G. H.

Raisoni College of Engineering , Nagpur

( An Autonomous Institutions under UGC affiliated to RTM, Nagpur University , Nagpur
Department of Electronics and Telecommunication Engineering

Unit-II: INTRODUCTION PROGRAMMABLE

LOGIC CONTROLLER (PLC)

Elective-VI-INDUSTRIAL AUTOMATION
(BECL351)

Year/ Semester : 4th / VIIth

Name of Faculty:
Dr. Umesh Sahu
Department of Electronics & Telecommunication Engineering
 Vision of the Department
To achieve excellent standards of quality education by keeping pace with
rapidly changing technologies and to create technical manpower of global
standards in electronics & telecommunication engineering with capabilities of
accepting new challenges.

Mission of the Department

• To create competent professionals who are trained in the design &
implementation of Engineering & Telecommunication systems.
• To contribute towards the advancement of engineering, science and
technology
• To impart quality and value based education to raise satisfaction of all stake
holders
• To promote research & development activities in the field of electronics &
telecommunication engineering and allied areas
 Syllabus
CO-II: (7 Hours)
INTRODUCTION PROGRAMMABLE LOGIC CONTROLLER
(PLC)
What is PLC? PLC versus microprocessor/microcontroller/computer,
advantages and disadvantages of PLC, architecture and physical forms of
PLC, BASIC PLC FUNCTIONS-Registers: holding, input and output
registers; Timers and timer functions; counters and counter functions.
 Contents

• What is PLC?
• Historical Background
• PLC Size
• Types of PLC Construction
• PLC versus microprocessor/
microcontroller/computer,
• Advantages and disadvantages of PLC
• Architecture and physical forms of PLC
• BASIC PLC FUNCTIONS
• Registers: holding, input and output registers;
• Timers and timer functions;
• counters and counter functions.
 What is PLC?
Definition: National Electrical Manufacturers Association
US (NEMA)

A PLC is a digital operating electronic apparatus which

uses a programmable memory for internal storage of
instruction for implementing specific function such as
logic, sequencing, timing, counting and arithmetic to
control through analog or digital input/output modules
various types of machines or process.
 What is PLC?
• Programmable logic controllers, also called programmable controllers or
PLCs, are solid-state members of the computer family, using integrated
circuits instead of electromechanical devices to implement control
functions.
• They are capable of storing instructions, such as sequencing, timing,
counting, arithmetic, data manipulation, and communication, to control
industrial machines and processes.

Figure: PLC conceptual

application diagram

Bryan, Luis A., and Eric A. Bryan. Programmable controllers: theory and
implementation. Industrial Text Company, 1997. (Chapter-1, Page-16)
 What is PLC?

 Several different terms used to described programmable

controllers:
i. PLC –Programmable Logic Controller (UK origin)
ii. PC – Programmable controller (US origin)

 Most referring to the functional operation of the machine.

 PLC has been used in this text to avoid confusion with the
personal computer.
 Historical Background

In 1968, a group of engineers from General Motors

developed the concept of PLC with an initial
specification. The PLC must be:
i. Easy to program.
ii. Not need rewiring the control system if
change the program.
iii. Smaller in size, cheaper and high reliability.
iv. simple construction and low maintenance
v. Cost- competitive

Bryan, Luis A., and Eric A. Bryan. Programmable controllers: theory and
implementation. Industrial Text Company, 1997. (Chapter-1, Page-17)
 PLC Size
 Small :
- it covers units with up to 128 I/O’s and memories up to 2 Kbytes.
- Capable of providing simple to advance levels or machine controls.

 Medium :
- Have up to 2048 I/O’s and memories up to 32 Kbytes.

 Large :
- The most sophisticated units of the PLC family. They have up to
8192 I/O and memories up to 750 Kbytes.
- Can control individual production processes or entire plant.
Bryan, Luis A., and Eric A. Bryan. Programmable controllers: theory and
implementation. Industrial Text Company, 1997. (Chapter-1, Page-34)
 Types of PLC Construction

Compact PLC
Modular PLC
PLC Plug-in Card

Manufacturer: OMRON, Allen Bradley,

Mitsubishi, NAIS, Siemens,
Toshiba, Festo etc.
 Types of PLC Construction

Figure: Compact PLC

 Types of PLC Construction

Figure: Modular PLC

 Types of PLC Construction

Figure: Plug-in Card PLC

 Typical Areas of Application
• For past 30 years PLC’s have been in the first level of control
because of their ability to run uninterrupted for extended
periods of time (usually measured in months or even years).

• The PLC layer in industrial applications is shown in figure

below

Bryan, Luis A., and Eric A. Bryan. Programmable controllers: theory and
implementation. Industrial Text Company, 1997. (Chapter-1, Page-29)
 PLCs Versus Other Types of Controls
A PLC is not the only choice for controlling a process. Sticking
with only basic relays may be of a benefit depending upon your
application. Yet, on the other hand, a computer might be the
way to go. The PLC vs. PC debate has been going on for a long
time. More often though it doesn't come down to an "either or"
situation but involves a mix of technologies.

• PLCS VERSUS RELAY CONTROL

• PLCS VERSUS COMPUTER CONTROLS
• PLCS VERSUS PERSONAL COMPUTERS

Bryan, Luis A., and Eric A. Bryan. Programmable controllers: theory and
implementation. Industrial Text Company, 1997. (Chapter-1, Page-25)
 Advantages and disadvantages of PLC
Advantages
• It has very faster scan time.
• It has capable to communication with computer in plant.
• It has great computational capabilities.
• It has shorter training time required.
• A wide range of control application.
• It Have interfacing for inputs and outputs already inside the controller.
• It is easily programmed and has an easily understood programming
language.
• It has project cost can be accurately calculated.
• It has supervisory control capability.
• It has small physical size.
• It has flexibility in programming and reprogramming.
• Troubleshooting is easier and faster.
• It has high speed counters.
• It has shorter project implementation time.
• It has reliability in operation.
[Online]:https://www.polytechnichub.com/advantages-disadvantages-
programmable-logic-controller-plc/
 Advantages and disadvantages of PLC
Disadvantages
• When a problem occurs, hold-up time is indefinite, usually long.
• There are limitations of working of PLCs under high temperature, vibration
conditions.
• some PLCs turns on when power is restored and may cause any accident.

[Online]:https://www.polytechnichub.com/advantages-disadvantages-
programmable-logic-controller-plc/
PLC Configuration
 What devices does a PLC interact with?
• INPUT RELAYS-(contacts)These are connected to the outside world. They
physically exist and receive signals from switches, sensors, etc. Typically they
are not relays but rather they are transistors.

• INTERNAL UTILITY RELAYS-(contacts) These do not receive signals from

the outside world nor do they physically exist. They are simulated relays and are
what enables a PLC to eliminate external relays. There are also some special
relays that are dedicated to performing only one task. Some are always on while
some are always off. Some are on only once during power-on and are typically
used for initializing data that was stored.

• COUNTERS-These again do not physically exist. They are simulated counters

and they can be programmed to count pulses. Typically these counters can count
up, down or both up and down. Since they are simulated they are limited in their
counting speed. Some manufacturers also include high-speed counters that are
hardware based. We can think of these as physically existing. Most times these
counters can count up, down or up and down.
 What devices does a PLC interact with?
• TIMERS-These also do not physically exist. They come in many
varieties and increments. The most common type is an on-delay
type. Others include off-delay and both retentive and non-retentive
types. Increments vary from 1ms through 1s.

• OUTPUT RELAYS-(coils)These are connected to the outside

world. They physically exist and send on/off signals to solenoids,
lights, etc. They can be transistors, relays, or triacs depending
upon the model chosen.

• DATA STORAGE- Typically there are registers assigned to

simply store data. They are usually used as temporary storage for
math or data manipulation. They can also typically be used to store
data when power is removed from the PLC. Upon power-up they
will still have the same contents as before power was removed.
Very convenient and necessary!!
 Architecture/ Block Diagram of PLC
Data BUS

ROM RAM Output

Input
Microproce
ssor/ CPU

Address Bus

Control Bus

Figure: Architecture/ Block Diagram of PLC

Bryan, Luis A., and Eric A. Bryan. Programmable controllers: theory and
implementation. Industrial Text Company, 1997. (Chapter-1, Page-22)
Architecture/ Block Diagram of PLC

PC
Program
Loader
Switches

Printer
I/O
Processor
Modules Machines
Cassette
Loader
Power
EPROM Memory Supply
Loader

Peripherals External Devices

Figure: Architecture/ Block Diagram of PLC

 Architecture/ Block Diagram of PLC

a. Central Processing Unit (CPU)

• The CPU controls, monitors and supervises all operations

within PLC.

• It is also caries out programmed instructions stored in the

memory.

• An internal communications highway also known as a bus

system, carries information to and from the CPU, memory
and I/O units under the control of the CPU.
 Architecture/ Block Diagram of PLC
b. Memory Unit
• For storage of programs.
• The user’s ladder logic program, the state of I/O in the
memory of PLC.
• The main program and the other programs necessary for
the operation of PLC.
• The organization of the data and information in the
memory is called memory map.

2 types of Memory

ROM RAM
 Architecture/ Block Diagram of PLC

TYPES OF MEMORY:

RAM ROM
Random Access Memory Read Only Memory (read)

This memory can be read from This memory can be read only
and written to.

Storing all user’s programs Storing all system’s program

Entire contents will be lost if power Memory content remain when the
is switched off. power is switched off.
 Architecture/ Block Diagram of PLC
c. Input/ Output (I/O) Unit

Input Unit:
Function as a medium that connects the external
input devices
(Switch, sensor & timer)

Output Unit:
Function as a medium that connects the external
output devices to the CPU within PLC.
( Lamp, motor & solenoid )
 Architecture/ Block Diagram of PLC

INPUT DEVICES: Push Button

Limit Switch

Thumbwheel
SW

Level SW

Flow SW
 Architecture/ Block Diagram of PLC

OUTPUT DEVICES:
 Architecture/ Block Diagram of PLC
d. Display and Indicator Unit
Referring to PLC standard display Internal Relay:

Console’s LCD Display

if user use Mnemonic Code Programming.
LCD Display

Monitor Screen
if user use software programming method.

Monitor Screen
 Architecture/ Block Diagram of PLC
e. Housing Unit
Protect PLC circuit and internal component

f. Programming Unit
Consist of 2 devices:
i. Programming Console
ii. Computer

g. Secondary Storage Unit

This unit related to CPU where all program
and information were kept.
 Architecture/ Block Diagram of PLC

h. Power Supply Unit:

Supplies DC power to the Central Processing Unit, Input Unit and

Output Unit.

i. Printing Unit
Used to print control system programming that controlled by PLC
wether graphically or text.
 Summary
We have looked at:
• What is PLC?
• Historical Background
• PLC Size
• Types of PLC Construction
• PLC versus microprocessor/
microcontroller/computer,
• Advantages and disadvantages of PLC
• Architecture and physical forms of PLC
• BASIC PLC FUNCTIONS
• Registers: holding, input and output registers;
• Timers and timer functions;
• counters and counter functions.
Thank You