PLC

Programmable
Logic
Controller

PLCs are small computers, dedicated to automation

tasks in industrial environment

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Control Relay
 A Control Relay is an electromagnetic switch aims to closing
and opening the circuits electromechanically.
Contact Points a + - a
11 Load1
10
Load 9
Load2

3
220VAC PL1
2
Coil 1 PL2

12VDC 4

Relay 8

Control Switch

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 Solid State Logic Circuits
 A solid state logic circuit is usually made from arrangements of
transistors.
 Using just transistors, we can build logic gates (AND,
NAND, OR, NOR, MUX etc.) as well as memory devices
(flip-flops, registers, etc.) and from there on, the
combinations, applications, and implementations are
endless.
 Solid-state logic circuits are small, reliable, low cost,
and can operate at very high speeds with a high life
expectancy. In the average control circuit, the inputs may
change from high to low and vice versa several times in a
second.
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Before the advent of solid-state logic circuits, logical control
systems were designed and built exclusively around
electromechanical control relays.

A relay control panel is comprised of a single to thousands of

relays.

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 The Need for PLCs
 Hardwired panels were consuming very long time
to wire, debug and change.
 GM identified the following requirements for
computer controllers to replace hardwired panels.
• Solid-state not electromechanical
• Easy to modify input and output devices
• Easily programmed and maintained by plant electricians

• Be able to function in an industrial environment

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Relays are far from obsolete in modern design, but
have been replaced in many of their former roles
as logic-level control devices, relegated most often
to those applications demanding high current
and/or high voltage switching.

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 What is a PLC ?
 PLCs are often defined as miniature industrial
computers that contain hardware and software
used to perform control functions.
 PLCs are designed for multiple arrangements of
digital and analog inputs and outputs with extended
temperature ranges, immunity to electrical noise,
and resistance to vibration and impact.

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The most important and essential characteristics of
a PLC that portray its unique aspects are:
1) It is field programmable by the user.
2) It contains programmed functions.
3) It scans memory and I/O in a deterministic manner.

4) It provides error checking and diagnostics.

5) It could be monitored.
6) It is packaged appropriately.
7) It has general purpose suitability.

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 Advantages of PLCs
In addition to cost savings, PLCs provide many other
benefits including:
1) Increased Reliability.

2) More Flexibility.

3) Lower Cost.

4) Communications Capability.

5) Faster Response Time.

6) Easier to Troubleshoot.

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PLC Basics
PLC
Power Supply

CPU

Output Section
Input Section

from Logic to
Inputs Solver Outputs
Push Buttons
Motor Starters
Limit Switches
Lights
Sensors
Valves
Smart Devices
Smart Devices

Memory
Program
User's
Loader/
Monitor program

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PLC Basics cont.
All the PLC components get their required power from
the PLC power supply.

External power supply is usually used to provide

the external input / output devices with the
necessary power to operate them.

The PLC power supply could be used to power the

external small input / output devices like sensors
and indicators.
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PLC Basics cont.
The logic solver reads these inputs and decides
what the output states should be, based on the
user's program logic.
The input modules convert the high-level signals
that come from the field devices to logic-level
signals that the PLC's processor can read
directly.
The output modules convert the logic-level output
signals from the logic solver into the high-level
signals that are needed by the various field
devices.
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 PLC Basics cont.
The program loader is used to enter the user's
program into the memory or change it and to
monitor the execution of the program.

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 I / O Configuration
1) Fixed I / O
o Is typical for small PLCs

o Comes in one package, with no

separate removable units.
o The CPU and I/O are
packaged together.
o Lower in cost, but lacks flexibility.

o For some models, if any part in the unit fails, the whole
unit has to be replaced.
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 I / O Configuration cont.
2) Modular I / O

o Is divided by compartments into which separate

modules can be plugged.

o This feature greatly increases the unit’s flexibility.

o All the modules are available and could be chosen
and mixed in any way.
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 I / O Configuration cont.
2) Modular I / O

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 Input Modules Wiring
1) Wiring of Sink Sensor and Two Wire Sensor to a
PLC Source Inputs Module.

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 Input Modules Wiring cont.
2) Wiring of Source Sensor and Two Wire Sensor to a
PLC Sink Inputs Module.

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Input Modules Wiring cont.
3) Wiring of Sink / Source PLC Inputs Module.

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Wiring of Output Modules

a) Wiring of a PLC Sink Outputs Module

b) Wiring of a PLC Source Outputs Module
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Wiring of Inductive Loads

1) Wiring of Inductive Load to AC Output Module

2) Wiring of Inductive Load to DC Output Module

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