Prelim: First and Second Week

Lecture 1: Overview of Programmable Logic Controller

Upon finishing the topics, the student shall be able to:

1. Define what PLC is

2. Determine the history of PLC
3. Identify the major components of PLC
4. Discuss how PLC operates
5. Identify what are discrete and analog inputs and outputs

What is PLC?
-it is a specialized computer used to control machines and processes
-uses programmable memory to store instructions and execute specific functions that
include on/off control, timing, counting, sequencing, arithmetic and data handling
-assembly of solid-state digital logic elements designed to make logical decisions and
provide outputs
-used for control and operation in the industrial environment and is equipped with special
input/output interfaces and a control programming language
-used to replace relay logic
-small and inexpensive compared to equivalent relay-based process control systems

History of PLC

 The first Programmable Logic Controllers were designed and

developed by Modicon as a relay re-placer for GM and Landis.
 These controllers eliminated the need for rewiring and adding
additional hardware for each new configuration of logic.
The new system drastically increased the functionality of the controls
while reducing the cabinet space that housed the logic.
 The first PLC, model 084, was invented by Dick Morley in 1969
 The first commercial successful PLC, the 184, was introduced in
Dick Morley
1973 and was designed by Michael Greenberg. Father of PLC

Benefits
1. Increased Reliability
-since all logic is contained in the PLCs memory, there is no chance of making logic
error
2. More Flexibility
-it is easier to create and change a program in a PLC
3. Lower Cost
4. Communications Capability
- it can communicate with other controllers or computer equipment to perform
functions such as supervisory control, data gathering, monitoring devices, process
parameters and download and upload of programs.
5. Faster Response Time
- PLCs are designed for high-speed and real-time applications
6. Easier to Troubleshoot
- PLCs have resident diagnostics and override functions

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Parts of a PLC

Parts Architecture

Components
1. CPU
2. I/O Section
3. Power Supply
4. Programming Device

Architecture
-PLC hardware, PLC software or both

1. Open Architecture
-allows the system to be connected easily to devices and programs made by other
manufacturers
-uses off-the-shelf components that conform to approved standards
2. Closed Architecture
-design is proprietary which makes it difficult to connect the system to other systems
*Most PLCs are proprietary in nature

Two Ways in which I/O is Incorporated to PLC

1. Fixed I/O
- 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 are available but
cannot be changed
-advantage: lower cost
-number of available I/O points varies and usually can be expanded by buying
additional units of fixed I/O
Disadvantage: lack of flexibility
2. Modular I/O
-divided by compartments into which separate modules can be plugged
-greatly increases your options and the unit’s flexibility
-consists of a rack, power supply, processor module (CPU), input/output (I/O
Modules) and an operator interface for programming and monitoring
*when the modules is slid into a 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

Power Supply
-supplies dc power to other modules that plug into the rack
*for larger systems - power to field devices is provided by external alternating
current or dc supplies
*for small and micro PLC systems- power supply is used to power field device

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Processor (CPU)
-”brain” of the PLC
-typical processor consists of a microprocessor for implementing the logic and
controlling the communications among the modules
-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
-designed so that the user can enter the desired circuit relay ladder logic
-accepts input data from various sensing devices,executes stored user program from
memory , and sends appropriate output commands to control devices
*a direct currect power source is required to produce the low-level voltage used by
the processor
*power supply can be housed in the CPU unit or may be a separately-mounted
module, depending on the PLC system manufacturer

I/O Section
-consists of input modules and output modules
-forms the interface by which the field devices are connected to the controller
*to electrically isolate the internal components from the input and output terminals,
PLCs employ an optical isolator, which uses light to couple the circuits together
*these devices are also referred to as “field” or “real-world” inputs and outputs

Programming Device or Terminal

-used to enter the desired program into the memory of the processor
*program is entered using relay ladder logic-most popular programming language
A) Handheld Programming Devices
- frequently used on the factory floor for troubleshooting equipment, modifying
programs, and transferring programs to multiple machines
-some of these program are entered using Boolean operators individually or in
combination to form logical statements
B) Personal Computers
-most commonly-used programming device
Additional optional PLC components are often available
 Operator Interface Devices
 Communication Adaptors for remote I/O
 Network Interfaces

Principles of Operation

Sample

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Modifying the Operation

Advantages of PLCs over Relay

1. PLCs are programmable
2. Many control relays can be replaced by software, which means less hardware failure.
3. It is easier to make changes in the software than the hardware.
4. Special functions such as time-delay actions, counters are easy to produce in software.
5. More reliable.
6. There is almost no task limit to tasks for which PLCs can be used.
7. It is cost-effective.

PLCs over PCs

PLCs PCs
Designed to be operated in industrial Designed to be operated in an environment
environment with wide range of ambient with ambient room temperature
temp., vibration and humidity conditions
Inputs are signals from control elements Inputs are drives, CD roms
like pushbuttons, limit switches,
temperature switches, pressure switches
and transducers
Outputs are final control elements like Output is a printer
contractors, solenoids, positioning valves,
indication lights and so forth
Not disc-based system Disc-based system
Operating system and application programs Operating system and application programs
are both stored in ROM are stored in different memory
Usually uses Ladder Logic Diagram, Uses high-level programming languages
Statement List, Functional Block Diagram

*The personal computer has infiltrated the PLC control industry. Software written and
run on the PC has changed how people work with PLCs. Basically, PLC software run on
a PC falls into the following two categories.
A) PLC software that allows the user to program and document gives the user the tools to
write a PLC program and document or explain the program in as much as detail as is
necessary.

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B) PLC software that allows the user to monitor and control the process is also called
man-machine, or operator, interface. It enables the user to view a process-or graphical
representation of a process-on a CRT, determine how the system is running, trend values,
and receive alarm conditions.

*Soft-logic Controllers
-PCs functioning as full-pledged PLC

Advantages of Personal-Computer-Based Control Systems

1. Lower initial cost
2. Less proprietary hardware and software
3. Straightforward data exchange with other systems
4. Speedy information processing
5. Easy customization

Basic Terminologies

1. Actuator - translates electrical signal from

PLC to physical condition understood by the
output device.

2. Connector Cables PPI (Point-to-point

Interface)
ex. connecting Siemens Programming Device and
S7-200 PPI protocol

3. Function Block Diagram

4. Hardware
- tangible part
-ex. PLC, programming device, connecting cables

5. Ladder Logic
6. Ladder Logic Diagram

7. Programming Device
8. Sensor

9. Software

10. Inputs
A) Analog Inputs

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-may vary to 0 to 20 milliamps, 4 to 20 milliamps or 0 to 10 volts
ex. level transmitter
– Sensing Devices
• Limit Switches
• Photoelectric Sensors
• Proximity Sensors

B) Discrete Inputs
Ex. – Switches and Pushbuttons
toggle switches, pushbuttons,
proximity switches, contact closures

11. Programming Device - used to input desired instructions

12. Operator Interface - allows process information to be displayed and new control
parameters to be entered

13. Output
A) Analog Output

B) Discrete Output

How does a PLC operate?

1. Input Scan
-Detects the state of all input devices that are
connected to the PLC
2. Program Scan
-Executes the user created program logic
3. Output Scan
-Energizes or de-energize all output devices that are
connected to the PLC.
4. Housekeeping
-This step includes communications with
programming terminals, internal diagnostics, etc...

PLC Size and Application

Five Classes of PLCs
1. Nano
-small enough to fit in shirt pocket and handles up to 16 I/O piints
2. Micro

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 -can connect up to 32 I/O points
*both nano and micro have instructions sets that have about 90% of the capacity of
large PLCs and are suitable for users who require powerful control but who do not need
high I/O count of a larger PLC
3. Small
- can handle up to 960 I/O points in a single rack
4. Medium
*small and medium-size PLCs offer specialty I/O modules that enhance a control
system
5. Large
- can handle several thousand I/O points

Criteria Used in Categorizing PLCs

1. Functionality
2. Number of Inputs and Outputs - most important
3. Cost
4. Physical Size

Three Major Types of PLC Application

1. Single-Minded
-involves only one PLC controlling one process
2. Multi-task
-usually calls for medium-sized PLC and involves one PLC controlling several
processes
3. Control Management
- involves one PLC controlling several other PLCs

Memory Size
-ranges from as little as 256 words for small systems to 2M(Mega) for larger systems
-usually expressed in K values: 1K, 6K, 12K and so on
*1K =1024

Although it is common for us to measure the memory capacity of PLCs in words, we

need to know the number of bits in each word before memory size can be accurately
compared

Ex. A PLC uses 8-bit words with a 6K capacity, what will be the number of bits of the
storage?
How about a PLC that uses 32-bit words with 6K memory?

Factors Affecting the Memory Size Needed for a Particular PLC Installation
1. Number of I/O used
2. Size of control program
3. Data-collecting requirements
4. Supervisory functions required
5. Future expansion

Instruction set for a particular PLC lists the different types of instructions supported.

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