Programmable Logic Controller

(PLC)

Ahmad Shukri
 Objective
 This training introduces the basic hardware and software
components of a Programmable Controller (PLC). It details
the architecture and basic instruction set common to all
PLC’s. Basic programming techniques and logic designs are
covered. This training describes the operating features of
the PLC, the advantages of the PLC over hard-wired control
systems, practical applications, troubleshooting and
maintenance of PLC’s.
 Introduction
PLC according to IEC -1131 purposes

 Electronic digital systems, designed for use by industry.

 Using a programmable memory for storing instructions, In
order to do work such as logic, sequencing, timing,
counting and Arithmetic
 Allows control over the digital or analoge inputs and
outputs, various types of machines or proses.
 Combined with the PC to enable the combination between
industrial control easily done.

International

Electrotechnical

Commission
 Advantages of PLC
 Less wiring.
 Wiring between devices and relay contacts are done in
the PLC program.
 Easier and faster to make changes.
 Trouble shooting aids make programming easier and
reduce downtime.
 Reliable components make these likely to operate for
years before failure.
 Industrial Evolution
 Before the industrial revolution began a process that is
done with hand, for example filling, labeling confusion and
packaging
 Industrial Evolution
 At the beginning of this century, the whole process is done
automatically as filling, capping, packing and labelling.
 It was carried out using an electro-mechanical control.
 Industrial Evolution
 When the computer was first introduced, there is a new
control system PLC.
 Introduced that will be more efficient and more flexible
than using relay control system
 Type Of PLC
Compact

 Fixed number of input and output

 Input module, output module and control unit in a house
 Type Of PLC
Modular

 Module installed separately from the CPU, input and output

is mounted on a rack (back plane) and can be substituted
with a specific module if needed.
 Module are connected to each other through the System
Bus
 PLC Parts
 PLC generally having five parts, namely: -

i) Input Section
ii) Output Section
iii) Central Processing Unit-CPU
iv) Memory
v) Programming Tools
 Input Section
 The ability of a PLC is in accordance with the existing
number of input points
 signals from switches or sensors are channeled through the
input point.
 Ouput Section
 Output modules are also important for the ability of a PLC
 Central Processing Unit (CPU)
 CPU is divided into three main sections Processor, Power
Supply and Memory
 Input and Output Device
 Computer System  Automation System
 Programming
 Programming equipment.

Programming data to be stored in memory to be written

and incorporated into the PLC. There are many ways to do
these things such as:

a) Through-PC Personal Computer

b) Hand-Held Console Programming.
 Communication
 Computer to PLC
 PLC to PLC
 PLC to Touch panel
 Selecting a PLC
Criteria

 Number of logical inputs and outputs.

 Memory
 Number of special I/O modules
 Scan Time
 Communications
 Software
 The 5 Languages of
IEC 61131-3
Ladder Diagram (LD)

 Form of electric circuit diagram in which there is a switch

and coil symbols.
 Ladder diagrams are very popular in USA and Japan.
 Very suitable to be used for easy connection.
 The 5 Languages of
IEC 61131-3
Instruction List (IL)

 Single Accumulator based execution model Based upon the

German ‘Anweisungsliste’, AWL Only one operation such as
storing a value in the accumulator register, is allowed per
line
 The 5 Languages of
IEC 61131-3
Structured Text (ST)

 High level language, block structured

 Syntax resembles PASCAL
 Complex statements and nested instructions possible
support for example:
 Iteration loops (REPEAT-UNTIL; WHILE-DO)
 Conditional execution (IF-THEN-ELSE; CASE)
 Functions (SQRT(), SIN())
 The 5 Languages of
IEC 61131-3
Function Block Diagram (FBD)

 Graphical language, widely used in Europe

 Allows program elements which appear as blocks to be
"wired" together in a form analogous to a circuit diagram
 Used in many applications that involve the flow of
information or data between control components
 The 5 Languages of
IEC 61131-3
Sequential Function Chart (SFC)

 Graphical language which provides a diagrammatic

representation of program sequences --> flowchart
 Based on the French Grafcet (IEC 848)
 Main structure and suitable for rapid diagnostics
 The basic elements are steps with action blocks and transitions
 Steps consist of a piece of program that is
carried out until a condition specified in the
transition is met
 Programming of complex tasks by dividing
in smaller parts
 Each element can be programmed in any
IEC-language