state of input and output

Function Block
The advantage of using FBD is that any number of inputs and outputs can be used on the
functional block. When using multiple input and output, you can connect the output of one
function block to the input of another. Whereby building a Function Block Diagram.

Example Functional Block Diagram

The figure below shows various function blocks used in FBD programming.
 Functional Block Programming
The figure below shows a ladder diagram and its function block equivalent in Siemens
notation.

Ladder to functional block

Ladder to functional block diagram

Structured Text Programming
Structured text is a textual programming language that utilizes statements to determine what
to execute. It follows more conventional programming protocols but it is not case sensitive. A
series of statements (logic) is constituted of expressing assignments and relationships using
several operators. The structures text operators are listed below in the image.

Structured Text Programming

PLC Programming Examples
A signal lamp is required to be switched on if a pump is running and the pressure is
satisfactory, or if the lamp test switch is closed. In this application, if there should be an
output from the lamp inputs from both pump and pressure sensors are required. Hence, AND
logic gates are used.
OR logic is used for the test input condition, it is required to give an output of lamp on
regardless of whether there is a signal from the AND system. By using END or RET
instruction in the ladder diagram, we can tell PLC has reached the end of the program. The
function block diagram and the ladder diagram are shown below in the figure.

PLC Program to Test Lamp Glowing

As another example, consider a valve that is to be operated to lift a load when a pump is
running and either the lift switch is operated or a switch operated indicating that the load has
not already been lifted and is at the bottom of its lift channel.

OR logic is used for two switches and an AND logic is used with two switches and the pump.
Valve will be operated only if the pump is ON and two switches are operated.

PLC Program to Operate Valve

Consider a drinks machine that allows the selection of tea or coffee, milk or no milk, sugar or
no sugar, and will supply the required hot drink on the insertion of a coin. From the below-
shown figure, it is seen that either tea or coffee is selected using the first OR logic gate.

The first AND gate give an output when either Tea or coffee is selected and a coin is inserted
into the machine. The output from this AND gate is given to the second AND gate. The
second AND gate operate only when hot water combines with tea. Milk and sugar are
optional additions that can occur after a coin has been inserted.

FBD for Drinking Machine

 Ladder Logic for Drinking Machine Application
History of PLCs
Many early PLCs were not capable of graphical representation of the logic, and so it was
instead represented as a series of logical expressions in a Boolean format (akin to Boolean
algebra).
As programming terminals evolved, it became more common for ladder logic to be used,
because it was a familiar format used for electro-mechanical control panels. More modern
formats, such as state logic and Function Block diagrams exist, but they are still not as
popular as ladder logic.

A possible reason for this is that programmers prefer the more visual appeal of ladder logic
over structured text programming.

Until approximately the mid-1990s, PLCs were programmed using proprietary programming
panels or special-purpose programming terminals, which often had dedicated function keys
representing the various logical elements of PLC programs.

Some proprietary programming terminals displayed the elements of PLC programs as graphic
symbols, but plain ASCII code representations of contacts, coils, and wires were common.
PLC Application for speed control of AC motor with variable speed drive:
AC Motor Drive Interface

A common PLC application is the speed control of AC motors with variable speed (VS)
drives. The diagram in Figure 1 shows an operator station used to manually control a VS
drive.

PLC Application for Speed Control of AC Motors With VSD (on photo: Three 30HP
pumps using corresponding variable frequency drives with bypass contactors. The 208V
3PH 4 wire 400A panel features a PLC based control system with backup floats and stand-
alone three pump controller and intrinsically safe barriers for level sensors; Credit:
dbcustomwiring.com)
The programmable controller implementation of this station will provide automatic motor
speed control through an analog interface by varying the analog output voltage (0 to 10
VDC) to the drive.

The operator station consists of:

1. a speed potentiometer (speed regulator),
2. a forward/reverse direction selector,
3. a run/jog switch, and
4. start and stop push buttons.

The PLC program will contain all of these inputs except the potentiometer, which will be
replaced by an analog output.

The required input field devices (i.e., start push button, stop push button, jog/run, and
forward/ reverse) will be added to the application and connected to input modules, rather
than using the operator station’s components.
The PLC program will contain the logic to start, stop, and interlock the forward/reverse
commands.
 Figure 1 – Operator station for a variable speed drive
Table 1 shows the I/O address assignment table for this example, while Figure 2 illustrates
the connection diagram from the PLC to the VS drive’s terminal block (TB-1). The
connection uses a contact output interface to switch the forward/reverse signal, since the
common must be switched.
To activate the drive, terminal TB-1-6 must receive 115 VAC to turn ON the internal relay
CR1. The drive terminal block TB-1-8 supplies power to the PLC’s L1 connection to turn
the drive ON. The output of the module (CR1) is connected to terminal TB-1-6. The drive’s
115 VAC signal is used to control the motor speed so that the signal is in the same circuit
as the drive, avoiding the possibility of having different commons (L2) in the drive
(the start/stop common is not the same as the controller’s common).

In this configuration, the motor’s overload contacts are wired to terminals TB-1-9 and TB-
1-10, which are the drive’s power (L1) connection and the output interface’s L1 connection.
If an overload occurs, the drive will turn OFF because the drive’s CR1 contact will not
receive power from the output module.

To have low-voltage protection, the auxiliary contact from the drive, CR1 in terminal TB-1-
7, must be used as an input in the PLC, so that it seals the start/stop circuit.
 Table 1 – I/O address assignment

Figure 2 – Connection diagram from the PLC to the VS drive’s terminal block.
Figure 3 shows the PLC ladder program that will replace the manual operator station. The
forward and reverse inputs are interlocked, so only one of them can be ON at any given
time (i.e., they are mutually exclusive).
If the jog setting is selected, the motor will run at the speed set by the analog output when
the start push button is depressed. The analog output connection simply allows the output to
be enabled when the drive starts. Register 4000 holds the value in counts for the analog
output to the drive. Internal 1000, which is used in the block transfer, indicates the
completion of the instruction.

Sometimes, a VS drive requires the ability to run under automatic or manual control
(AUTO/MAN). Several additional hardwired connections must be made to implement this
dual control.

Figure 3 – PLC implementation of the VS drive

The simplest and least expensive way to do this is with a selector switch (e.g., a four-pole,
single-throw, single-break selector switch). With this switch, the user can select either
the automatic or manual option. Figure 4 illustrates this connection.
Note that the start, stop, run/jog, potentiometer, and forward/reverse field devices shown
are from the operator station. These devices are connected to the PLC interface under the
same names that are used in the control program (refer to Figure 3).

If the AUTO/MAN switch is set to automatic, the PLC will control the drive; if the switch
is set to manual, the manual station will control the drive.
 Figure 4 – VS drive with AUTO/MAN capability

PLC Architecture and Types: With Comparison Table

In this article we’ll look at basic PLC architecture, the different types of PLCs used in
industrial automation, advantages and disadvantages of PLC types and compare them in a
handy reference table.

What Is PLC Architecture?

The term PLC architecture refers to the design specification of the various PLC hardware and
software components and the how they interact with one another to form the overall PLC
system. The architecture of a PLC is based on the same principles of that used in standard
computer architecture. However, PLC architecture does differ because the design is based
around providing high reliability, immunity to harsh industrial environment, ease of
maintenance and access to large amounts of peripheral inputs and outputs.
If a PLC system is described as having closed architecture it refers to a proprietary system of
hardware and software components that cannot (or is difficult to) connect to other
manufacturers components and software. However, if a PLC system is described as having
open architecture it refers to the PLC system as having off the shelf components that adhere
to a common standard and are easily connected to other manufacturer’s hardware and
software components.

The Basics of How PLC Architecture Works

The heart of the PLC system is the CPU (Central Processing Unit). It is made up of a control
unit and processor. The CPU control unit manages the interaction between the various PLC
hardware components while the CPU processor handles all the number crunching and
program (eg ladder logic) execution.

The block diagram below explains the basic architecture of a PLC….

PLC Architecture Block Diagram

PLC Architecture Block Diagram
Data flow is from the input devices, through the CPU processor and then to the output
devices. The CPU processor also exchanges data with the program and data memory. Once
all the data is gathered the program (eg ladder logic) is processed in a cyclic fashion. The
resulting data flows to the output interface for conditioning and execution of the output
devices.

The CPU also controls and exchanges data with the communication interface and devices.

An addressing system is used for data organization that is shared between the various
hardware components.

A programming terminal is used to formulate the PLC program (eg ladder logic), load the
program into the controller and monitor/control the PLC and its program.

The power supply is responsible for supplying and managing the power requirements of the
various PLC hardware components.

Types of PLC Architecture

PLC architecture has advanced tremendously since its inception of the PLC back in the
1960s. Today the options and variations available to the traditional PLC architecture types is
almost endless between different PLC manufacturers.

The 3 distinct types of PLC architecture available for use in industrial automation are known
as fixed, modular and distributed. The terminology surrounding PLC types can vary between
PLC manufacturers, especially when talking about fixed PLCs. There is also crossover
between PLC types with some fixed type PLCs having modular type features and some
modular type PLCs having distributed type features.

When considering PLC architecture types we can generally say that fixed PLCs are used for
smaller sized, less complex application. Modular PLCs are generally used for medium sized,
more complex applications. Whereas distributed PLCs are used for large sized, extensive
application spread across multiple location.

Fixed, Modular and Distributed PLC Types

Fixed, Modular and Distributed PLC Types
Let’s take a look at the 3 types of PLCs in more detail….

Fixed PLC Type Architecture

A fixed PLC employs single unit architecture where all the hardware components are
embedded into a single unit. Hardware components such as the power supply, CPU, memory,
input, output and communication interfaces are all are built into a fixed PLC. The most
common names given to fixed PLCs by different manufacturers are fixed, integrated, nano,
micro, compact, small, mini, basic, unitary, standard and brick.

Diagram of Fixed Type PLC Architecture

Diagram of Fixed Type PLC Architecture
Some examples of fixed PLC types by different manufacturers and the terminology they use
is shown below:

Allen Bradley PLC – Micro

Omron PLC – Compact
Siemens PLC – Basic
Delta PLC – Standard
Koyo PLC – Brick
Examples of Fixed PLC Types
Examples of Fixed PLC Types
Regardless of the different terminology that PLC manufacturers use to identify the type, size
and performance level of their PLCs, a fixed PLC is universally characterized by:

PLC naming convention – Fixed, integrated, nano, micro, compact, small, mini, basic,
unitary, standard and brick.
CPU processor – Low powered.
Program and data memory size – Small.
Power supply – Embedded.
Input Interface – Embedded.
Output Interface – Embedded.
Communication interface – Embedded.
Mounting system – Single unit.
Physical size – Small.
Flexibility – Input, output and communication interfaces are fixed.
Expandable – No
Customizable – No
Applications – Basic applications with small number of inputs and outputs.
Cost – Low $$$$$.
Advantages of Fixed PLCs
Fixed PLCs have some great advantages over other types of PLCs. They have been
specifically design to cater for smaller, low end automation projects. The advantages of a
fixed PLC are:

Small in size so they do not take up very much space in an enclosure.

Quick and easy to mount.
Low in cost so they are an economical solution for basic applications.
Disadvantages of Fixed PLCs
If you’re considering selecting a fixed PLC to automate your next application its prudent to
also consider some of disadvantages to make sure you are selecting the type of PLC that is
appropriate for your application. The disadvantages of a fixed PLC are:

CPU processing power is low and memory is small so complex tasks can be difficult to
realize.
Inflexible because the number of input, output and communication interfaces are fixed.
Only suitable for basic applications with small number of inputs and outputs.
The Modern Day Fixed PLCs
The majority of modern day fixed PLCs are far from what the traditional definition of a fixed
PLC is. Technology advancements and demand from industry has driven them away from
being a simple, low powered unit with fixed amount of input, output and communication
interfaces.

The modern day fixed PLC is feature packed with a large range of options such as powerful
CPU’s, expandable modules and network capabilities that are bordering and even overlapping
into modular and distributed PLC architecture. This has resulted in the fixed PLC expanding
its reach into a larger range of industrial automation applications.
For example the Omron Sysmac CP1L and Koyo DL06 PLCs have traditional fixed PLC
architecture but at the same time are expandable with built in slots to allow for extra plugin
modules. Another example of a modern day fixed PLC that incorporates modular PLC design
is the Delta DVP ES2 with a rack-less design and clip-in expansion I/O modules. The Allen
Bradley MicroLogix 1100 PLC range also has the ability to further extend using I/O
expansion modules to the side of the PLC using ribbon cable…..

Examples of Fixed PLCs with Expansion Modules

Examples of Fixed PLCs with Expansion Modules
Modular PLC Type Architecture
A modular PLC has a separate module for each of its hardware components. Each PLC
module is interconnected using a common mounting system. The mounting system has a
certain amount of modules that it can accommodate. This means a modular PLC can be
configured to be application specific.

Diagram of Modular Type PLC Architecture

Diagram of Modular Type PLC Architecture
A PLC module is a hardware component that carries out a specific function in accordance to
the architecture of the PLC system. The main modules used in a modular type PLC are the
processor module, power supply module, input modules, output modules and communication
modules. The design of these modules will vary for different manufacturers and usually
cannot be interchanged between PLC manufacturers.

Modular PLCs are used for automating industrial applications where a higher powered
processor and large numbers of input and output devices are required. These types of
applications that use modular PLCs are usually associated with a higher level of complexity
with regards to operation, process control and monitoring. Some examples of industries that
readily use modular PLCs are manufacturing, food and beverage, mining and logistics.

Some examples of modular PLC types by different manufacturers are shown below:

Examples of Modular PLC Types

Examples of Modular PLC Types
A modular plc is characterized by:

PLC naming convention – Modular.

CPU processor – Medium to High powered.
Program and data memory size – Medium to Large.
Power supply – Module.
Input Interface – Input Module.
Output Interface – Output Modules.
Communication interfaces – Communication Modules.
Mounting system – Rack, backplane, rail or chassis.
Physical size – Medium to Large.
Flexibility – High
Expandable – Yes
Customizable – Yes
Applications – Medium to High end applications with large number of inputs and outputs.
Cost – Medium to high $$$$$.
What are the Advantages of Using a Modular PLC Instead of a Fixed PLC?
Modular PLCs have some great advantages over other fixed PLCs. They have been
specifically design to cater for medium to high end automation projects.

The advantages of using a modular PLC instead of a fixed PLC are that modular PLCs have
lager memory, higher performance processors, larger number of input and outputs, increased
communication options, are fully customizable and are easily expanded. This enables the
modular PLC to handle larger scale applications and of higher complexity compared to a
fixed PLC.

Modular PLCs also have the ability to have remotely mounted input and output modules
(distributed I/O) that are interconnected using a communication link. This allows for increase
number of inputs and outputs, reduced cable requirements and installation flexibility.

The modular PLC also has maintenance advantages over fixed PLCs. Each hardware
component is separate housed in a module which can be replaced if it is faulty. Whereas a
fixed PLC has all its component embedded into a single unit. So when there is a fault the
whole unit must be replaced in its entirety and the faulty unit ends up in the trash.

Disadvantages of Modular PLCs

If you’re considering selecting a modular PLC to automate your next application it’s wise to
also consider some of disadvantages to make sure you are selecting the most suitable PLC for
your application. The disadvantages of modular PLC are:

Large in size so they take up more space in an enclosure than a fixed PLC.
The mounting system is more complex than a fixed PLC.
Higher in cost than a fixed PLC so may not be cost effective for smaller applications.
Distributed PLC Type Architecture
A distributed PLC is a high end PLC system with modular architecture and the capability to
interconnect hardware components across different locations via high speed communication
links. Each location in the distributed PLC system contains multiple hardware modules that
are housed in a mounting system and are usually called a node, rack or drop.

Each drop, node or rack in the Distributed PLC system must have a communication module
and can either contain a PLC processor module with input and output (I/O) modules or just
I/O modules. When there is a communication module with no PLC processor module and just
I/O modules then the node is called distributed I/O or remote I/O.

Architecture of a Distributed PLC Type

Architecture of a Distributed PLC Type
Distributed PLCs are used for large factories and large processing facilities because they are
not limited to physical location. They allow hardware components to be located in different
locations by utilizing high speed communication links to interconnect processors and
distributed I/O. The distributed PLC type is considered to be a site wide process control
solution.

The biggest differences between distributed PLCs and other types of PLCs is that they
contain high performance processors, large memories and are able to handle large volumes of
I/O, use higher level programming languages and can handle large amounts of complex
process control tasks.
In the past a Distributed Control Systems (DCS) was used for large process plants. But the
technology driven PLCs of today are performance packed and can handle the heavy demands
of a distributed control system.

Examples of Distributed PLC Types

Examples of Distributed PLC Types
In today’s world of advanced PLCs most modular PLCs have the features of a distributed
PLC. Regardless of the terminology used a distributed PLC is universally characterized by:

PLC naming convention – Distributed or Modular with Remote I/O.

CPU processor – High powered.
Program and data memory size – Large.
Power supply – Module.
Input Interface – Input Modules.
Output Interface – Output Modules.
Communication interfaces – Communication Modules.
Mounting system – Rack, backplane, rail or chassis.
Physical size – Medium to Large.
Flexibility – High
Expandable – Yes
Customizable – Yes
Applications –High end applications with large number of inputs and outputs.
Cost –High $$$$$.
What are the Advantages of Using a Distributed PLC?
Distributed PLCs have been designed to process and handle large amounts of data and
complex process control. As such they have the following advantages over other PLC
types….

Plant wide control network with multiple processors and remote I/O drops.
High performance processor.
Large program and data memory.
Able to handle large volumes of I/O.
Can handle large amounts of complex process control tasks.
Ease of maintenance.
Save time and money on installation costs.
Disadvantages of Distributed PLCs
Because of the high end features that a distributed PLC has they come with some
disadvantages that must be considered when selecting the type of PLC that is required for
your automation system….

Large in size with bigger installation footprint.

The mounting system is more complex than a fixed PLC.
Higher in cost than other types of PLC so they may not be cost effective for smaller less
complex applications.
Higher level programming skills may be required.
PLC Types Comparison Table
PLC TYPES FIXED PLCFixed PLC MODULAR PLC Modular PLC
DISTRIBUTED PLC Distributed PLC
CPU Performance Low Medium to High High
Program & Data Memory Size Small Medium to Large Large
Power Supply Embedded Module Module
Input InterfaceEmbedded Modules Modules
Output Interface Embedded Modules Modules
Communication Interface Embedded Modules Modules
Mounting System Single Unit Rack, Back plane, Rail or Chassis. Rack, Back plane,
Rail or Chassis.
Physical Size Small Medium to Large Medium to Large
Flexibility No Yes Yes
Customizable No Yes Yes
Applications Basic applications with small number of inputs and outputs.Medium to high
end applications with large number of inputs and outputs. High end applications and plant
wide control with a very large number of inputs and outputs.
Cost Low $$$$$. Medium $$$$$. High $$$$$.
In the next section we’ll learn about PLC hardware and the essential components that make
up a PLC system.
PLC Motor Control Ladder Logic Programming

A PLC has to start a Motor when the Start button is pressed. It has three interlocks which are
Motor Vibration High, Overload & Motor Temperature High.
if any of the interlock activated then PLC has to stop the motor immediately.
PLC has to stop the motor if the stop button is pressed.
PLC trip logic or interlock has to be enabled only when motor is in Remote mode.

PLC Motor Control

In above figure: Red LED indicator lights on the input and output cards of the PLC indicate if
those respective I/O channels are energized.

Note:
1. In above figure, Local Control Panel signals are not shown. Local control
panel is connected to motor feeder directly.
2. 24v DC power directly connected ( in general fuses or barriers will be used,
power will be distributed through bus bar)
PLC Inputs
 Start push button
 Stop push button
 Vibration High
 Temperature High
 Overload Trip
 Run feedback
 Local/Remote status
PLC Outputs
 Start Command (Remote Start)
 Stop Command (Remote Stop)
 Start Permissive (Optional)
The motor is a three phase, 415V AC powered device. So, by default high voltage equipment
will be powered from substations or motor control centres (MCC) which are maintained by
electrical.
So, we consider this motor is connected to a simple motor feeder in the substation.
Generally, the motor feeder have inputs from field (local control panel) & PLC also. Which
are shown in below figure.

Note : the motor feeder may have start, stop, some other trips indications like overload etc…
in the motor feeder panel which are not shown in the fig. These are mounted on the motor
feeder panel (in addition to LCP).

If motor feeder receives start & stop command inputs from PLC then we call them as Remote
Start & Remote Stop signals.

Similarly, if motor feeder receives start & stop command inputs from local control panel
(LCP) which is installed in field (near to motor) then we call them as Local Start & Local
Stop signals.
In common practice, this LCP has emergency stop & Local/Remote selection switch also.

The motor feeder also sends a Local/Remote status to PLC. If Local/Remote selection switch
is in Local mode then motor feeder will only consider signals from LCP and ignore the
commands from PLC.

Similarly if Local/Remote Selection switch in Remote Mode then motor feeder will consider
signals from Remote i.e. PLC and ignore the signals from LCP.

For example : if Local/Remote selection Switch in Remote Mode. If field operator pressed
the start push button from the field LCP then motor will not be started as the selection is in
remote mode.
Depends on the Local/Remote selection switch status the motor feeder will decides which
signals to be consider i.e. either PLC or LCP signals.
Note : Local/Remote Selection will not be applied for Emergency Stop or Stop Commands
either from PLC or LCP. Whatever mode it is, the Stop commands will be accepted by motor
feeder and stops the motor immediately. This is a safety concern.

Difference between Compact PLC and Modular PLC

Sr. No. Content Compact PLC Modular PLC

Compact PLC is also known Modular PLC is also known
01 Name
as Fixed PLC. as Rack-Mounted PLC.
In Compact PLC, the number of In Modular PLC, the number of
inputs and outputs are fixed. input and output are not fixed.
02 I/O
Because I/O capabilities are Inputs and outputs can be added
decided by the manufacturer but to the modular PLC systems by
not by the user. the user.
In this PLC, several components
It has inputs and outputs
03 Module are fitted on chassis or rack or
modular fitted with CPU.
bus with different slots.
Modular PLC is easy to
Compact PLC is not easily
04 Repair maintain and repair as compared
repaired.
to compact PLC.
It has fewer memory
It has more memory and
05 Memory capabilities to store
capabilities to store more data.
data/information.
It is useful for smaller It is used for industrial purposes
06 Use applications and most suitable and also for future industrial
for domestic purposes. expansion and growth.
It occurs in a large size with i/o
07 Size It is smaller in size. connectivity, power supply,
computing capabilities, etc.
08 Cost It is an economic model. It is costlier than Compact PLC.

Difference Between PLCs and Computers:

Programmable Logic Controllers (PLCs) have basic architecture compared to normal general-
purpose computers. A normal computer can be converted to PLCs by providing a way that
the computer can able to receive information or signal from the field devices such as push
buttons, switches and valve positions. The computer requires some software to process the
information obtained from the input to generate an output which decides whether to close or
open the valve position on the process side.

Some of the important features and characteristics that distinguish between the general-
purpose computers and Programmable Logic Controllers (PLCs) are given below:
 1) PLCs are designed to operate under industrial environments (PLCs have to
operate under a wide range of temperature conditions, humidity and other
environmental conditions). They are least affected by the electrical noise and
are inherent to electrical noise.
2) Programming in PLCs is through Relay Ladder Logic or other easily learned
languages. PLCs comes with program language built in its memory. PLCs do
not contain input and output devices such as keyboards, mouse, monitor, CD
drives and other hard disks. It is simply a self-contained box with
communication ports and set of terminals for input and output devices.
3) Unlike computers which perform numerous tasks simultaneously, PLCs
execute a single program in an orderly and sequential manner from first
instruction to the last instruction.
4) PLCs have been designed for installation and maintenance by plant
electricians. Programming in PLCs is simple (Relay Ladder Programming), it
does not include any advanced code. Troubleshooting is simpler and many
PLCs are designed to include fault details and written fault details on display
screen.

What’s the difference between a PLC and a computer?

1) It has physical input/outputs (I/Os); electrical inputs and outputs bring real world
information into the system and control real world devices based on that information.
A PLC’s, inputs can be thought of as “senses” like vision and touch; outputs can be
thought of as arms and legs.
2) It is deterministic and processes information and reacts to it within defined time
limits. PLCs operate on a timescale of milliseconds or even microseconds.
3) It is often modular; it can have I/O modules, communication modules or other special
purpose modules added to it for expansion. PLCs may also take the form of a
computer or a small single module.
4) It is programmed using several defined languages. Some languages allow the program
to be changed while the machine or system being controlled is still running.
5) Software and hardware are platform specific; components and programming software
usually can’t be used between different manufacturers. There are exceptions however.
6) It is rugged and designed for use in industrial environments.

What is a PLC?

A programmable logic controller is a small computer that can accept data and deliver
operational instructions through its inputs and outputs. A PLC’s primary duty is to control the
functions of a system using the underlying logic that has been programmed into it. PLCs are
used by businesses all over the world to automate their most critical procedures.
Types of PLC

PLCs are mainly classified into two. They are

 Fixed/Integrated/Compact PLC
 Modular PLC

Click here 25 to know the different types of plc

In this article, we are going to discuss Modular PLC

What is modular PLC?

The modular PLC is a form of PLC that allows for multiple expansions of the PLC system by
the use of modules, hence the name “modular.”

Modules provide extra functionality to the programmable logic controller, such as an

expanded number of I/O units, and they are typically easier to operate because each
component is independent of the others.

The power supply, communications module, and input/output module are all independent of
the microcontroller, so you must manually connect them to form your PLC control system.

Rack-mounted or rack-mount PLCs are a type of modular PLC. The communications module
of a rack mount PLC is housed in the rack itself, thus all connections are consolidated.

Difference between Modular PLC & Compact PLC 12

Advantages and Disadvantages of Modular PLC

Advantages of Modular PLC

 Expanded Memory
 Higher Number of I/Os
 Expansion available
 Easy to troubleshoot and less downtime
Memory

Fixed PLCs can only store a certain amount of data. This is due to the fact that all of the
necessary components are housed in a single entity. Furthermore, there isn’t much
opportunity for extending information beyond the very fundamental functions required.
Modular PLCs have significantly more memory and can store a greater volume of data.

Number of I/Os

The fixed PLC has a restricted number of I/O modules, restricting its performance. The
modular PLC can do more complex procedures, making it more advantageous.

Expansion available

When the need to expand your operation emerges, the fixed PLC will be unable to keep up.
Modular PLCs were created for this reason, to expand and tailor processes to allow for
continuous expansion.

Easy to troubleshoot and less downtime

Downtime is expensive, and no one wants a system that drains profits. Problems are not
detected by fixed PLCs. As a result, when they crash, troubleshooting takes a long time.
However, modular PLCs can readily troubleshoot difficulties while keeping some processes
operating. While fixed PLCs may be less expensive at first, the modular PLC provides more
long-term economic assurance.

Disadvantages of Modular PLC

 Cost is high
 Complex structure

Expanding an Existing PLC System

A small or fixed PLC is less expensive than a modular PLC and is utilised for standalone
duties.

If we want to expand an existing process, we must replace a fixed component. A modular

PLC does not need to be replaced because it can be expanded.

Modular PLCs or Rack type refers to a form of PLC that connects its power supply, CPU
unit, and I/O system via a backbone called Rack.

A small PLC system that is delivered fully assembled and cannot be modified or upgraded. A
modular PLC system is made up of pieces that may be swapped out, upgraded separately,
deleted, or replaced with new ones.
Compact PLCs contain fewer input and output modules than modular PLCs, but more
memory. They are commonly employed in industries.

Modular PLCs have significantly more capacity and can store a greater volume of
information, whereas compact PLCs have restricted input-output modules, restricting their
performance.