Programmable Logic

Controllers (PLCs)
Introduction
• A programmable logic controller (PLC) is an industrial grade computer
that is capable of being programmed to perform control functions.
• The programmable controller has eliminated much of the hardwiring
associated with conventional relay control circuits. Other benefits
include easy programming and installation, high control speed,
network compatibility, troubleshooting and testing convenience, and
high reliability.
• The programmable logic controller is designed for multiple input and
output arrangements, extended temperature ranges, immunity to
electrical noise, and resistance to vibration and impact.
Introduction…
• The programmable logic controller is, then, basically a digital
computer designed for use in machine control.
• Unlike a personal computer, it has been designed to operate in the
industrial environment and is equipped with special input/output
interfaces and a control programming language.
Why using PLC?
• Programmable controllers offer several advantages over a
conventional relay type of control.
• Relays have to be hardwired to perform a specific function. When the
system requirements change, the relay wiring has to be changed or
modified.
• The programmable controller has eliminated much of the hardwiring
associated with conventional relay control circuits.
Why using PLC?

Relay based control panel PLC-based control panel

Why using PLC?
• PLCs provide many other benefits including:
1. Increased Reliability. Once a program has been written and tested, it
can be easily downloaded to other PLCs.
2. More Flexibility. It is easier to create and change a program in a PLC
than to wire and rewire a circuit.
3. Lower Cost. PLCs were originally designed to replace relay control
logic, and the cost savings have been so significant that relay control
is becoming obsolete except for power applications.
Why using PLC?
4. Communications Capability. A PLC can communicate with other
controllers or computer equipment to perform such functions as
supervisory control, data gathering, monitoring devices and process
parameters, and download and upload of programs.
5. Faster Response Time. PLCs are designed for highspeed and real-
time applications.
6. Easier to Troubleshoot. PLCs have resident diagnostics and override
functions that allow users to easily trace and correct software and
hardware problems.
Parts of a PLC
• A typical PLC can be divided into parts, as illustrated in Figure below.
• These are the central processing unit (CPU) , the input/output (I/O)
section, the power supply, and the programming device.
Parts of a PLC

Modular type
Parts of a PLC

Fixed type
Parts of a PLC: I/Os (Inputs/Outputs)
• There are two ways in which I/Os (Inputs/Outputs) are incorporated
into the PLC: fixed and modular.
• Fixed I/O is typical of small PLCs that come in one package with no
separate, removable units. The processor and I/O are packaged
together, and the I/O terminals will have a fixed number of
connections built in for inputs and outputs.
• Modular I/O is divided by compartments into which separate modules
can be plugged. The basic modular controller consists of a rack, power
supply, processor module (CPU), input/output (I/O modules), and an
operator interface for programming and monitoring.
Parts of a PLC: I/Os (Inputs/Outputs)

Fixed I/O
Modular I/O
Parts of a PLC: Power Supply
• The power supply supplies DC
power to other modules that
plug into the rack.
• With larger systems, power to
field devices is provided by
external alternating current (AC)
or direct current (DC) supplies.
• For some small micro PLC
systems, the power supply may
be used to power field devices.
Parts of a PLC: Processor (CPU)
• The processor (CPU) is the “brain” of the PLC.
• A typical processor usually consists of a microprocessor for
implementing the logic and controlling the communications among
the modules.
• The processor requires memory for storing the results of the logical
operations performed by the microprocessor. Memory is also required
for the program EPROM or EEPROM plus RAM.
• The CPU controls all PLC activity and is designed so that the user can
enter the desired program in relay ladder logic.
Parts of a PLC: Processor (CPU)

Typical CPU modules

Parts of a PLC: I/O System
• The I/O system forms the interface by which field devices are
connected to the controller. The purpose of this interface is to
condition the various signals received from or sent to external field
devices.
• Input devices such as pushbuttons, limit switches, and sensors are
hardwired to the input terminals.
• Output devices such as small motors, motor starters, solenoid valves,
and indicator lights are hardwired to the output terminals.
• The external devices are also referred to as “field” or “real-world”
inputs and outputs.
Parts of a PLC: I/O System

Typical PLC
input/output (I/O)
system
connections.
Parts of a PLC: Programming Device
• A programming device is used to enter the desired program into the
memory of the processor.
• The program can be entered using relay ladder logic, which is one of
the most popular programming languages.
• Instead of words, ladder logic programming language uses graphic
symbols that show their intended outcome. A program in ladder logic
is similar to a schematic for a relay control circuit. It is a special
language written to make it easy for people familiar with relay logic
control to program the PLC.
Parts of a PLC: Programming Device
• Hand-held programming devices are sometimes used to program
small PLCs because they are inexpensive and easy to use. Once
plugged into the PLC, they can be used to enter and monitor
programs.
• Both compact hand-held units and laptop computers are frequently
used on the factory floor for troubleshooting equipment, modifying
programs, and transferring programs to multiple machines.
Parts of a PLC: Programming Device

Typical hand-held
programming device
Parts of a PLC: Programming Device
• A personal computer (PC) is the most commonly used programming
device.
• Most brands of PLCs have software available so that a PC can be used
as the programming device.
• This software allows users to create, edit, document, store, and
troubleshoot ladder logic programs.
Parts of a PLC: Programming Device

Typical PC software used

to create a ladder logic
program
PLC Scanning
• The CPU controls all PLC activity and is designed so that the user can
enter the desired program in relay ladder logic.
• The PLC program is executed as part of a repetitive process referred to as
a scan.
• A typical PLC scan starts with the CPU reading the status of inputs.
• Then, the application program is executed. Once the program execution
is completed, the CPU performs internal diagnostic and communication
tasks.
• Next, the status of all outputs is updated.
• This process is repeated continuously as long as the PLC is in the run
mode.
PLC Scanning

Typical PLC scan cycle

Principles of Operation
• To get an idea of how a PLC operates,
consider the simple process control
problem illustrated in Figure at Right .
• Here a mixer motor is to be used to
automatically stir the liquid in a vat
when the temperature and pressure
reach preset values.
• In addition, direct manual operation of
the motor is provided by means of a
separate pushbutton station.
• The process is monitored with
temperature and pressure sensor
switches that close their respective
contacts when conditions reach their
preset values. Mixer process control problem
Principles of Operation
• This control problem can be
solved using the relay method
for motor control shown in the
relay ladder diagram of Figure at
Right. The motor starter coil (M)
is energized when both the
pressure and temperature
switches are closed or when the
manual pushbutton is pressed.

Process control relay ladder diagram

Principles of Operation
• The same input field devices
(pressure switch, temperature
switch, and pushbutton) are
used. These devices would be
hardwired to an appropriate
input module according to the
manufacturer’s addressing
location scheme. Typical wiring
connections for a 120 VAC
modular configured input module
is shown in Figure at Right .
Typical wiring connections for a 120 VAC
modular configured input module.
Principles of Operation
• The same output field device
(motor starter coil) would also
be used. This device would be
hardwired to an appropriate
output module according to the
manufacturer’s addressing
location scheme. Typical wiring
connections for a 120 VAC
modular configured output
module is shown in Figure at
Right.
Typical wiring connections for a 120 VAC
modular configured output module.
Principles of Operation
• Next, the PLC ladder
logic program
would be
constructed and
entered into the
memory of the CPU.
A typical ladder
logic program for
this process is
shown in Figure at
Right. Process control PLC ladder logic program with typical
addressing scheme
Principles of Operation

Typical wiring
required to
implement the
process control
scheme using a
fixed PLC
controller.
Principles of Operation: Modifying the
Operation
• One of the important features of a PLC
is the ease with which the program
can be changed. For example, assume
that the original process control circuit
for the mixing operation must be
modified as shown in the relay ladder
diagram of Figure at Right. The change
requires that the manual pushbutton
control be permitted to operate at any
pressure, but not unless the specified
temperature setting has been
reached. PLC ladder logic program for the modified process
PLCs versus Computers
• The architecture of a PLC is basically the same as that of a personal
computer. A personal computer (PC) can be made to operate as a
programmable logic controller if you provide some way for the computer
to receive information from devices such as pushbuttons or switches.
• However, some important characteristics distinguish PLCs from personal
computers. First, unlike PCs, the PLC is designed to operate in the
industrial environment with wide ranges of ambient temperature and
humidity.
• A well-designed industrial PLC installation is not usually affected by the
electrical noise inherent in most industrial locations.
PLCs versus Computers

PLC installed in an industrial environment

PLCs versus Computers
• Unlike the personal computer, the PLC is programmed in relay ladder
logic or other easily learned languages.
• Computers are complex computing machines capable of executing
several programs or tasks simultaneously and in any order. Most PLCs,
on the other hand, execute a single program in an orderly and
sequential fashion from first to last instruction.
PLCs versus Computers
• Software associated with a PLC but written and run on a personal
computer falls into the following two broad categories:
1. PLC software that allows the user to program and document gives
the user the tools to write a PLC program—using ladder logic or
another programming language.
2. PLC software that allows the user to monitor and control the
process is also called a human machine interface (HMI). It enables
the user to 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.