07-Mar-21

PLC
Lecture 1 :Introduction to Programmable logic Controllers
Instructor :
Yusuf Abdul-Rahman
MSc in Control Engineering
usfece@gmail.com

Evaluation strategy
The marks of this course will be distributed as follows:
50 final exam
10 mid exam
5 homework
5 Attendance
30 Practical section ( 15 final lab test, 5 reports, 5 attendance, 5 project)

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Content
Overview of Programmable logic controllers – PLC .
PLC hardware components ( CPUs , I/O systems , peripherals etc)
Revision of electromagnetic control circuits ECC – Classic control
Data types and Addressing.
Basics of PLC Programming.
Programming Timers, Counters, Sequencers, Data Transfer, Mathematical Functions.
Communication protocols.
Applications

Introduction
Due to the development of the industrial fields, the control of industrial processes has been
developing constantly. The developing of electrical control starts with rotating camshafts then
comes the relays logic ( classic control ) and still used until now. After CPUs invention and with
the big industrial control requirements, the Programmable Logic controller becomes the best
solution. The competition between factories and industrial companies was increasing day by day.
As a result of that, the PLC devices must keep up with this competitions so the PLC companies
started enhancing the manufacturing of PLC devices including speed, memory size ( size of
program ), accuracy etc.

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What is PLC?
PLC stands for Programmable Logic Controller . PLC implements logic
control functions by means of a program.

PLCs were developed in the nineties and have evolved along with the
requirements of the industry to what they are today. A PLC is a
microprocessor based controller that uses a programmable memory to
store instructions and to implement functions such as logic, sequencing,
timing, counting and arithmetic in order to control machines and process.

Now the question is : when should PLCs be used ?

When should PLCs be used ?

Before answering this question, two terminologies must be introduced and discussed which are:

Automation and Control.

Automation is a set of technologies that results in operation of machines and systems without
significant human intervention and achieves performance superior to manual operation.

Control is a set of technologies that achieves desired patterns of variations of operational parameters
and sequences for machines and systems by providing the input signals necessary.

Now we can say that the PLCs should be used in every industry where automation is involved, from
individual machines to whole processes.

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classic control VS PLC

Classic control is called traditional control, relay logic control, electromagnetic control circuits ECC

By which tangible electromechanical relays, switches, contacts and wires are used without any
programming instructions. On the other hand, PLCs take advantage of programming instead of using
hardware components.

Advantages of using PLC instead of ECC

1. 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 .The program takes the place of much of the external
wiring that would normally be required for control of a process. PLCs also offer the reliability
associated with solid-state components.

2. 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

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Cont.
3. Lower Cost : PLCs were originally designed to replace relay control logic, and the cost savings
have been so significant that relay control is becoming obsolete except for power applications.
4. 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.
5. Faster Response Time: PLCs are designed for high speed and real-time applications.
6. Easier to Troubleshoot: Easy to check software and hardware errors.
7. Easier to Test Field Devices: A PLC control panel has the ability to check field devices at a
common points For example, a control system consisting of hundreds of input and output field
devices may be contained within a very large manufacturing area. Thus, it would take a
considerable amount of time to check each device at its location. By having each device wired
back to a common point on a PLC module, each device could be checked for operation fairly
quickly.

Types of commercial PLCs

The models of PLCs in markets are almost limited. The following are the most known PLCs model in industrial
fields :
 Siemens ( Germany )
 MITSUBISHI ( japan )
 ALLEN BRADELY ( Canada )
 LG ( Korea )
 Telemechanique - cooperated with Schneider ( Germany )
 APP
 Others

The principal concepts are the same in all these types , there might be slight differences in addressing,
memory allocation, and data handling for different models. Consequently, PLC programs cannot be
interchanged among different PLC manufacturers. Each type has its own programming software. During this
course, Siemens might be used more than the other types of PLCs.

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MITSUBISHI

Allen Bradely

Siemens – S71200 Telemechanique

Types of Siemens PLCs

LOGO Siemens

S7-300

S7-1200

S7-1500
S7-200
S7-400

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PLC vs Microcontrollers
Comparing PLCs and Microcontroller systems will be under different headings which include;

1) Architecture : PLCs generally can be referred to as a high level microcontroller. They are
essentially made up of a processor module, the power supply, and the I/O modules

2) Interfaces : PLCs are standard designed to interface with industrial grade sensors, actuators,
and communication modules and are thus given current and voltage ratings which are often
incompatible with microcontrollers without extra hardware.

3) Performance and Reliability: This is by far the point under which the PLC distinguishes itself
the most. PLC is used in harsh environment.

Cont.
5) Required Skill Level : One of the key attributes of the PLC is the low technical knowledge
required for programming, and generally operating it.

6) Programming: For the sake of simplicity and ease of use by all knowledge classes, PLCs were
originally designed to be programmed using a visual of programming that mimics the
connections/schematics of relay logic diagrams. However, Microcontrollers need good and
enough knowledge of High Level Languages and electricians might find that hard to deal
with.

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PLC application

How to start learning PLCs ?

PLC course is a very important specialized course depends on ONLY one thing which is Self-
learning.

To start learning PLC, you have to be good in designing electrical control circuits (ECC), have good
knowledge in Data types, and be up-to-date when it comes to PLCs providers updates.

Try not to be absent because topics are interconnected.

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Homework
Using one piece of paper, Write the differences between S7-200 and S7-300.

References needed
1. Slides given in each lecture.
2. Frank Petruzella - Programmable Logic Controllers 1(2016, McGraw-Hill) .
3. Manuals and guides given by PLCs’ companies.
4. Others (you might find useful).