‫بسم هللا الرحمن الرحيم‬

Hadramout University of Science & Technology

Engineering Collage
Dep. Of Electronic & Communication Engineering

Programmable Logic Controller (PLC)

By
Abdullah Ashoor Subih
 Responsibility
"The only people who achieve much are those who
want knowledge"
 Objective

To provide students with knowledge of the

parts and functions of a programmable logic
controller (PLC), its principles of operation
and writing programmes for simple operations

By
Abdullah Ashoor Subih
 Course Plan
Home works & Quiz 5
Test 20
The presence 5 150
Lab Performance 50
Final Exam 70
 Outline of Course
 Introduction and basic idea of Automation & Control
 Overview about electromagnetic control circuits (ECCs)
(Relay Control)
 Introduction to PLC Systems with Historical
Background for PLC Systems
 Basic Hardware Description of a PLC System
 Description of I/O Devices in PLC System **
 Description of System Software
 Applications of PLC Systems
 Trouble shooting in PLC Systems
 Communication of PLC

By
Abdullah Ashoor Subih
 Course References
• Programmable Control Theory and Implementation
By: L. A. Bryan & E. A. Bryan

• Automating Manufacturing System With PLCs

By: Hugh Jack

• Control Programmable Logic Controllers:

Programming methods and Applications Systems
Engineering
By: John R. Hackworth & Frederic D.

• Manual of Siemens

• WWW
Introduction and basic idea of
Automation & Control
 Introduction and basic idea of Automation &
Control
 Control system: An interconnection of components
forming a system configuration that will provide a
desired response.

 Automatic control has become important and

integral part of modern manufacturing and
industrial process
 The factory without PLC, the factory without soul.

By
Abdullah Ashoor Subih
 The control system can be classified as open loop control
system and closed loop control systems.

 In an open-loop control, the system does not measure the

actual output and there is no correction to make that output
conform to the desired output.
 In a closed loop control the system includes a
sensor to measure the output and uses feedback
of the sensed value to influence the control input
variable.

By
Abdullah Ashoor Subih
 Common component of control system
Error signal

Ref. Input
+-
PLC
Controller Actuator process
Output

Feedback
Sensor
 Error signal

Ref. Input Output

+- Controller Actuator process

Feedback
Sensor
Closed loop Open loop
Contain sensor Doesn’t Contain sensor
There are relations There aren’t relation
between input and output. between input and output.
More stable Less stable
More complex Less complex.
More performance Less performance.

By
Abdullah Ashoor Subih
Types of Control Circuit

Relay Control

Electronic Control

Programmable Control
 ‫بسم هللا الرحمن الرحيم‬
Hadramout University of Science & Technology
Engineering Collage
Dep. Of Electronic & Communication Engineering

Programmable Logic Controller (PLC)

By
Abdullah Ashoor Subih
 Electromagnetic Control Circuits
(ECC)

 Definition
 Elements
 Application
 Electromagnetic Control Circuits (ECC)
•The ECCs are circuits contain on electromagnetic elements
• Electromagnetic Control Circuits basic design of any
control circuits

The electromagnetic elements :

Contactors-Relay-Timers-Overload-Switches ….and etc.
Contactors
This device is the most well-known electromagnetic device
in control circuits, it consists of two main parts: Fixed part
[Coil] and movable part [contacts], and the movable part
consists two parts: main poles (power contact) and control
contact, a general description is illustrated in the figures below:
By
Abdullah Ashoor Subih
Used in PLC as Output
 Contactor has two parts

Fixed part movable part

power contact control contact

By
Abdullah Ashoor Subih
 Relay

- It is similar Contactor in the idea,

- It has no main poles (power contact).
- It consists of control contacts only
- Used in PLC as software or in output as activated

By
Abdullah Ashoor Subih
Thermal Overload
A device used to protect a motor from damage
resulting from an overcurrent.

The start current equal 6or7 times of operation current, Io.c *(110%- 120%) = Iov.c

Use in PLC as Input

 Timers
Types of timers functionality
ON-Delay Timer
OFF-Delay Timer Use in PLC as software
Flashing Timer
Programmable Timer
Switches Off-ON (Push-Buttons)
• ON Push-Buttons: to connect power to the circuit

• OFF Push-Buttons:to disconnect power to the circuit

• ON- OFF Push-Buttons

Use in PLC as Input

Limit Switches
 Use in PLC as Input Switches

By
Abdullah Ashoor Subih
 Application
1- Start and Stop Motor: Control Circuit
Power circuit
2- Operate Motor in two Direction:
Power circuit Control Circuit

By
Abdullah Ashoor Subih
3- Operate Motor Star-Delta:
Star Connection Way ( )

Delta Connection Way ( )

 Power circuit

By
Abdullah Ashoor Subih
 Control Circuit

By
Abdullah Ashoor Subih
 Relay Control
Group of relays with large number of contacts .
space required .
Fixed application,
Simple control tasks.
Difficult expansion and/ or modification.
Slow action.
ANY Question
 Home Work No.(1)

Correct the following circuit

 ‫بسم هللا الرحمن الرحيم‬
Hadramout University of Science & Technology
Engineering Collage
Dep. Of Electronic & Communication Engineering

Programmable Logic Controller (PLC)

By
Abdullah Ashoor Subih
 Introduction to PLC Systems

Definition Of The PLC

Historical Background
Advantages of Using PLC
PLC families
Components of a PLC

By
Abdullah Ashoor Subih
What is a PLC ?
 Definition Of The PLC

• A Programmable Logic Controller (PLC) is

an electronic device that control in machines
and processes. It is build depend on
microprocessor and it uses a programmable
memory to store instructions and
microprocessor execute specific functions that
include ON/OFF control, timing, counting,
sequencing, and arithmetic.
By
Abdullah Ashoor Subih
PLC Origin
• Early control systems consisted of huge control
boards consisting of hundreds to thousands of
electromechanical relays.
• Developed to replace relays in the late 1960s
• Costs dropped and became popular in 1980s
• Now used in many industrial designs
 HISTORICAL BACKGROUND

1968  The first PLC Construction by General Motors

1969  Hardware CPU controller, with logic instructions

1 K of memory and 128 I/O points

1974  Use of several (multi) processors within a

PLC - timers and counters; arithmetic
operations; 12 K of memory and 1024 I/O points

1976  Remote input/output systems introduced

By
Abdullah Ashoor Subih
1980  Intelligent I/O modules developed

1983  Low - cost small PLC’s introduced

1985  Networking of all levels of PLC, computer

and machine using SCADA software.
Why Use a PLC???
• Why Use a PLC???
The advantages of PLC:

– Handles much more complicated systems

– Flexible and can be reapplied to control other
systems quickly and easily
– Less and simpler wiring
– Allows for diagnostics “easy to troubleshoot”
and reduce downtime
– Reliable components, ensure operation for
years
– Less expensive
– Faster response time
By
Abdullah Ashoor Subih
The most popular PLC families
Basic Hardware Description of a PLC System

PLC

Hardware Software
 PLC Hardware Components

– Power supply module

– CPU module + memory
– Input / Output modules (digital, analog)
– Programming device (special device or a PC)
– Operator unit ‘Operator interface’ (HMI)

By
Abdullah Ashoor Subih
Major Components of a Common PLC
 Power supply unit

CPU
Input Output
Module Module

Memory Unit

Programming Device Operator Device

By
Abdullah Ashoor Subih
 Processor

 Processor is the brain of the PLC.

 A Processor Capable of interpreting and executing

programs.
The main function of the microprocessor is to analyze
data coming from field sensors through input modules,
make decisions based on the user’s defined control
program and return signal back through output modules
to the field devices.
Field sensors: switches, flow, level, pressure, temp.
transmitters, etc.
Field output devices: motors, valves, and lamps
By
Abdullah Ashoor Subih
 Memory

 The memory system in the processor module has

two parts: a system memory and an application
memory.
System memory
The System memory contains the operation system
of PLC and cannot be changed .
- System memory is generally built from read-only
memory devices.

By
Abdullah Ashoor Subih
 The Application memory is divided into the data table
area and user program area.

 The data table stores any data associated with the user’s
control program, such as system input and output status
data, and any stored constants, variables, or preset
values. The data table is where data is monitored,
manipulated, and changed for control purposes.

 The user program area is where the programmed

instructions entered by the user are stored as an
application control program.
 Memory Map Organization

Fixed memory
ROM
SYSTEM

Application memory APPLICATION

RAM
•Data Table
•User Program

By 57
Abdullah Ashoor Subih
Power Supply

The system power supply plays a major role in the

total system operation.

 Its responsibility is not only to provide internal DC

voltages to the system components (i.e.,
processor, memory, and input/output interfaces),
but also to monitor and regulate the supplied
voltages and warn the CPU if something is wrong.
 I/O Module
• The I/O interface section of a PLC connects it to
external field devices.

• The main purpose of the I/O Module is interfacing and

compatibility

• Input modules converts signals from discrete or analog

input devices to logic levels acceptable to PLC’s processor.

• Output modules converts signal from the processor to levels

capable of driving the connected discrete or analog output
devices.
By
Abdullah Ashoor Subih
 Input Module
Switch

Temperature
Sensor Input CPU
Module

Level
Sensor
 Output Module

Motor starter

Output
CPU Module

Relay

Lamp

By
Abdullah Ashoor Subih
 programming device
The programming device is used to enter the required
program into the memory of the processor. The
program is developed in the device and then
transferred to the memory unit of the PLC.
The personal computer communicates with PLC via
serial or parallel data link communication
 Operator unit ‘Operator interface’ (HMI)

Display the information about the process

Enter new Parameters

TD HMI

By
 SCADA

By
Abdullah Ashoor Subih
PLC Overview
 ‫بسم هللا الرحمن الرحيم‬
Hadramout University of Science & Technology
Engineering Collage
Dep. Of Electronic & Communication Engineering

Programmable Logic Controller (PLC)

By
Abdullah Ashoor Subih
 The Configuration of PLC
There are two type as standard of mechanical
design of PLC
Single Box Type
Modular and Rack Type

By
Abdullah Ashoor Subih
 Single Box Type
The features and specifications of this type can
be summarized in the following points:
All hardware in one section except a
programming device
The maximum input on the standard is forty
terminals
Maximum output of the terminals is forty
terminals
The Capacity of memory in this type there is the
possibility of storing up to one thousand
instruction
Used for simple applications
Single Box Type
 Modular and Rack Type
The features of this type and specifications can
be summarized in the following points:
Used for large applications.
Terminals input more than fifty terminals.
Terminals output more than fifty terminals.
The possibility of storage more than a thousand
instructions (memory capacity greater than
1000 step).
Hardware is in separate units.

By
Abdullah Ashoor Subih
Modular and Rack Type
 PLC Layout

PLC layout used to show how to connect input and

output devices with plc. Contact in plc is called
internal contact and it could be transistor (Dc), triac
(Ac) or relay (Ac/DC). Plc control of output devices
through internal contact (Dc or Ac or Ac/Dc)
 The internal contact can being by one of
methods below:

Transistor: used for high speed and low current

By
Abdullah Ashoor Subih
Triac: used for high speed and high current

Triac: used for high current and low speed

PLC Operating
 Self Scan
PLC Operating Cycle Check Inputs

PLC Program
The basic function of a SCAN

programmable controller is to
Update Execute
read all of the field input devices Outputs Code
and then execute the control
program, which according to the
logic programmed, will turn the
field output devices ON or OFF.

A PLC works by continually

scanning a program
 Scan Time
• The scan time is the total time which the plc
takes to complete the program and I/O
update scan. Scanning process from 0 step
to End step is called Cycle and the time
from 0step to End step is called scan time,

By
Abdullah Ashoor Subih
The program scan time generally depend on four
factors:

1- The CPU used.

2 -The size of the program to be scanned.
3 -The number of input/outputs to be read.
4 -The system functions that are in use
 Software of PLC
Software of plc does mean the method which use
to design control program, that explain for plc how
to execute the given commands. The purpose of a
plc program is to control the state of outputs based
on the current condition of plc input.

The function of all programming language is to

allow the user to communicate with PLC via a
programming device

By
Abdullah Ashoor Subih
 Programming Languages
PLC programs can be constructed using various
methods of representation. Some of the common ones
are, described below.

 Ladder (LAD) language:

 Function Block Diagram (FBD) language:
 Statement List (STL)
 Ladder (LAD) language
 Ladder language is the most commonly used
Programming Language
An electrical diagram consists of two vertical bus
lines or power lines, with current flowing from left
bus to the right bus.
Each electrical circuit in the diagram is considered
a rung.

By
Abdullah Ashoor Subih
 Symbols in Ladder Logic Diagram

- Normally Open Contacts (NO): The case may be

logical for this contact (close) when the status of
bit which control in this contact is (1)

- Normally Closed Contacts ( NC): The case may

be logical for this contact (open) when the status
of bit which control in this contact is (1) .

- Coils: The coils represent relay which energized

When the power flow to it, When the activation coil
will lead to the operation of the output by change
state bit which control in this output to logic (1)
Example