Lesson 1 : Introduction to

Programmable Logic Controller

1
 Introduction to Programmable Logic
Controller
• Programmable Logic Controllers (PLC’s) were
created to replace conventional relay controls
with solid state equipment.
• To make the transition from mechanical
controls to computers easier, much of the
symbol and terminology of relay ladder logic
was transported.
• This lesson is intended to introduce you to
programmable controllers and show you how
they might be used in place of conventional
mechanical relays.
2
Conventional Electrical Control Symbol

DISCRETE
DISCRETE OUTPUTS
INPUTS
OF
MAN F AUT
O

INTERNAL
CONTACT
S

3
Simple Relay Ladder Diagram
2L2 1L2

H1 H3 H2 H4

8 AMP X1 115 V X2 8 AMP

FU 4 PB2 FU 5
PB 1 START MOTORS
MASTER STOP
1 3 4 1 OL
2 HYDRAULIC AND COOLANT
1 1M
PUMP MOTOR STARTER 2
2 OL
1M 2M SPINDLE MOTOR
8 2M
2 STARTER 2

4
3 PB 4
PB 3
SPINDLE STOP SPINDLE START
4 9 10 LS 1 11 1
4 SPINDLE START
SPINDLE DIRECTION CR 5, 6, 10
CR 1 LEVER ENGAGED
5
CR 1
12 SOL 1 2 ENGAGE
6 SPINDLE CLUTCH
PS 1 13 1
7 FEED CLUTCH
TR ENGAGEMENT DELAY

4 TR 1 14 SOL 2
8 ENGAGE
FEED CLUTCH
15 WARNING
9 KLAXON
FAST SLOW
CR 1 16 SOL 3
10 SPINDLE AT
HIGH SPEED
17 SOL 4 2
SPINDLE AT
LOW SPEED

4 2

4
 Introduction to Programmable Logic
Controller
• A programmable controller is a special purpose
industrial computer for monitoring and controlling
industrial processes.
• PLCs utilize a specialized machine control
programming language.
• A PLC is designed for adverse industrial
environments.
• A PLC solves its program automatically
• PLCs replace electromechanical relays with less
expensive solid state components.
5
Basic Structure of PLCs

STATE
INPUT RAM
MODULE I
N
T IOP CPU
F
C
OUTPUT
MODULE USER’S
LOGIC

PROGRAMMING PANEL COMM.

OR HOST COMPUTER PROC.

6
Basic Structure of PLCs

STATE
INPUT RAM
MODULE I
N
T IOP CPU
F
C
OUTPUT
MODULE USER’S
LOGIC

PROGRAMMING PANEL COMM.

OR HOST COMPUTER PROC.

7
A Relay Control Example

1 2
MASTER MASTER
STOP PB START PB 3 4 5
FLS 1 PS 1 5 SEC
TR1 WARNING DELAY

1M1 TR1 7
WARNING HORN
6
10 1M HYDRAULIC PUMP
MOTOR STARTER

8 9

Typical Motor Control Circuit

8
Input Module Wiring Example
INPUT
1 MODULE 2
%I1.1
%I1.2

%I1.3
%I1.4

9
Output Module Wiring Example
OUTPUT
MODULE 4
3
%Q2.1
%Q2.2
1M

10
Motor Control Example using Ladder Logic
Software
1 2
%I1.1 %I1.2 %I1.3 %I1.4
5 %Q2.2
%TM0 8
IN TM
Q
%Q2.2 MODE :
3 4 TON
9
TB : 1s
TM.P : 5
10
%Q2.2 %Q2.1

6 7

11
Relational Diagram of Field I/O and Ladder Logic
INPUT OUTPU
MODULE
2 3
MODUL
T 4
1
%I1.1 E %Q2.1
%I1.2 %Q2.2
%I1.3 PLC 1M

%I1.4
User
Logic

1 2
5
%Q2.2
%I1. %I1. %I1.3 %I1. 8
1 2 4 %TMi
MODE : TON
%Q2.2 3 4 TB : 1 s 9
TM0.P: 5
MODIF : Y
10
%Q2.2 %Q2.1

6 7

12