EEAC006IU-Programmable

Logic Controller (PLC)

Long TonThat, Ph.D.
Room O2.206, School of Electrical Engineering
International University-VNU HCMC
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Email: [email protected]
 Course Structure

 Timetable:
 After 8 weeks, midterm exam
 Pre-requisite:
 Digital Logic Design & Digital Logic Design Lab
 Co-requisite:
 Programmable Logic Controller Lab
 Marking schemes:
 Assignments: 30%
 Midterm: 30%
 Final: 40%

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 Course Materials

 Textbooks
1. F. D. Petruzella, Programmable Logic Controllers, 4th edition, McGraw-Hill Education, 2011
2. Khaled Kamel and Eman Kamel, Programmable Logic Controllers, McGraw Hill Education, New
York, 2014
 References:
1. M. Rabiee, Programmable Logic Controller Hardware and Programming, Goodheart-Willcox,2018
2. Gary Dunning, Programmable Logic Controllers, Thompson Learning, 2006
 Other materials
1. Lecture notes
2. Online websites

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 Course Contents

Process and Industrial Device

• Brief Introduction of Industrial Process
• Introduction of Relay

PLC’s Hardware Architecture

• Siemens S7-1200 Processor, Power Supply…
• Input-Output Modules
• Memory Organization

PLC’s Software Programming

• Boolean Instructions
• Logic Gates and Truth Tables, Combinational Logic Design
• Ladder Logic Diagrams, Times and Counters Programming,… 4
 Learning Outcomes

 Understand the concepts of Process control

 Understand relationship between PLCs and Relay Logics
 Understand PLC architecture: hardware components, I/O modules, process memory
 Understand PLC Programming: Ladder logic, Instruction set, Counter and Timer,
Sequencer Instruction
 Be able to implement ladder diagram

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LECTURE 1:
PROCESS AND PROGRAMMABLE LOGIC
CONTROLLER

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 Contents

 Process Control
 Overview of PLC
 PLC Components
 Conventional Relay

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 Process Control

 Process refers to an interacting set of operations that leads to the manufacture or development
of some products
⁃ The end product must have certain specified properties that depend on the input conditions
 Control is used to describe the steps necessary to ensure that the regulated conditions produce
the correct properties in the product.
 A process can be described by an equation

where the -th process property, the th process variable, and is the time.

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 Example 1

 An example of automatic process is shown in Fig.1.

− Free water flows through a tank
− The tank acts in a way to slow the flow rate through the piping
structure
− The output flow rate is proportional to the water head in the
tank
− Water level inside the tank will rise as the input flow rate
increases
− At the same time, output flow rate will increase with a
Fig.1. Water flow tank process
noticeable increase in the tank water level
− Three primary variables: FLOW IN, FLOW OUT, and the
tank level (self-regulation).
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 Example 1 (cont.)

 Manual Control of level is shown in Fig.2.

− Widely available can be effective for simple and small
applications
− Humans are involved in monitoring the process and
carrying out necessary decisions to bring about desired
changes in the process
− Cost of operation and training can become a burden
− The two valves can be activated from an easy-to-use
operator interface
− Fig.2. Tank level manual control
Valve position variations are achieved through an operator
input based on observed real-time process conditions.

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 Overview of PLC

 Early machines were controlled by mechanical devices using cams, gears, levels, etc…
 Programmable Logic Controllers (or PLCs) are the most widely used Industrial Process Control
Technology
 Basically a digital computer designed for use in machine control
 Capable of being programmed to perform control functions
 An example of a real-time system, i.e. outputs controlled by the PLC depends on the input
conditions
 Programs or algorithms of control and operation of manufacturing process equipment and
machinery are typically stored in battery-backed or nonvolatile memory
 PLCs were made using transistor-transistor logic (TTL) logic gate chips, AND, OR, NOT,
NAND….
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 Overview of PLC (cont.)

Benefits:
1. Increased Reliability
− Eliminate much of the hardwiring associated with conventional relay control circuits
− PLCs also offer the reliability associated with solid-state components

2. More Flexibility
− Program in PLC can be easier to change than to wire and rewire a circuit

3. Lower Cost
− Initially, PLC was used to replace relay logic, if an application has more than about a half- dozen

control relays, it will probably be less expensive to install a PLC

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 PLC’s Components

Central Processing Unit (CPU):

− Usually consists of a microprocessor for implementing the
logic and includes system memory, serial communication ports
for printer, PLC LAN link and external programming device
− Memories are used for storing user program instructions,
numerical values, and I/O devices status
The Input / Output (I/O):
− Input devices are pushbuttons, limit switches, and sensors are
hardwired to the input terminals
− Output devices are small motors, motor starters, solenoid
valves and indicator lights are hardwired to the output
terminals
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 PLC’s Components

 The Power Supply

− Supply DC power to other modules
that plug into the rack
− Larger system, power to field
devices is provided by external
alternating current (AC) or direct
current (DC) supplies
− For some small micro PLC systems,
the power supply may be used to
power field devices

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 PLC’s Components

 Programming device and Programming

- Used to enter the desired program into the memory of the
process
- The program can be entered using relay ladder logic
(RLL), a series of instructions that directs the PLC to
execute the actions
- A program in ladder logic is similar to a schematic for a
relay control circuit
- The relay ladder logic is originally based on
electromechanical relay control
- The relay ladder logic program graphically represents
rungs of contacts, coils, and special instruction blocks
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 Conventional Relay

 An electromagnetic switch that has a coil and a set of

associated contacts (normally open or normally closed)
 An electromagnetic field is generated once voltage is
applied to the coil. This field generates a force that pulls
the contacts of the relay causing them to make or break
the controlled external circuit connection
 Used in automobiles and industrial applications. i.e.
control whether a high power device is switched on or off

Industrial Relays
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 Relay’s operation

 A relay is typically used to control a device that requires

high voltage or draws large current
 The relay allows full power to the device without needing a
mechanical switch that an carry the high current
 A control relay CR1 with two contacts normally open
(CR1-1) and normally close (CR1-2)
 Power is not applied to the coil (CR1) and the two contacts are
in the normal state
 In reverse, the power is applied to the coil and the two contacts
switch state

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 Relay’s Logic System

 Relay logic systems are control structures for

industrial applications
 Operations/processes that are controlled by
relay logic systems are hardwired
 Built directly into the device, be inflexible and
be difficult to modify after deployment
 Typically used to protect the application
against damage under overloads and other
undesired working condition
AND OR
 Schematic diagrams for relay logic circuits are Two relay circuits implementing two inputs: AND and
often called logic diagrams OR logic functions
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 Relay’s Logic and Circuit

 A relay logic circuit is an electrical diagram consists of lines/networks/rungs

 A typical circuit consists of a number of networks, with each controlling an output
- Each output is controlled through a combination of input or output conditions (e.g. switches and
control relays)
 Input/Output connection: Series/Parallel, or Series-Parallel
 Relay logic diagrams represent the physical interconnection of devices
- Possible to design a relay logic diagram directly from the narrative description of a process-control
event sequence

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Relay’s Logic and Circuit

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 Relay’s Circuit

 A simple relay circuit for controlling a bell using a

single pole, singe through (SPST) switch
- Two separate circuits: low-power dc side is connected to
the coil, whereas the high-power ac side is located in the
field away from the control room
- Two circuits are only connected through electromagnetic
field coupling
- Two sides are normally powered from two independent
sources Simple Relay circuit for controlling bell’s
- A switch is normally used to control the low-power side, sound
the relay-coil side
 Press the switch cause the bell to sound
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 Conclusions

 Process Control is introduced

 Programmable logic controller (PLC) and its main parts have been defined
and described
 Relay system, operation, and circuit have been introduced

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