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Programmable Logic
Controller
Lecture 3

Contents

Contents

• Introduction to PLC

• PLC Parts

• Principles of Operation

• Modifying the Operation

• PLC vs. Computers

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Introduction

Programmable Logic Controllers (PLC)

• 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.
• Initially the PLC was used to replace relay logic, but its ever-increasing
range of functions means that it is found in many and more complex
applications.
• The structure of a PLC is based on the same principles as those employed in
computer architecture.
• Hence, it is capable not only of performing relay switching tasks but also of
performing other applications such as timing, counting, calculating,
comparing, and the processing of analog signals.

History

Historical Background

• Programmable logic controllers (PLCs) first hit the scene in the late 1960s.
• Prior to the inven<on of the PLC, most factories used what is called “Relay Logic”. At one
<me, this was the only way to control a manufacturing process.
• Engineers would design huge banks of relays, some<mes whole rooms full of them, to
control their plants. Rudimentary and inefficient, manufacturers na<onwide sought a
change to drive produc<on forward.
• The primary reason for designing such a device was elimina<ng the large cost involved in
replacing the complicated relay based machine control systems for major U.S. car
manufacturers.
• The automo<ve industry adopted PLCs ini<ally for soOware revisions, which replaced
rewiring of control panels that were used during the changing of produc<on models.
• Before PLC crea<on, the process to change and update facili<es for its new models each
year was very expensive and <me-intensive since each relay had to be individually
rewired.

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History

Historical Background

• In 1968, General Motors reached out to many companies with the challenge to
replace their relay based control system with a “Standard Machine Controller”.
Richard E Morley (known as the “father” of PLC) answered the call.
• His company Bedford & Associates (where Morley worked) designed the first
prototype PLC’s.
• Morley designed a system that would use previously installed “Relay Logic”
designs, and condense the relay banks into a small, modular, solid-state controller
called a Modular Digital Controller (MODICON).
• So thereby invented the first Programmable Logic Controller, started as a
consultation project for the General Motors Company in 1968, thus PLC history
was born.
• Following this success, Bedford Associates changed its name to Modicon PLC.
They began producing the Modicon 084, the first PLC.

History

Historical Background

• Bedford Associates later sold Modicon to the German company now known as
AEG [Allgemeine Elektricitäts-Gesellscha5] (AEG; German for 'General electricity
company') .
• Schneider Electric in France is now the current owner of Modicon’s 084 PLC.
• The PLC is now a vital part of many manufacturing industries saving criUcal man-
hours and thousands of dollars, but the automoUve industry conUnues to be
perhaps the largest PLC user.
• PLCs met the requirements of modularity, expandability, programmability, and
ease of use in an industrial environment.
• These controllers were easily installed, used less space, and were reusable.
• The controller programming, although a liWle tedious, had a recognizable plant
standard: the ladder diagram format.

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Introduction

Programmable Logic Controllers…

• Benefits of PLC
• Increased Reliability. Once a program has been written and tested, it
can be easily downloaded to other PLCs.
• Since all the logic is contained in the PLC’s memory, there is no chance of
making a logic wiring error.
• The program takes the place of much of the external wiring that would
normally be required for control of a process.
• Hardwiring, though still required to connect field devices, is less intensive.
• PLCs also offer the reliability associated with solid-state components.

Introduction

Programmable Logic Controllers…

• Benefits of PLC
• More Flexibility. It is easier to create and change a
program in a PLC than to wire and rewire a circuit.
• With a PLC, the relaUonships between the inputs and
outputs are determined by the user program instead of
the manner in which they are interconnected.
• Original equipment manufacturers can provide system
updates by simply sending out a new program.
• End users can modify the program in the field, or if
desired, security can be provided by hardware features
such as key locks and by so^ware passwords.

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Introduction

Programmable Logic Controllers…

• Benefits of PLC
• 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.
• Generally, if an application has more than about a half-dozen control
relays, it will probably be less expensive to install a PLC.
• Communications Capability. 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

Introduction

Programmable Logic Controllers…

• Benefits of PLC
• Faster Response Time. PLCs are designed for high
speed and real-time applications.
• The programmable controller operates in real
time, which means that an event taking place in
the field will result in the execution of an
operation or output.
• Machines that process thousands of items per
second and objects that spend only a fraction of a
second in front of a sensor require the PLC’s quick-
response capability.

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Introduction

Programmable Logic Controllers…

• Benefits of PLC
• Easier to Troubleshoot. PLCs have resident diagnostics and override
functions that allow users to easily trace and correct software and
hardware problems.
• To find and fix problems, users can display the control program on a
monitor and watch it in real time as it executes

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PLC parts

Parts of PLC
• A typical PLC can be divided into parts, as illustrated in Figure. These are
the central processing unit (CPU), the input/output (I/O) secHon, the
power supply, and the programming device.

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PLC parts

Parts of PLC
• The term architecture can refer to PLC hardware, to PLC software, or to a
combination of both.
• An open architecture design allows the system to be connected easily to
devices and programs made by other manufacturers.
• Open architectures use off-the-shelf components that conform to
approved standards.
• A system with a closed architecture is one whose design is proprietary,
making it more difficult to connect to other systems.
• Most PLC systems are in fact proprietary, so you must be sure that any
generic hardware or software you may use is compatible with your
particular PLC.

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PLC parts

Parts of PLC
• Also, although the principal concepts are the same
in all methods of programming, there might be
slight differences in addressing, memory allocation,
retrieval, and data handling for different models.
• Consequently, PLC programs cannot be
interchanged among different PLC manufacturers.
• 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.

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PLC parts

Parts of PLC
• 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.
• The main advantage of this type of packaging is lower
cost.
• The number of available I/O points varies and usually
can be expanded by buying additional units of fixed
I/O.
• One disadvantage of fixed I/O is its lack of flexibility;
• you are limited in what you can get in the quantities and
types dictated by the packaging. Also, for some models, if any
part in the unit fails, the whole unit has to be replaced.

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PLC parts

Parts of PLC
• Modular I/O is divided by compartments into which
separate modules can be plugged. This feature greatly
increases your options and the unit’s flexibility.
• You can choose from the modules available from the
manufacturer and mix them any way you desire.
• 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.
• The modules plug into a rack. When a module is slid into the
rack, it makes an electrical connection with a series of
contacts called the backplane, located at the rear of the
rack.
• The PLC processor is also connected to the backplane and
can communicate with all the modules in the rack.
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PLC parts

Parts of PLC
• The power supply supplies DC power to other
modules that plug into the rack.
• For large PLC systems, this power supply does
not normally supply power to the field devices.
• 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.

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PLC parts

Parts of PLC
• The processor (CPU) is the “brain” of the PLC. A
typical processor (Figure) 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.

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PLC parts

Parts of PLC
• 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.

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PLC parts

Parts of PLC
• 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.
• To electrically isolate the internal components from the input and output terminals,
PLCs commonly employ an optical isolator, which uses light to couple the circuits
together.
• The external devices are also referred to as “field” or “real-world” inputs and outputs.
• The terms field or real world are used to distinguish actual external devices that exist
and must be physically wired from the internal user program that duplicates the
function of relays, timers, and counters.

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PLC parts

Parts of PLC
• 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.
• Hand-held programming devices are sometimes used to program small PLCs
because they are inexpensive and easy to use.
• 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.

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PLC parts

Parts of PLC
• A program is a user-developed series of instructions that directs the PLC to
execute actions.
• A programming language provides rules for combining the instructions so
that they produce the desired actions.
• Relay ladder logic (RLL) is the standard programming language used with
PLCs.
• Its origin is based on electromechanical relay control. The relay ladder logic
program graphically represents rungs of contacts, coils, and special
instruction blocks.
• RLL was originally designed for easy use and understanding for its users and
has been modified to keep up with the increasing demands of industry’s
control needs.

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PLC parts

Parts of PLC

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Operation

Principles of operation

• To get an idea of how a PLC operates, consider the

simple process control problem illustrated in
Figure.
• Here a mixer motor is to be used to automatically
stir the liquid in a container 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.

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Operation

Principles of operation

• This control problem can be solved using the relay method for motor
control shown in the relay ladder diagram of Figure.
• The motor starter coil (M) is energized when both the pressure and
temperature switches are closed or when the manual pushbutton is
pressed.

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Operation

Principles of operation

• Now let’s look at how a programmable logic

controller might be used for this application.
• 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.
• 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.

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Operation

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.
• The format used is similar to the layout of the hardwired relay ladder circuit.
• The individual symbols represent instructions, whereas the numbers represent
the instruction location addresses.

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Operation

Principles of operation

• The RUN operation for the process control scheme can be described by the following
sequence of events:
1. First, the pressure switch, temperature switch, and pushbutton inputs are examined
and their status is recorded in the controller’s memory.
2. A closed contact is recorded in memory as logic 1 and an open contact as logic 0.
3. Next the ladder diagram is evaluated, with each internal contact given an OPEN or
CLOSED status according to its recorded 1 or 0 state.

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Operation

Principles of operation

4. When the states of the input contacts provide logic continuity from left to
right across the rung, the output coil memory location is given a logic 1
value and the output module interface contacts will close.
5. When there is no logic continuity of the program rung, the output coil
memory location is set to logic 0 and the output module interface
contacts will be open.

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Operation

Principles of operation

6. The completion of one cycle of this sequence by the controller is called a scan. The process of
reading the inputs, executing the program in memory and updating the outputs is known as
Scanning.
7. The scan time, the time required for one full cycle, provides a measure of the speed of
response of the PLC.
8. Generally, the output memory location is updated during the scan but the actual output is not
updated until the end of the program scan during the I/O scan.

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Modify the 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.
• 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.

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PLC Vs Computers

PLCs vs Computers

• Unlike PCs, the PLC is designed to operate in the industrial environment

with wide ranges of ambient temperature and humidity.
• Unlike the personal computer, the PLC is programmed in relay ladder logic
or other easily learned languages.
• The PLC comes with its program language built into its memory and has no
permanently attached keyboard, CD drive, or monitor.
• Instead, PLCs come equipped with terminals for input and output field
devices as well as communication ports.
• 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.

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PLC Vs Computers

PLCs vs Computers
• Software associated with a PLC but written and run on a
personal computer falls into the following two broad
categories:
• 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 -
and document or explain the program in as much detail
as is necessary.
• 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
(Figure).
• Many operator interfaces do not use PLC software. PLCs can be
integrated with HMIs but the same software does not program
both devices.

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