Dr. Essam M.

Shaalan
 Chapter (2)
Introduction to
Programmable Logic
Controller (PLC)

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 What Programmable Logic Controller (PLC) ?

• Programmable Logic Controllers (PLC) is a

microprocessor based device that can be used to
control industrial process or system such as electric
motor, conveyor and robot according to the
designed program.

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 What Programmable Logic Controller (PLC) ?

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 Why Programmable Logic Controller (PLC) ?

Electromechanical relays are

 noisy
 slow
 relatively large
 mechanical problems
 The control panels that
hold the
electromechanical
relays are larger than
that of PLC
 Rewiring Modification
is difficult(expensive-
time consuming)

Electromechanical relay control panel

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 Why Programmable Logic Controller (PLC) ?

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 Why Programmable Logic Controller (PLC) ?
o When compared with relay systems, PLCs:
• Easily implement changes (Edit and modify in control Circuit) as changes
are implemented in software rather than more complex hardware
modifications that would be the case with a relay system
• Expanded by adding new modules to the PLC whereas hardware changes
are necessary with relay system (Ability to add more timers, counters,
relays and so decrease physical components and wires)
• More robust and reliable than relay systems with their large number of
mechanical components
• More compact than relay systems
• Require less maintenance than relay systems
• Operate faster than relay systems
• High capital cost but low overall cost (Economics)

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 PLC Vendors / Brands

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 PLC Vendors / Brands

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 PLC Types Based on Size

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 PLC Block Diagram

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 PLC Block Diagram

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 How Does a PLC work?

A PLC Scan Process includes the following steps

 The operating system starts cycling and monitoring of time.
 The CPU starts reading the data from the input module and
checks the status of all the inputs.
 The CPU starts executing the user or application program
written in relay-ladder logic or any other PLC-
programming language.
 Next, the CPU performs all the internal diagnosis and
communication tasks.
 According to the program results, it writes the data into the
output module so that all outputs are updated.
 This process continues as long as the PLC is in run mode.

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 PLC Components / Physical Structure
Programmable Logic Controllers continuously monitors the
input values from various input sensing devices (e.g.
accelerometer, weight scale, hardwired signals, etc.) and
produces corresponding output depending on the nature of
production and industry.
A typical PLC consists of five parts namely:
1. Rack or chassis
2. Power Supply Module
3. Central Processing Unit (CPU)
4. Input & Output Module
5. Communication Interface Module

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 PLC Components / Physical Structure
Rack or Chassis
 In all PLC systems, the PLC rack or chassis forms the most
important module and acts as a backbone to the system.
 PLCs are available in different shapes and sizes. When more
complex control systems are involved, it requires larger PLC
racks.
 Small-sized PLC is equipped with a fixed I/O pin
configuration. So, they have gone for modular type rack PLC,
which accepts different types of I/O modules with sliding
and fit in concept.
 All I/O modules will be residing inside this rack/chassis.

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 PLC Components / Physical Structure
Power Supply Module
 This module is used to provide the required power to the
whole PLC system.
 It converts the available AC power to DC power which is
required by the CPU and I/O module.
 PLC generally works on a 24V DC supply. Few PLC uses an
isolated power supply.

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 PLC Components / Physical Structure
CPU Module and Memory
 CPU module has a central processor unit, ROM & RAM
memory.
 ROM memory includes an operating system, drivers, and
application programs.
 RAM memory is used to store programs and data.
 CPU is the brain of PLC with an octal or hexagonal
microprocessor.
 Being a microprocessor-based CPU, it replaces timers, relays,
and counters.
 Two types of processors as a single bit or word processor can
be incorporated with a PLC. One bit processor is used to
perform logic functions. Whereas word processors are used
for processing text, numerical data, controlling, and
recording data.
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 PLC Components / Physical Structure
CPU Module and Memory
 CPU reads the input data from sensors, processes it, and
finally sends the command to controlling devices.
 CPU contains other electrical parts to connect cables used by
other units.

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 PLC Components / Physical Structure
Input and Output Module
 Have you ever thought about how to sense physical
parameters like temperature, pressure, flow, etc? using PLC?
 PLC has an exclusive module for interfacing inputs and
output, which is called an input & output module.
 Input devices can be either start and stop pushbuttons,
switches, etc
 Output devices can be an electric heater, valves, relays, etc.
 I/O module helps to interface input and output devices with
a microprocessor.

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 PLC Components / Physical Structure
Input and Output Module

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 PLC Components / Physical Structure
Input and Output Module
 The input module of PLC does four main functions.
1. Input module interface receives the signal from process
devices at 220 V AC
2. Converts the input signal to 5 V DC that can be used by
PLC
3. Isolator block is used to isolate/prevent PLC from
undergoing fluctuation
4. After which the signal is sent to the output end i.e the
PLC
 There are two main sections in the input module namely the
power section and the logical section. Both sections are
electrically isolated from each other.

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 PLC Components / Physical Structure
Input and Output Module
 Initially push button is closed. So, 220 V AC supply is given
to the bridge circuit through the resistors R1 and R2.
 A bridge rectifier (such as a diode bridge rectifier) is used to
convert the AC signal into DC and Zener diode is used to
provide a low voltage supply to LED.
 When the light from LED falls on the phototransistor, it
works in the conduction region. Finally, a 5V DC supply is
given to the processor.

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 PLC Components / Physical Structure
Input and Output Module
 The output module of PLC works similarly to the input
module but in the reverse process. It interfaces the output
load and processor. So here the first section would be logic
session and the power section comes next.
 So, here when the program logic high signal is generated
from the processor, the LED will turn ON and allow the light
to fall on a phototransistor.
 When the transistor goes to the conduction region, it
generates a pulse to the gate of the Triac. The isolator block is
used to isolate the logic section and control section.

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 PLC Components / Physical Structure
Communication Interface Module
 To transfer information between CPU and communication
networks, intelligent I/O modules are used.
 These communication modules help to connect with other
PLCs and computers which are placed at a remote location.

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