Introduction To Programmable

Logic Controllers
The concept: a machine that can be started from two remote places
 Inputs

Program

Outputs
 Inputs and Outputs Devices
Inputs Outputs
• Push Buttons • Motors
• Solenoids
• Proximity switches • Indicator lamps
• Photoelectric sensors • Resistive loads
• Temperature sensors • Contactors
• Pressure sensors

Push button Photo Pressure Motor

Sensor Sensor
 Relays

- +

+
-
Programmable Logic Controllers

Box Type Modular or Rack Type

 Typical PLC Applications
• Coin-Operated Carwash
• Conveyor Diverter Control
• Greenhouse Irrigation
• Lumber Mill Operation
• Oil recovery systems
 Three Phase Converter

• A machine requires
three phase power to
operate but only two
phase power is
available.
• A power converter must
be built using a three
phase converter.
Three phase
converter
 220 VAC
Converter Operation
• The power is
Power On/Off
switched on Switch

• To start the
converter’s Momentary
push button
motor the push
button is held for Starting
capacitor
1 to 2 seconds
3-Phase
converter
 3-Phase Converter

Remote
Lamp
Remote
Stop Stop 2-Pole
Remote Contactor
Start

Start Timer 1-Pole

Start
Relay Relay Contactor
3-Phase Converter
 3-Phase Converter
Start 2-Pole
Contactor
Remote
Start 1-Pole
Stop
PLC Contactor

Remote Remote
Stop Lamp
 Example: Process Safety
Pressure Emergency Release

Pressure
Pressure 10 Second
Solenoid Release
Sensor Timer
Valve

Counter
 Example Process

Sensors, PLC
Emergency (programmable Solenoids
Shut off logic controller)
A PLC replaces the wiring between input and
output devices. Instead of being wired
together, all equipment is wired to the PLC.
The logic implementd through wiring is now a
program inside the PLC

All Input All Output

PLC
Devices Devices
Programmable Logic Controllers
• PLCs (Programmable Logic Controllers) is
a miniature industrial computer performs
control functions [4]
• The first PLCs can be traced back to 1968
and became popular in the 1980’s [4]
• PLCs are rugged and designed to
withstand the industrial environment.
 Components of a PLC

Inputs
• Inputs
• CPU
• Memory CPU Memory
• Outputs

Outputs
 PLC Inputs and Outputs
Optoisolator
• Analog, Discrete or
Digital
• Protected by
Optoisolators
• Sourcing and Sinking
• Communications
 PLC Operation
• Scanning is the
process of running Check Input Status
the PLC program
• Cycle time is the total
time for one loop. Execute Program

Update Output Status

 PLC Programming
• Ladder logic is the main programming
method used for PLCs [39]
• It is a visual and symbolic programming
language that resembles relays logic
diagrams
• Ladder logic has been developed to mimic
relay logic to reduce amount of retraining
needed for engineers and trades people
[39]
 Ladder Logic
Button
• Compare a
circuits
Relay
diagram to a
ladder logic 24 V DC Motor
Input
diagram

Button Motor

Power Rails
Ladder Logic

Rung 1
Rung 2
Rung 3
Rung 4

Power Rails
 Ladder Logic
• Ladder logic uses a
variety of
Power rails
programming
symbols
Normally
• Power always flows Closed Contact
from left to right
Normally
• Output devices are Open Contact
in the ON state if
power flows through Output
Device or Coil
them
 Contacts
Power flows when
Contact
programmed
the input device is
normally open on

Power flows when

Contact
programmed the input device is
normally closed
off
 Ladder Logic
Button Motor
Motor output

Motor Off lamp

Contacts
Lamp for power
not applied
Motor On lamp

Lamp for power

applied
 Ladder Logic
Start Stop
button button Motor
• Latching is the
term for a self-
maintaining Motor
circuit.
 Pressure Pressure
sensor
emergency release Timer

PLC ladder
logic Counter

program Timer Solenoid

Wiring Pressure
sensor Solenoid
diagram
- + PLC + -
for PLC
Wiring diagram for PLC

Pressure
Sensor
- +
Safety
Sensor Solenoid
- + -
+
PLC
Manual
shut off
- +
PLC ladder logic program

Sensor Timer

Counter

Safety Manual
Timer sensor shut off Solenoid
 Industrial Mixer

• Filled with liquid

• Heated
• Mix for 10
minutes.
Sequential Function Chart
Fill with
State 1 liquid
Level full switch

State 2 Heat
Temperature Switch

State 3 Rotate
Timer
 Start
button Pump

1 1
Level full
Heater
floater
2 2
Temperature PLC Mixing
Motor
sensor

3 3
 Level full
Start button floater Pump

State 1 Pump

Level full Temperature

floater Sensor Heater

State 2
 Temperature
10 minute
Sensor
Timer

State 3
10 minute Mixing
Timer motor
 Ladder Logic
• Forcing
• Time checks
• Simulation
• Software testing
 Ladder Logic
• Registers and bits
• Data comparison
• Arithmetic operations
• Functions
• PID control
 PLCs solve problems
• Flexible
• Cost effective
• Computational abilities
• Trouble shooting
• Reliable
Questions?