Author: GURU Solutions
Tuesday, December 6, 2022

Myths About Programmable Logic Controller

A lot has been said about programmable logic controllers; it's hard to know what's the truth and what's not. We have researched and created this fantastic article to help you learn about the myths about programmable logic controllers.  

There are several myths about the programmable logic controller that you should know about; PLCs are only used in automotive and manufacturing applications, PLCs aren't very flexible, they are challenging to troubleshoot, take a long time to install and program, must be programmed in ladder logic, are expensive, all PLCs look the same, and PLCs are only for high-volume production.  

Read on to learn more about the importance of the programmable logic controller.

Myths About Programmable Logic Controller

Programmable logic controllers are critical components in industrial and manufacturing systems. However, because of their nature, they're prone to myths that paint them as mysterious, power-hungry devices that can cause injuries to unsuspecting users. While these myths have no basis in reality, it's essential to understand what they are and why they persist so we can help dispel them whenever possible.

Myths About Programmable Logic Controller

Myths about programmable logic controllers.

Myth 1. PLCs are only used in automotive and manufacturing applications

Not too long ago, PLCs were only associated with automotive and manufacturing applications, but today that couldn't be further from the truth. A PLC can do everything you need if you have a high-volume industrial operation or need a reliable piece of equipment for your business. 

Myth 2. PLCs aren't very flexible

PLCs are more static devices, but they can be very flexible. They can control multiple processes involving people, machines, and other items. PLCs have many programming features that you can make use of. One benefit is that you don't need to know how the process will run to program it.

Myth 3. PLCs are only for high-volume production

All it takes is one lousy program or an incorrect configuration to put the entire production line on hold, but PLCs can be used for both low and high-volume productions. How many lines of code PLCs can handle depends on the company. They can use small PLCs that do 2-4 tasks simultaneously, or they could use a giant PLC with hundreds of jobs being done at once.

Myth 4. PLCs must be programmed in ladder logic

It's a myth that PLCs need to be programmed in ladder logic. PLCs come in many different types, and it's essential to know the kind that is best for your application before deciding how you want it programmed. For example, a ladder logic PLC would not be appropriate for motion control applications, while using function block programming would be overkill.

Myths About Programmable Logic Controller

Myth 5. PLCs take a long time to install and program

PLCs can be difficult for those who have never programmed one before, and it is a skill that takes some time to acquire. However, the truth is that PLC installation and programming are more straightforward than most people expect. Installing a PLC typically takes only a few hours, with the programmed part taking less than an hour.

Myth 6. PLCs are difficult to troubleshoot

The truth is that a skilled troubleshooter can pick up most problems with a PLC in a short time. Learning and keeping up-to-date on new updates, the theory behind how PLCs work, and best practices will help you improve this skill.

Myth 7. PLCs are expensive

PLCs are not expensive if you do the research. PLCs come in a variety of configurations. The price depends on what is included, such as processor speeds, inputs and outputs, and networking. In this way, a system can be scalable to the needs of an individual plant or industrial facility and installed with little upfront investment.

Myth 8. All PLCs look the same

Programmable logic controllers are built for different purposes, so the type you need for your application may not look like other PLCs. Be sure you have a clear understanding of your project goals before deciding on which controller to use.

What's the importance of programmable logic controller

Myths About Programmable Logic Controller

Every industry uses programmable logic controllers to improve efficiency and production levels. PLCs are electronic devices that receive input, process it, and act upon it to control the output in real time. The more you know about these tools, the more you can benefit from them in your business operation. This article will look at how these useful devices work and their impact on businesses in today's digital world.

Importance of PLC to your business

1. Accuracy 

The accuracy of a PLC is controlled by how it reacts to the input given. The PLC can be programmed for more accurate timing, such as a timer if an input device is correct. A common mistake with programming logic controllers is that less information and detail are provided when errors are found during the operation. It can lead to improper functioning or an incomplete error message, increasing the time needed to troubleshoot the problem if no one else knows the installation.

2. Reliability

PLCs work with programming instructions to regulate and monitor the input devices, which will then control output devices to automate the production process. These devices can help improve reliability by saving your company time and money, improving safety, and producing a higher-quality product.

3. Minimized maintenance cost

Programmable logic controllers (PLCs) are a vital part of any machine as they function as the brains for a manufacturing process. These devices help maximize uptime and minimize maintenance costs by taking the thinking out of repetitive actions.

Myths About Programmable Logic Controller

4. Simplified vessel monitoring

A programmable logic controller (PLC) is a control device that coordinates industrial manufacturing processes that involve measurements and actuators. PLCs convert equipment settings into numeric values and are made up of combinations of logical expressions called ladder logic. They have many applications, including automation and sequencing for process industries.

5. Performance

Programmable logic controllers are systems that automate the control of devices, such as temperature and flow in HVAC systems. They do this using software to run algorithms controlling input and output devices. The PLC can monitor devices for process conditions and trigger corrective action when a set point is exceeded. It helps to decrease operator intervention and make the system more responsive to change.

6. Reduced IT requirements

Programmable logic controllers can reduce IT requirements significantly by automating data transfer. This will keep operations running smoothly while the company's IT team focuses on more complex infrastructure needs. These devices are cost-effective, so IT teams should consider investing in them if they want to take advantage of greater control and efficiency in their organization.

7. Security

Programmable logic controllers are a significant security risk to your organization; they can change the manufacturing process, which in turn will cause higher costs and disruption in business. Malicious threats can hack them, and without constant updates, the opportunity for dangerous data to leak is significant. These systems are always at risk in a constantly connected world due to outside intervention.

What are the Methods To Apply For Successful PLC Troubleshooting. 

PLC troubleshooting can seem impossible if you don't know where to start. Still, with the right approach, you can be confident that the problem will be identified quickly and the fix will be simple. The best methods for successful PLC troubleshooting are shown in the table below.

Troubleshooting Ground Loops
Maintaining a stock of spare parts is a good idea as this will minimize downtime that failures of a particular piece would otherwise cause when you've exhausted all other options and run out of fuel. Having the correct spare means a much shorter recovery time of just a few minutes rather than hours or days.
Diagnostic PLC Indicator Connecting an indicator to your programmable logic controller can check if a signal is acting up. The hand will provide immediate feedback on whether or not it's receiving a call from your device.
Troubleshooting PLC Output If you're in charge of troubleshooting a problem with your PLC output, it's essential to start by checking all your connections. Make sure you have a solid connection on all wires, especially power and ground.
Troubleshooting PLC Input

If an input module doesn't appear to power up, it could be due to a problem somewhere along the field device's power line with either the line's line one or the terminal connections. The input module's indicators can tell the user what's happening with the field device, the module, and the field device's wiring to the module.



Technology is wonderful. It's exciting, brings people together, and even makes life easier for certain aspects of living. But technology does have its downsides too. Regarding information about the latest and greatest products, you need to be extra cautious with your beliefs. Guru solutions offer efficient services in programmable logic controllers. 

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