What is a Programmable

Logic Controller (PLC) ?

 Agenda
• History
• PLC Overview
• Hardware
• Inputs/Outputs
• Operation
• Programming Software
• Communication
• What you need to know when specifying a PLC
• Glossary

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 2

 History of the PLC

• First Programmable Logic Controllers were designed and

developed by Modicon as a relay replacer 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 1973 which was designed by Michael Greenberg.

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 3

 What is a PLC?

The Basic Block

CPU

Inputs Outputs

A PROGRAMMABLE LOGIC CONTROLLER is a solid state control system

that continuously monitors the status of devices connected as inputs.
Based upon a user written program, stored in memory, it controls the status
of devices connected as outputs.

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 4

 What is a PLC with Distributed I/O?

Getting Complex
CPU

Inputs Outputs

Remote

Outputs

Inputs

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 5

 What is a PLC with Distributed Control?

Getting Really Complex

CPU CPU

Inputs Outputs
Inputs Outputs

Remote

Outputs

Inputs

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 6

 Inside a PLC

Communications
Port

C C
I i Central O i
n r u r
p c Processor t c
u u
i
Unit p u
i
t u
t (CPU) t t CR
s s

High High
Voltage Isolation Voltage
Isolation MEMORY Barrier
Barrier
program data

Low Voltage

AC Power Supply or DC Power Supply

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 7

 Inside a PLC
The CPU contains an “Executive” program that tells
the PLC how to:
• Execute the control Instructions
• User’s Program
• Communicate with other devices
• Other PLCs, Programming devices, I/O devices, etc.
• Perform Housekeeping activities
• Diagnostics, etc

This program is stored in “nonvolatile” memory

• Meaning that the program will not be lost if power is removed

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 8

 What are Inputs?
• Switches and Pushbuttons
• Sensing Devices
• Limit Switches
• Photoelectric Sensors
• Proximity Sensors
• Condition Sensors
• Pressure Switches
• Level Switches
• Temperature Switches
• Vacuum Switches
• Float Switches
• Encoders

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 9

 What are Outputs?
• Valves
• Motor Starters
• Solenoids
• Actuators
• Control Relays
• Horns & Alarms
• Stack Lights
• Fans
• Counter/Totalizer
• Pumps
• Printers

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 PLC Operating Cycle
• Four Steps in the PLC Operations
• Input Scan START
• Scan the state of the Inputs Housekeeping
Input
• Program Scan Scan
Output
• Processes the program logic Scan
• Output Scan
• Energize/de-energize the outputs
Program
• Housekeeping Scan

• This step includes communications, Internal

Diagnostics, etc.
• The steps are continually repeated - processed in a loop

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 Programming the PLC

Types of Programming Software Languages

 Ladder Logic (LL)

 IEC Format
 Function Block Diagram (FBD)
Structured Text (ST)
Instruction List (IL)
Ladder Diagram (LD)
Sequential Function Chart (SFC) - also known as “Grafcet”

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 Ladder Logic

Inputs Outputs

Read / Conditional Write / Control

Instructions Instructions
Start (Rung #1) || ()

|| || |/| ()

|| |/| ()

End (Rung #4) || |/| ()

||

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 IEC - Function Block Diagram (FBD)

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 IEC - Structured Text (ST)

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 IEC - Instruction List (IL)

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 IEC - Ladder Diagram (LD)

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 IEC - Sequential Function Chart (SFC)

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 Communication

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 1

 Communication Basics
• Protocols
• A set of rules for data exchange (format and timing of data) in a
communications system
• Stack / profile = selected set of protocols for a communication
application

• Communication Relationships
• Master / Slave - request / response & response only
• Peer-to-Peer - client / server, publisher / subscriber

• Communication Architectures
• Star (point-to-point)
• Bus, Ring, LAN (multidrop)

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 2

 Communication Protocols

• Ethernet • CAN-Open
• Modbus Plus • ASi
• Modbus • Seriplex
• S908 • FIPIO/FIPway
• LonWorks • RIO
• Interbus • HART
• Profi-bus • DIO
• DeviceNet • ControlNet
• Uni-Telway • ASCII

Protocols are similar to languages -

Devices must support the same protocol to understand each other

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 2

 What you need to know when specifying a PLC
• Quantity, Type and Location of I/O
• Number of Inputs and output points
• AC or DC voltage
• Analog or Discrete
• Concentrated or spread out (distributed)

• Communication Requirements
• Protocol/Network used
• Devices to communicate with (HMI, other PLCs, etc)

• Speed of Application
• Response time required (throughput) of the system
• How fast does the process change

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 2

 What you need to know when specifying a PLC
• Control Architecture Philosophy
• Centralized Control, Distributed Control or combination
• Redundancy - CPUs, Power Supplies, etc

• Programming Software
• IEC vs. 984
• Installed base / what is currently being used

• User Logic
• Size and complexity of Program
• Feedback control used
• etc.

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 2

 Alphabet Soup

HMI / MMI Human Machine Interface / Man Machine Interface

I/O Input(s) and/or Output(s)
LSB / MSB Least Significant Bit / Most Significant Bit
MODICON MOdular DIgital CONtoller
PID Proportional Integral Derivative (feedback control)
RF Radio Frequency
RTU Remote Terminal Unit
SCADA Supervisory Control And Data Acquisition
TCP/IP Transmission Control Protocol / Internet Protocol

What is a PLC presentation.ppt February 2003 G. Ziegler, Marketing Support Manager 2