By: Adisu Tadesse (M.Sc.

)
May, 2023
Harar, Ethiopia

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Introduction: PLC
Programmable
Logic
Controller
❑ A programmable logic controller (PLC)is a specialized computer used to
control machines and process.
❑ It uses a programmable memory to store instructions and specific
functions that include On/Off control, timing ,counting, sequencing,
arithmetic, and data handling
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Introduction: PLC
The First Programmable Logic Controllers (PLCs)
• Introduced in the late 1960’s
• Developed to offer the same functionality as the existing relay logic
systems
• Programmable, reusable and reliable:
– Could withstand a harsh industrial environment
– They had no hard drive, they had battery backup
– Used Ladder Logic for programming
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Introduction: PLC
Also known as programmable controller (PC) defined by the National
Electrical Manufacturers Association (NEMA) in 1978 as: a digitally
operating electronic apparatus which uses a programmable memory for the
internal storage of instructions for implementing specific functions such as :-
✓ Logic,
✓ Sequencing
✓ Timing
✓ Counting and arithmetic
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Introduction: PLC
Overview of PLC
• Low cost, compact, standard microprocessor architecture used in
the control of machines or processes
• Designed for ease of programming and maintenance
• Replace the old relay logic control systems in automated
manufacturing provide an easy and efficient replacements for the
bulky relay logic controllers

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Introduction: PLC
The Need for PLCs
• Hardwired panels were very time consuming to wire, debug and change.
• The following requirements for computer controllers to replace hardwired
panels.
– Solid-state not mechanical
– Easy to modify input and output devices
– Easily programmed and maintained by plant electricians
– Be able to function in an industrial environment
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Introduction: PLC
Advantages of PLC Control Systems
◦ Flexible

◦ Faster response time

◦ Less and simpler wiring

◦ Solid-state - no moving parts

◦ Modular design - easy to repair and expand

◦ Handles much more complicated systems

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Introduction: PLC
PLC’s Are

• Similar to a Microcontroller:
• Microprocessor Based
• Onboard Memory for Storing Programs
• Special Programming Language:
- Ladder Logic
• Input/Output Ports

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Introduction: PLC
Typical applications of PLC
➢ Embedded control in standard or custom-designed machines
➢ Control of conveyor systems
➢ Networked to manage large complex distributed control systems
➢ Security alarm monitoring system
➢ Elevator control
➢ Air-conditioning control panel
➢ Water treatment plant
➢ Underground coal-mining machines.
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Introduction: PLC
A PLC consists of two basic sections:

✓the central processing unit (CPU), and

✓the input/output interface system.

The CPU, which controls all PLC activity, can further be broken down into: the
processor, and memory system.

The input/output system is physically connected to field devices .(e.g. switches,

sensors, motor starters, light, valves, etc.), and provides the interface between the
CPU and the information providers (inputs) and controllable devices (outputs).
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Introduction: PLC

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Introduction: PLC
Hard wire panel system PLC System

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Introduction: PLC

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Introduction: PLC

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Introduction: PLC

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Introduction: PLC

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Introduction: PLC
PLC Size
1. SMALL- It has up to128 I/O’s and memories up to 2 Kbytes. - These PLC’s
are capable of providing simple to advance levels or machine controls.
2. MEDIUM - Have up to 2048 I/O’s and memories up to 32 Kbytes.
3. LARGE - The most sophisticated units of the PLC family. They have up to
8192 I/O’s and memories up to 750 Kbytes.
Can control individual production processes or entire plant.

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Introduction: PLC
The overall plc bus

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Introduction: PLC
Power Supply
❑ PLCs are usually powered directly from 120 or 240 V. The power supply converts
the AC into DC voltages for the internal microprocessor components. It may also
provide the user with a source of reduced voltage to drive switches, small relays,
indicator lamps, and the like.
Processor
❑ The processor is a microprocessor-based CPU and is the part of the PLC that is
capable of reading and executing the program instructions, one-by-one (such as
the rungs of a ladder logic program).
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Introduction: PLC
Program Memory
• The program memory receives and holds the downloaded program
instructions from the programming device. If this memory is standard
RAM, the program will be lost every time the power is turned off, requiring
it to be reloaded.
• To avoid this bother, the program memory may use an EEPROM
(Electrically Erasable Programmable ROM) or a battery-backup RAM, both
of which are capable of retaining data even when the power is off.
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Introduction: PLC
Data Memory
• Data memory is RAM memory, Temporarily store internal and external
generated data.
• For example, it would store the present status of all switches connected to
the input terminals and the value of internal counters and timers.
Programming Port
• The programming port, an input/output (I/O) port, receives the
downloaded program from the programming device (usually a PC).
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Introduction: PLC
Input and Output Modules
• The I/O modules are interfaces to the outside world. These control ports may
be built into the PLC unit or, more typically, are packaged as separate plug-in
modules, where each module contains a set of ports.
Switch
• A mechanical device that can allowing a current to flow or not. There are two
fundamental uses for switch.

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Introduction: PLC
Different types of switch
➢Pushbutton
There are two types of pushbutton, the momentary and maintained
The momentary pushbutton switch is activated when the button is pressed, and
deactivated when the button is released. The deactivation is done using an internal
spring.
The maintained pushbutton activates when pressed, but remains activated when it is
released. Then to deactivate it, it must be pressed a second time. on/off switches on
most desktop computers.
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Introduction: PLC
Limit Switch
• Limit switches are usually not operator accessible.
• Activated by physical contact with some movable object. An example is a car door
switch, which senses whether or not the door is closed. they are activated by
moving parts on the machine.
• Magnetic switches used on home security systems that sense when a window has
been opened .
• Mechanically operated limit switch is the switch on the refrigerator door that turns
on the light inside.
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Introduction: PLC

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Introduction: PLC
Indicator Lamps
Control panels include indicator lamps.
They tell the operator when power is applied to the machine and indicate the
present operating status of the machine.
The colors are usually red, green, and amber, but other colors are also available.

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Introduction: PLC
Light color and their indication
• Red lamps are reserved for safety critical indicators (power is on, the
machine is running, an access panel is open, or fault has occurred).
• Green lamps usually indicates safe conditions (power to the motor is off,
brakes are on, etc.).
• Amber lamps indicates conditions that are important but not dangerous
(fluid getting low, machine paused, machine warming up, etc.).

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Introduction: PLC
Relays
• Is a device that uses an electromagnet to provide the force to close or open
switch contacts, in other words, an electrically powered switch.
Relay contacts are described as being one of two kinds:
• Normally open contacts (NO), which are open in the Unenergized state, and
Normally closed contacts (NC), which are closed in the unenergized state.

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Introduction: PLC

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Introduction: PLC
In General, Relays Transform a Control Signal into a Control Action.
Relays Provide:
• Isolation Between Input and Output
• Leverage (Small Signal Can Control Large Action)
• Automation (Minimize Human Interaction with a Control Process)

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Introduction: PLC
Basic Relay Symbols

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Introduction: PLC

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Introduction: PLC

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Introduction: PLC

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Introduction: PLC
Ladder Logic - examples

Relay Normally open Relay Normally Closed

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Introduction: PLC
Ladder Logic - examples
Hot Power
Neutral

• Simple drawing of control circuit

• Power flow from left to right

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Introduction: PLC
Ladder Logic - examples
Open relay
Relay coils

Function block:
Timer On Delay
Preset: 0.5sec = 500ms
Accumulated time
start count from zero.

Closed relay

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Introduction: Digital Logic
Digital Logic
• Digital logic is the fundamental concept underpinning all
modern computer systems.
• It is the system of rules that allow us to make extremely
complicated decisions based on relatively simple ‘yes/no’ questions.
• Digital devices convert digital inputs into one or more digital

outputs.

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Introduction: Digital Logic
Digital systems are concerned with digital signals
Digital signals can take many forms
Here we will concentrate on binary signals since these are the most common form of digital
signals;
• Can be used individually
-perhaps to represent a single binary quantity or the state of a single switch
• Can be used in combination
-to represent more complex quantities

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Introduction: Digital Logic
• Digital Signals have two basic states:
 They may represent levels of ON or OFF, OPEN
or CLOSE, YES or NO, TRUE or FALSE e.t.c.
 A good example of binary is a light (only on or off)

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Introduction: Digital Logic
• A binary quantity is one that can take only 2 states

S L
OPEN OFF
CLOSED ON

S L
0 0
1 1
A simple binary
arrangement A truth
table

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Introduction: Digital Logic
• A binary arrangement with two switches in series

L = S1 AND S2

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Introduction: Digital Logic
• A binary arrangement with two switches in parallel

L = S1 OR S2

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Introduction: Digital Logic
• Three switches in series
Truth table

L = S1 AND S2 AND S3

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Introduction: Digital Logic
• Three switches in parallel Truth table

L = S1 OR S2 OR S3

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Introduction: Digital Logic
• A series/parallel arrangement Truth table

L = S1 AND (S2 OR S3)

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Introduction: Digital Logic
RS LOGIX 5000 software

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Introduction: Digital Logic
RS LOGIX 5000 software

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Introduction: Digital Logic
RS LOGIX 5000 software

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Introduction: Digital Logic
RS LOGIX 5000 software

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Introduction: Digital Logic
RS LOGIX 5000 software

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Introduction: Digital Logic
RS LOGIX 5000 software

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Introduction: Digital Logic
Logic Gates

• The building blocks used to create digital circuits are logic gates.
• There are three elementary logic gates and a range of other simple gates.
• Each gate has its own logic symbol which allows complex functions to
be represented by a logic diagram.
• The function of each gate can be represented by a truth table or using
Boolean function/notation.

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Introduction: Digital Logic
Combinational Logic
❑Digital logic circuits can be broken down in to two subcategories-
Combinational and sequential.
❑Combinational logic changes ‘instantly’-the output of the circuit responds
as soon as the input changes.
❑Sequential circuits have a clock signal, and changes propagate through
stages of the circuit on edges of the clock
❑Typically, a sequential circuit will be built up of blocks of combinational
logic separated by memory elements that are activated by a clock signal.
❑They are made of six(if you include NOT gate) basic logic gates:
AND gate, OR gate, XOR gate, NAND gate, NOR gate and NOT gate

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Introduction: Digital Logic
BOOLEAN ALGEBRA
 Defines the rules for expressing and simplifying binary logic statements.
The basic Boolean laws and identities follows

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Introduction: Digital Logic
• The AND gate

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Introduction: Digital Logic
• The OR gate

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Introduction: Digital Logic
• The NOT gate (or inverter)

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Introduction: Digital Logic
• A logic buffer gate

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Introduction: Digital Logic
• The NAND gate

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Introduction: Digital Logic
• The NOR gate

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Introduction: Digital Logic
• The Exclusive OR gate

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Introduction: Digital Logic
• The Exclusive NOR gate

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Introduction: Digital Logic
Combinational Logic
• Implementing a function from a Boolean expression
Example 1: Implement the function

X = A + BC

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Introduction: Digital Logic
• Implementing a function from a Boolean expression
Example 2: Implement the function
Y = AB + CD

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Introduction: Digital Logic
• Generating a Boolean expression from a logic diagram
Example 3: Generating a Boolean expression

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Introduction: Digital Logic
Example (continued)….. Boolean expression
– work progressively from the inputs to the output adding logic
expressions to the output of each gate

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Introduction: Digital Logic
• Implementing a logic function from a description
Example 4: The operation of the Exclusive OR gate can be stated as:
“The output should be true if either of its inputs are true, but not if both
inputs are true.”

This can be rephrased as:

“The output is true if A OR B is true,

AND if A AND B are NOT true.”

We can write this in Boolean notation as

X = (A + B) • (AB)

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Introduction: Digital Logic
Example (continued)….. logic function
The logic function X = (A + B) • (AB)
can then be implemented as before

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Introduction: Digital Logic
Example 5: Generating a Boolean expression

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Introduction: Digital Logic
Example 5: Generating a Boolean expression

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Introduction: Digital Logic
Example 5: Generating a Boolean expression

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Introduction: Digital Logic
Example 5: Generating a Boolean expression

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Introduction: Digital Logic
Example 5: Generating a Boolean expression

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 The end!

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 The end!

Adisu Tadesse|MSc|
Lecturer, Mechatronics Eng. | Agro-Technical and Technology College/ATTC/ - Menschen fuer Menschen
Foundation – MFM

Email: officialadisu1996@gmail.com |adisu.tmtmd19@sot.pdpu.ac.in

URL: http://www.mfmattc.edu.et/ | Harar, Ethiopia

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