Programmable Logic Controllers Explained

Programmable
Logic Controllers
In English
Instructor: Rana Muhammad Awais
So What is PLC?
Programmable Logic Controller (PLC):

Programmable Logic Controller is an industrial-grade Input CPU Output
computer used for automation of machinery and
processes in an industry by controlling inputs and outputs
through the programmed logic. It takes signals from
sensors (inputs) and energizes actuators (outputs) based
on the logic programmed while working in real time.
(Follows Standard IEC 61131-2 for PLC)

Input from Process
Benefits: Sensors
1. Higher reliability
2. More flexibility as changes can be made within program
3. Cost effective for controlling complex systems
4. Easier programming and troubleshooting PLC
5. Faster response time
6. Immune to electrical noise
Energizes
7. Resistance to Vibration Outputs
Rana Muhammad Awais | www.automationplay.com| automationplayonline@gmail.com | Facebook.com/automationplay | Youtube: Rana Muhammad Awais
PLC How PLC Works?
CONTROL LOOP
Programmable Logic Controller:
(PLC) is an industrial computer control

system that automate processes by: Operates Output
 Read Inputs
 Program Scan Control
Continuous
Loop (Scan
 Energizes the Outputs Program Scan
Cycle (in ms)
Cycle)
 Continuous Cycle
PLC can be divided into three parts: Read Inputs

 CPU
 Inputs/Outputs
 Programming Device
PLC OPERATION
Let’s have a look at a simple

process.
• Boxes being transported till it

reaches the sensor
• Motor is running the conveyor
• When the boxes reach the

sensor, the sensor sends a
signal to relay or PLC
• Thus stopping the motor Sensor (Input)
Motor (Output) Process (Boxes

transported through a
conveyor)
PLC OVERVIEW
Power Supply
INPUT Central Processing Unit Output
Module Module
User Memory Data Memory
Serial Port
Optical Optical
Isolation Isolation
Applications
PLC APPLICATIONS
Applications
PLCs are common choice for systems having discrete I/Os
and fixed logic. Also for machine control and motion
control. For higher Analog Control and Continuous
(process) applications, Distributed Control System (DCS)
Is preferred
PLCs have three major types of applications:
Single Task – single process being controlled by single plc

(stand – alone)
Multi Task – multiple processes being controlled by

single PLC having many I/Os
Control Management – Master PLC Controlling multiple

PLCs for complex processes
PLC Programming Languages
Programming Languages
Programmable Logic Controller:
PLC can be programmed using standard programming languages IEC

61131-1 standard. :
Currently Five Languages are commonly used:
• Functional Block Diagram (FBD) –Graphical (For Process Flow)

• Ladder Logic (LD) – Graphical (For Electrical Flow)
• Structured Text (Similar to Pascal) – Textual (Textual, Calculative)
• Instruction List (Similar to Assembly) – Textual (Boolean)
• Sequential Function Chart (SFC) – Graphical (Sequential Process)
Ladder Logic
PLC Hardware
Source: Siemens Rana Muhammad Awais | www.automationplay.com| automationplayonline@gmail.com | Facebook.com/automationplay | Youtube: Rana Muhammad Awais
PLC Hardware
PLC Hardware
PLC Hardware
PLC Programming Languages
Programming Concepts
TwoTYPES
TypesOFof Mechanical
MECHANICAL Design
DESIGN forSYSTEMS
FOR PLC PLC Systems
Programmable Logic Controller Brands:
• Compact / Standard / Single Box
• Rack Type / Modular
Two Types of Mechanical Design for PLC Systems
Inputs and Outputs
I/O Types:
Digital Inputs and Outputs

Analog Inputs and Outputs
Digital Signal:
O or 220 V meaning Low or High
Example: Photoelectric Sensor that measures object
presence through IR Wave
Analog Signal:
Continuous Signal meaning 0 to 10V or 4 to 20 mA
Example: Ultrasonic Sensor that measures object
distance though sound waves
Inputs and
INPUTS and OUTPUTS
Outputs
COMMON INPUTS
Start Push Stop Push Emergency Selector Switch Sensors (Limit

Buttons Buttons Stop Button Switches, Proximity,
Ultrasonic, IR etc…)
Rating: 220VAC or 24VDC
Inputs and
INPUTS and OUTPUTS
Outputs
COMMON OUTPTUS
Lamps Motor Valves
Rating: 220VAC or 24VDC
Applications
SELECTION OF PLC
CRITERIA:
• Digital and/or Analog I/Os

• No. of Inputs/Outputs (I/Os)
• Any special requirements (Temperature, load
cell etc)
• Size of control program
• Data-collecting requirements
• Future expansion
TIA Selection Tool

https://new.siemens.com/global/en/products/automation/topic-areas/tia/tia-
selection-tool.html
Siemens PLC Series
S7-200 S7-300 S7-400 S7-1200 S7-1500 ET-200 with

integrated CPU
• Compact PLC with Onboard • Compact Or Modular PLC • High performance and • Medium and Low end • Advanced and Modular
I/Os • Medium and Low end medium range performance range controller • Distributed I/O
• Micro PLC for lower performance range • Modular PLC • Compact PLC with onboard • High and medium end • with or without CPU
performance range • Software: Simatic Manager • For Process automation I/Os performance • Modular PLC
• Software: Step 7 Microwin • Cable/Interface: MPI / • DCS Applications • Software: TIA Portal • Highest system performance • High and medium end
• Cable/Interface: PPI / Profibus • Software: TIA Portal • Cable: Ethernet • Software: TIA Portal performance
Profibus • High and medium end • High and medium end • Cable / Interface: Ethernet / • Software: TIA Portal
performance performance Profinet • Cable/Interface: Ethernet /
• Cable/Interfaces: MPI DP / • Profinet Profinet
Profibus DP
• Software: PCS7 Package
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLCs
Siemens S7-300
Siemens S7-
300 CPU Model
Do you know?
S7 300 series is designed for

Medium and Low end performance
PLC Digital
range Status Inputs
Specifications: Indicators (08)
Net Weight: 0,458 Kg Run/Stop
Dimensions: 13,10 x 10,30 x 9,0010 /MRES
I/O: DI/6 DQ,
2 high-speed counters (10 kHz) Integer Switch
CPU Processing: 0.1 us for bit operation
MPI Interface
Programming:
Ladder/FBD/SCL/Graph/SCL
Software: STEP 7 V5.5 + SP1 or higher. Digital
24V DC Supply and MPI
Outputs
Interface (Programming
(06)
Cable)
Article
Number
Siemens S7-1200
Siemens S7- Digital Inputs
1200 (06)
Do you know?

range
Specifications: CPU Model
PLC
Net Weight: 0,458 Kg
Dimensions: 13,10 x 10,30 x 9,0010 Status
I/O: DI/6 DQ, Indicators
2 high-speed counters (10 kHz) Integer
Ethernet Interface
Programming:
Software: TIA Portal.
24V DC Supply and Digital Outputs
Ethernet Interface (04)
(Programming Cable)
Siemens S7-1200
Siemens S7-1200
Siemens S7-1200
Siemens S7-1200
Siemens S7-1200
Siemens S7-1200
Siemens S7- Digital Inputs
1200 (06)
Do you know?

range
Specifications: CPU Model
PLC
Net Weight: 0,458 Kg
Dimensions: 13,10 x 10,30 x 9,0010 Status
I/O: DI/6 DQ, Indicators
2 high-speed counters (10 kHz) Integer
MPI Interface
Programming:
Software: STEP 7 V5.5 + SP1 or higher.
24V DC Supply and MPI Digital Outputs
Interface (Programming (04)
Cable)
PLC Output Selection
Application
Setting up PLC
MPI Cable
SIMATIC MANAGER SOFTWARE
Rana Muhammad Awais | www.automationplay.com | automationplayonline@gmail.com | Facebook.com/automationplay | Youtube: Rana Muhammad Awais
PLC Output Selection
Application
Setting up PLC
TIA PORTAL
Industrial Ethernet (Profinet)
subnet
subnet Node
Node IP Address: 192.168.0.100
IP Address: 192.168.0.1 Subnet Mask: 255.255.255.0
Subnet Mask: 255.255.255.0
PLCSoftware
Output Selection
Application
Simulating Siemens S7-1200 PLC
TIA Portal (v15) S7-PLCSIM (v15)

Programming Software For Simulating Programs
for Siemens PLCs without PLC
In English and Urdu

Siemens PLC Communication
Siemens PLC Series
Siemens PLC Series
In English and Urdu

Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Siemens PLC Series
Function Block Diagram

Programmable Logic Controllers Explained

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Programmable

Programmable Logic Controller (PLC):

(Follows Standard IEC 61131-2 for PLC)

Programmable Logic Controller:

(PLC) is an industrial computer control

PLC can be divided into three parts: Read Inputs

Let’s have a look at a simple

• Boxes being transported till it

• Motor is running the conveyor

• When the boxes reach the

• Thus stopping the motor Sensor (Input)

Motor (Output) Process (Boxes

INPUT Central Processing Unit Output

PLCs have three major types of applications:

Single Task – single process being controlled by single plc

Multi Task – multiple processes being controlled by

Control Management – Master PLC Controlling multiple

Programmable Logic Controller:

PLC can be programmed using standard programming languages IEC

Currently Five Languages are commonly used:

• Functional Block Diagram (FBD) –Graphical (For Process Flow)

Programmable Logic Controller Brands:

• Compact / Standard / Single Box

• Rack Type / Modular

Digital Inputs and Outputs

Start Push Stop Push Emergency Selector Switch Sensors (Limit

Rating: 220VAC or 24VDC

Lamps Motor Valves

Rating: 220VAC or 24VDC

• Digital and/or Analog I/Os

TIA Selection Tool

S7-200 S7-300 S7-400 S7-1200 S7-1500 ET-200 with

S7 300 series is designed for

S7 1200 series is designed for

S7 1200 series is designed for

SIMATIC MANAGER SOFTWARE

Industrial Ethernet (Profinet)

TIA Portal (v15) S7-PLCSIM (v15)

Instructor: Rana Muhammad Awais

Instructor: Rana Muhammad Awais

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