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Control Applications
M1452

Lec.#03
Omar Salim; Ph.D.
Department of Electrical Engineering
Benha Faculty of Engineering
Benha University

April 2024
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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 execute specific
functions that include On/Off control, timing, counting, sequencing,
arithmetic, and data handling.

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Advantages of a PLC Control System
Eliminates much of the hard wiring that was associated with
conventional relay-based control circuits.

The program takes the place of much

of the external wiring that would be
required for control of a process.

Increased Reliability:
Once a program has been written and tested it can be 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.

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More Flexibility:
Original equipment manufacturers (OEMs) can provide system
updates for a process by simply sending out a new program.

It is easier to create and

change a program in a PLC
than to wire and rewire a
circuit.
End-users can modify
the program in the field.

Lower Costs:
Originally PLCs were designed to replace relay control logic. The
cost savings using PLCs have been so significant that relay
control is becoming obsolete, except for power applications.

Generally, if an application
requires more than about
6 control relays, it will
usually be less expensive
to install a PLC.

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Communications Capability:
A PLC can communicate with other controllers or computer
equipment.

They can be networked

to perform such functions
as: supervisory control, data
gathering, monitoring
devices and process
parameters, and downloading
and uploading of programs.

Faster Response Time:

PLCs operate in real-time which means that an event taking place
in the field will result in an operation or output taking place.

Machines that process

thousands of items per
second and objects that
spend only a fraction of
a second in front of a
sensor require the PLC’s
quick response capability.

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Easier To Troubleshoot:
PLCs have resident diagnostic and override functions that allows
users to easily trace and correct software and hardware problems.

The control program

can be watched in
real-time as it
executes to find
and fix problems

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Major Components of a Common PLC

POWER
SUPPLY

I M O M
N O U O
P D PROCESSOR T D
U U P U
From T L U L To
SENSORS E T E OUTPUT
Pushbuttons, Solenoids,
contacts, contactors,
limit switches, PROGRAMMING COMMUNICATION alarms
etc. DEVICE INTERFACE etc.

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I/O Configurations

Fixed I/O

• Is typical of small PLCs

• Comes in one package, with no separate

removable units.

•The processor and I/O are packaged together.

• Lower in cost – but lacks flexibility.

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Modular I/O

Is divided by compartments into which

separate modules can be plugged.

This feature greatly increases your options

and the unit’s flexibility. You can choose
from all the modules available and mix them
in any way you desire.

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Modular I/O

When a module slides into the rack, it

makes an electrical connection with a
series of contacts - called the backplane.
The backplane is located at the rear of
the rack.

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PLC System

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Power Supply

• Supplies DC power to other modules that plug

into the rack.

• In large PLC systems, this power supply does

not normally supply power to the field devices.

• In small and micro PLC systems, the power

supply is also used to power field devices.

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Processor (CPU)
• Is the “brain” of the PLC.

• Consists of a microprocessor for implementing

the logic, and controlling the communications
• among the modules.

• Designed so the desired circuit can be entered in Processor

relay ladder logic form. Module

• The processor accepts input data from various

sensing devices, executes the stored user
program, and sends appropriate output
commands to control devices.
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Memory Designs
The words random access refer to the ability of any location (address) in the
memory to be accessed or used. Ram memory is used for both the user memory
(ladder diagrams) and storage memory in many PLC’s.

RAM memory must have battery backup to retain or protect the stored program.

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Memory Designs
NON-VOLATILE
Has the ability to retain stored information when power is removed, accidentally or
intentionally. These memories do not require battery back-up.
Common Type of Non-Volatile Memory
ROM, Read Only Memory
Read only indicates that the information stored in memory can be read only and
cannot be changed. Information in ROM is placed there by the manufacturer for the
internal use and operation of the PLC.

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I/O Section

Consists of input modules and

output modules.

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Input Module

Forms the interface by which input field

devices are connected to the controller.

The terms “field” and “real world” are

used to distinguish actual external devices
that exist and must be physically wired
into the system.

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I/O Module
DC INPUT MODULE
IS NEEDED TO:
• Prevent voltage
Use to drop the transients from
voltage to logic damaging the
level processor.
•Helps reduce the
effects of electrical
noise

Current Buffer,
FROM OPTO-
Limiting Filter, TO
ISOLATOR
INPUT Resistor hysteresis PROCESSOR
DEVICE Circuits

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I/O Module
AC INPUT MODULE
IS NEEDED TO:
Converts the AC input • Prevent voltage
transients from damaging
to DC and drops the the processor.
voltage to logic level •Helps reduce the effects
of electrical noise

Rectifier, Buffer,
FROM Resistor OPTO- Filter, TO
INPUT Network ISOLATOR Hysteresis PROCESSOR
DEVICE Circuits

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Output Module

Forms the interface by which

output field devices are connected
to the controller.

PLCs employ an optical isolator

which uses light to electrically
isolate the internal components
from the input and output
terminals.

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I/O Module
DC / AC OUTPUT MODULE
IS NEEDED TO:
• Prevent voltage
transients from
damaging the
processor.
•Helps reduce the
effects of electrical
noise

Amplifier
FROM TTL OPTO- RELAY TO
PROCESSOR Circuits ISOLATOR TRIAC OUTPUT
X’SISTOR DEVICE

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Programming Device
PC with appropriate
software

• A personal computer (PC) is the most commonly used programming device.

• The software allows users to create, edit, document, store and troubleshoot
programs.
• The computer monitor is used to display the logic on the screen.
• PC communicates with the PLC via a serial or parallel data communications link.
• If the programming unit isn’t in use, it may be unplugged and removed. Removing
the programming unit will not affect the operation of the user program.

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Programming Device

Hand-held unit
with display

• Hand-held programming devices are sometimes used to program small PLCs.

• They are compact, inexpensive, and easy to use, but are not able to display as
much logic on screen as a computer monitor.
• Hand-held units are often used on the factory floor for troubleshooting,
modifying programs, and transferring programs to multiple machines.

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OUTPUTS

INPUTS MOTOR

CONTACTOR
LAMP

PUSHBUTTONS
PLC

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Allen-Bradley 1746-1A16

L1 L2 I= Input
Module
I:2 slot # in
rack
P. B SWITCH 0 Module
Terminal #
Address I:2.0/0
LADDER PROGRAM
INPUT MODULE
WIRING DIAGRAM

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CONTACTOR
L1 N.
L2 O
MOTOR
L2 •SOLENOID
C L1
•VALVES
FIELD •LAMP
WIRING •BUZZER

OUTPUT MODULE
WIRING
L1 O:4
L2

CONTACTOR 0
LADDER PROGRAM

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IN
OFF PLC
Logic 0 Input
Module
24 V dc

IN
OFF PLC
Logic 1 Input
Module
24 V dc

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I/O Circuits
Analog I/O
Circuits of this type sense or drive analog signals.
Analog inputs come from devices, such as thermocouples, strain gages, or
pressure sensors, that provide a signal voltage or current that is derived from
the process variable.
Standard Analog Input signals: 4-20mA; 0-10V

Analog outputs can be used to drive devices such as voltmeters, X-Y

recorders, servomotor drives, and valves through the use of transducers.
Standard Analog Output signals: 4-20mA; 0-5V; 0-10V

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Analog Input
An analog input is an input signal that has a continuous signal. Typical inputs may
vary from 0 to 20mA, 4 to 20mA or 0 to10V. Below, a level transmitter monitors the
level of liquid in the tank. Depending on the level Tx, the signal to the PLC can either
increase or decrease as the level increases or decreases.

IN
Level Transmitter
PLC
Analog
Tank
Input
Module

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Analog Output
An analog output is an output signal that has a continuous signal.
Typical outputs may vary from 0 to 20mA, 4 to 20mA or 0 to10V.

Electric to pneumatic transducer

OUT
PLC E Supply air
0 to 10V P

Analog
Output
Module Pneumatic control valve

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PLC Size Classification
Criteria: number of inputs and outputs (I/O count), cost, physical size

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Selecting a PLC
Criteria
1. Number of logical inputs and outputs.
2. Memory
3. Number of special I/O modules
4. Scan Time
5. Communications
6. Software

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PLC Mixer Process Control Problem

• Mixer motor to automatically stir the

liquid in the vat when the temperature and
pressure reach preset values.
• Alternate manual pushbutton control of
the motor to be provided.
• The temperature and pressure sensor
switches close their respective contacts
when conditions reach their preset values.

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Process Control Relay Ladder Diagram

Motor starter coil is energized when both the pressure and temperature
switches are closed or when the manual pushbutton is pressed.

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PLC Input Module Connections

The same input field devices are used.

These devices are wired to the input module

according to the manufacturer’s labeling
scheme.

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PLC Output Module Connections

Same output field device is used and

wired to the output module.
Triac

Triac switches motor

ON and OFF in accordance
with the control signal from
the processor.

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PLC Ladder Logic Program
The numbers represent addresses
I/O address format
will differ,
depending on
the PLC
manufacturer. You
give each input and
output device an
address. This lets
the PLC know
The format used is The symbols represent instructions where they are
similar to that of the physically
hard-wired connected.
relay circuit.
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Entering And Running The PLC Program

To enter the program into the PLC, place
the processor in the PROGRAM mode and
enter the instructions one-by-one using
the programming device.

To operate the program, the controller

is placed in the RUN mode, or
operating cycle.

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PLCs Versus Personal Computers

Same basic architecture

PLC
-Operates in the industrial
environment
-Programmed in relay ladder logic
-No keyboard, CD drive, monitor,
or disk drive
-has comm ports, and terminals for
input and output devices
PC
-capable of executing several
programs simultaneously, in
any order
-some manufacturers have software
and interface cards available so that
a PC can do the work of a PLC

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References
Text Books:
• Devdas Shetty and Richard A. Kolk, ‘Mechatronics System Design,’ 2nd Edition,
2011, Cengage Learning
• Frank D. Petruzella, “Programmable Logic Controllers”, 4th Edition, McGraw-Hill
2011

Lecture Notes:
• Omar Salim, Ph.D. Lecture notes for Industrial Control Systems and Fundamentals
of Instrumentations and Process control.

Software Packages:
• MATLAB Simulink, for Mathworks.

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