Introduction to

Programmable Logic
Controller(PLC)

Akram Hossain, Professor,

Purdue University Calumet
Hammond, IN 46323

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Definition of PLC

Programmable Logic Controllers are solid

state devices that can be programmed to
performed sequential and discrete state
operation on external equipment

They are designed to perform the logic

functions previously accomplished by
electromechanical relays, drum switches,
mechanical and electronic timers and
counters, standalone digital PID controllers
etc.
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Major Manufacturer of PLC

Allen-Bradley (AB)
General Electric
Gould-Madicon
Texas Instruments
Square-D

Reliance
Electric
Siemens

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Areas of PLC Applications

Annunciators
Auto Insertion
Bagging
Baking
Blending
Boring
Brewing
Calendaring
Casting
Chemical Drilling
Color Mixing
Compressors
Conveyors

Injection Molding
Assembly
Motor Winding
Oil Fields
Painting
Palletizers
Pipelines
Polishing
Reactors
Robots
Rolling
Security Systems
Stretch Wrap

Cranes
Crushing
Cutting
Digesters
Drilling
Electronic Testing
Elevators
Engine Test Stands
Extrusion
Forging
Generators
Gluing
Grinding
Heat Treating

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Slitting
Sorting
Stackers
Stitching
Stack Precipitators
Threading
Tire Building
Traffic Control
Textile Machine
Turbines
Turning
Weaving
Web Handling
Welding

History of PLC
The Hydramatic Division of the General Motors Corporation specified the design criteria for the first
programmable controller in 1968. Their primary goal was to eliminate the high costs associated with
inflexible, relay-controlled systems. The specifications required a solid-state system with computer
flexibility able to
(1) survive in an industrial environment,
(2) Be easily programmed and maintained by plant engineers and technicians, and
(3) Be reusable. Such a control system would reduce machine downtime and
provide expandability for the future. Some of the initial specifications
included the following:

The new control system had to be price competitive with the use of relay systems.

The system had to be capable of sustaining an industrial environment.

The input and output interfaces had to be easily replaceable.

The controller had to be designed in modular form, so that subassemblies could be removed
easily for replacement or repair.

The control system needed the capability to pass data collection to a central system.

The system had to be reusable.

The method used to program the controller had to be simple, so that it could be easily understood
by plant personnel.

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PLC and Computer

A PLC and a computer both are electronic processor unit. The architecture of a
PLCs CPU is basically same as that of a general purpose computer; however,
some important characteristics set them apart.
Unlike computer, PLCs are specifically designed to survive the harsh conditions
of the industrial environment. A well-designed PLC can be placed in an area with
substantial amounts of electrical noise, electromagnetic interference,
mechanical vibration, and noncondensing humidity.
Distinction of PLCs is that their hardware and software are designed for easy use
by plant electricians and technicians. The hardware interfaces for connecting
field devices are actually part of the PLC itself and are easily connected.
The modular and self-diagnosing interface circuits are able to pin point
malfunctions and moreover, are easily removed and replaced.
Software programming uses conventional relay ladder symbols, or other easily
learned languages, which are familiar to plant personnel.
A computer can execute a complex programming task and also multitasking. An
standard PLC is designed to executes a single program in an orderly fashion. As
PLCs are rapidly changing, modern PLCs have multitasking capabilities.

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Why PLCs ?
Soft Manufacturing Process
Flexible Manufacturing Process
Retrofit Existing Process
Less Maintenance
Easy to Debug

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Why PLCs are so Popular?

Programmable logic controller have made it possible to precisely

control large process machines and driven equipment with less
physical wiring and wiring time than it requires with standard electromechanical relays, pneumatic system, timers, drum switches, and so
on.

The programmability allows for fast and easy changes in the relay
ladder logic to meet the changing needs of the process or driven
equipment without the need for expensive and time consuming
rewiring process.

Modem PLCs are "electrician friendly", PLC can be programmed and

used by plant engineers and maintenance electricians without much
electronic and computer programming background. They can
programmed by using the existing ladder diagrams.
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Advantages of PLC
A.Flexibility
Universal Controller - can replace various independent/ standalone
controller.
B.Implementing Changes and Correcting Errors
Do not have to rewiring relay panel.
Change program using keyboard.
C.Large Quantity of Contact
Large number of' Soft Contact' available.
D.Lower Cost
Advancement in technology and open architecture of PLC will
reduce the market price.
E.Pilot Running (Simulation Capability)
A program can be simulated or run without actual input connection.
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Advantages of PLC
F.

G.

Visual Observation.
Can observe the opening and closing of contact switch on CRT .
Operator message can be programmed for each possible malfunction.
Speed of Operation
Depends on scan time -millisecond.
Asynchronous operation.

F.

Ladder or Boolean Programming Method.

Easy for 'Electrician ,

F.

Reliability
In general -very reliable

H.

Simplicity of Ordering Control Sys. Components

One package with Relay, Timers, Control Block, etc.

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Advantages of PLC
Documentation

K.

Printout of ladder logic can be printed easily

Security

L.

Software lock on a program (Password)

Ease of Changes by Programming

M.

Ability to program and reprogram, loading and down loading

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Disadvantages of PLC
A.

New Technology

Change from ladder and relay to PLC concept

B.

Fixed program Application

Not cost effective for single- function application

C.

Environment Consideration

Not adapted for very high temperature, high humidity level, high vibration, etc.

A.

Fail-safe operation

Does not start automatically when power failure ( can be programmed into )

Not "Fail-safe" -Fail-shorted rather than OPEN

Fixed-circuit operation

Fixed control system -less costly

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What is a Ladder
Diagram?
A complete control scheme normally drawn as a
series of contacts and coils arranged between
two vertical control supply lines so that the
horizontal lines of contacts appear similar to
rungs of a ladder. The control contacts (input
devices) are to left and coils (output devices) on
the right.
Ladder diagrams are an industrial standard for
representing relay-logic control system

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PLC Series 5 Input/Output

Chassis

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Allen-Bradley PLC Series 5

Processor Module

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PLC 5/25 Processor Mode of Operation

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A-B Series 5 Power Supply

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120 VAC Input Module Connection

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120 VAC Output Module

Connection

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Two Slot Addressing

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PLC Scan and Update Sequence

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How PLC Works?

Input
Map
00

Output
Map
00
I:001

01

03
04

01

02

03

O:001

I:001

04

01

00

01

00

01

02

03

04

O:001

O:001

01

03

O:001/01

03

01

120 VAC
Input
Module

Ladder Logic in
Processor Memory

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120 VAC
Output
Module

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PLC Input & Output

Mapping
M

START SW
STOP SW

RELAY COIL

M
SELF HOLDING FOR "M"

L1
CONTROL
POWER

ON LIGHT

START

STOP

L1

00

00

01

01

02

02

03

03

04

04

MOTOR
RELAY
COIL

I:
INPUT

0
RACK

01
SLOT

/ 03
ADDRESS

O:
OUTPUT

0
RACK

01
SLOT

I:001

MOTOR
ON LIGHT

01

03
ADDRESS

O:001

I:001
00

01

N
O:001/01
O:001

01

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O:001

03

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PLC Program and Data Files

Program Files
-Reserved Files (File # 0)
-SFC file (File # 1 )
-Ladder file (File #2- 999) -File #2: Main Ladder File
-Subroutine file (File #3 -999)
-Selectable Interrupt file (File #3 -999)
-Fault Routine File (File #3 -999)

Data Files
-Files which store data of the I/0 module.
-Can be integer data, floating point (real) data, timer
data, counter data, discrete input data, discrete output data, etc.

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Input/Output Addressing

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Memory Organization for Data

Files

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Memory Map of File Types

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A-B PLC Series-5 Data

Organization

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Floating Point Files

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Timer and Counter Data

Files

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Control Data File

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PLC Logical Addressing

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General Instruction Format

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General Instruction Format

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Status File

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TIME ON DELAY (TON)

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