Department Of Mechatronics Engineering

Faculty Of Engineering And Information Technology

An-Najah National University

Programmable
Logic Controllers
(10651572)

Dr. Mohammad Abuabiah

[email protected]

Office: 11-4-130 1
Chapter 1

An Overview

2
 Chapter Objectives 3
Dr. Mohammad Abuabiah

• Define what a programmable logic controller (PLC) is and list its

advantages over relay systems.

• Identify the main parts of a PLC and describe their functions.

• Outline the basic sequence of operation for a PLC.

An-Najah National University

• Identify the general classifications of PLCs.

 4
Industrial Automation (Video)
Dr. Mohammad Abuabiah An-Najah National University
 5
1.1 Introduction
Dr. Mohammad Abuabiah An-Najah National University
 6

??
1.1 Introduction
Dr. Mohammad Abuabiah An-Najah National University
 1.1 Introduction 7
Dr. Mohammad Abuabiah

• A programmable logic controller (PLC) is an industrial grade

computer that is capable of being programmed to perform
control functions.
An-Najah National University
 1.1 Introduction 8
Dr. Mohammad Abuabiah

• The programmable controller has eliminated much of the

hardwiring associated with conventional relay control circuits.
• Other benefits include fast response, easy programming and
installation, high control speed, network compatibility,
troubleshooting and testing convenience, and high reliability.
An-Najah National University
 1.1 Introduction 9
Dr. Mohammad Abuabiah

• The PLC is designed for multiple input and output arrangements,

extended temperature ranges, immunity to electrical noise, and
resistance to vibration and impact.
• A PLC is an example of a real-time system since the output of the
system controlled by the PLC depends on the input conditions.
An-Najah National University
 1.1 Introduction 10
Dr. Mohammad Abuabiah

• Increased Reliability. Once a program has been written and

tested, it can be easily 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.
An-Najah National University

User Program
 1.1 Introduction 11
Dr. Mohammad Abuabiah

• More Flexibility. It is easier to create and

change a program in a PLC than to wire
and rewire a circuit. With a PLC the
relationships between the inputs and
outputs are determined by the user
program instead of the manner in which
they are interconnected.

• Easier to Test Field Devices. A PLC control

panel has the ability to check field
An-Najah National University

devices at a common point. For example,

a control system consisting of hundreds of
input and output field devices may be
contained within a very large
manufacturing area.
 1.1 Introduction 12
Dr. Mohammad Abuabiah

• Communications Capability. A PLC can communicate with other

controllers or computer equipment to perform such functions as
supervisory control, data gathering, monitoring devices and
process parameters, and download and upload of programs.
An-Najah National University
 1.1 Introduction 13
Dr. Mohammad Abuabiah

• Faster Response Time. PLCs are designed for highspeed and real-
time applications. The programmable controller operates in real
time, which means that an event taking place in the field will
result in the execution of an operation or output.
An-Najah National University
 1.1 Introduction 14
Dr. Mohammad Abuabiah

• Easier to Troubleshoot. PLCs have resident diagnostics and

override functions that allow users to easily trace and correct
software and hardware problems. To find and fix problems, users
can display the control program on a monitor and watch it in real
time as it executes.
An-Najah National University
 1.2 Parts of a PLC 15
Dr. Mohammad Abuabiah

• A typical PLC can be divided into the following parts, central

processing unit (CPU), the input/output (I/O) section, the power
supply, and the programming device.
An-Najah National University
 1.2 Parts of a PLC 16
Dr. Mohammad Abuabiah

• There are two ways in which I/Os (Inputs/Outputs) are

incorporated into the PLC: fixed and modular.
• Fixed I/O is typical of small PLCs that come in one package with
no separate, removable units.
An-Najah National University
 1.2 Parts of a PLC 17
Dr. Mohammad Abuabiah

• 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 the modules
available from the manufacturer and mix them any way you desire.
An-Najah National University
 Siemens PLC (Modular I/O) 19

RACK
Dr. Mohammad Abuabiah
An-Najah National University

Power CPU DI AI DO AO Function Communication

Supply Module Processor
 1.3 Principles of Operation 20
Dr. Mohammad Abuabiah

• To get an idea of how a PLC operates,

consider the simple process control
problem illustrated in the Figure.
– Here a mixer motor is to be used to
automatically stir the liquid in a vat when
the temperature and pressure reach preset
values.
– In addition, direct manual operation of the
motor is provided by means of a separate
An-Najah National University

pushbutton station.
– The process is monitored with temperature
and pressure sensor switches that close their
respective contacts when conditions reach
their preset values.
 1.3 Principles of Operation 21
Dr. Mohammad Abuabiah

• This control problem can be solved using the relay method for motor
control shown in the relay ladder diagram. The motor starter coil (M) is
energized when both the pressure and temperature switches are
closed or when the manual pushbutton is pressed.
An-Najah National University
 1.3 Principles of Operation 22
Dr. Mohammad Abuabiah

• Now let’s look at how a

programmable logic controller
might be used for this application.
• The same input field devices
(pressure switch, temperature
switch, and pushbutton) are used.
• These devices would be hardwired
An-Najah National University

to an appropriate input module

according to the manufacturer’s
addressing location scheme.
 1.3 Principles of Operation 23
Dr. Mohammad Abuabiah

• The same output field device

(motor starter coil) would also
be used.
• This device would be
hardwired to an appropriate
output module according to
An-Najah National University

the manufacturer’s addressing

location scheme.
 1.3 Principles of Operation 24

• Next, the PLC ladder logic program would be constructed and

Dr. Mohammad Abuabiah

entered into the memory of the CPU.

An-Najah National University
 1.3 Principles of Operation 25
Dr. Mohammad Abuabiah

• Figure below shows the typical wiring required to implement the

process control scheme using a fixed PLC controller.
An-Najah National University
 1.4 Modifying the Operation 26
Dr. Mohammad Abuabiah

• One of the important features of a PLC is the ease with which the program
can be changed.
• For example, assume that the original process control circuit for the mixing
operation must be modified as shown in the relay ladder diagram.
• The change requires that the manual pushbutton control be permitted to
operate at any pressure, but not unless the specified temperature setting
has been reached.
An-Najah National University
 1.4 Modifying the Operation 27
Dr. Mohammad Abuabiah

• If a relay system were used, it would require some rewiring of the

circuit to achieve the desired change.
• However, if a PLC system were used, no rewiring would be necessary.
The inputs and outputs are still the same. All that is required is to
change the PLC ladder logic program.
An-Najah National University
 1.5 PLCs versus Computers 28
Dr. Mohammad Abuabiah

• The architecture of a PLC is basically the same as that of a personal

computer.
• A personal computer (PC) can be made to operate as a
programmable logic controller if you provide some way for the
computer to receive information from devices such as pushbuttons or
switches. You also need a program to process the inputs and some
way to turn devices on and off.
An-Najah National University

• However, some important characteristics distinguish PLCs from

personal computers. First, unlike PCs, the PLC is designed to operate in
the industrial environment with wide ranges of ambient temperature
and humidity.
 1.5 PLCs versus Computers 29
Dr. Mohammad Abuabiah

• A well-designed industrial PLC installation, such as that shown in

Figure below, is not usually affected by the electrical noise inherent in
most industrial locations.
An-Najah National University
 1.5 PLCs versus Computers 30
Dr. Mohammad Abuabiah

• Unlike the personal computer, the PLC is programmed in relay ladder logic
or other easily learned languages.
• The PLC comes with its program language built into its memory and has no
permanently attached keyboard, CD drive, or monitor.
• Instead, PLCs come equipped with terminals for input and output field
devices as well as communication ports.
• PLC control systems have been designed to be easily installed and
maintained.
An-Najah National University

• Troubleshooting is simplified by the use of fault indicators and messaging

displayed on the programmer screen.
• Input/output modules for connecting the field devices are easily connected
and replaced.
 1.5 PLCs versus Computers 31
Dr. Mohammad Abuabiah

• Software associated with a PLC but written and run on a personal computer falls
into the following two broad categories:

1) PLC software that allows the user to program and document gives the user the
tools to write a PLC program using ladder logic or another programming language
and document or explain the program in as much detail as is necessary.
An-Najah National University
 1.5 PLCs versus Computers 32
Dr. Mohammad Abuabiah

2) PLC software that allows the user to monitor and control the process is also
called a human machine interface (HMI). It enables the user to view a
process or a graphical representation of a process—on a monitor,
determine how the system is running, trend values, and receive alarm
conditions.
An-Najah National University
 1.6 PLC Size and Application 33
Dr. Mohammad Abuabiah

• The criteria used in categorizing PLCs include functionality, number of inputs

and outputs, cost, and physical size.
• I/O count is the most important factor.
• In general, the nano is the smallest size with less than 15 I/O points. This is
followed by micro types (15 to 128 I/O points), medium types (128 to 512 I/O
points), and large types (over 512 I/O points).
An-Najah National University
 1.6 PLC Size and Application 34
Dr. Mohammad Abuabiah

• There are three major types of PLC application: single-ended,

multitask, and control management.
• A single-ended or stand-alone PLC application involves one PLC
controlling one process. This would be a standalone unit and would
not be used for communicating with other computers or PLCs.
An-Najah National University
 1.6 PLC Size and Application 35
Dr. Mohammad Abuabiah

• A multitask PLC application involves one PLC controlling several

processes. Adequate I/O capacity is a significant factor in this type of
installation.
• A control management PLC application involves one PLC controlling
several others. This kind of application requires a large PLC processor
designed to communicate with other PLCs and possibly with a
computer.
An-Najah National University
 1.6 PLC Size and Application 36
Dr. Mohammad Abuabiah

• Memory is the part of a PLC that stores data, instructions, and the control
program. Memory size is usually expressed in K values: 1 K, 6 K, 12 K, and so
on.
• Depending on memory type, 1 K can mean 1024 bits, 1024 bytes, or 1024
words.
• The amount of memory required depends on the application. Factors
affecting the memory size needed for a particular PLC installation include:
– Number of I/O points used
An-Najah National University

– Size of control program

– Data-collecting requirements
– Supervisory functions required
– Future expansion
 37
1.6 PLC Size and Application
• PLC Brands
Dr. Mohammad Abuabiah An-Najah National University
 1.6 PLC Size and Application 38
Dr. Mohammad Abuabiah

• WHAT ARE THE MAJOR PLC MANUFACTURERS?

• RSLogix 5000
• Studio 5000
An-Najah National University

SLC 500 PAC Micro Logix

 1.6 PLC Size and Application 39
Dr. Mohammad Abuabiah

• WHAT ARE THE MAJOR PLC MANUFACTURERS? • SIMATIC STEP7

• TIA Portal
An-Najah National University

SIMATIC stands for Siemens Automatic

 1.6 PLC Size and Application 40
Dr. Mohammad Abuabiah

• WHAT ARE THE MAJOR PLC MANUFACTURERS?

• ABB Automation Builder software

An-Najah National University