Introduction To

PLC System
Prepared by: Aftas Azman
jke/psa/jun2012
Introduction
Before we learn PLC , first we have to
study as follows :

PLC Definition
PLC Background
PLC Function
PLC Types
PLC Advantage
PLC Hardware Design
PLC Definition
The PLC, also known as programmable controller
is defined by the National Electrical Manufacturers
Association (NEMA) in 1978 as:

A digitally operated electronic apparatus which
uses a programmable memory for the internal
storage of instructions for implementing specific
functions such as logic, sequencing, timing,
counting, and arithmetic to control, through digital
or analog input/output modules, various types of
machines or processes.
- National Electrical Manufacturers Association (NEMA)
PLC Background
Early factor that intend to design and
develop programming control systems are:

Lower cost
Usage intelligently
Easy to control
First PLC been designed by a team of
engineers in General Motor (GM),
United States in year 1968 when that
company find another method to
change complicated relay control
system.

They also has prescribed that new control
system specification needs :

Easy to programmed

No need to rewiring the control system when
changing the programmed

Smaller, cheap and high efficiency.

Shorter time to developed and low cost in
maintenance.

Competitive cost.
Function and type of PLC
Function
PLC can perform various functions, as
follows :
Sequential Control
Function:

a. Conventional Logic, Eg. Relay Control
b. Timer / Counter
c. Control Card, Eg. Printed Circuit Board
d. Machine Control and Automatic Control,
semi-automatic and Manual Process
Sophisticated control
Function

a. Resolve Mathematical Operation
b. Manage Information
c. Analog Control ( temperature, pressure ect. )
d. Servo Motor Control
e. Stepper Motor Control
f. P.I.D Control
( Proportional Integral - Derivation )

Supervision control
Function

a. Display process and Alarm
b. Diagnosis and Fault Display
c. Interface with Computer ( RS 232C / RS 422
d. Printed interface / ASCII
e. Factory Automation Network
g. Local Area Network (LAN)
h. Wide Area Network (WAN)
i. Factory Automation (FA), Flexible machine
supervision (FMS), computer integrated
machine (CIM) ect.
PLC fabrication
Compact PLC
PLC Plug in Card
Modular PLC
12
Compact PLC
Omron
Mitsubishi
Zelio
TECOMAT
TC600
13
Modular PLC
Omron
Mitsubishi
Eaton
14
Plug in card PLC
Initial Specifications
The new control system had to be price
competitive with the use of relay systems.
The system had to be capable of sustaining an
industrial environment.
The input and output interfaces had to be
easily replaceable.
The controller had to be designed in modular
form, so that subassemblies could be removed
easily for replacement or repair.
Initial Specifications
The control system needed the capability to
pass data collection to a central system.
The system had to be reusable.
The method used to program the controller had
to be simple, so that it could be easily
understood by plant personnel
Recent PLCs
Changes include both hardware (physical
components) and software (control program)
upgrades
Faster scan times are being achieved using new,
advanced microprocessor and electronic technology.
Small, low-cost PLC, capable of replacing four to ten
relays, now have more power than their predecessor,
the simple relay replacer.

PLC Advantages
Short period project
implementation
Easy to modify the
programming.

Fixed project cost.

Need short training time.

System control design can be
changed by using software.

Wide Control application.


Easy maintenance.

High reliability.

Standard hardware
accessory.

Resilience to environmental
problem process eg.
temperature, moisture, noise
and voltage instability ) .

PLC Advantages and Disadvantages
Advantages Disadvantages
Many inputs and outputs, excellent for
controlling and monitoring many
processes
Do not use the full capabilities of the
microprocessor
Designed for industrial environments,
robust and reliable
Ladder logic programming style is
cumbersome and prone to mistakes
Reprogrammable Only good for yes/no decisions
Modular Do not handle continuous inputs and
outputs, not good for direct control
Ideally suited to supervisory control Inflexible (compared to microprocessors)
Easy to set up, good for FMS
environment
PLC design and devices
Hardware of the PLC
Hardware of the PLC are
only consist of several
components; such as Power
Supply Unit, CPU Unit,
Memory Unit and I/O Unit.

At the small PLC; Power
Supply, CPU, Memory and
I/O stay in the same Unit but
at the big PLC; Power
Supply, CPU, Memory and
I/O in the separate Unit.

PLC - CPU
CPU controller processing unit
This unit are most important unit in a PLC.
Microprocessor chip in this unit control overall PLC
operational process. Microprocessor contain arithmetic
unit, control unit and a few memory number of units
which known as registrar.
Memory
There are two types of memory in the PLC

1. Random access memory (RAM)

2. Read only memory (ROM)
RANDOM ACCESS MEMORY
RAM is read / write memory type and easy
programmed and repaired.

All user programming kept in this memory.

The programming will be lost when no
power supply in to RAM.
READ ONLY MEMORY
ROM is just read memory type. System
program kept in this memory.
The program will not lose when no power
supply in to him.
Need special equipment to cancel the
program.
Input and Output unit
Input and output unit are
unit at the internal PLC
design.
Input unit is where input
device ( switch, sensor )
connect to it.
While Output Unit is the unit
for output device ( light,
motor ) connect to it.
DISPLAY AND INDICATOR UNIT
Display and indicator unit referring to PLC
internal relay and standard display.
This can be display at programming
console if used mnemonic code and
computer screen if used programming
software.
Housing unit
This unit are protecting the PLC circuit and
internal component.
Programming unit
Programming unit consisting of two type:

Programming Console.

Computer.
Programming unit
Hand-held programming devices are sometimes used to
program small PLCs
They are compact, inexpensive, and easy to use, but are not
able to display as much logic on screen as a computer monitor
It is often used on the factory floor for troubleshooting,
modifying programs, and transferring programs to multiple
machines

A personal computer (PC) is the most commonly used
programming device
The software allows users to create, edit, document, store and
troubleshoot programs
The personal computer communications with the PLC
processor via a serial or parallel data communications link

Programming unit
SECONDARY STORAGE UNIT
This unit correlated with CPU where all
program and information are stored.
Video Display Unit
This unit process operational information
and display system status by PLC.
Power Supply Unit
This unit provide power to CPU, Input and
Output.
Printing Unit
This unit used to print control system
program that controlled by PLC in
graphically or text format.
Input Devices

PLCs can receive input from either automated or manual devices.
The PLC could receive data from the user via a pushbutton switch,
keyboard, or similar device.

Automated input could come from a variety of devices:
microswitches, timers, encoders, photosensors, and so on. Some
devices, like the Limit Switch shown below, turn ON or OFF when
the equipment actually makes contact with it.

Other devices, like the Photoelectric Switch and Proximity Switch
shown below, use other means, such as light or inductance, in order
to get information about the equipment being monitored.

Output Devices

A PLC can output to a myriad of devices for use in automated
control. Almost anything that you can think of could be controlled
(perhaps indirectly) by a PLC.

Some of the most common devices are motors, Solenoids,
Servomotors, Stepping Motors, valves, switches, indicator lights,
buzzers, and alarms.

Some of these output devices; such as the motors, Solenoids,
Servomotors, Stepping Motors, and valves; affect the controlled
system directly. Others; such as the indicator lights, buzzers, and
alarms; provide output to notify personnel.

PLC wiring system
Normally PLC Supply Voltage are 240VAC or
24VDC.
PLC are also used +24VDC or -24VDC as
common supply to the PLC.
If PLC used +24VDC common supply, I/O
devices will used -24VDC supply as their
common.
If PLC used -24VDC common supply, I/O
devices will used +24VDC supply as their
common.



PLC wiring system
INPUT
DEVICES
OUTPUT
DEVICES
Step 1: Connect the PLC to the +24VDC common
Step 2: Connect the Input Devices to the -24VDC
common
Step 3: Connect the Output Devices to the
-24VDC common
Step 4: Connect each Input Devices to Input
Module
Step 5: Connect each Output Devices to Output
Module