Programmable Logic

Controllers
By:
Engr. Muhammad Nadeem Iqbal
 Programmable Logic
Controller (PLC)
Programmable Logic Controllers (PLCs), also
referred to as programmable controllers, are
in the computer family. They are used in
commercial and industrial applications.

A PLC monitors inputs, makes decisions based

on its program, and controls outputs to
automate a process or machine.
Programmable Logic
Controller (PLC)
Solutions Communities [1]
Solutions Communities are:

Automotive Metals
Cement Mining
Chemical Oil & Gas
Food & Beverage Pharmaceutical
Glass Production Machines
Machine Tools Pulp & Paper
Marine Semiconductor
MES
Solutions Communities [2]
Solutions Communities [3]
Ten Fundamental Questions [1]

1. What is a programmable controller?

A programmable controller is a
microprocessor-based industrial
controller, the functions of which are
determined by a stored program.
2. What is a program?
A program is a set of instructions
'telling' the controller how to
behave. It is stored in the
controller's memory.
 Ten Fundamental Questions [2]

3. How does a programmable controller differ from

a computer?
A computer is optimized for calculation and
display tasks and is programmed by specialists. A
programmable controller is optimized for control
and regulation tasks and can be programmed by
non-specialists. It is also well adapted to the
industrial environment.

A Common Example of Regulation Task is Traffic

Signals.
 Ten Fundamental Questions [3]
4. Why are programmable controllers so
common?
Because they are cost-effective and have
significant advantages over traditional control
systems based on relays or pneumatics.

5. Where are they used?

In virtually every industry where automation is
involved, from individual machines to whole
processes, in commercial, institutional and
industrial premises.
Ten Fundamental Questions [4]
6. What are the main advantages?
A control system based on a programmable
controller is flexible, reliable and compact
and can be assembled at a relatively low
cost.
7. Are all programmable controllers the
same?
They are broadly similar in a functional
sense, but they differ in size, programming
detail and mechanical design. Most
manufacturers offer several models with
different levels of performance.
Ten Fundamental Questions [5]
8. What tasks does a programmable
controller perform?
The control tasks previously undertaken
with electrical and/or pneumatic controls,
e.g. interlocking, sequencing, timing and
counting. It can, in addition, perform a
variety of calculation, communication and
monitoring tasks.
9. Does a programmable controller eliminate
contactors and valves?
No, but these items are brought under the
programmable controller's influence in
modern control systems.
Ten Fundamental Questions [6]
10. Are there drawbacks?
Yes. Programmable controllers still do not
enjoy the same trust or acceptance as
traditional control techniques, even though
the technology is nearly 35 years old. The
natural resistance to accept the 'new'
technology is understandable; most of our
current industrial staff were educated and
trained before this technology became
common. Some technical adaptations have
to be made in implementing programmed
control.
 Control System Overview [1]
There are three characteristic features of a
control system, whether it is programmable or
not:
1.There are certain actions to be taken (such as
turning a valve ON or OFF or regulating its
position).

2.There are certain rules governing those actions.

3.The rules take account of certain relevant

conditions in the plant (such as manual switches,
sensors for level, pressure, temperature,
position).
Control System Overview [2]
 Basic PLC Operation [1]

•PLCs consist of input modules or points, a

Central Processing Unit (CPU), and Output
modules or points. (Refer to Figure)
•An input accepts a variety of digital or analog
signals from various field devices (sensors) and
converts them into a logic signal that can be
used by the CPU.
•The CPU makes decisions and executes control
instructions based on program instructions in
memory.
Basic PLC Operation [2]

INPUT CPU
OUTPUT
MODULE CENTRAL MODULE
PROCESSING
UNIT

Programming Operator
Device Interface
Basic PLC Operation [3]

•Output modules convert control

instructions from the CPU into a digital or
analog signal that can be used to control
various field devices (actuators).
•A programming device is used to input
the desired instructions.
•These instructions determine what the
PLC will do for a specific input.
•An operator interface device allows
process information to be displayed and
new control parameters to be entered.
 PLC Operation Example

Pushbuttons (sensors), in this simple example,

connected to PLC inputs, can be used to start
and stop a motor connected to a PLC through a
motor starter (actuator).
 Hard Wired Control or WLC

•Prior to PLCs, many of these control tasks

were solved with contactor or relay controls.
This is often referred to as hardwired control.

•Circuit diagrams had to be designed, electrical

components specified and installed, and wiring
lists created.

•Also Referred to as Wired Logic Control (WLC)

WLC Example
For lamp H2 to illuminate, switch S3 or S4 must be closed.
This dependency of the output state on the input states is S3 S4
referred to as an OR logic operation.
This means that at least one of the two switches--S3 or S4--
must be closed in order for lamp H2 to illuminate.
H2
The symbol for this operation is
Parallel circuit with normally
open contacts

OR Logic Table for OR Block:

Input 1 Input 2 Input 3 Output
S3 > 0 0 0 0
S4
H2 0 0 1 1
x
0 1 0 1
0 1 1 1
1 0 0 1
1 0 1 1
The state of the OR output =1 if the state of at least 1 1 0 1
one input = 1. An unconnected input pin in this 1 1 1 1
block is automatically assigned state = 0.
 Hard Wired Control or WLC

•If an error was made the wires had to be

reconnected correctly.

•A change in function or system expansion

required extensive component changes
and rewiring.

•A programmable controller can be

reprogrammed to accommodate a change
of rules—no rewiring is needed
 Advantages of PLCs [1]

The same (WLC), as well as more complex

tasks, can be done with a PLC.
Wiring between devices and relay contacts
is done in the PLC program.
Hard-wiring, though still required to connect
field devices, is less intensive.
Modifying the application and correcting
errors are easier to handle.
It is easier to create and change a program in
a PLC than it is to wire and rewire a circuit.
 Advantages of PLCs [2]

• Smaller physical size than hard-wire

solutions.
• Easier and faster to make changes.
• PLCs have integrated diagnostics and
override functions.
• Diagnostics are centrally available.
• Applications can be immediately
documented.
• Applications can be duplicated faster
and less expensively.
Applications [1]

1. Automobile Industries
Automatic drilling/assembly and test equipment, painting
facilities, shock absorber test benches.
2. Plastic Industries
Blow, injection and thermal molding machines, synthetic
production systems, temperature & pressure control.
3. Heavy Industries
Molding equipment, industrial furnaces, rolling mills,
temperature control systems.
4. Chemical Industries
Proportioning & mixing systems, temperature & pressure
control, boiler & chiller control.
5. Food & Beverages Industries
Centrifuging, batch processing, temperature & pressure
control, boiler & chiller control.
Applications [2]
6. Machinery's
Packing, wood-working, machine control, machine tools,
drilling mills, fault alarm centers, welding technology.
7. Building Services
Elevators, climate control, ventilation, lighting, alarm &
security systems.
8. Transport Systems
Transport and sorting equipment, ware-houses, conveyor
and crane systems, traffic signals.
9. Energy, Gas, Water & Air
Pressure booster stations, standby power supplies, pump
control, water & air treatment, filtering and gas recovery
systems, emergency systems.
10. Textile Industries
AC/DC drive control, temperature control, heating/drying
control, spinning, dying and color mixing.
History of PLCs
•The first PLC systems evolved from conventional computers
in the late 1960s and early 1970s.
•These first PLCs were mostly installed in automotive plants.
Tradi­tionally, the auto plants had to be shut down for up to a
month at model change­over time.
•The early PLCs were used along with other new automation
techniques to shorten the changeover time. One of the major
time-consuming changeover procedures had been the wiring
of new or revised relay and control panels.
•The PLC keyboard reprogramming procedure replaced the
rewiring of a panel full of wires, relays, timers, and other
components.
•The new PLCs helped reduce repro­gramming time to a
matter of a few days.
 Knowledge Level For PLC
Programming

• A person knowledgeable in relay logic

systems can master the major PLC function in a
few hours.
• These functions might include coils, contacts,
timers, and counters.
• The same is true for a person with Knowledge
of digital principles, however, the learning
process takes more time.
Remember: A relay is digital in nature because
it is basically an on/off, two-state device.
Terminology

 The language of PLCs consists

of a commonly used set of
terms; many of which are unique
to PLCs.
 In order to understand the
ideas and concepts of PLCs, an
understanding of these terms is
necessary.
PLC Related Terms [1]

Sensor: A sensor is a device that converts a

physical condition into an electrical signal for
use by the PLC. Sensors are connected to the
input of a PLC.
 A pushbutton is one example of a sensor
that is connected to the PLC input.
PLC Related Terms [2]
Actuator: Actuators convert an electrical
signal from the PLC into a physical
condition. Actuators are connected to the
PLC output.
A motor starter is one example of an actuator that
is connected to the PLC output. Depending on the
output PLC signal, the motor starter will either
start or stop the motor.
PLC Related Terms [3]
Discrete Input: A discrete input, also
referred to as a digital input, is an input
that is either in an ON or OFF condition.

 In the ON condition a discrete input

may be referred to as a logic 1 or a logic
high. In the OFF condition a discrete input
may be referred to as a logic 0 or a logic
low.
 Examples are: Pushbuttons, Limit
Switches, Proximity Switches.
PLC Related Terms [4]
Discrete Output: A discrete output is an
output that is either in an ON or OFF
condition. Discrete outputs may also be
referred to as digital outputs.

 Examples are: Solenoids, contactor coils,

and lamps
PLC Related Terms [5]
Analog Input: An analog input is an input
signal that has a continuous signal.
Examples are: Temperature Sensor, Level
Sensor

Analog Output: An analog output is an

output signal that has a continuous signal.
Examples are: Analog Meters to display
speed, weight etc.
PLC Related Terms [6]
CPU: The central processor unit (CPU) is a
microprocessor based system that contains
the system memory and it is the PLC
decision making unit. The CPU monitors the
inputs and makes decisions based on
instructions held in the program memory.
Programming: A program consists of one or
more instructions that accomplish a task.
Programming a PLC is simply constructing
a set of instructions. There are several
ways to look at a program such as ladder
logic, statement lists, or function block
diagrams.
PLC Related Terms [7]
Ladder Logic: Ladder logic (LAD) is one
programming language used with PLCs.
Ladder logic uses components that
resemble elements used in a line diagram
format to describe Wired Logic Control.
PLC Related Terms [8]
Statement List (STL): STL represents the
program as a sequence of operation
mnemonics. A statement has the following
format:
PLC Related Terms [9]
Function Block Diagram (FBD): FBD
represents logic operations with graphics
symbols.
More Terms
1. Software (e.g. STEP-7 by Siemens)
2. Hardware (Actual PLC)
3. Programming Device
4. Connector Cable
General Instruction Set
1. Boolean Logic Operation
(AND, OR, AND before OR, OR before AND)
2. Flip Flop Operations (RS and SR)
3. Timer Operations (Five Types)
4. Counter Operations (UP and DOWN)
5. Comparison Operation (Six Types)
6. Jump Operations (To Jump between
Blocks)
7. Analog Value Processing
8. Troubleshoot common software/hardware
errors
PLC Manufacturers
 Around 100 various manufacturers all
over the world
 Leading Manufacturers are:

1. SIEMENS
2. ALLEN BRADLEY
3. OMRON
4. MITSUBISHI
5. GE FANUC
Link for Complete List: http://www.plcs.net/chapters/links.htm
Recommended Links
www.sea.siemens.com

www.plcs.net

www.mhj-software.com/de/

www.gefanuc.com/en/

www.siemens.com/logo

www.automation.siemens.com/s7-200/index_76.htm

www.automation.siemens.com/s7-200/html_76/primer.htm
Recommended Books

Programmable Controllers by Dennis Collins & Eamon Lane

A Guide To Understanding PLCs by Phil Melore –

The PLC Tutor

Programmable Logic Controllers

by Max Rabiee - Goodheart-Wilcox

Programmable Logic Controllers by Frank D. Petruzella

Fundamentals of Programmable Logic Controllers,

Sensors, and Communications by Jon Stenerson
 Q/A
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