ELE 2613 - Industrial Automation

Programmable Logic Controllers

Amar Khoukhi (revised and edited by Bashar Ahmad)

Programmable Logic Controllers [PLCs] — An
Overview

Source: Courtesy GE Intelligent Platforms

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Learning Objectives
1 Define what a PLC is and its advantages over relay systems
2 Explain the basic operation of a PLC
3 Identify the general classifications of PLC’s
4 Identify the main parts of a PLC and describe their functions

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PLC
1 PLCs Initially used to replace relay
logic
2 A PLC is a computer built to
operate in industrial environments.
3 PLCs are equipped with
input/output interfaces and a
control programming language.
4 PLC perform a wide range of
functions includes timing, counting,
arithmetic operations, logical
operations, and analog signal
processing. Image used with Permission of
Rockwell Automation, Inc.
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Why PLCs?
1 Eliminates much of the hardwiring associated with
conventional relay control circuits.
2 Increased Reliability as all the logic is contained in
the PLC’s memory, therefore eliminating wiring
errors.
3 More Flexibility since it is easier to create and
change a program in a PLC than to wire and rewire a
circuit.
4 It is generally cheaper to install a PLC system than a
hard-wired relay system if the application has more
than about a halfdozen control relays,
Source: Courtesy Mid-lllini
Technical Group, Inc.
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Why PLCs?
1 PLCs offer communications capability with other
PLCs or computers.
2 Faster Response Time - Machines that process
thousands of items per second and objects that
spend only a fraction of a second in front of a sensor
require the PLC’s quick-response capability.
3 Easier to Troubleshoot - To find and fix problems,
users can display the control program on a monitor
and watch it in real time as it executes.

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PLC Components

Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 6/1
PLC Components
1 The power supply provides DC power to all modules that plug into the rack. For large
PLC systems, this power supply does not normally supply power to the field devices.
2 The processor (CPU) consists of a microprocessor for implementing the logic and
controlling the communications among the modules.
3 The processor requires memory for storing the results of the logical operations
performed by the microprocessor as well as the operating system and the PLC
program.
4 A programming device is used to enter the desired program into the memory of the
processor.

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Input/Output Modules
The I/O (Input/Output) system forms the interface by which field devices are connected to
the controller.

Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 8/1
Remote I/O Rack
One benefit of a PLC system is the ability to locate the I/O modules near the field devices
to minimize the amount of wiring required.

Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 9/1
Processor Unit: CPU
The processor executes the operating system, manages memory, monitors inputs,
evaluates the user logic, and turns on the appropriate outputs.

1 Status indicators provide system diagnostic

information.
2 Key switch allows you select different modes of
operation.

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Processor Modes Of Operation
RUN Position
1 Places the processor in the Run mode
2 Executes the ladder program and energizes output devices
3 Prevents you from performing online program editing in this position
4 Prevents you from using a program/operator interface device to change the
processor mode
PROG Position
1 Places the processor in the program mode
2 Prevents the processor from scanning or executing the ladder program, and
controller outputs are de-energized
3 Allows you to perform program entry and editing
4 Prevents you from using a program/operator interface device to change the
processor mode
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Processor Modes Of Operation-1
REM Position
1 Places the processor in the Remote mode: either REMote Run, REMote Program,
or REMote Test mode
2 Allows you to change the processor mode from a programmer/operator interface
device
3 Allows you to perform program online program editing

Amar Khoukhi (revised and edited by Bashar Ahmad) ELE 2613 - Industrial Automation 20th August 2020 12 / 1
PLCs versus Computers
1 The architecture of a PLC is
basically the same as that of a
personal computer.
2 Unlike PCs, the PLC is designed
to operate in the industrial
environment.
3 Computers are capable of
executing several programs
simultaneously and in any order.
4 PLCs execute a single program in
an orderly and sequential fashion
Photo courtesy Ardent
from first to last instruction.

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Human Machine Interfaces
(HMIs)
A human machine interface (HMI) can be connected to communicate with a PLC
and to replace pushbuttons, selector switches, pilot lights, thumbwheels, and
other operator control panel devices ( see the figure shown ). Luminescent touch-
screen keypads provide an operator interface that operates like traditional
hardwired control panels. Human machine interfaces give the ability to the
operator and to management to view the operation in real time. Through personal
computer–based setup software, you can configure display screens to:

• Replace hardwired pushbuttons and pilot lights with realistic-looking icons. The
machine operator need only touch the display panel to activate the pushbuttons.
• Show operations in graphic format for easier viewing.
• Allow the operator to change timer and counter presets
by touching the numeric keypad graphic on the
touch screen.
• Show alarms, complete with time of occurrence and
location.
• Display variables as they change over time.