INTRODUCTION TO PLC SYSTEM

ROSLINDA BINTI ISMAIL

PROGRAMMABLE LOGIC
CONTROLLER
A digitally operating apparatus which uses a
programmable memory for the internal storage of
instructions by implementing specific functions such as
logic sequencing, timing, counting and arithmetic to
control through digital or analog input/output modules,
various types of machines or processes.
Programmable Logic Controller (PLC)
In a traditional industrial control system, all control devices are wired
directly to each other according to how the system is supposed to operate.
In a PLC system, however, the PLC replaces the wiring between the devices.
Thus, instead of being wired directly to each other, all equipment is wired to
the PLC. Then, the control program inside the PLC provides the “wiring”
connection between the devices.
The control program is the computer program stored in the PLC’s memory
that tells the PLC what’s supposed to be going on in the system. The use of
a PLC to provide the wiring connections between system devices is called
softwiring.
EXAMPLE

• Let’s say that a push button is supposed to control the operation of a

motor.
• In a traditional control system, the push button would be wired
directly to the motor. In a PLC system, however, both the push button
and the motor would be wired to the PLC instead.
• Then, the PLC’s control program would complete the electrical circuit
between the two, allowing the button to control the motor.
• The soft-wiring advantage provided by programmable controllers is
tremendous.
In fact, it is one of the most important features of PLCs. Soft-wiring
makes changes in the control system easy and cheap.
• If you want a device in a PLC system to behave differently or to
control a different process element, all you have to do is change the
control program.
• In a traditional system, making this type of change would involve
physically changing the wiring between the devices, a costly and time-
consuming endeavor
PLC Advantages
In addition to the programming flexibility we just mentioned, PLCs offer
other advantages over traditional control systems.
• These advantages include:
• high reliability
• small space requirements
• computing capabilities
• reduced costs
• ability to withstand harsh environments
• expandability
A PLC basically consists of two elements:

1. Central processing unit

2. Input/output system
The Central Processing Unit

The central processing unit (CPU) is the part of a programmable

controller that retrieves, decodes, stores, and processes information.

It also executes the control program stored in the PLC’s memory. In

essence, the CPU is the “brains” of a programmable controller.

It functions much the same way the CPU of a regular computer does,
except that it uses special instructions and coding to perform its
functions.
 The CPU has three parts:
The CPU the processor
has three
parts: the memory system

the power supply

 The processor is the section of the CPU that
codes, decodes, and computes data.

Memory system is the section of the CPU

that stores both the control program and
CPU data from the equipment connected to the
PLC.
Power supply is the section that provides
the PLC with the voltage and current it
needs to operate.
The Input/Output The input/output (I/O) system is the section of a PLC to which all
of the field devices are connected.
System If the CPU can be thought of as the brains of a PLC, then the I/O
system can be thought of as the arms and legs.

The I/O system is what actually physically carries out the control
commands from the program stored in the PLC’s memory.

The I/O system consists of two main parts:

the Rack
I/O modules
The rack is an enclosure with slots in it that is connected to the
CPU.
• I/O modules are devices with connection terminals to which the field
devices are wired. Together, the rack and the I/O modules form the
interface between the field devices and the PLC.
• When set up properly, each I/O module is both securely wired to its
corresponding field devices and securely installed in a slot in the rack.
• This creates the physical connection between the field equipment and
the PLC. In some small PLCs, the rack and the I/O modules come
prepackaged as one unit.
• All of the field devices connected to a PLC can be classified in one of two categories:
inputs
outputs
• Inputs are devices that supply a signal/data to a PLC.
• Typical examples of inputs are push buttons, switches, and measurement devices.
Basically, an input device tells the PLC, “Hey, something’s happening out here…you
need to check this out to see how it affects the control program.”
• Outputs are devices that await a signal/data from the PLC to perform their control
functions. Lights, horns, motors, and valves are all good examples of output devices.
• These devices stay put, minding their own business, until the PLC says, “You need to
turn on now” or “You’d better open up your valve a little more,” etc.
 Contacts are instructions that refer to the input
conditions to the control program—that is, to the
information supplied by the input field devices. Each
CONTRO contact in the control program monitors a certain field
device.

L The contact waits for the input to do something in

particular (e.g., turn on, turn off, etc.—this all depends
PROGRA on what type of contact it is).

M Then, the contact tells the PLC’s control program, “The

input device just did what it’s supposed to do. You’d
better check to see if this is supposed to affect any of
the output devices.”
Coils are instructions that refer to the outputs of the control program—
that is, to what each particular output device is supposed to do in the
system.

Like a contact, each coil also monitors a certain field device. However,
unlike a contact, which monitors the field device and then tells the PLC
what to do, a coil monitors the PLC control program and then tells the
field device what to do.
EXAMPLE
In PLC talk, this three-step process of monitoring the inputs, executing the PLC control program, and changing the status of the outputs
accordingly is called the scan.
PLC SELECTION PROCEDURE
Choosing a PLC or Controller for your Process is very important as it helps in Cost optimization. To
determine the most suitable PLC to be used in the automation task, there are several basic considerations
to be made:

• Necessary input/output capacity

• Types of I/O required

• Size of memory required

• Speed and power required of the CPU and instruction set

• Manufacturer’s support and backup

1. Number of I/O’s:
It is very important that you know the exact number of input and output that
are going to be used in the process for best and economical use. PLC 36 system
must have enough termination points to connect all signal and control lines for
the process.

2. Type of I/O’s:
On selecting PLC, we have to consider what types of I/Os are needed, such as
digital input like Sensor, Push Buttons etc, or analog inputs like pressure and
temperature. Just like that we consider output, digital outputs are Relay,
Contactor, Lamp etc. or you need an Analog output like Drive and Control Valves.
3. Memory and Programming Requirements:
• Memory size is normally related to the amount of I/O points required in the system. The other factor that affects the
amount of memory required is the control program that is to be installed.

• Program size is also related to the number of I/O points since it must include instructions for reading from or writing to
each point.

4. Compact or Modular PLC :

• PLC can select between modular and compact types, modular type allows us to design the PLC for our purpose and which
has Power supply and controller in different housing while Compact Type PLC are those which has Power supply and
controller in the same housing.

5. Instruction Set/CPU:
• All PLC handle logic control, sequencing, etc, but difference in the area of data handling, special functions and
communications. Larger programmable controllers tend to have more powerful instructions than smaller ones in these
areas.
• 6.PLC Scan Time:
• PLC scan time is a time needed for PLC to completely Scan one cycle of PLC. It may consist of reading
PLC input status, clearing PLC memory, Executing the PLC program and updating the Output. It is
sometimes needed PLC with less scan time but it finds costly.

• 7. Sinking & Sourcing PLC:

• Making a PLC at the source in Input or causing a PLC to sink into the input depends on the user’s
requirements for the PLC to be chosen in that way. Some PLCs can support both sink and source 62
input and output.

• 8. Manufacturer’s Support and Backup:

• Before choosing a PLC from a manufacturer, it should be considered the manufacturer’s assistance and
service provided. It is a great advantage if the supplier/manufacturer can offer assistance with the
system design work.