Lect 001

Programmable Logic
Controllers
Lecture 01
Introduction to PLCs
Definition And History Of The PLC
• A PLC is a user-friendly, microprocessor-based specialized
computer that carries out control functions of many types and levels
of complexity.
• Its purpose is to monitor crucial process parameters and adjust
process operations accordingly.
• Used extensively because the PLC – Is easy to set up and
program
– Behaves predictably
– Ruggedized
• It can be programmed (to a degree), controlled, and operated

by a person unskilled in operating (programming) computers.
• Essentially, a PLC's operator draws the lines and devices of
ladder diagrams with a keyboard/mouse onto a display screen.
• The resulting ladder diagram is converted into computer machine
language and run as a program.
Example PLCs
Allen-Bradley PLC5 Allen-Bradley SLC500
Allen-Bradley Micrologix Allen-Bradley Picocontroller

Components in a PLC system
• CPU module, containing the processor and memory
• Input and output modules, to allow the PLC to read sensors
and control actuators
– A wide variety of types are available
• Power supply for the PLC, and often sensors and low power
actuators connected to I/O modules
• A rack or bus so the PLC can exchange data with I/O modules
Additional PLC components
• A programming unit is necessary to create, edit and download a
user program to the PLC
• Additional components can include:
– Network interfaces: to allow PLCs to function in a networked
environment
– Communication adapters for remote I/O devices: so I/O
devices do not have to be physically close to the CPU
module
– Operator interface devices: allow monitoring and/or data
entry by operators
• The PLC takes the place of much of the external wiring required
for control of a process.
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• The PLC will operate any system that has output devices that go
on and off (known as discrete, or digital, outputs).
• It can also operate any system with variable (analog) outputs.
• The PLC can be operated on the input side by on-off devices

(discrete, or digital) or by variable (analog) input devices.
• The first PLC systems evolved from conventional computers in the

late 1960s and early 1970s.
– These first PLCs were installed primarily 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 changeover time to a matter of a
few days.
PLC Advantages
• Flexibility
– In the past, each different electronically controlled production
machine required its own controller; 15 machines might require 15
different controllers.
– Now it is possible to use just one model of a PLC to run any one
of the 15 machines.
– Furthermore, you would probably need fewer than
15 controllers, because one PLC can easily run many machines.
– Each of the 15 machines under PLC control would have its own
distinct program (or a portion of one running program).
PLC Advantages
• Implementing Changes and Correcting Errors
– With a wired relay-type panel, any program alterations require
time for rewiring of panels and devices.
– When a PLC program circuit or sequence design change is
made, the PLC program can be changed from a keyboard
sequence in a matter of minutes.
– No rewiring is required for a PLC-controlled system.
– Also, if a programming error has to be corrected in a PLC
control ladder diagram, a change can be typed in quickly.
PLC Advantages
• Large Quantities of Contacts

– The PLC has a large number of contacts for each coil
available in its programming.
– Suppose that a panel-wired relay has four contacts and
all are in use when a design change requiring three more
contacts is made.
•Time would have to be taken to procure and install a
new relay or relay contact block.
– Using a PLC, however, only three more contacts would
be typed in.
•Contacts are now a “software” component
PLC Advantages
• Lower Cost
– Increased technology makes it possible to
condense more functions into smaller and less
expensive packages.
– Now you can purchase a PLC with numerous
relays, timers, and counters, a sequencer, and other
functions for a few hundred dollars.
• Pilot Running
– A PLC programmed circuit can be evaluated in the lab.
The program can be typed in, tested, observed, and
modified if needed, saving valuable factory time.
PLC Advantages
•Visual Observation
– A PLC circuit's operation can be seen during
operation directly on a CRT screen.
– The operation or mis-operation of a circuit can be
observed as it happens.
– Logic paths light up on the screen as they are
energized.
– Troubleshooting can be done more quickly during visual
observation.
PLC Advantages
• Ladder or Boolean Programming Method
– The PLC programming can be accomplished in the
ladder mode by an engineer, electrician or possibly
a technician. Alternatively, a PLC programmer
who works in digital or Boolean control systems
can also easily perform PLC programming.
• Reliability and Maintainability
– Solid-state devices are more reliable, in general,
than mechanical systems or relays and timers.
Consequently, the control system maintenance
costs are low and downtime is minimal.
PLC Disadvantages
• Fixed Program Applications

– Some applications are single-function applications. It does not pay
to use a PLC that includes multiple programming capabilities if
they are not needed.
– Their operational sequence is seldom or never changed, so the
reprogramming available with the PLC would not be necessary.
• Fail-Safe Operation
– In relay systems, the stop button electrically disconnects the circuit;
if the power fails, the system stops.
– This, of course, can be programmed into the PLC; however,
in some PLC programs, you may have to apply an input voltage to
cause a device to stop. These systems may not be fail-safe.
PLC Advantages
• Documentation
– An immediate printout of the true PLC circuit is
available in minutes, if required.
– There is no need to look for the blueprint of the circuit in
remote files.
– The PLC prints out the actual circuit in operation at a
given moment.
– Often, the file prints for relay panels are not
properly kept up to date. A PLC printout is the circuit at
the present time; no wire tracing is needed for
verification.

Lect 001

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Lect 001

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Programmable Logic

• It can be programmed (to a degree), controlled, and operated

Allen-Bradley PLC5 Allen-Bradley SLC500

Allen-Bradley Micrologix Allen-Bradley Picocontroller

• It can also operate any system with variable (analog) outputs.

• The PLC can be operated on the input side by on-off devices

• The first PLC systems evolved from conventional computers in the

• Traditionally, the auto plants had to be shut down for up to a month at

• The PLC keyboard reprogramming procedure replaced the

• Large Quantities of Contacts

• Fixed Program Applications

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