What is PLC? Programmable logic controller A programmable control system with functions to control logic, sequencing, timing, counting and arithmetic data manipulation Heart of the control system replace electromechanical relays as logic elements, substituting instead a solid state digital computer with a stored program electromechanical relays Tedious work in installation and troubleshooting Higher maintenance cost Difficulty in changing system operation 1960’s Bedford Associates released – MODICON Modular Digital Controller Advantages of PLC 80 % wire reduction Fast and easy detection of error Easy system operation change Cheaper Reliabilty is greater- less moving part Occupy lesser space Communication capability Faster response time Components of the PLC Processor (CPU) Is the “brain” of the PLC Consists of a microprocessor for implementing the logic, and controlling the communications among the modules Designed so the desired circuit can be entered in relay ladder logic form accepts input data from various sensing devices, executes the stored user program, and Sends appropriate output commands to control devices. Programming Device PC is the most commonly used programming device software allows users to create, edit, document, store and troubleshoot programs Input modules Forms the interface by which input field devices are connected to the controller Output modules Forms the interface by which output field devices are connected to the controller PLC Mixer Process Control Problem Mixer motor to automatically stir the liquid in the vat when the temperature and pressure reach preset values Alternate manual pushbutton control of the motor to be provided The temperature and pressure sensor switches close their respective contacts when conditions reach their preset values Ladder Diagram PLC Input Module Connections PLC Output Module Connections PLC Ladder Logic Program Modifying A PLC Program