Programmable Logic Controllers 

(PLC) 

       
PLC Presentation Contents

• Introduction
• What is a PLC
• PLC Types
• Choosing PLC
Hardware
• PLC Applications
• Programming PLC’s
• Advantages of PLCs
• Questions
What is a PLC?
 Nema Definition circa 1978
. The PLC, also known as programmable controller
is defined by the National Electrical Manufacturers
Association (NEMA) in 1978 as:

"a digitally operating electronic apparatus which

uses a programmable memory for the internal
storage of instructions for implementing specific
functions, such as logic, sequencing, timing,
counting and arithmetic, to control through digital
or analog input/output, various types of
machines or process".
 Traditional PLC Concept

• PLC performs relay equivalent functions

• PLC performs ON/OFF control
• Ladder diagram programming
• Designed for industrial environment
 Relay Logic vs. PLC & Ladder Logic

PB1 LS1 SOL2 Inputs Outputs

Programmable
Logic
Controller
LS1 PB2 CR3
C
R

LS3

I/4 I/6 O/0

|| || ()

CR3 LS4 M1 I/7 I/5 B/0

|| || ()
|/|
I/8
||
B/0 O/1
I/9
|/| || ()
Input Wiring: PLC input is the load in the
circuit, sensing if voltage is present
Terminal Isolation
Block Barrier

Input Devices
1
2
3
L1 4
5 P
L1 6 L
7
8 C
9
10
L2 COM
 Input Devices
• Pushbuttons • 120/230 VAC
• Selector Switches • 24 VDC
• Limit Switches – Sourcing
• Level Switches – Sinking
• Photoelectric Sensors
• Proximity Sensors
• Motor Starter Contacts
• Relay Contacts
• Thumbwheel Switches
Output Wiring: PLC output is the switch,
controlling current flow to load
Isolation Terminal
Barrier Block
Output Devices
OUT 1 L1
CR
OUT 1 L2
OUT 2
OUT 2
P OUT 3 L1
L2
L OUT 3
OUT 4
C OUT 4
OUT 5
OUT 5
OUT 6
OUT 6
 Output Devices
• Valves • Relays
• Motor Starters – 120 VAC/VDC
• – 240 VAC
Solenoids
– 24 VAC/VDC
• Control Relays
• Triac
• Alarms
– 120/230 VAC
• Lights
• Transistor MOSFET
• Fans – 24 VDC
• Horns
 Inside a PLC
Communications

C C
I i O i
n r u r
p c Central t c
u u Processor p u
t i u i
t t t CR
s s

High High
Voltage Isolation
Voltage
Isolation MEMORY Barrier
Barrier
program data

Low Voltage
AC Power Supply External
85-264 VAC, or DC Power Supply
50/60Hz
 PLC Operating Cycle

START

Housekeeping Input Scan

Internal checks on The status of external inputs
memory, speed and (terminal block voltage) is written
operation. Service to the Input image (“Input file”).
any communication
requests, etc.

Output Scan Program Scan

The Output Image data
is transferred to the
external output
circuits, turning the
output devices ON or
OFF.
Each ladder rung is scanned
using the data in the Input file.
The resulting status (Logic
being solved) is written to the
Output file (“Output Image”).
PLC Hardware Types
 Most Basic of PLC Systems

In the most basic of PLC systems, a self contained

(shoe box) PLC has 2 terminal blocks, one for
Inputs and one for Outputs
Today, most PLC’s in this category are know as
Micros. Typically they provide front panel LED
status indication of I/O and Processor states
Inputs Outputs

Programmable
Controller
C
R
 Modular Chassis Based PLC’s

The vast majority of PLC’s installed today are

modular chassis based systems consisting of:
2. Processor Module (CPU)
3. Input & Output Modules
4. Chassis
5. Power Supply
 Modular Chassis-less PLC Systems

Also available from many vendors are “Chassis less”

but still Modular PLC systems. These systems still
require a Processor, I/O Modules, and Power
Supply, but in place of a chassis these components
mount directly onto a panel, din rail, and many use
a tongue and grove system to allow easy insertion
and removal
Choosing PLC Hardware
 PLC Application Considerations

• Inputs/Outputs
– Type, • Functions required
• AC, DC, sourcing, – Instruction set
sinking, etc. • Messaging
– Number of • PID
• 10, 16, 20, 32, 156 • PTO, PWM

• Memory – Arithmetic
– Type – Communications
• DeviceNet, Ethernet
• Flash or Battery backed
• Remote I/O, DH+
– Size
• 1k, 6k, 12k, 16k, 64k
– Report generation
 SOURCING vs. SINKING

SOURCING SINKING Pushbutton

Pushbutton (NPN)
(PNP)
+VDC

+
+ DC
Power
DC
Suppl
Power
y
Suppl
y
-
- DC COM
 SOURCING vs. SINKING DC Inputs

SOURCING SINKING
(PNP) (NPN)

+VDC
Field
Device IN1 +
DC DC
+ DC Power
DC Suppl
Power y Input
Suppl -
y
Input Field Modul
- DC COM
Device IN1
e
Modul
e
 Rules

RULES

• Field devices on the positive side (+VDC) of the field

power supply are sourcing field devices.
• Field devices on the negative side (DC COM) of the
field power supply are sinking field devices.
• Sourcing field devices must be connected to sinking
I/O cards and vice versa.
• Sinking field devices must be connected to sourcing
I/O cards and vice versa.
PLC Applications
 Installed and Running Systems in RI
- Conveyors - Pharmaceuticals
- Curtain rods - Plastics
- Deodorants - Plating
- Donuts - Plating Machines
- Duplex Receptacles - Power Generation
- Fibers - Power Supplies
- Filters - Product Assembly Machines
- Forged Parts - Rubber products
- Glass - Seafood Processing
- Goggles - Soda
- Grinding and Polishing - Staples
- Heat Treating Metal Products - Warehouse Automation
- Jails - Waste Water Systems
- Lenses - Drinking Water Systems
- Nails - Water Heaters
- Natural Gas - Web Handling (paper/plastic)
- Paper - Wire / Cable
 Typical PLC Application

Solenoid 1 Solenoid 2
Motor
Ingredient A Ingredient B

Sensor 1

Sensor 2

Solenoid 3
Operation of Mixer (Sequence of Control)

• Solenoid 1 • Solenoid 3
– On = Sol 3 is off, and Motor is – On = Sol 1 is off, and Sol 2 is
off, and Sensor 2 is off, and off, and Motor has run for 30
Auto Switch is on
sec.
– Off = Sol 3 is on, or Motor is
on, or Sensor 2 is on – Off = Solenoid 3 has been on
for 60 sec.
• Solenoid 2
– On = Sol 3 is off, and Motor is Solenoid 2
Solenoid 1
off, and Sensor 2 is on Ingredient
Motor
Ingredient
A B
– Off = Sol 3 is on, or Motor is
on, or Sensor 1 is on
• Motor
Sensor 1

– On = Sensor 1 is on, and Sensor 2

Solenoid 2 is off, and Solenoid
1 is off
– Off = Solenoid 3 on
Solenoid 3
 PLC Applications: Packaging

De-Palletizing, Washing, Filler, Capper, Case

Packaging, Wrapping, Cartoning, Labeling, &
Bagging Machines
 PLC Application: SCADA & RTU

Supervisory Control and Data Acquisition

(SCADA)/Remote Terminal Unit (RTU)
• puts the remote site report data at your fingertips, but also provides
affordable remote communications and control, minimizing the
likelihood of remote site issues.
 PLC Applications: Material Handling

• Control of rollerbed conveyors or towveyors, and

mobile equipment including transfer vehicles,
elevated transfer vehicles, lifts and hoists, and
stacker cranes.
 PLC Applications: Distribution

Start and stop conveyors, control traffic at merge

points, redirect packages at divert points, and
control a wide assortment of OEM machines such
as palletizers and accumulators.
PLC Programming
 Programming PLC’s

The purpose of a PLC Program is to control the state

of PLC outputs based on the current condition of
PLC Inputs

Different PLC’s support different languages, but the

most popular PLC language is know as “Ladder
Logic”.

PLC Ladder Logic purposely resembles Relay Logic

 Ladder Logic Concepts

Read / Conditional Write / Control

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

|| |/| ()

|| || |/| ()

|| |/| ()
||

End (Rung #5) || |/| ()

Ladder Logic Concepts

Read / Conditional Write / Control

Instructions Instructions

|/| || ()
T F F
No Logical Continuity

|/| |/| ()
T T T
Logical Continuity
Logical AND Construction

IF input 4 AND input 5 have power

THEN energize output 0

On
I/4 I/5 O/0
|| || ()
T T T
Logical Continuity
 Logical OR Construction

IF input 4 OR input 5 have power

THEN energize output 0
T On
I/4 O/0
|| ()
Logical Continuity
F I/5
||
F On
I/4 O/0
|| ()
Logical Continuity
T I/5
||
Complex Construction

I/4 I/0 I/1 I/9 I/10 O/0

|| |/| || || || ()
I/5 I/1 I/7 I/8
|| |/| |/| |/|
I/2 I/3
|| ||
I/11 I/1
|/| ||
 Read Instructions

Supply

Voltage

LS 1

Unused Unused COM I/0 I/1 I/2 I/3 I/4 COM I/5 I/6 I/7 I/8 I/9

The instruction is:

If the The input
Examine ON Examine OFF
input bit is
device is -| |- -|/|-
XIC XIO

Open (0) Logic 0 False True

Closed (1) Logic 1 True False

 Write Instruction

|| |/| ()
T T T Rung Output Output
State Bit Terminal

OTE
TRUE ON ENERGIZED
Output Energize
-( )-
FALSE OFF De-energized

L1 L2/N GND VAC O/0 VAC O/1 VAC O/2 VAC O/3 VAC O/4 O/5
VDC VDC VDC VDC VDC

Supply
Voltage
 Putting it Together

Supply
PB1
Voltage

Unused Unused COM I/0 I/1 I/2 I/3 I/4 COM I/5 I/6 I/7 I/8 I/9

L1 L2/N GND VAC O/0 VAC O/1 VAC O/2 VAC O/3 VAC O/4 O/5
VDC VDC VDC VDC VDC

Supply
Voltage

I/8 O/0
|| ()
 Addressing Example

L1 L2
PB1 LS1 PS2 SOL6 I/5 I/6 I/7 O/0
|| || || ()

DEVICE ADDRESS
HHP Logix
PB1 I/5 I:0/5

LS1 I/6 I:0/6

PS2 I/7 I:0/7

SOL6 O/0 O:0/0

 Relay Logic to Ladder Logic

PB1 LS1 SOL2 I/4 I/6 O/0

|| || ()

I/7 I/5 B/0

LS1 PB2 CR3
|| || ()
LS3 I/8
||
B/0 O/1
I/9
CR3 LS4 M1 |/| || ()
|/|

INPUT Address Assignment:

PB1- I/4 PB2- I/5
LS1- I/6 LS2- I/7
LS3- I/8 LS4- I/9

OUTPUT Address Assignment:

SOL2- O/0 M1- O/1
Advanced Instructions

• SEQUENCERS

• SHIFT REGISTERS

• DATA HANDLING

• HIGH SPEED COUNTER

• SUBROUTINES
Advantages of a PLC
 Basic PLC Advantages

• Ease of programming
• Ease of maintenance
• Designed for industrial environment
• Quick installation
• Adaptable to change

Source: A-B’s Micro Solutions Presentation

 Advantages over Relays

• All the capabilities of the earlier systems

• Dramatic performance increase over the relay
logic systems
• Greater reliability
• Little maintenance due to no moving parts
• No special programming skills required by
maintenance personnel
• Physical size of the PLC system is much smaller
than the conventional relay based logic
• And most importantly much lower cost

Source: C.Maynard@curtin.edu.au
 Advantages over SBC’s (single board
computers)
• SBC’s have high design costs
– Contract or Staff with overhead and maintenance issues associated with each
• SBC’s are Repair / Service nightmare for customers
– Depending on markets served supplier must develop/support services
• SBC’s requires high level of technical expertise by
technicians
– Specialized circuit boards require specialized equipment and technical staff
• SBC’s not stocked through local distributors
– Suppliers sell the controller imbedded, replacement parts are not readily available
even in emergency situations
• SBC’s typically do not meet worldwide standards
– Certifications cost money, typically a single controller does not warrant the
investment. Volumes are not high enough and re-certification on each revision is
unrealistic
• SBC’s typically a “Domestic” product
– Because of these issues many manufacturers limit themselves to a single market.
Source: A-B’s Micro Solutions Presentation
Advantages over Computer based Software
• Maintenance personnel already experienced in PLC
troubleshooting and servicing relay latter logic
programming, not PC software

• Better power failure response

• Cost advantages for simple machine control

• Higher reliability that minimizes the expense of shutdown,
troubleshooting, repair, & startup

• Industrially hardened packaging

• Long availability and support for product models without

the rapid obsolescence of PCs.