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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. PLCs can be thought of in simple terms as industrial computers with specially designed architecture in both their central units (the PLC itself) and their interfacing circuitry to field devices (input/output connections to the real world).

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The central processing unit The input/output interface system The central processing unit (CPU) governs all PLC activities. The following three components, form the CPU: The processor The memory system The system power supply

During its operation, the CPU completes three processes: (1) it reads, or accepts, the input data from the field devices via the input interfaces, (2) it executes, or performs, the control program stored in the memory system, and (3) it writes, or updates, the output devices via the output interfaces.

Programming device, usually a personal computer or a manufacturers mini programmer unit, is required to enter the control program into memory The programming device must be connected to the controller when entering or monitoring the control program.

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Small PLCs Medium PLCs Large PLCs Very large PLCs

The ladder diagram has and continues to be the traditional way of representing electrical sequences of operations.+ 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.

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The CPU forms what can be considered to be the brain of the system. The three components of the CPU are: The processor The memory system The power supply

Very small microprocessors (or micros)integrated circuits with tremendous computing and control capabilityprovide the intelligence of todays programmable controllers. The CPU of a PLC system may contain more than one processor (or micro) to execute the systems duties and/or communications, because extra processors increase the speed of these operations. Standard word lengths are 8, 16, and 32 bits. This word length affects the speed at which the processor performs most operations.

The basic function of a programmable controller is to read all of the field input devices and then execute the control program, which according to the logic programmed, will turn the field output devices ON or OFF.

What occurs during the scanning operation of a programmable controller if the signal(s) from an input field device behave as shown in Figures a and b?

The common scan method of monitoring the inputs at the end of each scan may be inadequate for reading certain extremely fast inputs. Some PLCs provide software instructions that allow the interruption of the continuous program scan to receive an input or to update an output immediately.

Referencing Figure illustrate how, in one scan, (a) an immediate instruction will respond to an interrupt input and (b) the same input instruction can update an immediate output field device, like a solenoid

The immediate instruction will interrupt the control program to read the input signal. It will then evaluate the signal and return to the control program, where it will resume program execution and update outputs. Immediate update of an output. As in part (a), the immediate instruction interrupts the control program to read and evaluate the input signal. However, the output is updated before normal program execution resumes

The PLCs processor constantly communicates with local and remote subsystems or racks as they may also be called I/O interfaces connect these subsystems to field devices located either close to the main CPU or at remote locations Error-checking techniques are also incorporated in the continuous communication between the processor and its subsystems. These techniques confirm the validity of the data transmitted and received..

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The processor uses error-checking techniques to monitor the functional status of both the memory and the communication links between subsystems and peripherals, as well as its own operation. Common error-checking techniques include parity and checksum. Parity or vertical redundancy check (VRC). Checksum Cyclic redundancy check (CRC) The most common error-detecting and error-correcting code is the Hamming code.

The processor is responsible for detecting communication failures, as well as other failures, that may occur during system operation. Typical diagnostics include memory OK, processor OK, battery OK, and power supply OK.

The system power supply plays a major role in the total system operation. In fact, it can be considered the firstline manager of system reliability and integrity. Require a 120 VAC or 220 VAC power source, while a few controllers will accept 24 VDC. Constant Voltage Transformers

Undercurrent conditions can cause unpredictable operation of the I/O system. Undercurrent condition sometimes arises in applications where an excessive number of special purpose I/O modules are used. When power supply loading limits have been exceeded and overload occurs, the normal remedy is to either add an auxiliary power supply or to obtain a supply with a larger current capability.