EE 402 – ELECTIVE 2

Programmable Logic Controller

in Manufacturing and Power
Systems
Engr. Darwin B. Pagcaliwagan, REE, RME
Batangas State University, The National Engineering University
Electrical and Computer Engineering Department
 Topic Outcomes

✓ Define what a Programmable Logic Controller (PLC)

is.
✓ Advantages of a Programmable Logic Controller
over Microcontrollers and Relay Systems.
✓ Main parts of a PLC and its functions.
✓ Basic Sequence and Working Principle for a
Programmable Logic Controller
Programmable Logic
Controller (PLC)
 Programmable Logic
Controller (PLC)
• Is an industrial grade computer that is capable of being programmed
to perform control functions.
• A ruggedized digital computer used in industries that have been
adapted for controlling manufacturing processes. These
manufacturing processes included robotic devices, assembly lines,
or any activity requiring ease of programming, high reliability, and
process fault diagnosis.
• The programmable controller has eliminated much of the hardwiring
associated with conventional relay control circuits.
• Fast Response, Easy Programming and Installation, High control
speed, Network Capability, Troubleshooting and Testing
Convenience, and High Reliability.
 Programmable Logic
Controller (PLC)
• The PLC is designed for multiple input and output arrangements,
extended temperature ranges, immunity to electrical noise, and
resistance to vibration and impact
• Real-time system since the output of the system controlled by
the PLC depends on the input conditions.
• PLC was used to replace relay logic, but its ever-increasing
range of functions means that it is found in many and more
complex applications.
 Programmable Logic
Controller (PLC) Brands
• ABB
• Allen-Bradley
• Siemens
• Honeywell
• Mitsubishi
• Yokogawa
• Toshiba
• General Electric
• Schneider
 Advantages of PLC over Relay
Systems
1. Increased Reliability
• Once a program has been written and tested, it can be easily downloaded to
other PLCs. Since all the logic is contained in the PLC’s memory, there is no
chance of making a logic wiring error.

2. More Flexibility
• It is easier to create and change a program in a PLC than to wire and rewire
a circuit.

3. Lower Cost
• PLCs were originally designed to replace relay control logic, and the cost
savings have been so significant that relay control is becoming obsolete
except for power applications.
 Advantages of PLC over Relay
Systems
4. Communications Capability
• Once a program has been written and tested, it can be easily downloaded to
other PLCs.
5. Faster Response Time
• PLCs are designed for highspeed and real-time applications. The
programmable controller operates in real time, which means that an event
taking place in the field will result in the execution of an operation or output.
6. Easier to Troubleshoot
• PLCs have resident diagnostics and override functions that allow users to
easily trace and correct software and hardware point.
Relay Based Control Panel
PLC Based Control Panel
 Motor Control
• Motor control refers to the process of managing the operation, speed, direction,
and performance of electric motors. It involves various techniques and
technologies to regulate the behavior of motors, ensuring they operate as desired in
different applications. Motor control is used in a wide range of industries and
settings, including industrial automation, robotics, HVAC systems, automotive,
consumer electronics, and more.
 Motor Control
The primary goals of motor control are to:
1. Start and Stop: Motor control systems allow for controlled starting and stopping of
motors. This is important to prevent sudden mechanical stresses on the motor and the
connected machinery.
2. Speed Control: Motor speed can be adjusted to meet specific requirements.
Depending on the application, motors might need to run at different speeds to optimize
performance and energy efficiency.
3. Direction Control: Some applications require motors to rotate in different directions.
Motor control systems enable the selection of rotation direction based on the
application's needs.
4. Acceleration and Deceleration: Smooth acceleration and deceleration are crucial for
preventing mechanical wear and tear. Motor control ensures gradual changes in speed
and torque.
5. Position Control: In some applications, precise positioning of a motor is necessary.
Motor control systems can be used to accurately control the motor's position, often
utilizing feedback mechanisms like encoders.
 Motor Control
The primary goals of motor control are to:

6. Energy Efficiency: By optimizing motor performance and controlling speed and torque,
motor control systems contribute to energy efficiency by reducing wasted power and
improving overall system efficiency.

7. Safety and Protection: Motor control includes protective features such as overload
protection and fault detection. These mechanisms prevent damage to the motor and
connected equipment in case of abnormal operating conditions.

8. Automation and Integration: In industrial settings, motor control systems are often
integrated into larger automation systems, allowing for coordinated control of multiple
motors and other equipment.
 Motor Control
• Motor control involves the use of various electrical components
to start, stop, regulate the speed, and protect electric motors.
These components are commonly used in industrial,
commercial, and residential applications.
• Motor control can be achieved using various methods and
components, as mentioned in the previous response. These
methods range from basic on/off control using switches to more
advanced techniques involving microcontrollers, programmable
logic controllers (PLCs), and complex algorithms
• Motor control is a crucial aspect of various technologies and
industries, enabling efficient and precise operation of electric
motors for diverse applications.
 Motor Control Components
Contactors
• Contactors are electromechanical switches designed to control high-current
loads. They allow you to remotely control the power supply to a motor.
Contactors have main contacts that can handle the motor's current and
auxiliary contacts for control signals
• A contactor is a special type of relay designed to handle heavy power loads
that are beyond the capability of control relays
• Unlike relays, contactors are designed to make and break higher powered
circuits without being damaged. Such loads include lights, heaters,
transformers, capacitors, and electric motors for which overload protection is
provided separately or not required.
 Motor Control Components
Contactors
 Motor Control Components
Overload Relay
• These devices protect motors from overheating due to excessive current draw. There
are thermal overload relays that use the heat generated by the current to trigger the
protection, and electronic overload relays that sense current directly and provide more
accurate protection.
 Motor Control Components
Motor Starters
• A motor starter is designed to provide power to motors. The
motor starter is made up of a contactor with an overload relay
attached physically and electrically to it.
• They include thermal or electronic overload relays to protect
the motor from excessive current, which could damage the
motor. Starters are used to initiate motor operation and provide
protection against overloads.
 Motor Control Components
Motor Starters
 Motor Control Components
Circuit Breakers
• Circuit breakers provide overcurrent protection to the motor
circuit. They can interrupt the current flow in the event of a
short circuit or overload, preventing damage to the motor and
the wiring.
 Motor Control Components
Circuit Breakers
 Motor Control Components
Push Button
• These components provide local control over the motor operation. Push
buttons are used for start and stop functions, while selector switches enable
you to choose different operating modes or directions for the motor.
• Pushbutton switches are the most common form of manual control. A
pushbutton operates by opening or closing contacts when pressed.
• Commonly used types of pushbutton switches, which include:
• Normally open (NO) pushbutton, which makes a circuit when it is
pressed and returns to its open position when the button is
released.
• Normally closed (NC) pushbutton, which opens the circuit when it
is pressed and returns to the closed position when the button is
released.
 Motor Control Components
Push Button
• Normally open (NO) pushbutton, which makes a circuit when it is pressed and
returns to its open position when the button is released.

• Normally closed (NC) pushbutton, which opens the circuit when it is pressed
and returns to the closed position when the button is released.
 Motor Control Components
Pilot Lamp (Indicator Light)
• Motor control pilot lamps, also known as indicator lights or pilot lights, are small visual
indicators used in motor control systems to provide visual feedback about the status of
a motor or a related component. These lamps help operators and maintenance
personnel quickly assess the condition of the motor and its associated controls. They
are often used in control panels, switchgear, and other control systems.
Motor control pilot lamps typically have a built-in light source (such as an LED or
incandescent bulb) that illuminates when voltage is applied. The color of the light often
corresponds to a specific status or condition of the motor or system. For example:
•Green Lamp: Indicates that the motor is running or in an "on" state.
•Red Lamp: Indicates an alarm condition, fault, or a dangerous situation.
•Amber/Yellow Lamp: Can represent a warning, a standby state, or a condition requiring
attention.
•Blue Lamp: Sometimes used to indicate that the motor is operating in a specific mode or
under certain conditions.
 Motor Control Components
Pilot Lamp (Indicator Light)
 Motor Control Components
Relay
• Relays are electromagnetic switches used to control lower-
power circuits using signals from higher-power circuits. They
can be used in motor control circuits to perform various control
functions
 Motor Control Components
Relay
 Motor Control Components
Control Transformer
• Transformers are used to step down voltage levels for control circuits,
ensuring the correct voltage is supplied to control components without
affecting the main motor power.
 Motor Control Components
Timers and Sequencers
• These devices provide time-based control over motor
operations. Timers can delay or sequence events, useful in
applications where specific time intervals are critical.
PLC vs Microcontrollers
 PLC vs Microcontrollers
1. The I/O capacity and flexibility of a PLC is far more comprehensive than that of a
Microcontroller.
2. Modern PLC’s have more than one CPU that allows it to run dedicated safety-critical or
scan critical tasks. Microcontrollers currently do not.
3. PLC’s have pre-built, well-tried and tested hardware and software watchdogs and
system routines.
4. PLC’s generally have redundancies built-in, giving them the ability to be single fault
tolerant. Microcontrollers do not have this ability.
5. PLC distributed I/O (Remote I/O) can be placed and operated in hazardous areas. This
can be difficult with Microcontrollers.
6. PLC’s have the ability to bridge many open and industrial communication protocols.
Microcontrollers simply can not.
7. PLC’s are more reliable and robust to use in industrial applications so mean-time to
failure is much longer than that of a microcontroller.
PLC vs Microcontrollers
All the Logic is contained in the PLC’s
Memory

The common types of memory used in

PLCs are Read Only Memory (ROM)
and Random Access Memory (RAM).
A ROM location can be read, but not
written. ROM is used to store programs
and data that should not be altered. For
example, the PLC's operating programs
are stored in ROM.
Relationships between the inputs and outputs
are determined by the user program

All the logic is contained in the PLC's

memory. Contactor, Light, Solenoid are
Outputs. Inputs are Pushbutton, Limit switch,
Sensor.
PLC Communication Module

Communication modules digitally

transfer data between PLCs and other
devices within the factory facility. This
becomes especially important as more
factories are being equipped with
Industrial Internet of Things (IIoT) or
Industry 4.0 technology.
 Parts of a PLC
• Architecture
• Input/Output Section
• Power Supply
• Processor (CPU)
• Programming Device
Parts of a PLC- Architecture
Can refer to PLC hardware, To PLC Software, or to a combination of both.
1. Open Architecture
• Allows the system to be connected easily to devices and programs made by other
manufacturers.
• Use off-the-shelf components that conform to approved standards.

2. Closed Architecture
• Whose design is proprietary, making it more difficult to connect to other systems
• Most PLC systems are fact in proprietary, so you must be surer that any generic
hardware or software you may use is compatible with your particular PLC.
• Consequently, PLC programs cannot be interchanged among different PLC
manufacturers
Parts of a PLC- Input/Output Section
1. Fixed I/O
• Typical of small PLCs that come in one package with no separate, removable units.
• The processor I/O terminals will have a fixed number of connections built in for
inputs and outputs.
• Main advantage is Lower Cost. The number of available I/O points varies and usually
can be expanded by buying additional units of fixed I/O.
• One disadvantage is lack of flexibility; you are limited in what you can get in the
quantities and types dictated by the packaging. Also, for some models, if any part in
the unit fails, the whole unit has to be replaced.
Parts of a PLC- Input/Output Section
1. Fixed I/O
Parts of a PLC- Input/Output Section
2. Modular I/O
• Divided by compartments into which separate modules can be plugged.
• You can choose from the modules available form the manufacturer and mix them any
way you desire,
• The basic modular controller consists of rack, power supply, processor module
(CPU), input/output (I/O modules), and an operator interface for programming and
monitoring.
Parts of a PLC- Input/Output Section
2. Modular I/O
Parts of a PLC- Input/Output Section
2. Modular I/O
Parts of a PLC-Power Supply
3. Power Supply
• Supplies DC power to other modules that plug into the rack.
• Power Supply PLC needs 24 volts DC supply for its operation.
• Some PLCs work with 230 volts AC supply.
• The power supply details of PLC depend on the type of PLC model, manufacturer of
PLC, or as per the geographic location and standards.
• For large PLC systems, this power supply does not normally supply power to the field
devices.
• With larger systems, power to field devices is provided by external alternating current
(AC) or direct current (DC) supplies.
Parts of a PLC-Power Supply
3. Power Supply
Parts of a PLC-Processor (CPU)
4. Processor (CPU)
• “Brain” of the PLC
• Usually consists of a microprocessor for implementing the logic and controlling the
communications among the modules.
• Requires memory for storing user program instructions, numerical values, and I/O
devices status.
• Controls all the PLC activity and is designed so that the user can enter the desired
program in ladder logic.
Parts of a PLC-Processor (CPU)
4. Processor (CPU)
Typical PLC Scan Cycle
PLC I/O System
 Parts of a PLC-Programming Device
5. Programming Device
• Used to enter the desired program into the memory of the processor.
• The program can be entered using relay ladder logic, which is one of the most
popular programming languages.
Most Popular types of PLC Programming Languages
1. Ladder Diagram (LD)
2. Sequential Function Charts (SFC)
3. Function Block Diagram (FBD)
4. Structured Text (ST)
5. Instruction List (IL)
Parts of a PLC-Programming Device
Program
• A user-developed series of instructions that directs the PLC to execute actions.
• A programming language provide rules for combining the instructions so that they
produce the desired actions.

Relay ladder logic (RLL)

• The standard programming language used with PLCs
• Origin is based on electromechanical relay control.
• Graphically represents rungs of contacts, coils, and specific instruction blocks.
• Designed for easy use and understanding for its users and has been modified to keep
up with the increasing demands of industry’s control needs..
Parts of a PLC-Programming Device