What is a PLC?

PLC stands for “Programmable Logic Controller”. A PLC is a computer specially

designed to operate reliably under harsh industrial environments – such as extreme
temperatures, wet, dry, and/or dusty conditions.

PLCs are used to automate industrial processes such as a manufacturing plant’s

assembly line, an ore processing plant, or a wastewater treatment plant.PLCs share
many features of the personal computer you have at home. They both have a power
supply, a CPU (Central Processing Unit), inputs and outputs (I/O), memory, and
operating software (although it’s a different operating software).

The biggest differences are that a PLC can perform discrete and continuous functions
that a PC cannot do, and a PLC is much better suited to rough industrial environments.
A PLC can be thought of as a ‘ruggedized’ digital computer that manages the
electromechanical processes of an industrial environment.PLCs play a crucial role in
the field of automation, using forming part of a larger SCADA system.

A PLC can be programmed according to the operational requirement of the process.

In the manufacturing industry, there will be a need for reprogramming due to the
change in the nature of production. To overcome this difficulty, PLC-based control
systems were introduced. We’ll first discuss PLC basics before looking at various
applications of PLCs.

History of PLCs
Many early PLCs were not capable of graphical representation of the logic, and so it
was instead represented as a series of logical expressions in a Boolean format (akin to
Boolean algebra).

As programming terminals evolved, it became more common for ladder logic to be

used, because it was a familiar format used for electro-mechanical control panels.
More modern formats, such as state logic and Function Block diagrams exist, but they
are still not as popular as ladder logic.

A possible reason for this is that programmers prefer the more visual appeal of ladder
logic over structured text programming.

Until approximately the mid-1990s, PLCs were programmed using proprietary

programming panels or special-purpose programming terminals, which often had
dedicated function keys representing the various logical elements of PLC programs.

Some proprietary programming terminals displayed the elements of PLC programs as

graphic symbols, but plain ASCII code representations of contacts, coils, and wires
were common.
PLC Basics
PLCs were invented by Dick Morley in 1964. Since then PLC has revolutionized the
industrial and manufacturing sectors. There is a wide range of PLC functions like
timing, counting, calculating, comparing, and processing various analog signals.

The main advantage of PLC over a “hard-wired” control system is that you can go
back and change a PLC after you’ve programmed it, at little cost (just the cost of the
programmer’s time). In a hard-wired control system, you’re essentially having to rip
out wires and start from scratch (which is more expensive and takes longer). Let’s
look at an example to better understand this advantage.

Imagine you have a light connected to a switch. In general, the light operates under
two conditions – ON and OFF. Now you are given a task that when you turn ON the
switch, the light should glow only after 30 seconds. With this hard-wired setup –
we’re stuck. The only way to achieve this is to completely rewire our circuit to add a
timing relay. That’s a lot of hassle for a minor change.

Light Switch

This is where a programmable logic controller comes into the picture, which doesn’t
require any additional wiring and hardware to make sure of a change. Rather it
requires a simple change in code, programming the PLC to only turn on the light 30
seconds after the switch is turned ON. So, by using a PLC, it is easy to incorporate
multiple inputs and outputs.

This is just a simple example – a PLC has the ability to control much larger and more
complex processes. A PLC can be customized depending on the application and needs
of the user.

Light operated by a PLC

Physical Structure of PLC
The structure of a PLC is almost similar to a computer’s architecture.

PLC Block Diagram

Programmable Logic Controllers continuously monitors the input values from various
input sensing devices (e.g. accelerometer, weight scale, hardwired signals, etc.) and
produces corresponding output depending on the nature of production and industry. A
typical block diagram of PLC consists of five parts namely:

 Rack or chassis
 Power Supply Module
 Central Processing Unit (CPU)
 Input & Output Module
 Communication Interface Module
Rack or Chassis
In all PLC systems, the PLC rack or chassis forms the most important module and
acts as a backbone to the system. PLCs are available in different shapes and sizes.
When more complex control systems are involved, it requires larger PLC racks.

Small-sized PLC is equipped with a fixed I/O pin configuration. So, they have gone
for modular type rack PLC, which accepts different types of I/O modules with sliding
and fit in concept. All I/O modules will be residing inside this rack/chassis.
 Breakdown of PLC Rack

Power Supply Module

This module is used to provide the required power to the whole PLC system. It
converts the available AC power to DC power which is required by the CPU and I/O
module. PLC generally works on a 24V DC supply. Few PLC uses an isolated power
supply.

CPU Module and Memory

CPU module has a central processor, ROM & RAM memory. ROM memory includes
an operating system, drivers, and application programs. RAM memory is used to store
programs and data. CPU is the brain of PLC with an octal or hexagonal
microprocessor.

Being a microprocessor-based CPU, it replaces timers, relays, and counters. Two

types of processors as a single bit or word processor can be incorporated with a PLC.
One bit processor is used to perform logic functions. Whereas word processors are
used for processing text, numerical data, controlling, and recording data.

CPU reads the input data from sensors, processes it, and finally sends the command to
controlling devices. DC power source, as mentioned in the previous discussion is
required voltage signals. CPU also contains other electrical parts to connect cables
used by other units.

Input and Output Module

Have you ever thought about how to sense physical parameters like temperature,
pressure, flow, etc? using PLC? Of course, PLC has an exclusive module for
interfacing inputs and output, which is called an input & output module.

Input devices can be either start and stop pushbuttons, switches, etc and output
devices can be an electric heater, valves, relays, etc. I/O module helps to interface
input and output devices with a microprocessor. The input module of PLC is
explained in the below figure.

PLC Input Module

Circuit Diagram of PLC Input Module

The input module of PLC does four main functions.

1. Input module interface receives the signal from process devices at 220 V AC
2. Converts the input signal to 5 V DC that can be used by PLC
3. Isolator block is used to isolate/prevent PLC from undergoing fluctuation
4. After which the signal is sent to the output end i.e the PLC

There are two main sections in the input module namely the power section and the
logical section. Both sections are electrically isolated from each other. Initially push
button is closed. So, 220 V AC supply is given to the bridge circuit through the
resistors R1 and R2.
A bridge rectifier (such as a diode bridge rectifier) is used to convert the AC signal
into DC and Zener diode is used to provide a low voltage supply to LED. When the
light from LED falls on the phototransistor, it works in the conduction region. Finally,
a 5V DC supply is given to the processor.

The output module of PLC works similarly to the input module but in the reverse
process. It interfaces the output load and processor. So here the first section would be
logic session and the power section comes next. The working of the output module is
shown in the below figure

PLC Output Module

So, here when the program logic high signal is generated from the processor, the LED
will turn ON and allow the light to fall on a phototransistor. When the transistor goes
to the conduction region, it generates a pulse to the gate of the Triac. The isolator
block is used to isolate the logic section and control section.

Communication Interface Module

To transfer information between CPU and communication networks, intelligent I/O
modules are used. These communication modules help to connect with other PLCs
and computers which are placed at a remote location.

Types of PLCs
The two main types of PLC are fixed / compact PLC and modular PLC.

Compact PLC
Within a single case, there would be many modules. It has a fixed number of I/O
modules and external I/O cards. So, it does not have the capability to expand the
modules. Every input and output would be decided by the manufacturer.

Modular PLC
This type of PLC permits multiple expansion through “modules”, hence referred to as
Modular PLC. I/O components can be increased. It is easier to use because each
component is independent of each other.
 A Modular Type PLC

PLC are divided into three types based on output namely Relay output, Transistor
output, and Triac Output PLC. The relay output type is best suited for both AC and
DC output devices. Transistor output type PLC uses switching operations and used
inside microprocessors.

According to the physical size, a PLC is divided into Mini, Micro, and Nano PLC.

Some of the manufacturers of PLCs include:

 Allen Bradley
 ABB
 Siemens
 Mitsubishi PLC
 Hitachi PLC
 Delta PLC
 General Electric (GE) PLC
 Honeywell PLC
PLC Applications
PLCs have a variety of applications and uses, including:

1. Process Automation Plants (e.g. mining, oil &gas)

2. Glass Industry
3. Paper Industry
4. Cement Manufacturing
5. In boilers – Thermal Power Plants
PLC Programming
When using a PLC, it’s important to design and implement concepts depending on
your particular use case. To do this we first need to know more about the specifics of
PLC programming.

A PLC program consists of a set of instructions either in textual or graphical form,

which represents the logic that governs the process the PLC is controlling. There are
two main classifications of PLC programming languages, which are further divided
into many sub-classified types.
1. Textual Language
 Instruction list
 Structured text
2. Graphical Form
 Ladder Diagrams (LD) (i.e. Ladder Logic)
 Function Block Diagram (FBD)
 Sequential Function Chart (SFC)