Introduction to

Programmable Logic
Controllers
(PLC's)
Dr. Eng. Wael Soliman

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 1 of 47
 The Need for PLCs

• Hardwired panels were very time consuming to wire,

debug and change.
• PLCs identified the following requirements for
computer controllers to replace hardwired panels.
 Solid-state not mechanical
 Easy to modify input and output devices
 Easily programmed and maintained by plant electricians
 Be able to function in an industrial environment

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 2 of 47
 The First Programmable Logic Controllers (PLCs)

• Introduced in the late 1960’s

• Developed to offer the same functionality as the
existing relay logic systems Programmable, reusable
and reliable
 Could withstand a harsh industrial environment
 They had no hard drive, they had battery backup
 Could start in seconds
 Used Ladder Logic for programming

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 3 of 47
 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 specific functions that include On/Off control,
timing, counting, sequencing, arithmetic, and data
handling

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 4 of 47
 Advantages of PLC Control Systems

 Flexible
 Faster response time
 Less and simpler wiring
 Solid-state - no moving parts
 Modular design - easy to repair and expand
 Handles much more complicated systems
 Sophisticated instruction sets available
 Allows for diagnostics “easy to troubleshoot”
 Less expensive

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 5 of 47
 Advantages of PLC Control Systems

The program takes the place

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

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 6 of 47
 Advantages of PLC Control Systems
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.

Conversely ......

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 7 of 47
 Advantages of PLC Control Systems
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.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 8 of 47
 Advantages of PLC Control Systems
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.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 9 of 47
 Advantages of PLC Control Systems
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.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 10 of 47
 Advantages of PLC Control Systems
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.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 11 of 47
 Advantages of PLC Control Systems
Easier To Troubleshoot:
PLCs have resident diagnostic and override functions allowing 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

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 12 of 47
 PLC Architecture

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 13 of 47
 PLC System

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 14 of 47
 PLC Architecture
 An open architecture design allows the system to be connected easily to
devices and programs made by other manufacturers.

 A closed architecture or proprietary system, is one whose design makes it

more difficult to connect devices and programs made by other
manufacturers.

NOTE:
When working with PLC systems that are proprietary in nature you must be sure that any
generic hardware or software you use is compatible with your particular PLC.
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 15 of 47
 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.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 16 of 47
 I/O Configurations

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.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 17 of 47
 I/O Configurations

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.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 18 of 47
 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.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 19 of 47
 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
relay ladder logic form.
 The processor accepts input data from various
sensing devices, executes the stored user program,
and sends appropriate output commands to control
devices.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 I/O Section

 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
relay ladder logic form.
 The processor accepts input data from various
sensing devices, executes the stored user program,
and sends appropriate output commands to control
devices.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 I/O Section

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.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 I/O Section

Output Module
 Forms the interface by which
output field devices are connected
to the controller.

 PLCs employ an optical isolator

which uses light to electrical- ly
isolate the internal components
from the input and output
terminals.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 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 personal computer communicates with the PLC processor
via a serial or parallel data communications link
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 Programming Device

 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
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 Programming Device

 Hand-held units are often used on the factory floor for

troubleshooting, modifying programs, and transferring programs to
multiple machines.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 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

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 Process Control Relay Ladder Diagram

Motor starter coil is energized when both the

pressure and temperature switches are closed or
when the manualpushbutton is pressed

 Motor starter coil is energized when both the pressure and

temperature switches are closed or when the manual
pushbutton is pressed
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 Process Control Relay Ladder Diagram

 The same input field devices are used

 These devices are wired to the input

module according to the
manufacturer’s labeling scheme

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLC Output Module Connections
Same output field device
is used and wired to the
output module

Triac switches motor ON

and OFF in accordance
with the control signal
from the processor
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLC Ladder Logic Program

 The format used is similar to that of the hard-wired relay circuit

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLC Ladder Logic Program

The symbols represent instructions

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLC Ladder Logic Program

 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 where they are physically connected
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 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 operatingcycle

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLC Operating Cycle
During each operating cycle, the
controller examines thestatus of
input devices, executes the user
program, and changes outputs
accordingly

The completion of one cycle

of this sequence is called
a scan. The scan time, the
time required for one full
cycle, provides a measureof
the speed of response of
the PLC

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLC Operating Cycle

Each can be though of as a set of normallyopen contacts

The can be considered to represent a coil that, when energized, will close a set of contacts

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLC Operating Cycle

Coil O/1 is energized when contacts I/1 and I/2 are closed or when
contact I/3 is closed. Either of these conditions provides a continuous
path from left to right across the rung that includes the coil.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 Modifying A PLC Program

Relay ladder diagram for

modified process

The change requires that the manual pushbutton control should

be permitted to operate at any pressure but not unless the
specified temperature setting has been reached.
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 Modifying A PLC Program

Relay ladder diagram for

modified process

If a relay system were used, it would require some

rewiring of the system, as shown, to achieve the
desired change.
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 Modifying A PLC Program

PLC ladder logic

diagram for modified
process.

If a PLC is used, no rewiring is necessary!

The inputs and outputs are still the same.
All that is required is to change the PLC program
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLCs Versus Personal Computers

Same basic
architecture

PC
PLC  Capable of executing several
 Operates in the industrialenvironment programs simultaneously, in any
 Is programmed in relayladder logic order
 Has no keyboard, CD drive,monitor, or  Some manufacturers have
disk drive software and interface cards
 Has communications ports,and available so that a PC can dothe
terminals for input andoutput devices work of a PLC
Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PC Based Control Systems

Advantages
 Lower initial cost
 Less proprietary hardwareand software
required
 Straightforward data exchangewith other
systems
 Speedy information processing
 Easy customization

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PC Based Control Systems

Criteria
 Number of inputs and outputs (I/O count)
 Cost
 Physical size

Nano PLC
 Smallest sized PLC
 Handles up to 16 I/O points

Micro PLC
 Handles up to 32 I/O points

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLC Size Classification

Allen-Bradley SLC-500 Family

 Handles up to 960 I/O points

Allen-Bradley PLC-5 Family

 Handles several thousand I/O
points

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 PLC Instruction Set

The instruction set for a particular

PLC type lists the different types of
instructions supported.

An instruction is a command that will cause a PLCto

perform a certain predetermined operation.

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47
 Typical PLC Instructions
XIC (Examine ON) . . . . . . . Examine a bit for an ON condition
XIO (Examine OFF) . . . . . . Examine a bit for an OFF condition
OTE (Output Energize) . . . . Turn ON a bit (non retentive)
OTL (Output Latch) . . . . . . Latch a bit (retentive)
OTU (Output Unlatch) . . . . Unlatch a bit (retentive)
TOF (Timer Off-Delay) . . . . . Turn an output ON or OFF after its
rung has been OFF a preset timeinterval
TON (Timer On-Delay) . . . . Turn an output ON or OFF after its
rung has been ON for a preset time interval
CTD (Count Down) . . . . . . . Use a software counter to count down
from a specified value
CTU (Count Up) . . . . . . . . . Use a software counter to count up
to a specified value

Dr.Eng. Wael Soliman Lecture – Introduction to PLC’s – MTI Faculty of Engineering – Winter 2021 20 of 47