PLC IN ACTION

STUDENT NAME: Alec Lopez Salutem

STUDENT NUMBER: 1810333

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

What is a PLC?

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

Programmable Logic Controller (PLC)
• PLC is a computer specially designed to operate reliably under harsh
industrial environments – such as extreme temperatures, wet, dry,
and/or dusty conditions.
• An electronic device capable of programmable functions for specific
uses in the industry.
• PLC can perform discrete and continuous functions that a PC cannot
do, and a PLC is much better suited to rough industrial environments.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 PLC Functions

One of the basic function of PLC is to emulate an electromechanical

relay functions.
The difference of PLC to a relay is far more advance with its
programmable feature and logic designing.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 PLC Advantages

Flexibility to modify the input control logic.

It analyzes changes in the process parameters.
It is cost effective for controlling complex systems.
Has a lot of input and output ports.
High reliability in control systems.
Communication Capability.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Example
Task that when you turn ON the switch, the light should glow only after 30 seconds.

• Imagine you have a light connected to a

switch.
• the light operates under two conditions –
ON and OFF Programming the PLC to only turn on the light 30 seconds after
the switch is turned ON.
The only way to achieve this is to completely rewire our circuit to
add a timing relay. That’s a lot of hassle for a minor change. So, by using a PLC, it is easy to incorporate multiple inputs and
outputs.
Electronics 3: Electronic Systems and Design R.A. ALIMUIN
 PLC Block Diagram

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Physical
Structure of
PLC

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 A typical block diagram of PLC
consists of five parts

• Rack or chassis
• Power Supply Module
• Central Processing Unit (CPU)
• Input & Output Module
• Communication Interface Module

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Rack or Chassis

• The PLC rack or chassis forms the most

important module and acts as a backbone to

the system.

• When more complex control systems are

involved, it requires larger PLC racks.

• Small-sized PLC is equipped with a fixed I/O pin

configuration. So, they have gone for modular

type rack PLC, which accepts different types of

I/O modules with sliding and fit in concept.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Power Supply Module

• used to provide the required power to the whole PLC system

• It converts the available AC power to DC power which is required by the CPU and I/O module

• PLC generally works on a 24V DC supply

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Input and Output Module
The input module of PLC does four main functions.

• Input module interface receives the signal from

process devices at 220 V AC

• Converts the input signal to 5 V DC that can be used

by PLC

• Isolator block is used to isolate/prevent PLC from

undergoing fluctuation

• After which the signal is sent to the output end i.e the
PLC

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Input and Output Module

The output module of PLC works similarly to

Circuit Diagram of PLC Input Module
the input module but in the reverse process.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Types of PLCs

• Programmable Automation

• Compact PLC Controllers (PACs)

• Modular PLC • Programmable Controller

• Programmable Logic Relays (PLRs) Configurations

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

Fixed/Integrated/Co
mpact PLC

• This type of PLC is most commonly called the Fixed I/O PLC.
• “Fixed I/O” actually stands for Fixed “Input/Output”. When you buy Compact PLCs, you will notice that the
input section and the output sections of the PLC are integrated into the microcontroller itself.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Modular PLC

• The modular PLC is a type that allows multiple expansions of the PLC system through the use of modules, hence
the term “modular”.
• Modules give the programmable logic controller additional features like increased number of I/O units, and they are
usually easier to use because each component is independent of each other.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 advantages of using Modular PLC
• Scalability - can always add modules over and over again
• Number of I/Or - because the Modular PLC is scalable, the number of input devices to be scanned by the PLC, as
well as the number of output control capability that it has, is way higher than the Fixed I/O PLC.
• Easier Fault Detection - because each function is separated by each module of the Modular PLC.
• Less Downtime - easier to repair because the modules have separate systems.
• Module Combinations - you can mix and match the different modules however you want to achieve a system goal.
• Memory - modular PLCs are capable of having memory expansions for higher storage capacity.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Programmable Logic Relays (PLRs)

A programmable logic relay (PLR) is a solid-state control device that includes internal relays, timers, counters, and other control
functions that can be programmed and reprogrammed to automatically control small residential, commercial, and industrial circuits.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Programmable Automation Controllers (PACs)

A programmable automation controller (PAC) is a combination of a PLC and a PC-based CPU control device that is
designed to operate in an industrial environment.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Programmable Controller Configurations

The configuration of a programmable controller’s system is determined by the type and quantity of required I/O devices, required
communication between devices, programming types and requirements, and any future needs.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

Programmable Logic Controller (PLC) Industrial Applications

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 PLC Timer Applications
Four on-delay stand-alone timers are used for a basic stoplight timing sequence application.

• The red lamp turns on for 30 sec.

• The red lamp turns off and the yellow lamp turns on for 5 sec.

• The yellow lamp turns off and the green lamp turns on for 40 sec.

• The green lamp turns off and the yellow lamp turns on for 5 sec.

• The yellow lamp turns off and the red lamp turns on for 30 sec.

• Timer 4 resets the circuit and the sequence start over.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN
 PLC Timer Applications
A programmable timer line diagram is automatically drawn on the computer screen as the circuit
is programmed.

• The inputs are addressed as I: 0.0-0 (stop button) and I: 0.0-1 (start button).

• The outputs are addressed as 0:0.0-0 (red lamp), 0:0.0-1 (yellow lamp), and 0:0.0-2

(green lamp).

• The relays are addressed as B3-0 (first relay), and B3-1 (second relay).

• The timers are addressed as T4:1 (timer 1), T4:2 (timer 2), T4:3 (timer 3), and T4:4

(timer 4).

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Input and Output Address Identification

Numbers and letters are used to assign addresses to inputs, outputs,

timers, and other internal and external components. The numbering/letter
assignments are made as follows:
I = Input (pushbutton, limit switch, etc.)
O = Output (solenoid, lamp, motor starter, etc.)
T = Timer (internal PLC timer)
C = Counter
: = Slot number (physical slot number [1, 2, 3, etc.] of the I/O module)

For example, I:0/1 identifies an input in slot number 0 at terminal 1 and

0:0/4 identifies an output in slot number 0 at terminal 4.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Welding

Programmable logic controllers can be used to control and automate industrial welding processes.

The controller can be used to determine whether parts are running low and can be set to automatically turn the line on and off
as required.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Machine Control
Controls must be synchronized when machines are linked together to form an automated system.
Controllers are used to controlling and synchronizing individual machine operations with other
machines.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Industrial Robot Control

A PLC can be used to control all operations such as rotate, grip,

withdraw, extend, and lift. A controller is recommended because
most robots operate in an industrial environment.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Fluid Power Control

Fluid power cylinders are normally chosen

when a linear movement is required in an
automated application. Controllers can be
used to control linear and rotary actuators in
an industrial fluid power circuit.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Pneumatic cylinders

Pneumatic cylinders are common because they are easy to install and

most plants have access to compressed air. Pneumatics work well for

most robot grippers, drives, and positioning cylinders, as well as machine

loading and unloading and tool-working applications.

Hydraulic cylinders are used when a manufacturing process requires high

forces. Hydraulic systems of several thousand psi are often used to

punch, bend, form, and move components.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Industrial Drive Control

Motors are often directly connected to the power lines and operate at a set speed. As
systems become more automated, variable motor speed is required. Adjustable
speed controllers are available to control the speed of AC and DC motors

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Pulp and Paper Industries

Pulp and paper production processes can involve equipment that

covers a large area. The control of pulp and paper production
processes is ideal for a PLC because most control logic
includes start/stop, time delay, count sequential, and interlock
functions.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Batch Process Control Systems

In a batch process control system, an operator interface is used for

instrumentation or other monitoring functions. An operator interface is
added as part of the system. This interface may be in the form of an
instrumentation and process control station, an HMI, or any other type of
interface.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 languages
Textual Language
• Instruction list
• Structured text
Graphical Form
• Ladder Diagrams (LD) (i.e. Ladder Logic)
• Function Block Diagram (FBD)
• Sequential Function Chart (SFC)

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Ladder Logic

Ladder logic is the simplest form of PLC programming. It is

also known as “relay logic”. The relay contacts used in relay
controlled systems are represented using ladder logic.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

Functional Block Diagram (FBD) is a simple and graphical method to
program multiple functions in PLC. PLC open has described using
FBD in the standard IEC 61131-3. A function block is a program
Functional
instruction unit that, when executed, yields one or more output values. Block Diagrams

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

Structured Text Programming

Structured text is a textual programming language

that utilizes statements to determine what to
execute. It follows more conventional programming
protocols but it is not case sensitive. A series of
statements (logic) is constituted of expressing
assignments and relationships using several
operators.

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 Reference:

https://electricala2z.com/motors-control/programmable-
logic-controller-plc-industrial-applications/
https://www.electrical4u.com/programmable-logic-
controllers/#PLC-Basics

Electronics 3: Electronic Systems and Design R.A. ALIMUIN

 PLC IN ACTION

STUDENT NAME: Alec Lopez Salutem

STUDENT NUMBER: 1810333

Electronics 3: Electronic Systems and Design R.A. ALIMUIN