Chapter 1 - Introduction To PLC

OPENCOURSEWARE | OCW.UTEM.EDU.
MY
OpenCourseWare | ocw.utem.edu.my
Universiti Teknikal Malaysia Melaka
PLC AND AUTOMATION
CHAPTER 1: INTRODUCTION TO
PLC
Ts. Mohd Hanif Che Hasan | hanif.hasan@utem.edu.my
Ts. Ahmad Zubir bin Jamil | zubir@utem.edu.my
Ts. Maslan bin Zainon | maslan@utem.edu.my
UNIVERSITI TEKNIKAL MALAYSIA MELAKA

OPENCOURSEWARE | OCW.UTEM.EDU.MY
LESSON OUTCOMES
By the end of this lesson, you should be able:
• State the PLC background such as definition, historical track, and

operation principle.
• Explaining how PLC is different compared to hardwire, PC, and
microcontroller.
• State architecture, type, size, brand and specification of PLC.
• Describe PLC communication and programming devices
• Giving example of PLC applications

CONTENTS
LESSON OUTCOMES 2
CONTENTS 3
WHAT IS A PLC? 4
DEFINITION 5
PRINCIPLE OPERATION 6
PLC VS HARDWIRED VS PC VS µCONTROLLER 8
ARCHITECTURE, TYPE, SIZE, MANUFACTURER 11
INPUT OUTPUT SPECIFICATION 15
COMMUNICATION 23
PROGRAMMING DEVICES 25
APPLICATION 26

WHAT IS A PLC?

WHAT IS A PLC?
A special computer for logic controls using

ladder logic programming.
Hardwired controller

PLC-based system

DEFINITION
1. PLC = Programmable Logic Controller

2. PLC is a solid state device designed for use to control automation system and processes
in industrial environment
3. PLC applications are found in both process and discrete manufacturing industries.
4. PLC replaced hard-wired controller (relays, contactor, counters, timers, sequencer, etc.)
5. PLC definition based on National Electrical Manufacturing Association (NEMA) ICS3-1978
“A programmable controller which is a digital electronic apparatus with a
programmable memory for storing instructions to implement specific
functions, such as logic, sequencing, timing, counting and arithmetic to control
machines and processes.”
6. The role of the PLC is commonly regarded as the brain of the automation system.

HISTORICAL BACKGROUND
1. 1940 - Mid 1960s: Hardwire logic, relays, timers,

etc in automation system
2. 1968 – Dick Morley (Bedford Associates)
introduced Modular Digital Controller (MODICON)
Model 084
3. 1977 – MODICON sold to Gould Electronics, later
acquired by German Company AEG, and then by
French Schneider Electric, the current owner.
4. 1980s – micro-PLC introduced
5. Mid 1990s – nano-PLC invented, much smaller &
cheaper.
6. Father of PLC : Dick Morley (Richard E. Morley)

PRINCIPLE OPERATION
1. Replaced the using of

conventional
relay/coil/counter/timer

Advantages of PLC’s
• Flexible and programmable

• Easy to installation and implementation
• Reliable in industrial environment
• Ease of maintenance and troubleshooting
• Long lasting
• Cost saving

Disadvantages of PLC’s
• Handling large amount of Data

• Displaying Data
• Handling Databases
• Complex data handling

PLC a Real-World Relay

Replacement
Switch controlling AC
Real world Parts: circuit or bell
• Switch
• Bell
• Relay
Relay

PLC a Real-World Relay

Replacement
Relay Coil Relay Normally

Symbol open Contact
Symbol
PLC Output PLC Input

Symbol Symbol

Example of a Motor Control

START
STOP
output
EQUIVALENT DIAGRAMS
START STOP
output
Normally Normally
Open Contact Closed Contact
How to program PLCs?
• Using a specialized Ladder Logic Software

• Allen-Bradley uses RsLogix 500 software to program
SLC, Micrologix and so on
• Omron uses Cx Programmer software for its SYSMAC

PLCs
• Other manufacturers has their own software

PLC VS HARDWIRED
PLC Hardwired
Environment Robust to dust, vibration, noise, high Robust to dust, vibration, noise, high
temperature, humidity, EMI temperature, humidity, EMI
Controlled device (hardware) General purpose Specific purpose
Area occupied Take less space Take large space especially for medium scale
application
Application scale Medium & large Small & medium
Delivery period Almost immediate Several days
Maintenance Easy Difficult
Reliability High Intermediate (Relays is less reliable)
Power consumption Low (solid state device) Intermediate (Relays use solenoid – use
significant current)
Speed High (suitable for PWM-based control) Low
Self-diagnosis function Yes No

Communication capability/ Yes No
Supervisory control

PLC VS PC
PLC PC
Design for Extreme industrial environment Data processing and
calculation
Reliability Robust to dust, high temperature, Sensitive to dust, high

humidity and EMI temperature, humidity and EMI
Processing speed Slow and medium Fast
Memory No secondary memory available (in the Lots of secondary memory

PLC) available
Task capability Optimized for single task Multitasking capability

PLC VS MICROCONTROLLER
PLC Microcontroller
Size Large Small
Price Quite expensive Cheap
I/O interface Can be extended (Modular PLC) Fixed
Reliability Robust to dust, vibration, high Sensitive to dust, vibration,

temperature, humidity and EMI high temperature, humidity
and EMI
Operating System (OS) Equipped with OS to handle No OS
communication protocol and
programming languages

PLC ARCHITECTURE
Basically, all PLC have FIVE major sections:

1. Power supply
2. Input module
3. Output module
4. CPU (Central Processing Unit)
5. Programming device

* Just for illustration, may vary by PC
PLC TYPE
• Modular • Fixed
• Divided into several compartments • Typical of small PLCs

in which modules can be plugged • Processor & IO packaged
• Modules slides into rack, making together with no removable
electrical connection through a units
backplane • Less flexibility

SIZES
Size of PLC depending on functionality, cost, physical size and I/O numbers
Size I/O Count

Large > 1024
Medium < 1024
Small < 256
Micro ≤ 32
Nano ≤ 16

PLC MANUFACTURER
We use
this
brand for
this
subject

I/O SPECIFICATION
PLC: I/O RATINGS

PLC COMMUNICATIONS
Common Uses of PLC Communications Ports
 Changing resident PLC programs - uploading/downloading from a

supervisory controller (Laptop or desktop computer).
 Control I/O points and memory elements from a remote terminal.
 Linking a PLC into a control hierarchy containing several sizes of PLC
and computer.
 Real time monitoring

PLC COMMUNICATIONS
Serial
• RS 232 communication
Used in short-distance computer communications,
with the majority of computer hardware and
peripherals. Has a maximum effective distance of
approx. 30 m at 9600 baud (bits/s)
• RS 422 / RS 485
Used for longer-distance links, often between
several PCs in a distributed system. RS 485 can
have a maximum distance of about 1000 meters.
• Local Area Network (LAN)
Provide the common, high-speed data
communications bus which interconnects any or all
devices within the local area, medium to the
internet.
• Universal Serial Buses (USB)
For program downloading/uploading and monitoring
purpose at short distance by using laptop/notebook

How to program PLCs?
• Using a specialized Ladder Logic Software

• Allen-Bradley uses RsLogix 500 software to program
SLC, Micrologix and so on
• Omron uses Cx Programmer software for its SYSMAC

PLCs
• Other manufacturers has their own software

PLC PROGRAMMING DEVICE
Handheld unit / Console PC/notebook Human machine interface (HMI)

APPLICATIONS: CONVEYOR SYSTEM

APPLICATIONS: PACKAGING PROCESS

APPLICATIONS: FILLING PROCESS

APPLICATIONS: TRAFFIC LIGHT

APPLICATIONS: GENSET

APPLICATIONS: LIFT

CONCLUSION
What have we learned?

• The PLC background - definition, historical track, and operation principle.
• PLC advantages and disadvantages compared to hardwire, PC, and
microcontroller.
• PLC architecture, type, size, brand and specification of PLC.
• PLC communication and programming devices
• PLC applications example in various fields

REFERENCES
1. PETRUZELLA, F. D. (2017), “PROGRAMMABLE LOGIC CONTROLLERS”, 5TH ED.,

MCGRAW-HILL EDUCATION
2. GROOVER, M. P. (2019), “AUTOMATION, PRODUCTION SYSTEMS, AND COMPUTER

INTEGRATED MANUFACTURING”, 5TH ED., PEARSON.
3. BOLTON, W. (2015), “PROGRAMMABLE LOGIC CONTROLLERS”, 6TH ED., NEWNES.
4. LAMB, F. (2013), “INDUSTRIAL AUTOMATION: HANDS-ON”, MCGRAW-HILL

EDUCATION.
5. MACAULAY, TYSON (2012), CYBERSECURITY FOR INDUSTRIAL CONTROL

SYSTEMS: SCADA, DCS, PLC, HMI, AND SIS, CRC PRESS.
36

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OPENCOURSEWARE | OCW.UTEM.EDU.

PLC AND AUTOMATION

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

By the end of this lesson, you should be able:

• State the PLC background such as definition, historical track, and

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

A special computer for logic controls using

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

1. PLC = Programmable Logic Controller

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

1. 1940 - Mid 1960s: Hardwire logic, relays, timers,

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

1. Replaced the using of

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

• Flexible and programmable

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

• Handling large amount of Data

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

PLC a Real-World Relay

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

PLC a Real-World Relay

Relay Coil Relay Normally

PLC Output PLC Input

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Example of a Motor Control

How to program PLCs?

• Using a specialized Ladder Logic Software

• Omron uses Cx Programmer software for its SYSMAC

• Other manufacturers has their own software

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Self-diagnosis function Yes No

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Reliability Robust to dust, high temperature, Sensitive to dust, high

Memory No secondary memory available (in the Lots of secondary memory

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Reliability Robust to dust, vibration, high Sensitive to dust, vibration,

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Basically, all PLC have FIVE major sections:

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

• Divided into several compartments • Typical of small PLCs

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Size I/O Count

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

PLC: I/O RATINGS

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Common Uses of PLC Communications Ports

 Changing resident PLC programs - uploading/downloading from a

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

How to program PLCs?

• Using a specialized Ladder Logic Software

• Omron uses Cx Programmer software for its SYSMAC

• Other manufacturers has their own software

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

PLC PROGRAMMING DEVICE

Handheld unit / Console PC/notebook Human machine interface (HMI)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

APPLICATIONS: CONVEYOR SYSTEM

UNIVERSITI TEKNIKAL MALAYSIA MELAKA