Programmable Logic Controller Operation

Segment 1: Elements of Programmable Controllers

Objective 1: Describe the Function of a Programmable Logic Controller
PLC Function
A Programmable Logic Controller (PLC) is a general-purpose industrial computer that
can be programmed to control different types of machines and processes.
PLCs are designed to wire directly to input and output devices. Common input devices include
pushbuttons, selector switches, and limit switches. Examples of output devices include indicator
lamps and solenoids.
Origin of the PLC
PLCs were developed to control automated machines that previously used
electromechanical relays. These relays were wired together to create a sequence of machine
movements. In most cases, this sequence involved machine actions that were very simple,
either on or off. The benefit of the PLC was that it enabled the sequence to be changed by
reprogramming, rather than re-wiring relays.
In 1968, the Gould Corporation designed the first PLC for General Motors. Their goal
was to replace hardwired components, such as relays and timers. Gould knew a computer-
controlled system would have many advantages, including faster reprogramming compared to
rewiring relays.
PLC Operation
A PLC controls a machine by monitoring the status of the machine input sensors to
control machine output devices. The program determines the sequence of outputs that are
turned on and off based on the inputs' status. PLCs use a specialized programming language
that is designed for machine control applications. Programs can be created on a computer and
downloaded to the PLC.
PLC Programming
A PLC controls a machine by monitoring the status of the machine input sensors to
control machine output devices. The program determines the sequence of outputs that are
turned on and off based on the inputs' status. PLCs use a specialized programming language
that is designed for machine control applications. Programs can be created on a computer and
downloaded to the PLC.
PLC Capabilities
PLCs have advanced greatly since they first began replacing relay circuits. Today, PLCs
perform high-speed motion control like a CNC, communicate with other devices over computer
networks, and handle large amounts of data.
PLCs are made in many different sizes and capabilities, from small low-cost units that control
simple machines to powerful units that control entire processes.
PLC Applications
PLCs are used to control machines in many different types of manufacturing facilities.
Just a few of the types of machines controlled by PLCs are:
• Assembly Machines
• Automatic Transfer Lines
• Packaging Lines
• Robots
• Machining Processes
• Material Flow

Objective 2: Describe the Basic Components of a PLC

PLCs Styles
There are many brands and models of PLCs. Each manufacturer offers models with a
wide range of capabilities. This allows each manufacturer to offer PLCs for applications ranging
from small standalone machines to large networked systems.
PLCs are often classified by their enclosure style. The two common enclosure styles are:
• I/O Chassis Style
• Brick-Style
I/O Chassis-Style PLC
An I/O chassis-style PLC is a modular system consisting of a PLC and I/O modules
mounted in a rack called a chassis. This system can be expanded to a larger number of I/O by
adding modules, using a larger chassis, or linking to other chassis.
The I/O chassis-style PLC also has many more types of modules available than a brick-style PLC.
Options include: digital and analog I/O modules, communications modules, and motion control
modules.
Basic PLC Components: Chassis Style
Regardless of the capabilities of the specific model, most chassis-style PLCs include
these basic components:
Input Modules - Input devices, such as limit switches and pushbuttons, are wired to the
terminals of an input module. The PLC uses these inputs to sense the condition of the machine.
Output Modules - The PLC controls devices such as motors and solenoids that are wired to the
output terminals of the output modules.
Processor Module (or Controller) - The processor, or controller, is the actual computer. It
consists of the CPU and memory. The program is stored in the processor’s memory.
Communications Port - The communications port is used to connect a programming device
such as a computer to the PLC. It can also be used to connect or network PLCs together. The
communications port may be a USB, serial, or Ethernet port.
Status Indicators - The status indicators are used to display the current status of the PLC.
Typical status indicators are Power On, Run, Communicating, and Fault.
Power Supply - The power supply provides the power to the PLC. Some PLC models include an
internal power supply. Others require an external power supply.
Brick-Style PLCs
A brick-style PLC includes a processor and a fixed number of digital and analog Inputs
and Outputs (I/O) in one enclosure. This I/O is called embedded I/O.
Brick-style PLCs can be expanded using plug in modules. However, the amount of additional I/O
that can be plugged into a brick-style PLC is limited.
Brick-style PLCs are used for smaller machines and basic applications.
Basic PLC Components: Brick Style
Brick-style PLCs use the same basic components as chassis-style PLCs but they are all
contained in the same enclosure.
Knowledge Check: PLC Basic Component Identification

Objective 3: Describe the Basic Operation of a PLC

Segment 2: PLC Programming Software

Objective 4: Describe Types of PLC Program Languages
Objective 5: Describe the Basic Structure of a PLC Ladder Logic Program
Objective 6: Describe the Basic Components of Rockwell CCW PLC ProgramminG
Software
Objective 7: Describe How to Open and View a PLC Project
Segment 3: PLC Program Execution
Objective 8: Describe How to Download and Upload a PLC Project
Objective 9: Describe How to Run and Monitor a PLC Program