PROGRAMABLE LOGIC CONTROLLERS 2.

More Flexibility
(PLC) OVERVIEW
It is easier to create and change a
program in a PLC than to wire and rewire a
circuit. With a PLC the relationships between the
inputs and outputs are determined by the user
program instead of the manner in which they are
interconnected
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.
Generally, if an application has more than about
a half-dozen control relays, it will probably be less
expensive to install a PLC.
Programmable Logic Controllers 4. Communications Capability
An industrial grade computer that is A PLC can communicate with other
capable of being programmed to perform control controllers or computer equipment to perform
functions. The programmable controller has such functions as supervisory control, data
eliminated much of the hardwiring associated gathering, monitoring devices and process
with conventional relay control circuits. parameters, and download and upload of
The PLC is designed for multiple input programs.
and output arrangements, extended temperature 5. Faster Response Time
ranges, immunity to electrical noise, and
resistance to vibration and impact. 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.
6. Easier to Troubleshoot
PLCs have resident diagnostics and
override functions that allow users to easily trace
Advantages of Programmable Logic and correct software and hardware point. For
Controllers example, a control system consisting of hundreds
of input and output field devices may be
1. Increased Reliability contained within a very large manufacturing area.
Once a program has been written and Thus, it would take a considerable amount of time
tested, it can be easily downloaded to other to check each device at its location. By having
each device wired back to a common point on a
PLCs. Since all the logic is contained in the PLC’s
memory, there is no chance of making a logic PLC module, each device could be checked for
wiring error. operation fairly quickly.
 PARTS OF A PLC actuators and motors. Their primary function is to
take digital signals generated by the PLC and
A typical PLC can be divided into parts. These are
convert them into physical control signals that can
the central processing unit (CPU), the
drive the connected devices.
input/output (I/O) section, the power supply, and
the programming device.

1. Power Supply
5. Memory
The Primary role of the power supply is to
It serves as a critical component for
provide electrical power to all the internal
storing the control program, data, and system
components of the PLC, including the central
information. Two main types of memory exist in a
processing unit (CPU), input and output modules,
PLC: RAM (Random Access Memory) and ROM
memory, and communication interfaces.
(Read-Only Memory).
2. Processor (CPU)
6. Programming Device
It is the brain of the PLC. A typical
Used to enter the desired program into the
processor usually consists of a microprocessor
memory of the processor. The program can be
for implementing the logic and controlling the
entered using relay ladder logic, which is one of
communications among the modules. The
the most popular programming languages.
processor requires memory for storing user
Instead of words, ladder logic programming
program instructions, numerical values, and I/O
language uses graphic symbols that show their
devices status.
intended outcome.
3. Input Modules
7. Program
Input modules serve as the crucial link
A user-developed series of instructions that
between external devices like sensors and
directs the PLC to execute actions. A
switches and a Programmable Logic Controller
programming language provides rules for
(PLC). Their primary function involves converting
combining the instructions so that they produce
the varied physical signals produced by these
the desired actions. Relay ladder logic is the
external devices into a standardized digital
standard programming language used with PLCs.
format, ensuring compatibility with the digital logic
The relay ladder logic program graphically
of the PLC. This transformation enables the PLC
represents rungs of contacts, coils, and special
to effectively interpret and respond to the
instruction blocks.
information provided by the external devices.
4. Output Modules
Output modules play a crucial role in a
Programmable Logic Controller (PLC) by
interfacing with external devices such as
 ARCHITECTURE
Open Architecture Design
It 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.
Closed Architecture Design
A closed architecture is one whose design is
proprietary, making it more difficult to connect to Wiring connections for a 120 VAC modular
other systems. configured input and output module.

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.

PRINCIPLES OF OPERATION

To program the controller, you enter these

instructions one by one into the processor
memory from the programming device. Each
input and output device is given an address,
which lets the PLC know where it is physically
connected. Note that the I/O address format will
differ, depending on the PLC model and
manufacturer.

SEQUENCE OF OPERATION
Power-up and Initialization
Here a mixer motor is to be used to
automatically stir the liquid in a vat when the • When power is applied, the PLC goes
temperature and pressure reach preset values. In through a self-check and initializes its
addition, direct manual operation of the motor is internal components.
provided by means of a separate pushbutton • Input and output modules are configured
station. and checked for proper functioning.
Scan Cycle

• The PLC continually scans the input

devices to read their status.
• Input status is stored in the PLC's
memory.
 Program Execution PLCs have programming languages that usually
only allow ladder logic programs to be created.
• The PLC executes the user-
programmed logic, typically written in Medium PLC
ladder logic, function block diagram,
A medium PLC is a computer that can
or other programming languages.
control larger machines such as assembly lines
• The logic evaluates the current state
and motors. It has more functionality than the
of inputs and determines the
other two classes of PLCs due to its large
appropriate state for outputs.
memory size, expanded communication ports,
Output Update higher processing speeds, and additional
input/output devices.
• The determined output states are
updated based on the program logic. Examples of medium programmable
• The PLC updates the physical output controllers are digital-to-analog converters
devices (actuators, motors, valves, (DACS), serial communications ports configured
etc.) to reflect the desired state. to communicate with field actuators via networks
or buses like Ethernet or DeviceNet, and analog
input modules for local sensors configured to
* What if there is a sudden change within the monitor physical parameters like pressure,
requirement that the pushbutton will only operate temperature, and weight.
at any pressure but not unless the specified Large PLC
temperature has been reached.
A large PLC is a computer that can control
very large machines such as whole building
blocks or power-producing turbines. It has more
functionality than the other two classes of PLCs
due to its high memory size, expanded
communication ports, high processing speeds,
and additional input/output devices.
Some examples of large programmable
controllers are analog output modules for local
actuators configured to monitor physical
parameters like speed or torque output from
motors connected to them, digital-to-analog
CLASSIFICATION OF PLC converters (DACS), serial communications ports
configured to communicate with field actuators
• PLC Types Based On Size via networks or buses like Ethernet or DeviceNet,
• PLC Types Based on Hardware Setup and other peripheral devices.
• PLC Types Based on Power Supply

PLC Types Based On Size PLC Types Based On Hardware Setup

Small PLC
A small PLC computer can control smaller
machines such as conveyors and motors. It has
less functionality than the other two classes of
PLCs and contains enough memory to store
ladder logic programs for monitoring local I/O
devices. Some small PLCs are integrated into the
controller in which they are used. These small
 Compact PLC
A compact PLC is a small,
microprocessor-based controller designed to
handle small automation tasks. It consists of a
built-in programming language and an extensive,
user-friendly set of instructions that simplify the
type of coding needed for specific applications.
The primary components in a compact
PLC include inputs, outputs, power supply,
processing unit, and terminals or connectors that
link with devices such as sensors and switches.
Modular PLC
A Modular PLC controller is a control
system that uses programmable hardware
components instead of the fixed-function
controllers used in traditional manufacturing
process control.
By allowing users to configure and
reconfigure their controller as needed, modular
PLCs save manufacturers money on the front end
by easing installation and configuration
requirements.
In addition, they can be switched out with
upgrades or replacements easily, instead of being
discarded when more advanced technology
becomes available. That makes them attractive
for high-growth companies planning to expand
quickly into new markets.

PLC Types Based On Power Supply

PLCs can be divided into two main types
depending on their power supply, those with a
built-in power supply and those that require an
external power supply.
PLC without built-in power supply must
be connected to an external power source such
as batteries.
PLC with the built-in power supply
does have a built-in DC voltage DC24V or DC48V
for the circuit inside the machine, so it will never
need a separate battery or transformer.