CONTROLLERS

LOGIC
P R O G R A M M A B L E

LOOK AT
AN OVERALL

-1
INTRODUCTION
logic (PLC We then
controller
we describe a programmable
In this introductory chapter.
the present-day PIc
computer systems into We
discuss the evolution ofrelay logic and disadvantages of using a PLC over other
c"
trol
and
s o m e advantages
also list and discuss PLC programming and operatin
is
the knowledge level required for
systems. Finally.
evaluated.
and modules that
make up a PLC control svsteem
We also describe the components includes
e n c i o s u r e s . each of which
is housed in one or poOSSiDIy two
A simple PLC system a large process, may have three to
unctions. A more complex PLC, controlling
multiple the PLC subsystems,.
interconnected enclosures containing
five or more separate
shown, as are general connection
of the various subparts of a PLC are
lllustrations
various PLC parts are described in general
paths. The electrical interconnections of the
terms.Details of the connections are discussed in chapter 27.
Most PLC electrical connecting is easily done with single cables between units. How-
ever connecting the input/output (1/O) modules to the outside world can be fairly compli
cate /O module connections to the processes are discussed in this chapter and throughout
the book. The proper setting of module switches is also described in this chapter.
Today, the industrial computer is available to carry out PLC programming and. in
some cases. take the place of a PLC Used as a sophisticated programming device. the
computer must be able to run PLC software that allows it to operate as a PLC. When
functioning as a full-fledged PLC, the computer has to have. of course, some way to re-
ceive information from sensors and transducers and. in
turn, to actuate relays, coils, lights.
and These
motors. personal computer systems are also discussed herein.
PLC systems operate at
different computer rates. The rate, commonly called the bulud
rute, depends on what parts of the PLC system are
later in the chapter. communicating.
We discuss baud rates

1-2 DEFINITION AND HISTORY OF THE

PLC
Originally. the PLC was represented by the
confusion with using the acronym PC. As you can
computer. Therefore, PLC
acronym, as PC is, imagine,
today, commonly accepted soonal there was me

is now
APLC is a understood to mean to
represent pe
user-friendly, programmable logic controller out
many typesmicroprocessor-based
control functions of
specialized
complexity. lts computer that caricucia!
process parameters and and levels of
controlled, and operatedadjusta process operations purpose is to monitor
nonetheless, PLC-literate. by person unskilled inaccordingly. It can be progra
ladder Essentially, a PLC's operator operating computers, bu
into diagrams
with a
computer machine keyboard onto a
display draws the lines and f
devi
computer takeslanguage
The and run as a screen, The resulting
the place of user drawing 1s Co verted
process. The PLC will much of program.
as
discrete, or digital, operate any system that the external wiring ol of a
The PLC can outputs). It has
output devices required 1or
be can also
variable (analog) operated on the input operate any system with that go on an noWn
input devices. side by
on-off devices variable (anaio
(analog) outputs.
or by
(discrete, or ag
 DEINITION AND UISTORY OF THE PLC

Tday.the big unit growth in the PLC

industry is at the low end-where small keeps
geting smaller. When a few years ago the
micro PLC entered the market, some thought
that these devices had "bottonmed out."
Now, nano PLCs-generally defined as those with
16or fewer /0are spreading. Some can fit into your shirt pocket, being no larger than a
deck of cards. in faet, PLCDirret has introduced a
PLC the size of a box of Tic-Tac candy
that includes many features of current micro
models.
The tirst PLC systems evolved from
conventional computers in the late 1960s and
early 197Os. These tirst PLCs were installed primarily in automotive
the auto plants had to be shut down for plants. Traditionally.
up to a month at model changeover time. The early
PLCs were used along with other new automation
time. One of the major
techniques to shorten the changeover
or revised
time-consuming changeover procedures had been the wiring of new
relay and control panels. The PLC keyboard reprogramming procedure replaced
the rewiring of a panel full of wires.
relays, timers. and other components. The new PLCs
helped reduce changeover time to a matter of a few days.
There was a major
problem with these early 1970s computer/PLC
procedures. The programs were complicated and required a highly trained reprogramm1ng
programmer to
make the changes. Through the late 1970s,
make them somewhat more user
improvements were made in PLC programs to
friendly: 1972, the introduction of the microprocessor
in
chip increased computer power for all kinds of automation systems and lowered the com-
puting cost. Robotics, automation devices, and compuiers of all ypes, including the PLC.
consequently underwent many improvements. PLC programs, written in high-level lan-
guage, became more understandable to more people, and PLCs became more affordable.
In the 1980s. with more computer power per dollar available. the PLC came into
exponentially increasing use. Some large electronics and computer companies and some
diverse corporate electronics divisions found that the PLC had
become their greatest
volume product. The market for PLCs grew from a volume of $80 million
in 1978 to $1
billion per year by 1990 and is still growing. Today it is close
to $I.4 billion. Even the
machine tool industry, where computer numerical controls (CNCs) have been used in the
past. is using PLCs. PLCs are also used extensively in building energy and security control
systems. Other nontraditional uses of PLCs, such as
in the home and in medical equipment,
have exploded and will increase further in the new millennium.
A person
knowledgeable in relay logic systems can master the major PLC functions
in few hours. These functions might include coils, contacts, timers,
a
and counters. The
same is true for a
person with a digital logic background. For persons untamiliar with
ladder diagrams or digital
principles, however, the learning process takes more tie.
A person knowledgeable in relay logie cun master advanced PLC funetions in a few
days with proper instruction. Company schools and operating uanuals are very helptul in
astering these advanced functions. Advanced functions in order of leaning might include
sequenceldrunm controller, register bit use, and move funetions.
Figure 1-I shows an older relay-type control panel used in process control. t is large
and contains lots of wiring, interconnections, and relays, which can have maintenance prob-
lems. Figure 1-2 shows a lypical PLC, which replaces the relay pnel and pertorms the same
logic control task. Of course, he wiring to the process is the same for each type of control.
However, the PLC is smaller and more reliable. For control system logie changes, the relay
panel must be rewired, whereas the PLC is quickly reprogrammed for any changes.
 wwwww
FIGURE1-1
Relay Panel for Logic Control
FIGURE 1-2
PLC or
logic Conrol (Courtesy of Modicoan(
 M.ANUFACTURING AND ASSEMBLY PROCESSES
1-3 MANUFACTURING AND ASSEMBLY PROCESSES
In an industrial setllmg. PLOCs are used to autonate manulacturing and
assenbly processes.
B p e s . ne mean a step by step procedure wlhereby a product is manulactured and
embled. ltis the espmsibility of the product engincerng (P'L) department to plan for
the manufature of new o moditied products. Acconding to Rehg and Kraebber. in their
boo.Conpuier-lutegrated M:anufacturing. 2nd ed. the PE plan has seven elements:
1. Process planning
Poduction machine programming
Tool and tinture
engineering
4. Work and production standards
5. Plant engineering
6. Analysis lor manulacturability and assembly
7. Manutfacturing cost estimating
ALYprcal manufacturing process is illustrated in tigure 1-3. Other proceses might
imvolke the tilling and capping of botles, the printing of newspapers. or the assembly of
automobiles. The list is endless. In many such manufacturing situations. PLCS play an
mportant role in carrying out the various processes.
FIGURE 1-3
"ypical Manufacturing Process (Courtesy of Giddings & Lewis Controls)
 L
AN OVERALL LOOK AT PROGRAM
PLC ADVANTAGES AND DISADVANTAGES
Following are 13 nmajor advantages of using a programmable controller:
Flexibility. In the past, each diflerent clectronically controlled production ma
requird its own contnoller: 15 machines might require 15 dilferent controllers. N machine
possible to use just one model of a PLC to un any one of the 15 machines. Furtherm.
Now it is
vou would pnibably need fewer than 15 controllers, because one PLC can easily run mo
machines. Each of the 15 machines under PLC control would have its own di
tinct
program.
Implementing Changes and Correcting Errors. With a wired
relay-type panel, anv
program alterations require time for rewiring of panels and devices. When a PLC proora
circuit or sequence design
change is made. the PLC program can be changed from a
keyboard sequenee in a matter of minutes. No rewiring is required for a
stem. Also, if a proyramming error has to be corrected in a PLC control
PLC-controlled
ladder diagram.
a
change be typed in quickly.
can
Large Quantities of Contacts. The PLC has a large number of contacts
available in its for each coil
in use when a
programming. Suppose that a panel-wired relay has four contacts and all are
design change requiring three more contacts is made. Time
would have to be
taken to procure and install
three more contacts would be
a new
relay or relay contact block. Using a PLC, however. only
typed in. The three contacts would be
the PLC. Indeed, a
in
hundred contacts can be used from one automatically available
memory is available. relay-if sufficient computer
Lower Cost. Increased
smaller and less technology makes it possible to condense
expersive packages.
Now
more functions into0
imers, and counters, a you can purchase a PLC with
ith numerous
sequencer, and other functions for numerous relays.
relays.
Pilot under a hundred dollars.
Running. A PLC
programmed circuit can be
lab. The prerun and
program can be
typed in, tested, evaluated in the oftnee
factory ime. In contrast, observed, and modified if needed, saving
conventional
fioor. which can be
very time
relay systems have been best tested on thevaluabi
Visual
consuming. rac
Observation. APLC circuit's
CRT
screen. The operation or operation can be seen
Logic path: misoperation of during operation dire ly on a
light circuit can be observed as it ns
up a
on the screen ens.
quickly dunng Visual as they are energized. happ
In advanced
observation. Troubleshooting can be do
PlC
ble systems,
malfunction. The maltunction
an
operator
message can be
appears on the programmed
is
detected by the PlC deseription tor
c
PLC logie (lor
sy slems also
have example, "MOTOR #7 IS sereen when the
example, nput #l nay
n the deseriptions of the OVERLOADED).
DED"). Advanced
A t. For
diagrain as desenpion. diagram could have funetion of
a each circuit
com
Speed of Operation. "CONVEYOR LIMIT SWITC an the
operational speed tor theRelays can take an
is
determnined PLC
by scan ume, program is very fast. unacceptable
amount of timme actuate.
The
which is The to
a
matter of speed for the PLC 1OE ner operation
milliseconds.
PLC ADVANTAGES AND DISADVANTAGES
Ladder or Boolean Programming Method. The PLC
programming can be accom-
plished in the ladder mode by an electrician or technician. Alternatively, a PLC program-
mer who works in digital or Bovlean control
systems can also easily perform PLC
programming.
Reliability and Maintainability. Solid-state devices are more reliable, in general, than
mechanical systems or relays and timers. The PLC is made of solid-state components with
very high reliability rates. Consequently. the control system maintenance costs are low and
downtume is minimal.
Simplicity of Ordering Control System Components. A PLC is one device with one
delivery date. When the PLC arrives, all the counters, relays, and other components
also arrive. In designing a relay panel, however, you may have 20 different relays and
timers from 12 ditferent suppliers. Obtaining the parts on time involves various deliv-
erydates and availabilities. With a PLC you have one product and one lead time for
delivery. In a relay system, forgetting to buy one component would mean delaying the
startup of the control system until that component arrives. With the PLC, one more
relay is always available-provided that you ordered a PLC with enough extra
computing power.
Documentation. An immediate printout of the true PLC circuit is available in minutes, if
required. There is no need to look for the blueprint of the circuit in remote files. The PLC
prints out the actual circuit in operation at a given moment. Often, the file prints for relay
panels are not properly kept up to date. A PLC printout is the circuit at the present time; no
wire tracing is needed for verificatioD.
Security. APLC program change cannot be made unless the PLC is properly unlocked and
programmed. Relay panels tend to undergo undocumented changes. People on late shifts do
not always record panel alterations made when the office area is locked up for the night.
Ease of Changes by Reprogramming. Since the PLC can be reprogrammed quickly.
mixed production processing can be accomplished. For example, if part B comes down the
assembly ine while part A is still being processed, a program for part B's processing can
be reprogrammed into the production machinery in a matter of seconds.
These 13 items are some of the advantages of using a PLC. There will, of course. be
other advantages in individual applications and industries.
Following are some of the disadvantages of, or perhaps precautions involved in,
using PLCs:
Newer Technology. It is difficult to change the thinking of some personnel trom ladders
and relays to the PLC computer concept. Although today, with the pervasive use of
on the factory floor, acceptanee of the
computers not only at home and in the office but
a powerful and reliable productivity-enhancing tool is, if not
universal, almost
computer as
so. Electricians and technicians are lining up to take courses on PLCs because they know
that doing so contributes to job security and advancement
It does
Fixed Program Applications. Some applications are single-function applications.
are not
not pay to use a PLC that includes multiple programming capabilities if they
AN OVERALL LOOK AT PROGRAMMABLE LOGIC CONTROLLERS
necded. One example is in the use of drum controller/sequencers. Some equipment manu
facturers still use a mechanical drum with pegs at an overall cost advantage. Their opera-
tional sequence is seldom or never changed. so the reprogramming available with the PLC
would not be necessary.
Environmental Considerations. Certain process environments, such as high heat and
vibration. interfere with the electronic devices in PLCs, which limit their use.
Fail-Safe Operation. In relay systems, the stop button electrically disconnects the circuit.
if the power fails. the system stops. Furthermore, the relay system does not automatically
restart when power is restored. This,
of course, can be programmed into the PLC: however.
in some PLC programs. you may
have to apply an input voltage to cause a device to stop
These systems are not fail-safe. This disadvantage can be overcome by
adding safety relays
to aPLC system, as shown later in this text.
Fixed-Circuit Operation. If the circuit in operation is never altered. a tixed
system (such as a mechanical drum) might be less
contro
costly than a PLC. The PLC 18 mos
effective when peiodic changes in operation are made.