Section 01

Haward Technology Middle East
PIONEERS IN TECHNOLOGY TRANSFER
Industrial Instrumentation and New

Generation of Digital Process
Control Systems: Smart Protection
Devices and Network Equipment
Control & Monitoring (ICS & SCADA)
©2014 Haward Technology Middle East. This document is the property of the course instructor and/or Haward Technology Middle East. No part
of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical,
photocopying, recording, or otherwise, without the prior written permission of Haward Technology Middle East
Industrial Instrumentation and New Generation of Digital Process
Control Systems: Smart Protection Devices and Network
Equipment Control & Monitoring (ICS & SCADA)
Course Objectives
Upon the successful completion of this course, each
participant will be able to:
 Apply a comprehensive knowledge on Programmable Logic
Controllers (PLC) and employ SCADA programming in process control
 Analyze the system parts & power supplies of a PLC hardware
including the block diagram of a typical PLC, PLC processor module
& memory organization
 Discover the underlying principles of a PLC software including the
programming devices, number systems, memory components, data
structures, operating modes and limitations
Section 1 Haward Technology Middle East 2

Course Objectives
 Discuss the PLC systems design, installation and maintenance and
review the documentation & troubleshooting techniques used in the
system
 Practice PLC programming using Allen Bradley and Siemens Simulators
 Apply the concepts & common elements of IEC 1131-3 including its
programming languages, instruction list, function block diagram an
sequential function chart
 Employ the principles of data communications & Object Linking and
Embedding in Process Control (OPC) and be able to recognize their
importance in PLC & SCADA systems

Course Objectives
 Implement the concept of Operator Interfaces (OIU) and
describe the operator interface programming such as its
configuration, graphical languages, good & bad parts
 Determine the concept, terminology & components of SCADA
system and increase in-depth knowledge on SCADA software
 Implement the complete procedures & requirements in
SCADA programming and be able to practice how to create &
configure a SCADA system using the various utilities, process
control, commands & system components

Section 1
PLC Overview

Welcome to the Section Materials
Typical PLCs
Topics to be Discussed
 Hard-Wired Control
 Conventional Control Panel
 Brief Historical Background
 Typical Areas of PLC Applications
 PC vs. PLC
 PLC and Other Controls
 Advantages & Disadvantages of PLCs
 Terminology
 Number Systems
 Basic Elements of PLC
Hard-Wired Control Circuit Diagram
Prior to PLCs, many of control tasks were

460 VAC Moooε
solved with contactor or relay controls.
This is often referred to as hardwired
control. Circuit diagrams had to be
designed, electrical components specified
and installed, and wiring lists created.
24 VAC
Start
Stop

Conventional Control Panel

During sixties and seventies, relays were
used to operate automated machines,
and these were interconnected using
wires inside the control panel.
Disadvantages of a classic control panel are:
 Too much work required in connecting

wires
 Difficulty with changes or replacements
 Difficulty in finding errors; requiring
skillful work force
 When a problem occurs, hold-up time is
indefinite, usually long

Brief Historical Background

Before the PLCs, automated manufacturing processes had
to be controlled using hardware devices such as rotating
cams in lathes.
However, in mid 1970s advances in micro-electronics
have made a revolution in industrial control. Electronic
programmable controller has replaced relay-based, hard-
wired electrical systems.
The first PLC systems evolved from conventional
computers in the mid - 70s and were mostly used in
automotive industry.

PLC
 Relay Control
 1968 GM Specification
 Bedford Associates (MODICON), AB responded
 1969 MODICON 084
 1970 AB PDQ II
 1971 AB PMC, GE PC-45
 1972 AB Programming Device
 1973 MODICON 184, GE PC Logitrol
 1974 AB PLC Bulletin 1774
 1975 MODICON 284/384
 1978 AB PLC2
 1970’s sequencer state-machines, based on AMD 2901
and 2903 (AB PLC-3)

PLC
 1981 AB PLC-3, GE Series 6 PLC
 1983 GE Series 1 PLC
 1985 AB PLC-5 on Motorola 68000, GE Series 3 PLC
 1986 MODICON 984
 1988 GE Fanuc Series 5 PLC
 1990 GE Fanuc 90-30, 90-70
 1991 AB SLC500
 1992 AB low cost Block I/O
 1994 MODICON Quantum
 1995 AB 1 millionth PLC
 1998 AB ControlLogix, GE Fanuc VersaMax
 2002 GE Fanuc RX7i, RX3i PAC
PLC Communications History
 1973 Communications Modbus

 1979 Modbus Network, AB DH (Data Highway) Network
 1980’s GM MAP standardization
 1990’s 1131 standardization
 1992 MODICON Profibus and Ethernet
 1993 AB Ethernet and TCP/IP
 1994 AB DeviceNet Open Network
 1994 ISO OSI Standard 7498 - 1

According to National Electrical

:Manufacturers’ Association, a PLC is
 A digital electronic device using a programmable

memory to store instructions and to implement
specific functions such as logic, sequence, counting,
timing and arithmetic to control machines and
processes.

According to National Electrical

:Manufacturers’ Association, a PLC is
 Programmable logic controllers are the most widely

used electronic devices in the control of production
and assembly process in most automated factories due
to its simplicity and versatility.
 A programmable logic controller is a user-friendly,
microprocessor based, specialized computer carrying
out control functions of many types and levels of
complexity in industrial applications.

Typical Areas of PLC Applications


 Because the applications of programmable controllers

are extensive, it is impossible to list them all.

PLCs Versus Personal Computers
PLC PC
 Operates in the industrial  Capable of executing
environment several programs
 Is programmed in relay ladder simultaneously, in any order
logic  Some manufacturers have
 Has no keyboard, CD drive, software and interface cards
monitor, or disk drive available so that a PC can
 Has communications ports, and do the work of a PLC
terminals for input and
 output devices
PC Based Control Systems
Advantages
 Lower initial cost
 Less proprietary hardware and
software required
 Straightforward data exchange
with other systems
 Speedy information processing
 Easy customization

PLC Size Classification

Criteria
 Number of inputs and outputs (I/O count)
 Cost
 Physical size
Nano PLC
 Smallest sized PLC
 Handles up to 16 I/O points
Micro PLC

PLC Size Classification
Allen-Bradley SLC-500 Family

Allen-Bradley PLC-5 Family

 Handles several thousand I/O
points

Advantages of a PLC Control System

 Eliminates much of the hard wiring that was associated
with conventional relay control circuits.
The program takes the

place of much of the
external wiring that
would be required for
control of a process.


 Increased Reliability.
Once a program has been written and tested it can be
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.
Conversely


 More Flexibility.
Original equipment manufacturers (OEM5) can provide system
updates for a process by simply sending out a new program.
It is easier to create and

change a program in a
PLC than to wire and
rewire a circuit. End-
users can modify the
program in the field.


 Lower Costs.
Originally PLCs were designed to replace relay control logic.
The cost savings using PLCs have been so significant that relay
control is becoming obsolete, except for power applications.
Generally, if an
application requires
more than about 6
control relays, it will
usually be less
expensive to install a
PLC.


 Communications Capability.
A PLC can communicate with other controllers or computer
equipment.
They can be networked to

perform such functions as:
supervisory control, Data
gathering, monitoring
devices and process
parameters, and
downloading and uploading
of programs.


 Faster Response Time.
PLCs operate in real-time which means that an event taking
place in the field will result in an operation or output taking
place.
Machines that process

thousands of items per
second and objects that
spend only a fraction
of a second in front of
a sensor require the
PLC’s quick response
capability.


 Easier To Troubleshoot.
PLCs have resident diagnostic and override functions
allowing users to easily trace and correct software and
hardware problems.
1. Wiring to output
device
Machines that process
De-energized - off
Output module
2. Output device.
thousands of items per
status indicator
On
Possible problem
source
second and objects
Wiring to output
device
that spend only a
Output device fraction of a second
in front of a sensor
Output device
condition
Off
require the PLC’s
quick response
capability.
?What to Do
Programmable Logic Controllers
are in the computer family. Drive Motors
They are used in commercial

and industrial applications. A Lights Pumps
PLC monitors inputs, makes

decisions based on its program,
and controls outputs to
automate a process or machine.
This course is meant to supply
you with basic information on Photo Sensors Pushbutton
Switches
the functions and configurations
of PLCs.
?What to do
PLC Conceptual Application Diagram

Terminology
The language of PLCs consists of a commonly used set of

terms; many of which are unique to PLCs. In order to
understand the ideas and concepts of PLCs, an
understanding of these terms is necessary.

Terminology
Sensor
A sensor is a device that converts

a physical condition into an
electrical signal for use by the Pushbutton
PLC. Sensors are connected to (Sensor)
the input of a PLC. A pushbutton
is one example of a sensor that is
connected to the PLC input. An
electrical signal is sent from the
pushbutton to the PLC indicating
the condition (open/closed) of
the pushbutton contacts

Terminology
Actuators
Actuators convert an electrical signal from the PLC into a

physical condition. Actuators are connected to the PLC
output. A motor starter is one example of an actuator that
is connected to the PLC output.
Motor Starter
(Actuator)

Terminology
Discrete Input
A discrete input, also Normally Open Pushbutton

referred to as a digital
input, is an input that is Normally Closed Pushbutton
either in an ON or OFF
condition. Pushbuttons, Normally Open Switch
toggle switches, limit
switches, proximity Normally Closed Switch
switches, and contact

closures are examples of Normally Open Contact
discrete sensors which are
connected to the PLCs Normally Closed Contact
discrete or digital inputs.

Terminology
Discrete Input
One side of the pushbutton is
connected to the first PLC input. PLC
Input 1
The other side is connected to Off
Logic 0
an internal 24 VDC power
supply. Many PLCs require a 24 VDC
separate power supply to power

the inputs. In the open state, no PLC
voltage is present at the PLC Input 1
input. This is the OFF condition. Off

Logic 1
When the pushbutton is
24 VDC
depressed, 24 VDC is applied to
the PLC input. This is the ON
condition.
Terminology
Analog Inputs
An analog input is an input

signal that has a continuous
signal. Typical analog inputs
may vary from 0 to 20
milliamps, 4 to 20 milliamps,
or 0 to 10 volts.
In the example, a level transmitter monitors the level of
liquid in a tank. Depending on the level transmitter, the
signal to the PLC can either increase or decrease as the
level increases or decreases.
Terminology
Discrete Outputs
A discrete output is an
output that is either in an
ON or OFF condition.
Solenoids, contactor coils,
and lamps are examples of
actuator devices connected
to discrete outputs.
Discrete outputs may also be referred to as digital

outputs. In the following example, a lamp can be turned
on or off by the PLC output it is connected to.

Terminology
Analog Outputs Meter
An analog output is an PLC Current-to-Pneumatic Transducer

output signal that has a Outputs
continuous signal. The Air Supply
output may be as simple Air-Operated Flow-Control Valve

as a 0-10 VDC level that
drives an analog meter.
Examples of analog meter outputs are speed, weight, and
temperature. The output signal may also be used on more
complex applications such as a current-topneumatic
transducer that controls an air-operated flow-control
valve.
Terminology
CPU 10.0 10.1 00.0
The central processor 10.4 00.1
unit (CPU) is a
10.5
microprocessor system
that contains the system
memory and is the PLC
decisionmaking unit.
The CPU monitors the inputs and makes decisions based on
instructions held in the program memory. The CPU
performs relay, counting, timing, data comparison, and
sequential operations.

Terminology
Programming
A program consists of one or more instructions that
accomplish a task. Programming a PLC is simply
constructing a set of instructions. There are several ways
to look at a program such as ladder logic, statement lists,
or function block diagrams.
Ladder Logic
Ladder logic (LAD) is one programming language used with
PLCs. Ladder logic uses components that resemble
elements used in a line diagram format to describe hard-
wired control.
Terminology
Ladder Logic Diagram
The left vertical line of a ladder Power Conductor
logic diagram represents the Network 1

10.0 10.1 00.0
Output Element
power or energized conductor. Or Instruction
The output element or instruction

represents the neutral or return Network 2
10.4 00.1
path of the circuit. The right

vertical line, which represents the 10.5
return path on a hard-wired

control line diagram, is omitted.
Ladder logic diagrams are read
from left-to-right, top-to-bottom.

Terminology
Statement List
A statement list (STL) provides

another view of a set of
instructions. The operation, what
is to be done, is shown on the
left. The operand, the item to be
operated on by the operation, is
shown on the right.
A comparison between the statement list shown below,

and the ladder logic shown on the previous page, reveals a
similar structure. The set of instructions in this statement
list perform the same task as the ladder diagram.
Terminology
Function Block Diagrams
Function Block Diagrams

(FBD) provide another
view of a set of
instructions.
Each function has a name to designate its specific task.
Functions are indicated by a rectangle. Inputs are shown
on the left-hand side of the rectangle and outputs are
shown on the right-hand side. The function block diagram
shown below performs the same function as shown by the
ladder diagram and statement list.
Terminology
RAM
Random Access Memory (RAM) is memory where data can

be directly accessed at any address. Data can be written
to and read from RAM. RAM is used as a temporary storage
area. RAM is volatile, meaning that the data stored in RAM
will be lost if power is lost. A battery backup is required
to avoid losing data in the event of a power loss.

Terminology
ROM
Read Only Memory is a type of memory that data can be
read from but not written to. This type of memory is used
to protect data or programs from accidental erasure. ROM
memory is nonvolatile. This means a user program will not
lose data during a loss of electrical power. ROM is
normally used to store the programs that define the
capabilities of the PLC.

Terminology
EPROM
Erasable Programmable Read Only Memory (EPROM)

provides some level of security against unauthorized or
unwanted changes in a program. EPROMs are designed so
that data stored in them can be read, but not easily
altered. Changing EPROM data requires a special effort.
UVEPROMs (ultraviolet erasable programmable read only
memory) can only be erased with an ultraviolet light.
EEPROM (electronically erasable programmable read only
memory), can only be erased electronically.

Terminology
Firmware
Firmware is user or application specific software burned

into EPROM and delivered as part of the hardware.
Firmware gives the PLC its basic functionality.


Number Systems
Since a PLC is a computer, it stores information in the

form of On or Off conditions (1 or 0), referred to as binary
digits (bits). Sometimes binary digits are used individually
and sometimes they are used to represent numerical
values.


Decimal System
Various number systems are used by PLCs. All number

systems have the same three characteristics: digits, base,
weight. The decimal system, which is commonly used in
everyday life, has the following characteristics:
Ten digits 0, 1, 2, 3, 4, 5, 6, 7, 8, 9
Base 10
Weights 1, 10, 100, 1000, ...


Number Systems
Binary System
The binary system is used by programmable controllers.
The binary system has the following characteristics:
Two digits 0, 1
Base 2
Weights Powers of base 2 (1, 2, 4, 8, 16, ...)
Most Significant Bit Least Significant Bit
27 26 25 24 23 22 21 20
128 64 32 16 8 4 2 1
0 0 0 1 1 0 0 0


Number Systems
Converting Binary to Decimal


Number Systems
Bits, Bytes, and Words
Each binary piece of data is a bit. Eight bits make up one

byte. Two bytes, or 16 bits, make up one word.
Bit
Byte
Word


Number Systems
Binary-Coded Decimal (BCD) Decimal BCD
Numbers Numbers
BCD are decimal numbers 0
1
0000
0001
where each digit is 2 0010
3 0011
represented by a four-bit 4 0100
binary number. BCD is 5
6
0101
0110
commonly used with 7 0111
8 1000
input and output devices. 9 1001
A thumbwheel switch is one example of an input device that

uses BCD. The binary numbers are broken into groups of four
bits, each group representing a decimal equivalent. A four-digit
thumbwheel switch, like the one shown here, would control 16
(4 x 4) PLC inputs.

Number Systems
Hexadecimal
Hexadecimal is another system used in PLCs. The hexadecimal

system has the following characteristics:
16 digits 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, F
Base 16
Weights Powers of base 16 (1, 16, 256, 4096 ...)

Every Bit is Meaningful
Three motors M1, M2 and M3 can be represented with

three bits in a binary number:
 101 – motors M1 and M3 are on

 111 – all motors are on
 000 – all motors are off

Basic Elements of PLC
Program
Inputs PLC Outputs

Brief Historical
Basic Elements of PLC Background
CPU
PLCs consist of Input Central Processing
Output
Module Module
input modules or Unit
points, a Central
Processing Unit
(CPU), and output
Programming Operator
modules or points. Device Interface
An input accepts a variety of digital or analog signals from

various field devices (sensors) and converts them into a
logic signal that can be used by the CPU.
Basic Elements of PLC

A PLC system contains four main Screw terminals
parts, which are: for input lines
PLC controller
 CPU module
Input adjustable level
Power
Supply
 Input and Output
Memorija
Commu CPU
modules(I/O modules) nication
 A power supply module

Line for output adjustable
Extension level
 Peripheral equipments
PC for PLC Screw terminals
programming for output lines


PLC Architecture

PLC System

PLC Architecture
 An open architecture design allows the system to be
connected easily to devices and programs made by
other manufacturers.
 A closed architecture or proprietary system, is one
whose design makes it more difficult to connect
devices and programs made by other manufacturers.
NOTE: When working with PLC systems that are

proprietary in nature you must be sure that any generic
hardware or software you use is compatible with your
particular PLC.

I/O Configurations
 Is typical of small PLCs

 Comes in one package,
with no separate
removable units.
 The processor and I/O
are packaged together.
 Lower in cost — but
lacks flexibility.

I/O Configurations
Is divided by compartments
into which separate modules
can be plugged.
This feature greatly increases

your options and the unit’s
flexibility. You can choose
from all the modules
available and mix them in any
way you desire.

I/O Configurations
When a module slides into

the rack, it makes an
electrical connection with
a series of contacts -
called the backplane. The
backplane is located at
the rear of the rack.

Power Supply
 Supplies DC power to other
Modules that plug into the
rack.
 In large PLC system, this
power Supply does not
normally supply power to the
field devices.
 In small and micro PLC
systems, The power supply is
also used to power Field
devices.

Processor (CPU)
 Is the “brain” of the PLC
 Consists of a microprocessor
for implementing the logic,
and controlling the
communications among the
modules.
 Designed so the desired circuit
can be entered in relay ladder
logic form.
 The processor accepts input
data from various sensing
devices, executes the stored
user program, and sends
appropriate output commands
to control devices.
I/O Section
Consist of:
 Input Modules
 Output modules

I/O Section
 Forms the interface by

which input field
devices are connected
to the controller.
 The terms “field” and
“real world "are used
to distinguish actual
external devices that
exist and must be
physically wired into
the system.
I/O Section
 Forms the interface by

which output field
devices are connected
to the controller.
 PLCs employ an optical
isolator which uses
light to electrically
isolate the internal
components from the
input and output
terminals.
Programming Device
 A personal computer (PC) is the most commonly used

programming device
 The software allows users to create, edit, document, store
and troubleshoot programs
 The personal computer communicates with the PLC
processor via a serial or parallel data communications link

Programming Device
 Hand-held programming devices are sometimes used to

program small PLCs
 They are compact, inexpensive, and easy to use, but
are not able to display as much logic on screen as a
computer monitor

Programming Device
 Hand-held units are often used on the factory floor for

troubleshooting, modifying programs, and transferring
programs to multiple machines.


Basic System Requirements
In order to create or change a Programming

program, the following items Software
Device
are needed: Step 7 – Micro/WIN32
 PLC
 Programming Device PC/PPI
Connector Cable
 Programming Software
 Connector Cable S7-200 PLC

Sourcing and Sinking Input Module
+
Input +
Input Input
module
device module
- -
Input
device
Sourcing Sinking

Sink and Source Output Modules

Optocoupler Load +
Fuse Current
Flow
Output
-
PLC
Optocoupler +
Output
Current
Fuse Flow
Load -
PLC

COURSE RECAP

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Haward Technology Middle East

PIONEERS IN TECHNOLOGY TRANSFER

Industrial Instrumentation and New

Section 1 Haward Technology Middle East 2

Section 1 Haward Technology Middle East 3

Section 1 Haward Technology Middle East 4

Section 1 Haward Technology Middle East 5

Welcome to the Section Materials

Hard-Wired Control Circuit Diagram

Prior to PLCs, many of control tasks were

Section 1 Haward Technology Middle East 8

Conventional Control Panel

 Too much work required in connecting

Section 1 Haward Technology Middle East 9

Brief Historical Background

Section 1 Haward Technology Middle East 10

Section 1 Haward Technology Middle East 11

PLC Communications History

 1973 Communications Modbus

Section 1 Haward Technology Middle East 13

According to National Electrical

 A digital electronic device using a programmable

Section 1 Haward Technology Middle East 14

According to National Electrical

 Programmable logic controllers are the most widely

Section 1 Haward Technology Middle East 15

Typical Areas of PLC Applications

Section 1 Haward Technology Middle East 16

Typical Areas of PLC Applications

Section 1 Haward Technology Middle East 17

Typical Areas of PLC Applications

 Because the applications of programmable controllers

Section 1 Haward Technology Middle East 18

PLCs Versus Personal Computers

PC Based Control Systems

Section 1 Haward Technology Middle East 20

PLC Size Classification

Section 1 Haward Technology Middle East 21

PLC Size Classification

Allen-Bradley SLC-500 Family

Allen-Bradley PLC-5 Family

Section 1 Haward Technology Middle East 22

Advantages of a PLC Control System

The program takes the

Section 1 Haward Technology Middle East 23

Advantages of a PLC Control System

Since all the logic is

Section 1 Haward Technology Middle East 24

Advantages of a PLC Control System

It is easier to create and

Section 1 Haward Technology Middle East 25

Advantages of a PLC Control System

Section 1 Haward Technology Middle East 26

Advantages of a PLC Control System

They can be networked to

Section 1 Haward Technology Middle East 27

Advantages of a PLC Control System

Machines that process

Section 1 Haward Technology Middle East 28

Advantages of a PLC Control System

They are used in commercial

PLC monitors inputs, makes

PLC Conceptual Application Diagram