Programmable Logic Controllers

Fundamentals

By

Engr. Kufre Esenowo Jack

Engr. Kufre Esenowo Jack 1
 Introduction
PLCs are solid state device which controls industrial processes
based on input instructions given to the controller.

Programmable Logic Controllers (PLC) are often defined as

miniature industrial computers that contain hardware and
software used to perform control functions. More specifically, a
PLC would be used for the automation of industrial
electromechanical processes, such as control of machinery on
factory assembly lines, amusement rides, or food processing.
They are designed for multiple arrangements of digital and
analog inputs and outputs with extended temperature ranges,
immunity to electrical noise, and resistance to vibration and
impact. A PLC will consist of two basic sections: the central
processing unit (CPU) and the Input/Output (I/O) interface
system. Engr. Kufre Esenowo Jack 2
 PLCs Operational Steps & Advantages
Operational Steps Advantages
i. Input Scan :Detects the state of all i. Flexibility
input devices that are connected to
the PLC ii. Ease of Troubleshooting
ii. Program Scan : Executes the user
created program logic iii. Space Efficient
iii. Output Scan : Energizes or de-
energizes all output devices that are iv. Low Cost
connected to the PLC
iv. Housekeeping : Includes v. Testing
communicating with programming
devices and performing internal vi. Visual Observation
diagnostics
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Component Parts of a PLC
1. The Central Processing Unit (the CPU) contains
an internal program that tells the PLC how to
perform the following functions:
▪ Execute the control instructions contained in
the User's Programs. This program is stored in
"nonvolatile" memory, meaning that the
program will not be lost if power is removed
▪ Communicate with other devices, which can
include I/O Devices, programming devices,
networks, and even other PLCs.
▪ Perform housekeeping activities such as
communications, internal diagnostics, etc.
2. Inputs are the set of ladder instruction given to
the PLC using ladder logic.
3. Output devices are motors solenoid valve,
motor starters, light indicators, which are
hardwired and connected to the output module.

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 Types of PLC
Fixed PLC Modular PLC
These are used for small scale These are used for medium scale
industry, it is not expandable. The industry and it is expandable. The
maximum input and output is maximum input and output is
about 208. about 2048

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 Types of PLC cont.
Rack PLC
This is used for large industry, it is expandable. The maximum input and
output is about 16000. This PLC is arranged in parallel such that if one
rack is bad, other racks can still be functional.

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 Brands of PLC
• AB - Allen Bradley • KEYENCE
• ABB - Asea Brown Boveri • OMRON
• SIEMENS • GE-FANUC: General Electric
Factory Automation
• MITSUBISHI Numerical and Coding Control
• SCHNEIDER • MESSUNG PLC
• GSM • TOSHIBA
• TELEMICAQUE
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 Programming Languages Used for PLCs
• Ladder Diagram Language [LD]

• Functional Block Diagram [FBD]

• Sequential Function or flow Chat [SFC]Language

• Instruction List [IL]

• Structural Text [ST]

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Basic Ladder Logic Symbol

Engr. Kufre Esenowo Jack 9

 The AND function The OR Function

Ladder Logic equivalent of AND Function

Electrical Circuit equivalent of AND Function

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Hands on 3hours Practical Session

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