PLC Introduction

COURSE TRAINANG
Programmable Logic Controller

“PLC”
level 1
Eng.Ahmad Yousef engahmadyahmad@yahoo.com 1

Course main topics:
1- Introduction.
2- Wiring
 Connecting power supply

 Connecting inputs and outputs
 Switch-on behavior
3- Integrated functions
 Connectors
 Basic functions
 Special functions

4- Operation on device
 Control for operation
 First program
 LOGO! in run mode

* Configuring LOGO!
5- LOGO! Soft Comfort V8.2

Help functions
 Realizing typical tasks step by step

Introduce your self
# Name
# Company
# Job title

What Is a Programmable Logic Controller ?
A programmable logic controller (PLC) is a specialized computer used to

control machines and processes . It uses a programmable memory to
store instructions and execute specific functions that include
onloffcontrol. timing. counting. Sequencing. arithmetic,
and data handling.

PLCs provide many other benefits
including:
Increased Reliability. More Flexibility. Lower Cost.
Communications Capability. Faster Response Time. Easier to Troubleshoot.

PARTS OF A PLC
Po
su
pl
er
w
y
p
1 n.c
switch
Input Cpu Output
0 n.o module module
switch

BASIC COMPONENTS:
# Power supply
# Central Processing Unit (CPU)
# Inputs Modules
# Outputs Modules

1- Power Supply Module
There are several types of power supply module:
240V ac
110V ac
24V dc
Provides all the voltage level needed to operate the PLC. Converts 110V ac or 240V ac into
the dc voltage required by the CPU, memory, I/O interface

2- Central Processing Unit (CPU
Consist of:
# Processor
# Memory
Receives information from input interface, process according to the program stored,
update the output information.

What Are PLC Inputs?
The term PLC inputs refers to the devices and transducers which are entrusted with taking
in information about the physical world to the PLC. Keep in mind that it also refers to the
PLC hardware that connects to those devices, sensors and transducers. The PLC uses this
input information to make decisions based upon its program whether to energize and de-
energize the outputs controlled by the PLC.

Analog and binary signals:
Binary signals can assume only 2 signal states: signal state 1 (voltage present) and
signal state 0 (no voltage present). In control engineering, it is frequently necessary to
read, process and output analog signals in addition to binary signals. In contrast to
binary signals, analog signals take on any number of values within a specific range.
Possible analog variables include:
● Temperature ● Pressure ● Speed ● Fill level ● pH value

Controllers are only capable of processing analog values in the form of bit patterns. For this
purpose, transducers which can be connected to the analog module measure physical variables
such as pressure or temperature. The analog input module reads this analog value in the form
of current, voltage or resistance. To enable the CPU to process the current or voltage measured,
an integrated analog-to-digital converter in the analog input module converts the value into a
16-bit integer value. Depending on the type of measurement, you can use the following
transducers:
● Voltage transducers
● Current transducers
– 2-wire transducers
– 4-wire transducers
● Resistance transducers
– 4-wire connection
● Thermocouples

Example:
Speed is acquired using a transducer which converts the speed range of 0
to 1500 rpm to a voltage range of 1 to 5 V. At a measured speed of 865
rpm, the transducer outputs a value of 3.3 V.
The resulting voltage value is calculated as

follows:

The graph below illustrates voltage acquisition:
Speed measurement

Analog-to-digital conversion
A CPU processes information exclusively in digital format. The analog value is therefore converted into a
bit pattern. Conversion is done using an integrated ADC (analog-to-digital converter) in the analog input
module. For the CPU, this conversion always returns a 16-bit word for SIMATIC products. The ADC used
digitalizes the analog signal and approximates its value with a stepped curve. Resolution and conversion
speed are the most important ADC parameters.

Digital-to-analog conversion
Once the CPU has processed the digital signal, an integrated DAC (digital-
to-analog converter) in the analog output module converts the output
signal to an analog current or voltage value. The resulting value of the
output signal corresponds to the output value used to control the analog
actuators. Such actuators include, for example, small servo drives or
proportional valves

Visualization of the measuring range at a resolution of 13 bits and 16
bits
The unipolar measured value from a module having a resolution of 13 bits (= 12

bits + S) is segmented into a total of 212 = 4096 increments. The smallest
increment in a measuring range of 0 to10 V is 10 V/4096, equal to 2.4 mV. A
module with16-bit (= 15 bits + S) resolution thus provides an increment of 0.3 mV.
If the resolution increases by one bit, the number of increments doubles and the
width of an increment halves
If the resolution increases from 13 bits to 16 bits, the number of increments increases
eightfold from 4096 to 32768. With a resolution of 13 bits, the smallest value that can
be displayed is therefore 2.4 mV. By contrast, this value is approximately 0.3 mV at a
resolution of 16 bits.

Types of PLC
- Smart relay .
- Compact type.
- Module type.

SMART RELAY COMPACT

compact PLCs
are typically designed to perform basic functions. They are small and
consist of a power supply and the CPU and I/O systems, which are all
housed in one entity. The proper functioning of all processes largely
depends on the flawless execution of every component.

Modular PLCs:
also known as rack-mounted units, consist of bases allowing for many

independent components, such as the installation of numerous I/O
modules. These are easier to repair

PLC Programming Methods :
A PLC is a Programmable Logic Controller and was first used to replace relay circuits.
IEC 61131-3 is the electrical standard for PLC programming methods,

Ladder Diagram :
This is the most common of the PLC Methods. The diagram looks like a wiring schematic for a relay circuit
with the power line on the left and the outputs on the right. This is the main programming method for PLCs
in industrial controls. It is referred to as a ladder diagram because when you look at it, it looks like a ladder
with the inputs and outputs of the program contained on each rung. As an example, you have a proximity
sensor that when triggered, sends 24VDC to the PLC. In the program, you want that trigger to power on a
motor. The rung for that sequence will look like this: --||-----( )--, where --||-- represents the input from the
proximity sensor and –( )--represents the motor output.

Function Block Diagram:
The function block diagram method is also a pictorial method of programming. It consists
of blocks for each function that show the inputs and outputs for more complex sequences
and lines drawn between each block illustrating what each output will do and what will
affect each input.

Sequential Function Chart:
The sequential function chart method is another pictorial method. It most

closely resembles a flow chart, only it’s more complex. There are three primary
elements in a sequential function chart: steps, actions and transitions. Each
step contains the logic for a particular portion of the process

Structured Text:
This is a text language and is not used often with PLCs, though many manufacturers do allow for this
within their PLCs' programming software. It is very similar to Pascal or BASIC, and for people trained with
computer programming, it can be the easiest. Complex math or decision making processes are often
easier to accomplish with structured text as it can be done on one page versus many rungs of a ladder
diagram.

Instruction List:
The instruction list method is probably the most complicated method, as it most closely
resembles Assembly language. This can be useful for processes that repeat a small function
often. Though it is a powerful method, it is often easier to just program the process in a
ladder diagram than it is to learn how to program with an instruction list

Hardware and software needed

Programming with
LOGO! Soft Comfort

A "circuit diagram" must be opened in order to
generate a new switching program. To do this, press the "New" button (Fig. 1.15, a).
This circuit diagram is displayed as standard in FBD
format (function block). The "Properties" windows is opened at the same time as the
circuit diagram.
The individual elements of the circuit diagram are subsequently inserted. To do this, the
catalog with the elements of the switching program is opened in the left margin of the screen
(Fig.1.16, d). It could be the case that this window is so narrow that it is not even visible. The
width must then be increased by dragging with the mouse (Fig. 1.16, f). The catalog contains
all elements available in LOGO! Soft which can be used to generate the program.
To insert the elements, select the desired objects in the catalog. The output terminals Q are
marked in Fig. 1.17 g. There are two methods for inserting the elements h:
– by dragging & dropping into the circuit
diagram
or
– by inserting by mouse click into the circuit
diagram.
32
Grain store (sequential circuit)
Task description
A grain store (Fig. 4.1) is to be modernized. The old controller is to be replaced by a

LOGO! Control relay. The old operating concept with the
operator panel (Fig. 4.2) is to be retained so that retraining of the employees is
unnecessary. The new controller should be planned on the basis of the existing circuit
diagrams (Fig. 4.3). The
cheapest version should be selected.
Eng.Ahmad Yousef 33
Hardware configuration
# Selection of LOGO!
Various parameters must be discussed in order
to define the LOGO! modules
# Number of inputs and outputs

Software configuration
analysis and planning of software
During the system analysis (Fig. 4.8), the total system is divided into objects. If possible, these
are spit into further objects The smallest possible units are then programmed and simulated.
The objects are subsequently combined into a total system, and tested using simulation.

The grain store can be divided into the following
objects:
• Object 1: Conveyor worm

• Object 2: Cyclone
• Object 3: Elevator
• Object 4: Switch-on interlocking
• Object 5: Switch-off interlocking
• Object 6: Signal lamps

Program preparation
# "Properties" window
# Connection table and connection names

# start program
38
# Simulation
When clicking the "Simulation" button,
an input bar is displayed at the bottom
margin of the screen.
# Transfer of program
1- Connection of PC/notebook to the LOGO!
2- Setting the interface

When using the serial ports, the interface must be set in LOGO! Soft Comfort. This setting is
made in the menu:
Tools q Options q Interface (Fig. 2.26)
The port can also be determined automatically with this option 1

4-Setting of PC -----LOGO! mode
If the control relay is in run mode, the stop status must be established prior to transfer of the
program. This is possible in two ways:
• From the PC using the "LOGO! mode" button
2
• On the control relay using the ESC button
and >STOP.
When starting the program transfer, the PC----LOGO! mode

is set automatically
Transfer of programs from the LOGO!

(download)
The same requirements apply to the downloading

of programs from the control relay as those
applying to uploading. To start the program
transfer, click the "LOGO! q PC" button

Logo Practice Training
All exercises can be solved by using logo
soft comfort v8.2
My friends please don’t forget to save

the program on your own PC
Project # 1 Packaging Machine

Project # 2 Drilling Control Operation
43
Project # 3 Filling / Draining Control Operation
44
Project # 4 Part Sorting

# Project 6 Analog value processing
in a labeling machine

# project 7 Greenhouse with
PI controller

Tips:
# for more exercises refer to

Thank you

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COURSE TRAINANG

Programmable Logic Controller

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 1

 Connecting power supply

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 2

 LOGO! in run mode

5- LOGO! Soft Comfort V8.2

 Realizing typical tasks step by step

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 3

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 4

A programmable logic controller (PLC) is a specialized computer used to

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 5

Increased Reliability. More Flexibility. Lower Cost.

Communications Capability. Faster Response Time. Easier to Troubleshoot.

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 6

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 7

# Central Processing Unit (CPU)

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 9

There are several types of power supply module:

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 10

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 11

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 12

● Temperature ● Pressure ● Speed ● Fill level ● pH value

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 13

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 14

The resulting voltage value is calculated as

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 15

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 16

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 17

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 18

The unipolar measured value from a module having a resolution of 13 bits (= 12

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 19

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 20

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 21

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 22

also known as rack-mounted units, consist of bases allowing for many

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 23

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 24

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 25

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 26

The sequential function chart method is another pictorial method. It most

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 27

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 28

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 29

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 30

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 31

A grain store (Fig. 4.1) is to be modernized. The old controller is to be replaced by a

# Number of inputs and outputs

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 34

analysis and planning of software

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 35

• Object 1: Conveyor worm

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 36

# Connection table and connection names

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 37

2- Setting the interface

Eng.Ahmad Yousef engahmadyahmad@yahoo.com 39

When starting the program transfer, the PC----LOGO! mode