Chapter 1

Introduction to Programmable Logic

Controllers

1
Introduction to Programmable Logic Controllers Chapter 1

1.1 Definition
Programmable logic controllers,
• Called programmable controllers or PLCs.
• Solid-state device instead of electromechanical devices.
• Storing instructions (sequencing, timing, counting, arithmetic, data manipulation,
and communication).
….to control industrial machines and processes.

HCM City Univ. of Technology, Faculty of Mechanical Engineering 2 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.1 Definition
o Field devices (input/output
connections to the real world).
o Programmable Controller
(PLC). Digital/Analog

Digital/Analog

HCM City Univ. of Technology, Faculty of Mechanical Engineering 3 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.2 A Historical Background

o The first programmable controller was introduced in 1968 by General Motors.
o The goal was to eliminate the high costs associated with inflexible, relay-controlled
systems.
o This solid-state system with computer flexibility able to:
▪ survive in an industrial environment
▪ be easily programmed and maintained by plant engineers and technicians
▪ be reusable
▪ reduce machine downtime
▪ provide expandability for the future
▪ be easily installed and use less space.
HCM City Univ. of Technology, Faculty of Mechanical Engineering 4 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.2 A Historical Background

o Today’s programmable logic controllers are advanced with many technologies.
o The following list describes some recent PLC hardware enhancements:
▪ faster scan times
▪ high-density input/output (I/O) systems providing space-efficient interfaces
▪ provide more protocol interface for communication
▪ provide special interface allowing to connect a certain device.
o The future of programmable controllers relies not only on the continuation of new
product developments.
o PLCs are being incorporated, through networks, combining their power and
resources with numerical controls, robots.
HCM City Univ. of Technology, Faculty of Mechanical Engineering 5 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.3 Principles of Operation

o A programmable controller consists of two basic sections:
▪ the central processing unit
▪ the input/output interface system.

HCM City Univ. of Technology, Faculty of Mechanical Engineering 6 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.3 Principles of Operation

o The central processing unit (CPU) governs all PLC activities.
o It consists of three components:
▪ the processor
▪ the memory system
▪ the system power supply.

HCM City Univ. of Technology, Faculty of Mechanical Engineering 7 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.3 Principles of Operation

o The input/output (I/O) system is physically connected to the field devices.
o Field devices may be digital or analog input/output devices.
▪ Example:
Digital input devices Analog input devices

HCM City Univ. of Technology, Faculty of Mechanical Engineering 8 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.3 Principles of Operation

o The input/output (I/O) system is physically connected to the field devices.
o Field devices may be digital or analog input/output devices.
▪ Example:
Digital output devices Analog output devices

HCM City Univ. of Technology, Faculty of Mechanical Engineering 9 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.3 Principles of Operation

o The CPU completes three processes:
▪ It reads the input data from the field devices.
▪ It executes the control program stored in the memory
system.
▪ It writes to change the state of the field output devices.
o This sequence is known as a scanning.
o The system power supply provides all the voltages required
for the proper operation of the various central processing unit
sections.

HCM City Univ. of Technology, Faculty of Mechanical Engineering 10 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.3 Principles of Operation

HCM City Univ. of Technology, Faculty of Mechanical Engineering 11 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.4 PLCs versus Other Types of Controllers

Relay circuit controller Microcontroller circuit Industrial Computer

controller

HCM City Univ. of Technology, Faculty of Mechanical Engineering 12 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.4 PLCs versus Other Types of Controllers

o Is there a need for flexibility in control logic changes?
o Is there a need for high reliability?
o Are space requirements important?
o Are increased capability and output required?
PLC
versus o Are there data collection requirements?
Relay o Will there be frequent control logic changes?
control
o Will there be a need for rapid modification?
o Must similar control logic be used on different machines?
o Is there a need for future growth?
o What are the overall costs?
HCM City Univ. of Technology, Faculty of Mechanical Engineering 13 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.4 PLCs versus Other Types of Controllers

o PLCs are specifically designed to survive the harsh conditions of
the industrial environment.
o A well-designed PLC can be placed in an area with substantial
amounts of electrical noise, electromagnetic interference,
PLC
versus mechanical vibration, and noncondensing humidity.
Computer o PLCs is that their hardware and software are designed for easy
Control
use by plant electricians and technicians.
o Programming language for PLCs is easier than that of computer.

HCM City Univ. of Technology, Faculty of Mechanical Engineering 14 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.5 PLC Product Application Ranges

o The PLC market can be segmented into five groups:
1. micro PLCs
2. small PLCs
3. medium PLCs
4. large PLCs
5. very large PLCs
The A, B, and C overlapping areas reflect
enhancements, by adding options, of the
standard features of the PLCs within a
particular segment.
HCM City Univ. of Technology, Faculty of Mechanical Engineering 15 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.5 PLC Product Application Ranges

o Common PLCs brands: Programming software:
Tia Portal
Siemens
Compact Module

S7 – 1200 series S7 – 1500 series

HCM City Univ. of Technology, Faculty of Mechanical Engineering 16 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.5 PLC Product Application Ranges

o Common PLCs brands: Programming software:
GX Works2/3
Mitsubishi
Compact Module

Fx series Q, R, A series
HCM City Univ. of Technology, Faculty of Mechanical Engineering 17 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.5 PLC Product Application Ranges

o Common PLCs brands: Programming software:
CX One
OMRON
Compact Module

CP1 series CS1 series

HCM City Univ. of Technology, Faculty of Mechanical Engineering 18 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.5 PLC Product Application Ranges

o Common PLCs brands: Programming software:
ISPSoft
DELTA
Compact Module

DVP series AS series

HCM City Univ. of Technology, Faculty of Mechanical Engineering 19 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.5 PLC Product Application Ranges

o Common PLCs brands: Programming software:
MPE720
Yaskawa

MP2300 series MP3300 series

HCM City Univ. of Technology, Faculty of Mechanical Engineering 20 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.5 PLC Product Application Ranges

o Common PLCs brands: Programming software:
Proficy Machine Edition
GE - Fanuc
Compact Module

Micro VersaMax VersaMax

HCM City Univ. of Technology, Faculty of Mechanical Engineering 21 Duong Van Tu
Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Ladder
o The ladder diagram has and continues to be the traditional way of representing
electrical sequences of operations.
o These diagrams represent the interconnection of field devices in such a way that
the activation, or turning ON, of one device will turn ON another device according
to a predetermined sequence of events.

HCM City Univ. of Technology, Faculty of Mechanical Engineering 22 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Graphical languages Text based languages

• Ladder • Instruction List (IL)
• Step Ladder (STL) • Structured Text (ST)
• Sequence Function Chart
(SFC)
• Function Block Diagram (FBD)

HCM City Univ. of Technology, Faculty of Mechanical Engineering 23 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages Instruction

Ladder Contact

Coil

NC
contact

NO
contact

HCM City Univ. of Technology, Faculty of Mechanical Engineering 24 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Ladder

Device
address

User’s
comment

Contact
symbol
GW Works Tia portal

HCM City Univ. of Technology, Faculty of Mechanical Engineering 25 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Ladder

Scenario 1

HCM City Univ. of Technology, Faculty of Mechanical Engineering 26 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Ladder

Scenario 2

HCM City Univ. of Technology, Faculty of Mechanical Engineering 27 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Ladder

Scenario 3

HCM City Univ. of Technology, Faculty of Mechanical Engineering 28 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Step Ladder (STL)

HCM City Univ. of Technology, Faculty of Mechanical Engineering 29 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Sequence Function Chart (SFC)

HCM City Univ. of Technology, Faculty of Mechanical Engineering 30 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Instruction List (IL)

Ladder IL

HCM City Univ. of Technology, Faculty of Mechanical Engineering 31 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.6 PLC Programming Languages

Structured Text (ST)

IF Manual AND NOT Alarm THEN

Level:=Manual_Level;
Mixer:=Start AND NOT Reset
ELSE_IF Other_Mode THEN
Level:=Max_Level;
ELSE Level:=(Level_Indic ´ 100)/Scale;
END_IF;

HCM City Univ. of Technology, Faculty of Mechanical Engineering 32 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.7 Advantages of PLCs

o It is modular and flexible, allowing to expand as the requirements change.
o A PLC system is reliability and repeatability to programmability.
o Reduce hardware/wiring cost and space requirements.
o It is easily installed and replaced with a unit.
o It is applied widely in factory.
o It is easy to maintenance.
o It is easy to programming, debug.

HCM City Univ. of Technology, Faculty of Mechanical Engineering 33 Duong Van Tu

Introduction to Programmable Logic Controllers Chapter 1

1.7 Advantages of PLCs

Programmable controller I/O connection
diagram showing no physical connections
between the inputs and outputs.

HCM City Univ. of Technology, Faculty of Mechanical Engineering 34 Duong Van Tu