Programmable Logic Controler (PLC)

PROGRAMMABLE LOGIC CONTROLER
(PLC)
Introduction
What is a PLC?
Is a specialized computer that uses a programmable
memory to store instructions and to implement functions
such as logic sequencing, timing, counting in order to
control machines and processes.
The term logic is used because programming is primarily

concerned with implementing logic and switching
operations, e.g. if A or B occurs switch on C.
Intro cont…
PLCs are similar to computers but whereas computers are
optimized for calculation and display tasks, PLCs are
optimized for control tasks and the industrial environment.
Thus PLCs are:
• Rugged and designed to withstand vibrations, temperature,

humidity and noise.
• Have interfacing for inputs and outputs already inside the

controller.
• Are easily programmed and have an easily understood

programming language which is primarily concerned with
logic and switching operations. 3
Intro cont
In a traditional industrial control system, all control devices
are wired directly to each other . In a PLC system, however,
the PLC replaces the wiring between the devices.
Instead of being wired directly to each other, all equipment is

wired to the PLC. Then, the control program inside the PLC
provides the "wiring" connection between the devices.
The use of a PLC to provide the wiring connections between

system devices is called softwiring.
4
Advantages of PLCs
• Softwiring makes changes in the control system easy and cheap.
If you want a device in a PLC system to behave differently or to
control a different process element, all you have to do is change
the control program. In a traditional system, making this type of
change would involve physically changing the wiring between the
devices.
• Flexibility: Software based system
• Compact: Replace hundreds of relays, timers and counters
• Reliable: Less mechanical parts (Moving parts)
• Reduced costs: Replaced relay control logic circuit

• Easy to troubleshoot: Diagnosis equipment are available
• PLCs take Less floor space than relay control panels. 5
Components of the PLC
The basic components of PLC are;
a) Input module
b) Output module
c) CPU
d) Power supply
e) Programming
device
Schematic representation of PLC
6
The input and output (I/O) modules
Are the connections to the industrial

machine/process that is to be controlled
A PLC can only recognize an electrical

signals
Therefore inputs to the controller are electrical signals from
sensors such as limit switches, pushbuttons, proximity and
other measuring devices.
The output signal are the ones which influence the system to
be controlled. The signals are amplified into switching
signals via actuators or converted into other energy form to
operate contactors, cylinders with solenoid valves, stepper
motors, lamps, buzzers, bells etc. 7
CPU continuously read current input status and activate or
deactivate output status according to the program
Input module output module
Input on Output on
CPU
8
There are two basic types of input and output devices:
• Discrete • Analog
Discrete devices are inputs and outputs that have only two
states: on and off.
1 means that the device is on and 0 means that the device is
off.
Analog devices are inputs and outputs that can have an

infinite number of states. These devices can not only be on
and off, but they can also be barely on, almost totally on,
not quite off, etc.
9
CPU - Central Processing Unit
It consists of a microprocessor for
implementing the logic, and
controlling the communications
among the modules. This is the
‘brain’ of the PLC, while I/O
modules acts as arms and legs
The CPU accepts input data from

sensors, executes the stored user
program, and sends appropriate
output commands to control
devices
Power Supply: Supply DC power to
the modules.
10
Programming device
Can be PC or Hand-held unit with
display which can communicate
with the PLC processor via a serial
or parallel data communication
link.
Theses devices are provided with
software enable to crate, edit,
document, store and trouble shoot
programs
11
PLC PROGRAMMING LANGUAGE
There are three basic language methods by which user
communicates information with PLC.
• Ladder diagram
• Boolean, and
• Function chart
Boolean
Function chart
Ladder diagram 12
Ladder diagram Language
It is primary and still popular programming language of PLC,
developed from electromechanical relay system-wiring
diagram.
To understand ladder logic programming start by simple
switch circuits and convert to relay logic and then to PLC
ladder logic.
Logic Control Elements

There are three basic elements of Logic Control, which are
also called Logic Gates:
• AND
• OR
• NOT
13
Other elements are derived from these three basic elements
above like NOR, NAND etc.
Normally the binary values 0 or 1 are both used for input and
output to represent OFF and ON respectively.
AND Gate (Series connection)

Gives outputs value of 1 if all of the inputs are 1, and 0
otherwise.
Network symbol
X1 ● X2=Y
Boolean equation
Hardwired logic circuit Truth Table
14
OR Gate (Parallel connection)
Gives outputs value of 1 if either of the inputs have a value of
1, and 0 otherwise.
X1 +X2=Y
15
NOT Gate
Has a single input and a single output too gives output 1 if
input is 0 and vice versa.
16
NAND Gate
Combine an AND and NOT gate in sequence
NOR Gate
Combining an OR gate and NOT gate
17
Basic Ladder Logic Contact Symbols
Normally opened (NO): Passes power (on) when if the

coil driving the contact is on (closed)
Normally closed (NC): Passes power (on) if coil is off
(opened)
Output or Coil: If any left-to-right path of contacts
passes power, the output is energized (motor, alarm,
solenoid etc).
18
Examples 1.
For process control, it is desired to have the process start (by
turning on a motor) after a part touches a limit switch, and
an emergency switch will stop the process any time when it
is pushed. Write the ladder program for this process
LS PB Motor
Relay circuit →
Relay logic circuit 19
Ladder Diagram Language Representation
PLC Wiring Diagram
20
Example 2.
For the following logic instructions; The output Y is on when
(A is on and B is on and C is off) or D is on or E is off.
Draw;
a. Logic diagram
b. Relay logic diagram
c. Ladder diagram , and
d. Develop Boolean logic equation
Solution
a) Logic diagram
21
b) Relay logic diagram
Determine the type of contact status at normal condition
before turning ON the output Y
A→ Normally opened (NO)
B→ NO
C→ Normally closed (NC)
D→ NO
E→ NC
Relay logic diagram 22

c) Ladder logic diagram
Ladder logic diagram
d) Boolean logic equation
23
Relay logic in PLC
p u sh b u to n s
p o w er
su p p ly
+ 2 4 V
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PLC
in p u ts
adl d er
lo g ci
A B C
o u tp u ts
115 aVc lig h t

A C p o w er
n eu t.
24
Program Scan
During each operating cycle, the processor reads all inputs,
takes these values, and energizes or de-energizes the outputs
according to the user program. This process is known as scan
Because the input can change at any time, the PLC must
carry on this process continuously 25
Scan Process
26
Data Flow Overview
27
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PROGRAMMABLE LOGIC CONTROLER

The term logic is used because programming is primarily

• Rugged and designed to withstand vibrations, temperature,

• Have interfacing for inputs and outputs already inside the

• Are easily programmed and have an easily understood

Instead of being wired directly to each other, all equipment is

The use of a PLC to provide the wiring connections between

• Reliable: Less mechanical parts (Moving parts)

• Reduced costs: Replaced relay control logic circuit

The basic components of PLC are;

Are the connections to the industrial

A PLC can only recognize an electrical

Input module output module

Analog devices are inputs and outputs that can have an

The CPU accepts input data from

Logic Control Elements

AND Gate (Series connection)

Normally opened (NO): Passes power (on) when if the

PLC Wiring Diagram

Relay logic diagram 22

Ladder logic diagram

d) Boolean logic equation

115 aVc lig h t

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