PLC  SEMINAR    
 
   
BY : HOSSEIN  TOOTOONCHY  
 
www.coursovie.com
 PLC  Vs  Relays  
Electrical  relays  are  versa2le  and  
reliable  and  you  can  perform  any  
control  func2on  by  relays  and  wires  
BUT  

They  are  subject  to  wear  out  due  to  

their  moving  parts  and  reconfiguring  a  
relay  based  control  system  is  a  tedious  
task  at  best…  
Typical  hard  wired  controller  panel  with  
wiring  and  diagram  
 PLC  

 A  very  prac2cal  alterna2ve  to  relay  or  gate  

 based  control  systems  is  to  use  a    
 
   Programmable  Logic  Controller  or  PLC  
 What  is  a  PLC  ?  
 
A  computer  equipped  with  the  necessary  input  
and  output  peripheral  circuits  configured  to  
be  easily  programmed  by  technical  personnel  
for  virtually  any  logic  task  is  called  a  
programmable  logic  controller  .  
 IEC1131    
PLC  Standard    

The  Interna2onal  electro  technical  commission  has  

set  a  unique  programming  language  for  PLCs  yet  
there  are  a  lot  of  differences  between  the  PLCs  
manufactures  and  IEC  standard  
It  took  12  years  to  make  a  comprehensive  standard  
for  PLCs  which  includes    
Installa2on,  test  ,  programming  and  
communica2ons    
 IEC1131  standard  
•  The  big  manufacturers  who  helped  the  IEC  
commiQee  in  standard  prepara2on  were      

                             Siemens      and    Allen Bradley

This  made  other  companies  to  follow  them  even  

today    
IEC1131  Standard  Sec2ons  
General  Sec2on  

Hardware  and  
Programming   Test    
manual  
requirements  

Programming  
Fuzzy  logic     languages  types  

Communica2ons   User  manuals    

 PLC  Manufacturers  
• Zilog            Schneider        LG        Siemens      
Small  Projects   ABB  

Medium  size     • Omron        Modicon            Mor                Toshiba  

Projects  

Factories  and  
• Siemens                                            Allen  Bradley    
huge  projects  
 Why  use  PLCs  ?  
•  There  is  no  need  to  disconnect  and  reconnect  circuit  
and  wires  for  changes  in  procedures  all  are  done  by  
soZware  configura2on.  

•  PLCs  have  an  internal  self  diagnosis  which  can  report  

the  cause  of  fault.  

•  PLCs  do  not  occupy  a  lot  of  space  and  there  is  no  need  
for  confusing  wiring.  

•  If  you  need  to  repeat  a  previously  done  project  by  PLC,  

you  need  to  copy  the  soZware  which  is  very  2me  
saving.  
 PLCs  are  Industrial  PCs  
•  PLCs  are  nothing  more  than  industrial,  special  
purpose  PCs,  with  below  differences  :  
 
•  They  enjoy  a  very  reliable  opera2ng  system            
(  a  PLC’s  opera2ng  system  never  needs  to  be  changed)    

•  As  a  rule  PLCs  do  not  have  Hard  drives  and  

fans  or  any  moving  part  at  all.                                                              
(  This  is  an  interna2onal  design  decision)  
 Parts  of  a  PLC  

•  Power  supply  
•  I/O  module  
•  CPU  
•  Programming  device  
 PLCs  capabili2es  
•  All  this  requirements  have  made  PLCs  reliable  
computers  which  can  be  trusted  in  ambient    
where  vibra2on,  high  temperature  varia2ons,  
humidity  and  dust  is  constantly  present.    
 Logo  PLCs  
•  Small  PLC  systems  consists  of  all  Power  
supply  ,  CPU,  I/O  points.  These  PLCs  are  
normally  used  for  small  projects  and  typically  
less  expensive  than  their  cousins  but  are  also  
more  limited  in  I/O  and  func2onality  and  must  
be  removed  if  failures  happens.  
 
LOGO  PLC  
 PLC  System  
•  PLC  system  consists  of  a  rack  into  which  circuit  
“Cards”  are  plugged.  These  cards  includes  
processors,  I/O  modules,  communica2on  
ports  etc.    

•  Such  modular  configura2on  enables  us  to  

easily  replace  a  faulty  module  without  
interrup2ng  the  whole  system.  
PLC    
Allen  Bradley  SL500  
Allen  Bradley  Controllogix  5000  
Siemens  S7-­‐300  
 The  least  expensive  PLC  in  the  world    

KOYO  click    
 
8  discrete  input    
6  discrete  output  
 
Less  than  80  $  (US)  in  2009    
 Semi  modular  PLCs  

Other  semi-­‐modular  PLCs  expand  

using  I/O  cards  that  plug  in  to  
the  base  unit  not  unlike  
tradi2onal  rack-­‐based  PLC  
systems.  
 
 The  Koyo  DirectLogic  DL06  is  a  
good  example  of  this  type  
of  semi-­‐modular  PLC,  the  
following  photograph  showing  a  
model  DL06  accep2ng  a  
thermocouple  
input  card  in  one  of  its  four  
available  card  slots.  
 Strictly  monolithic  PLCs  
•  They  do  not  accept  I/O  cards  or  modules.    
 PLC  I/O  Capabili2es  
•  Every  programmable  logic  controller  must  have  some  
means  of  receiving  and  interpre2ng  signals  from  real-­‐
world  sensors  such  as  switches,  and  encoders,  and  also  
be  able  to  affect  control  over  real-­‐world  elements  such  
as  solenoids,  valves,  and  motors.  This  is  generally  
known  as  input/output  or  I/O  capability.  Monolithic  
(“brick”)  PLCs  have  a  fixed  amount  of  I/O  capability  
built  into  the  unit,  while  modular  (“rack”)  PLCs  use  
individual  circuit  board  “cards”  to  provide  customized  
I/O  capability.  
PLC  rack  and  modules  
 PLC  I/O    

PLC  I/O  types  :    

 

Discrete  

Analog    

Network    
 Discrete  I/O  
•  The  discrete  I/O  point  has  only  two  states    On-­‐Off  

Proximity   Push   Limit  

switches   BuQons   switches  
How  discrete  input  channels  work  ?  

Signal  comes  into  PLC  discrete  

channel  

A  light  Emilng  diode  is  

energized    

The  light  from  LED  shines  on  a  

photo  electric  device    

A  bit  inside  the  PLC’s  memory  

is  set  to  1  represen2ng  the  
reserved  data  
Two  discrete  I/O  modules  
 Analog  I/O  Channels  
•  In  early  days  the  processor  speed  and  memory  of  a  PLC  
were  so  limited  that  only  discrete  signaling  was  possible.  

•  Modern  PLCs  have  found  the  way  to  manage  

con2nuously  changing  signals  or  Analog  signals.  

•  All  PLCs  are  digital  devices  in  nature  thus  in  order  to  
interface  them  with  analog  signals  we  need  some  sort  of  
“ Signal  TranslaAon”  between  Analog  and  Digital  worlds.  
 Analog  I/O  Channels  

•  Inside  every  input  analog  module  there  is  a  ADC  or  Analog  to  
Digital  Converter    circuit  to  convert  the  analog  signals  
understandable  for  PLC  units  (mul2  bit  binary  word).  

•  Conversely  every  Analog  output  channel  is  equipped  with  a  

DAC    or  Digital  to  Analog  Converter  to  convert  digital  signals  
to  analog  ones.  
 Different  types  of  Analog  signals  

•  Voltage  (  0-­‐10  v,  0-­‐5v)  

•  Current  (  0-­‐20mA,  4-­‐20mA)  
•  Thermocouple  (milivoltage)  
•  RTD  (milivoltage)  
•  Strain  Gauge  (  milivoltage)  
 Network  I/O  
•  The  PLC  to  PLC  connec2on  needs  a  specific  
protocol  that  would  mange  both  on  a  master  
slave  configura2on.  
•  Two  most  famous  protocols  are  :  
Network  
Protocols  

Modbus     Profibus  
 Logic  Programming  
Not  all  the  PLCs  support  the  following  programming  
methods  but  they  all  support  the  LD.  

•  Ladder  Diagram  (LD)  

•  Structured  Text  (ST)  
•  Instruc2on  List  (IL)  
•  Func2on  Block  Diagram  (FBD)  
•  Sequen2al  Func2on  Chart  (SFC)  
 PLC  programming  is  simple    
Programming  for  many  industrial  devices  are  simple  by  
nature  there  are  two  reasons  for  that  :    
 
•  Simplicity:    
•  Any  programming  language  understandable  for  people  with  
no  background  in  computer  programming  should  be  simple.  
 
•  Safety:    
•  The  more  flexible  and  unbounded  a  programming  language  is,  the  
more  poten2al  will  be  run  2me  errors  that  are  hard  to  
troubleshoot.  
 Memory  Maps  and  I/O  addressing  
         Familiarity  with  the  I/O  addressing  is  the  very  first  step  every  
programmer  should  learn  
 
 
 Ladder  Diagram  (LD)  
This  language  is  invented  for  the  express  purpose  of  making  PLC  
programming  feel  “natural”  to  electricians  familiar  with  relay-­‐
based  logic  and  control  circuits.    
 
A  redundant  flame  sensing  system  
Ladder  logic  
A  DRILLING  MACHINE  
Latching  
Ladder  logic  showing  latching  
 HMI  
•  Modern  PLCs  Many  modern  PLC  systems  are  
equipped  with  computer-­‐based  interface  
panels  which  human  
operators  use  to  observe  data  gathered  by  the  
PLC  and  also  enter  data  to  the  PLC.  These  
panels  are  generally  referred  to  as  Human-­‐
Machine  Interfaces,  or  HMI  panels.  
 HMI  
HMIs may take the form of general-purpose
("personal") computers running special graphic
software to interface with a PLC, or as special-
purpose computers designed to be mounted in
sheet metal panel fronts no performing no task but
the operator-PLC interface. The first photograph
shows an example of the former, and the second
photograph an example of the latter:
Introduc2on  to  Sima2c  S7  
 Memory  alloca2ons  

MB15 MB16 MB17 MB18

MW15 MW17

MW16 MW18

MD15