UNIT 3

INTRODUCTION TO PLC SYSTEM

BASIC CHARACTERISTIC
OF PLC
section 3.1
 STUDENTS LEARNING OUTCOME
At the end of the lesson, students will be able
• to define plc .
• To define PLC terminology.
• To explain PLC background.
• To explain PLC functions.
• List type of PLC according to size and construction
• Explain advantages of PLC
DEFINITION according to National Electrical
Manufacturer Association (NEMA)

Programmable Logic Controllers ( PLCs ) is a digital electronics

system which uses a programmable memory for implementing
specific functions such as logic, sequencing, timing, counting and
arithmetic to control through analog or digital input/output
module, various types of machine or processes.
PLC BACKGROUND

PLC was initially conceived by a group of engineers from

General Motors in 1968. The initial specifications provide
controller must be:
• Easily programmed and reprogrammed, preferably in-plant,
to alter its sequence of operations.
• Easily maintained and repaired- preferably using plug-in
modules.
• More reliable in a plant environment.
• More rugged and has noise immune capability
• Smaller than its relay equivalent.
• Cost –competitive, with solid-state and relay panels then in
PLC BACKGROUND
year nature of development
1968 programmable controller concept developed
1969 hardware CPU controller, with logic instructions. 1 K of memory and
128 I/O pints
1974 use of several processor within a PLC –timer; counter; arithmetic
operations; 12K memory and 1024 I/O points.
1976 Remote input/output systems introduced
1977 microprocessor based PLC introduced
1980 intelligent I/O modules developed
enhanced communications facilities
enhanced software feature (e.g documentation )
use of personal microcomputers as programming aids
1883 low cost small PLC introduced
1885 on networking of all levels of PLC , computer and machine under
standard GM MAP specification.
Distributed, hierarchical control of industrial plants
PLC FUNCTIONS

PLC s are initially designed to replace Relay, therefore its

functions include connection of contacts; either normally close
or Normally Open, in series and parallel to achieve logical
control task.

It then include:
• Timer :
• to provide on-delay and off-delay functions
• Counter:
• up /down counting function to count event
• Shift register:
• storing sequential condition in sequential control
• Data manipulation:
• moving data among PLC register, obtain data from table
PLC FUNCTIONS

• Arithmetic function:
•To process data in registers by using arithmetic functions

• Communication function:
• link with host computer and programming console for
program download and monitoring
• For HMI( human machine interface )
• Networking with other PLC in Multi PLCs control system.
 Sequential control

function:
Conventional logic example. relay control
Timer / counter
Control Card, PCB
Machine Control and automation control,
semi –automatic and Manual Process
 Sophisticated control

Function:
•Resolve Mathematical Operation
•Manage information
•analog control
•Servo Motor control
•Stepper motor control
•PID Control
 Supervision control
Function:
•Display process and alarm
•Diagnosis and Fault Display
•Interface with Computer (RS 232c)
•Printed interface /ASCII
•Factory Automation network
•Local Area Network (LAN)
•Wide Area Network (WAN)
•Factory Automation (FA), Flexible machine,
supervision (FMS), Computer integrated
machine (CIM)
TYPE OF PLC ACCORDING TO SIZE

• Different forms and sizes of control tasks has resulted in

producing a range of PLCs with various levels of performance
and facilities.
• Typical rough definitions of PLC size are given in terms of
program memory size and the maximum number of
input/output points.

PLC size max I/O points user memory size ( number of

instruction
small < 40 1K

medium 140 - 250 4 K – 8K

large > 250 >8K

TYPE OF PLC ACCORDING TO SIZE

• Small PLC
• Designed as robust, compact units which can be mounted on or beside the
equipment to be controlled.
• Mainly used to replace hard-wired logic relays, timers, counters, etc that
control individual items of plant or machinery.
• I/O can be expanded by adding one or two I/O modules.
• Smart or intelligent relay also can be categorized as small PLC or by itself
under intelligent relays group.( some call it Pico PLC )

OMRON INTELLIGENT
RELAY
OMRON CPM1 CPM2 SIEMENS S7-200
TYPE OF PLC ACCORDING TO SIZE

• MEDIUM SIZE PLC

• PLCs are in the form of modular construction with plug-in modules based
around EUROCARD 19 inch rack format or another rack mounting system
• Allows simple upgrading or expansion of the system by fitting additional I/O
cards into the rack.
• Communications facilities are provided, enabling the PLC to be used in a
distributed control system.

MITSUBISHI MELSEC
OMRON CJ1 SIEMENS S7-300 OnAS
TYPE OF PLC ACCORDING TO SIZE

• LARGE SIZE PLC

• Use for control system which requires very large numbers of input and
output points or requires complex control functions .
• Use in large plants or on large machines requiring continuous control.
• In modular form with a wide range of function cards available including
analogue input/output modules.
• Can be used for closed-loop PID control, position control, floating point
numerical calculation remote input/output rack and with communication
facilities.

SIEMENS S7-400 MITSUBISHI MELSEC

OMRON CVM1 SYSTEM Q
 Advantages of PLC control system
• Wiring of the system usually reduces by 80%
compared to conventional control system
• Power consumption is greatly reduced.
• Self diagnostic function enable easy and fast
troubleshooting of the system
• Flexible. Control sequence can be changed by
reprogramming.
• Faster response time
• More robust and reliable because less moving part
• Modular design- easy to repair and expand.
• Less expensive
• Hardcopy of documentation can be easily printed
out and maintained.
PASSED YEAR
QUESTION
Q2
Explain FOUR advantages of using PLC sesi jun
2014/JUN 2016(EJ501/DEJ5153)
• Program can be change easily
• High reliability
• The implantation of a short control project
• Be made renovation line up
• Computation of the exact cost of the project
• Required a shot training time
• Design flexible control system using software
• Easy maintenance
• Resistance to the problems of the environment (temperature,
moisture, instability and noise ) is good
Identify FOUR (4) advantages of PLC with respect to
Microcomputer for the purpose of industrial
automation sesi dis 2013

• Durable
• The program is easy to understand
• Resistance to noise
• easy made modification program in plant
• low cost for the entire system
• suitable for all temperature
• save time
List TWO (2) types of PLC sesi jun 2013

• - Modular
• -Compact
• -Plug in card
Q2 Identify FOUR(4) functions of PLC in the control
sophisticated type Sesi dis 2015

•Arithmetic Operation (+,-,X, /)

•Information handling
•Analog control (Temperature, Pressure)
•Proportional Integral Derivation (PID)
•Servo Motor Control
•Stepper Motor Control
Differentiate the classification of PLC below based on
memory size and number if input/output data

Micro – They have less then 32 I/O

Memories up to 750KB
Mini – They have between 32 to 128 I/O
Memories up to 750 K bytes
Identify FOUR (4) advantages of PLC with respect to
Microcomputer for the purpose of industrial
automation

•Durable
•The program is easy to understand
•Resistance to noise
•easy made modification program in plant
•low cost for the entire system
•suitable for all temperature
•save time
Explain FIVE(5) reasons why PLC is widely used in
industries sesi jun 2013

• No need rewiring
• Easy to troubleshoot
• Required small space
• Low power consumption
• Reliable
• Low Maintenances
• Cheap
• Portable
• Temperature resistance
• Ladder can be print for later references
 q4. Explain the definition of PLC according to National
Electrical Manufacturers Association (NEMA) sesi jun
2014

Programmable Logic Controllers ( PLCs ) is a digital electronics

system which uses a programmable memory for implementing
specific functions such as logic, sequencing, timing, counting
and arithmetic to control through analog or digital input/output
module, various types of machine or processes.
PLC SELECTION
PROCEDURE
section 3.2
PlC SELECTION
Once the basic control application has been
defined,
The selection of PLC is based on:

• input/output capacity
• type of input/output
• memory size
• software language
• future system expansion
• support and backup

Prepare BY: Tan Ee Chin (PUO)

input/output capacity

Determining the amount of I/O

needed:

• By counting the devices that will be

monitored or controlled.
• Allow 10 to 20% extra for spare and
future expansion.

Prepare BY: Tan Ee Chin (PUO)

Type of input/output

There are 4 different groups of

I/O

• Discrete/digital/logical input and output

• Analogue Inputs/Outputs
• Special Function Inputs/Outputs.
• Remote Inputs/Outputs.

Prepare BY: Tan Ee Chin

(PUO)
Discrete/digital/logical input

• handles signals which represent

ON/OFF
• Signals generated from:
o limit switches, push button switches, and
proximity sensors

• To prevent faulty operation and provide

protection, input circuit may contain:
o debouncing circuitry, surge protection, noise
filtering and optical isolation.

Prepare BY: Tan Ee Chin (PUO)

Discrete/digital/logical output

• generate ON/OFF signals to drive

ON/OFF devices:
o pilot lamp, alarm, control valves, motor
starter

• Can be relay output:

• for devices that do not demand high speed
switching- indicator lamp, alarm

• can be transistor output:

• for devices which demand higher switching
speed-PWM output for d.c motor speed control.
Prepare BY: Tan Ee Chin (PUO)
Analogue input
• To handle continuous signals generated
by tranducers:
o temperature sensor, pressure sensors and
flow sensors and etc.

• may need signal conditioning module:

o transform the signals into a standard current
or voltage range: –10 to +10 V, 0 to +10 V, 4 to
20 mA, and 10 to 50 mA.

• An (ADC) is needed to convert the

continuous signal into equivalent digital
value to be processed by PLC.
Prepare BY: Tan Ee Chin (PUO)
Analogue output

• An (DAC) is needed to convert the

digital signal into equivalent analogue
value to drive analogue output devices.
• pneumatic valve in process control or a heater

Prepare BY: Tan Ee Chin (PUO)

Special Function
Inputs/Outputs

• Use Special function I/O modules and

smart modules for application requires
a special type of I/O conditioning (e.g.,
positioning, fast input, frequency, etc.)
• Example:
• PID, three-axis positioning, and stepper motor
modules

Prepare BY: Tan Ee Chin (PUO)

Remote Inputs/Outputs.

• Remote I/O module is used when the

field devices are located far away from
the CPU.
• Using twisted-pair cables for
connection.
o Can reduce wiring costs.

Prepare BY: Tan Ee Chin (PUO)

Memory size

• The amount of memory required for a

given application depend on:
• total number of inputs and outputs to be
controlled.
• the complexity of the control.
• the best way to obtain memory requirement
data is to create the program and count the
number of words used.

Prepare BY: Tan Ee Chin (PUO)

Software language
• The instructions available for a
certain PLC will determine the
ability of the PLC to execute certain
complicated task easier than
others.
o PID and motor speed control function

• Availability of Software package for

writing PLC program in the form of:
o ladder diagram, Sequential function chart,
instruction text or function block and simulation
program.

Prepare BY: Tan Ee Chin (PUO)

Future system expansion

If a control task is expected to be expanded

in a later stage, then a modular PLC should
be considered because it allows add-in I/O
and memory modules to rack for further
expansion.

Prepare BY: Tan Ee

Chin (PUO)
Support and backup

Support and backup that can be provided

by the supplier is one of the important
factors to be considered when selecting
PLC:

o availability of Manual and document

o Support while developing program
o Support while troubleshooting
o Provide Training

Prepare BY: Tan Ee Chin (PUO)

PASSED YEAR
QUESTION
List down the criteria that needed to be
considered when selecting the PLC that will
be placed in a cabinet sesi Jun 2016
(EJ501)
Input and Output Capacity
Means the number of terminal connections available in the
input/output unit
Before start the PLC system, a user must select the input and
output capacity of the PLC, so that the PLC will have sufficient
connection

Types of input/ output

Memory Size – refer to the ability to save program space in
PLC memory system. The memory size is according to the type
of CPU
Software language
Future system expansion
Support and backup
 BASIC BUILDING
STRUCTURE OF PLC
section 3.3
 STUDENTS LEARNING OUTCOME

At the end of the lesson, students will be able

• To describe the function of the com. Port, input /output

terminals, power supply terminals on OMRON PLC.
• to draw structural block diagram of PLC.
• to describe the function of CPU, Memory, input /output
interface, power supply and communication blocks.

• to differentiate input device and output device of PLC

AC power supply is connected to Input devices are
these terminal connected to these input
terminals

OMRON PLC
Indicator
LED to
COM port for
display the
connecting to host status of
computer input/output
devices and
the running
conditions of
24V dc output voltage
output devices PLC
are
provided by PLC
connected to these output
terminals
 Questions
• What is the function of the COM. Port ?

• What is the function of the input terminals?

• What is the function of the output terminals?

What is inside PLC ?
 –To receive and convert field
–Provide D.C. signals
power tofrom push buttons, sensors
varies section orof switches
the PLC into a form that can be
as well as fieldused by the CPU. Also provide
devices(
such as sensorisolation of the internal circuit to
or switches
) in–Provide the outside
–Store
small PLClinkage world by using optical
to the
hostprogram
Processor that executes
Power isolator.
and Input
inputinterface
and output
computer, programming circuit stored in the
program
supply and other
console status
–Takes
network
signal from the CPU and
memory
devices. translates them into forms that are
Memory
appropriate to produce
RAM/RO CPU control
Communi action
M by external devices such as
cation indicator light, solenoids or motor
starter. Also provide isolation of the
Output interface
internal circuit to the outside world
circuit
by using optical isolator.
The processor (CPU)

• The "brain" of the PLC.

• Usually consists of a microprocessor for implementing the
logic and controlling the communications among the unit.
• The processor accepts (reads) input data from various
sensing devices. executes the stored user program from
memory and sends appropriate output commands to
control devices.
• The I/O section
• consists of input interface and output interface.
• Field devices are connected to the controller through these
interfaces.
• The purpose of this interface is to condition , to reduce noise
interference for the various signals received from or sent to
external field devices.
• Input devices such as pushbuttons. limit switches, sensors, Selector
switches. and thumbwheel switches are hardwired to terminals on
the input modules.
• Output devices such as small motors, motor starters, solenoid
valves and indicator lights are hardwired to the terminals on the
output modules.
• 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.
 Optical isolator

Input Modules
•Protection against high induced voltage
•Voltage adaptation
•Reduces electrical noise level from signal
Memory

• Memory is the component that stores information, programs, and data in a

PLC.
• The process of putting new information into a memory location is called
writing.
• The process of retrieving information from a memory location is called
reading.
• Common types of memory used in PLCs are Read Only Memory (ROM) and
Random Access Memory (RAM).
• A ROM location can be read, but not written. ROM is used to store programs
and data that should not be altered. For example, the PLC’s operating
programs are stored in ROM.
• A RAM location can be read or written. This means the information stored in
a RAM location can be read and/or altered. User programs are stored in RAM.
• When a new program is loaded into a PLC’s memory, the old program that
was stored in the same locations is replaced by new program.
Power Supply
• PLCs are powered by standard commercial AC power lines.
• However, many PLC components, such as the CPU and memory,
utilize 5 volts or another level of DC power.
• PLC power supply converts AC power into DC power to support
those components of the PLC.
Display and indicator unit

• Most of the PLCs have LED indicators to show the input and
output devices status.
• It also shows the operation status of the PLC; whether the
PLC is in run mode, has error and etc.
• For some very small PLC a built in display is also available for
entering program instruction and monitoring program
execution.
 Questions
• Name the 6 blocks in PLC ?
• What is the function of the CPU block of PLC?
• What is the function of the memory block in
PLC?
• What is the function of the power supply
block in PLC ?
• What is the function of the communication
block of PLC?
PASSED YEAR
QUESTION
 Identify a basic PLC structure with a
suitable diagram sesi jun 2016 (EJ501)

Signal Power Supply Signal

from from
switch / Input Output solenoid
Memory
sensor module module / motor
etc etc
CPU

Programming
Device
The picture below show a PLC building
structure. Identify each of the items
below

Display/ indicator

A B D
C

Power supply
Explain the functions of these important parts in PLC
sesi dis 2013

• CPU – control all operations performed in the PLC

• MEMORY – store information, program and data in a PLC
• INPUT and OUTPUT Unit – condition(interface) where
the various signals received from input devices or sent to
external output devices
• POWER SUPPLY – to give power to all the parts
 Show the building structure of PLC in
the form of diagram sesi dis 2013
Power supply

signal from Input Memory Output signal to

switches,sens
ors, etc unit unit solenoid,
lamp
sensor motor, etc
CPU

Programming device
q5 Complete the PLC block diagram as shown below:
sesi jun 2014

Programming Program & data Memory Communication

console interface

Processor
Output Interface
Input interface

Power Supply
PLC SYSTEM UNITS
section 3.4
 STUDENTS LEARNING OUTCOME

At the end of the lesson, students will be able

• To identify and describe HMI ,Programming unit used in a

PLC system.
• To identify and describe power supply unit and secondary
storage unit used in a PLC system
• To identify input and output devices.
• To describe the function of input and output devices
PLC SYSTEM COMPONENTS

Programming
Console

printer

Power supply
HMI ( Human Machine Interface )

• Provides a visual representation of a control system and provides real time data
acquisition.
• Provides graphical interface that allows humans and machines to interact.
• Three basic types :
• pushbutton replacer, data handler, and the overseer.
HMI ( Human Machine Interface )

• the pushbutton replacer

• To centralize all the functions of each button into one location.
• the data handler
• For data trending, data logging, reporting and alarm handling/logging
• the overseer:
• To oversee the whole control process in SCADA system
Programming device

• Used to enter the desired program into the memory of the processor.
• Handheld programming devices are used to enter and monitor program
in small PLCs and in factory floor for troubleshooting , modify program
and transferring program to multiple machines
• A PC with programming software can be used as host computer for
writing program in ladder logic format ( or other format , such as function
chart ) to be downloaded into PLC.
Programming device

• Once linked with the PLC, it can use to monitor the execution
of program in PLC . Editing and debugging of the program can
be done on the computer if error occurred.
• It also can be used to back up the program in hard disk and
generate a hard copy through printer.
Power supply unit

• To provide appropriate supply ( D.C or A.C ) to input and

output devices in order for them to operate in the system.
• Provide 12V to 24V D.C. supply to most of input sensors.
• The external power supply unit is safer to use than the
internal supply provided by PLC because it has short circuit
protection.
Secondary storage

• Hard disk of the host computer can be used as the secondary

storage for the PLC ‘s program.
• For some of the small PLC, program can be burned into
EPROM for permanent storage.
 Input device
• Input devices to PLC are like sensory organ to human
being. Without them, PLC can not function properly .
• They provide information signals about the controlled
system to the PLC so that based on these information
PLC can generate output signal accordingly
• Example of the input devices are:
• Push button switches, toggle switches, limit switches,
proximity switches or sensor, analog sensor
Limit switches
Push button and toggle switch
Proximity switch
 Output devices
• Output devices to PLC are like hand and leg
to human being. Without them, PLC couldn’t
do any work.
• Output devices are the device to be
controlled by the PLC such as :
• Relay contact, AC contactor ,Small dc motor,
pilot lamp, buzzer , electro pneumatic control
valve, solenoid ,LED display and etc.
relay
magnetic contactor
Small dc motor
buzzer
siren
Pilot and indicator lamp
Led display
solenoid
Control valve
PASSED YEAR
QUESTION
2b) List THREE examples of input devices and THREE
examples of output devices that mostly used in PLC
system sesi jun 2014

Input devices:
• Contact switch: Push Button /limit switch
• Proximity sensor: Inductive/Capacitive sensor
• Optical sensor: Through beam/Retroreflective
• Output devices:
• Lamp/Buzzer/Relay/Contactor/LED display/Solenoid valve/DC
Motor