Ministry of Higher Education and Scientific Research

Kasdi Merbah University - Ouargla

Faculty of New Information and Communication Technologies

Department of Electronics and Telecommunications

Telemetry and SCADA

Course support

Programmable logic controller

Dr. ACHBI Mohammed Said

2023/2024
2. PLC: The Hardware Part ................................................................................................ 3
2.1 Introduction .............................................................................................................. 3
2.2 Historical ................................................................................................................... 5
2.3 Definition of Programmable Logic Controller (PLC) .......................................... 6
2.4 Main characteristics of PLCs: ................................................................................. 7
2.5 Areas of use of PLC .................................................................................................. 7
2.6 Advantages of PLCs: ................................................................................................ 7
2.7 Disadvantages of PLCs: ........................................................................................... 8
2.8 PLC builders ............................................................................................................. 8
2.9 External appearance of PLCs ................................................................................. 8
a) Compact PLCs: ............................................................................................................ 8
b) Modular PLC : ............................................................................................................. 9
2.10 Structure of PLC ...................................................................................................... 9
2.10.1 Rack or Chassis: ................................................................................................... 9
2.10.2 Power supply: ..................................................................................................... 10
2.10.3 Central Processing Unit (CPU): ........................................................................ 10
2.10.4 The Input / Output modules (Signal modules) ................................................ 11
2.10.5 Function module ................................................................................................. 14
2.10.6 The communication module .............................................................................. 15
2.10.7 Interface module: ............................................................................................... 16
2.10.8 Programming Device: ........................................................................................ 16
2.11 PLC choice .............................................................................................................. 17
2.12 Required hardware and software ......................................................................... 17
2.13 Memory areas of the CPU and the SIMATIC memory card ............................. 18
2.14 STEP 7 Professional (TIA Portal) programming software ................................ 19

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Course 2 Programmable Logic Controller (PLC)

2. PLC: The Hardware Part

2.1 Introduction
Programmable logic controllers (PLCs) appeared at the end of the 1960s, at the request of the
American automobile industry (General Motors or GM), which demanded more flexibility
from their control systems.

Figure 2.1: Comparison between the old automobile assembly line and the modern line (nowadays we
can clearly see that human beings are replaced by robots controlled by PLCs)

Before PLCs, electromagnetic relays and pneumatic systems ⇒ ( wired logic) were used to
create the control part (PC).

Figure 2.2: Electromagnetic relays a basic element of hardwired logic

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Course 2 Programmable Logic Controller (PLC)
Disadvantages: expensive technology, no flexibility, no communication possible.

Solution: use of microprocessor-based

microprocessor systems ⇒ ( programmed logic ⇒ PLC
PLC) allowing easy
modification of automated systems by simply modifying the programming.

Figure 2.3: Microprocessor the basic element of programmed logic

 Definition :
In French, it's called: AP (Automate Programmable Industriel),
API
In English, PLC (Programming Logic Controller).

A programmable logic controller (PLC), also referred to as a programmable controller, is a

type of computer commonly used in commercial and industrial control applications. It uses a
programmable memory to store instructions and specific functions
functions that include On/Off
control, timing, counting, sequencing, arithmetic, and data handling.

Figure 2.4: PLCs.

A (PLC) is a programmable electronic device intended for controlling industrial processes

through sequential processing. This system performs automation functions to ensure the
control of pre-actuators
actuators and actuators based on logical, analog or digital information. The
programmable controller operates by cyclical execution of the program.

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Course 2 Programmable Logic Controller (PLC)
PLCs have taken the place of relay boxes because of their flexibility (putting into service,
modification, etc.), and also because in complex command automated systems, the costs of
wiring and debugging were becoming prohibitive.

2.2 Historical

Sequential automation based on electromagnetic relays has been produced for a long time.
The downside is that it is a wired system . This requires a complete overhaul of the wiring for
the slightest modification in the sequencing of sequences. At the request of the North
American automobile industry, the first logic control devices appeared easily modifiable
called PLC ( Programmable Logic Controller ) designed by Allen Bradley, Modicom and
Digital Equipment.

Richard MORLEY and his team created the MODICON company (MOdular Digital
CONtrol). The first PLC was named Modicon 084 because it concretized the 84th project of
the company, and was presented at the end of 1969.

Modicon 084 :
 256 I/O, 4 KB memory,
 LADDER programming,
 Dimension L 500 x H 1200 x D 340,
 Weight 46 Kg.

Figure 2.5: The first PLC.

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Course 2 Programmable Logic Controller (PLC)

2.3 Definition of Programmable Logic Controller (PLC)

It is a programmable electronic device, adapted to the industrial environment, which performs

automation functions to ensure the control of pre-actuators
pre actuators and actuators based on logical,
analog or digital information (programs).

Modern production machines are practically all controlled by systems programmable . This
means that the operation of this type of machine is completely governed by a program
consisting of a series of instructions stored in a memory.
memory. These instructions are executed
sequentially by a single central processor.

Figure 2.66: Siemens PLC installed in a control panel

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Course 2 Programmable Logic Controller (PLC)

2.4 Main characteristics of PLCs:

- Designed to operate in industrial environments which can be severe.

- Handle a large number of I/O signals in real time.

- Has languages adapted to automation functions and which do not require any particular

computer knowledge (simple programming).

- Flexible and quick assembly (modular structure).

2.5 Areas of use of PLC

The areas of use are very diverse:

- Used in all industrial sectors; for controlling machines (conveying, packaging, etc.).
- In production chains (automobile, food industry, etc.) where they provide process
regulation functions (metallurgy, chemistry, etc.).
- In the field of tertiary and industrial buildings (control of heating, lighting, security or
alarms, etc.).

2.6 Advantages of PLCs:

- Less space used in the control cabinet (for logic).
- Less internal wiring.
- Making changes made easier.
- Easy to recover the changes made, just read the program to see the changes.
- Lower cost (compared to relays).
- Easy maintenance: the PLC itself is relatively reliable and can help humans in their search
for faults (LEDs, indicator bits, messages, dialog screens, etc.).
- Possibility of planning remote maintenance (telephone modem, Internet, etc.).
- Possibilities for communication with the outside world (computer, other PLC) that relays
do not have.
- Evolution of the automation profession.
-

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Course 2 Programmable Logic Controller (PLC)

2.7 Disadvantages of PLCs:

- Need for training for the user (is this a disadvantage or an evolution of the profession?).
- Is the PLC a Black Box? we cannot directly see what is happening inside.
- Diversity of brands and models which leads to a diversity of languages and identification
of variables.

2.8 PLC builders

Among the largest manufacturers, we can cite: ALLEN BRADLEY, TELEMECANIQUE,
SIEMENS, OMRON, SCHNEIDER, MARLIN-GERIN, MITSUBISHI, ABB…

2.9 External appearance of PLCs

The PLC can be compact or modular.

a) Compact PLCs:

They integrate the processor, power supply, inputs and outputs in the same box. Depending on
the models and manufacturers, they can perform certain additional functions (rapid counting,
analog I/O, etc.) and receive a limited number of extensions. These PLCs, which are simple to
operate, are generally intended for controlling small automation systems.

Figure 2.7: Compact automation systems from SIEMENS (left) and Schneider (right).

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Course 2 Programmable Logic Controller (PLC)
b) Modular PLC :

The processor, power supply and I/O interfaces reside in separate units (modules) and are
attached to one or more racks. These PLCs are integrated into complex automation systems
where; power, processing capacity and flexibility are required.

Figure 2.8: Branded modular PLCs SIMATIC S7-300 from Siemens (left) and M340 from
Schneider (right).

2.10 Structure of PLC

PLCs are available in modular form (different types of microprocessors and inputs-outputs)
and various presentations: case, rack, or boards.
For difficult atmospheres (temperature, dust, risk of projections, etc.) the PLCs used are
contained in a sealed box, capable of withstanding a broad temperature range.
The structure of a Programmable Logic Controller (PLC) can be composed into several key
components, each of which plays a crucial role in its operation. PLCs are used for industrial
automation and control systems and are designed to perform specific tasks based on input
conditions.:

2.10.1 Rack or Chassis:

The base is quite simply the rack in which you plug in all your input-output boards. In some
PLC systems, especially modular ones, the components mentioned above are housed in a rack
or chassis. This allows for flexibility in adding or removing modules as needed.

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Course 2 Programmable Logic Controller (PLC)

Figure 2.9: A base rack

2.10.2 Power supply:

The power supply board is used to power all of the PLC's boards installed in the base. This
type of board is most often powered with 24 VDC via a stabilised filtered 230VAC/24VDC
power supply. You must always use a 230VAC power outlet taken from the uninterruptible
power supply to power a PLC.

Figure 2.10: Various power supply boards

2.10.3 Central Processing Unit (CPU):

The CPU is the brain of the PLC. It processes and executes the control program stored in
memory. It scans inputs, executes the program, and updates outputs based on the program's
logic.
PLCs have different types of memory, including program memory (where the user-defined
control logic is stored), data memory (for storing variables and values), and system memory
(used for internal PLC operations).

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Course 2 Programmable Logic Controller (PLC)

Figure 2.11: Central Processing Unit (CPU)

Each CPU has a mode switch making it possible to change operating mode. This is essentially
a removable key switch that is used to switch between the RUN and STOP operating modes.

The following operating modes are possible: (PG means Programming console.)
To run the program
RUN-P All the PG functions are enabled
To run the program
RUN Only the PG read functions are enabled
The program is not run.
STOP All the PG functions are enabled
MRES Position in which you can perform a general memory reset.

Figure 2.12: A CPU's various operating modes

2.10.4 The Input / Output modules (Signal modules)

The input interface has input addresses. Each sensor is connected to one of these addresses.
The output interface similarly has output addresses. Each pre-actuator
pre actuator is connected to one of
these addresses. The number of these inputs and outputs varies depending
depending on the type of PLC.

Input
nput devices are usually switches or sensors that send electrical signals to the CPU through
input channels on input signal modules. Similarly, output devices receive electrical signals
from the CPU through output channels on output signal modules. These output devices are
sometimes called actuators and are used to control a machine or process.

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Course 2 Programmable Logic Controller (PLC)
PLCs have two broad categories of inputs and outputs (I/O), digital I/O and analog I/O.
Digital I/O devices, also called discrete I/O devices,
devices, are either on or off and are connected to
digital I/O channels. Analog I/O devices use continuously variable voltage or current signals
and are connected to analog I/O channels.
Each analog input signal is converted by an analog input signal modul
module to a stream of
numerical values represented in binary. This is necessary for the CPU to process this
information. Because each analog output device requires a variable voltage or current signal,
the stream of numerical values provided from the CPU is converted
converted by an analog output
signal module to an analog signal compatible with the associated device.

1) The digital input module (DI)

The digital input board will allow us to monitor all the logic inputs of the following types:
 Valve end-of-travel
travel (Fin de course
cou de la vanne),
 Pushbutton,
 Motor operating feedback, Pressure switch, Thermostat,
 Level detector,
 Etc
These Digital Input boards may have 8, 16, 32 or 64 channels. They are equipped with LEDs
which indicate to us the logic status of the inputs assigned on the board.

Figure 2.13: A CPU's various operating modes

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Course 2 Programmable Logic Controller (PLC)
2) The analog input module (AI)
The analog input board will allow us to have all the measurements of the following types in
the PLC: Pressure, Flow rate, Temperature, Level, Etc.

Figure 2.14: Analog input module (AI)

3) The digital output module (DO)
Output modules interface with external actuators and devices, such as motors, valves, and
relays. They receive commands from the CPU and provide the necessary output signals to
control these devices.
The digital output board allows us to command all actuators of the following types:
 Solenoid valve (Electrovanne), Motor command, Indicator light, Etc……

Figure 2.15: Digital output module (DO)

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Course 2 Programmable Logic Controller (PLC)
1) The analog output module (AO)
The analog output board will allow us to regulate all the following actuators:
Regulation valve, Speed variator, Etc.
You must take care, because analog input and out boards look very much alike, you are
therefore advised to examine carefully the references of the boards which are often indicated
on each board.

Figure 2.16: Analog output module (AO)

2.10.5 Function module

Specific cards for: networks, control, regulation, counting, etc.
Each input/output module includes a connection terminal block and a set of LEDs displaying
the logic state of each channel.

Figure 2.17: Function Module, 2 Counters, 32 Bit

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Course 2 Programmable Logic Controller (PLC)

2.10.6 The communication module

PLCs may have communication ports to connect to other devices, such as computers, other
PLCs, or SCADA (Supervisory Control and Data Acquisition) systems.

Figure 2.18: Interface module.

This enables data exchange and remote monitoring and control.

220V AC
PS CPU DI DO AI AO CP

24V DC

Figure 2.19: Principle of reading and command of the plc

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Course 2 Programmable Logic Controller (PLC)

2.10.7 Interface module:

The interface module (IM) used in PLC for data transfer between I/O modules (Racks) or
between PLCs.

Figure 2.20: Interface module.

2.10.8 Programming Device:

To create or modify the control program, a programming device like a computer is used.
Engineers and technicians use specialized software to write ladder logic, function block
diagrams, or other programming languages, which is then loaded onto the PLC's memory.
The PLC use program to monitor and control a machine or process. In doing so, the program
scans the I/O modules via input addresses (%I) and addresses their output addresses (%Q).
The Siemens PLCs are programmed with the STEP 7 software (Tia Portal).

Figure 2.21: TIA PORTAL software for Siemens PLCS.

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Course 2 Programmable Logic Controller (PLC)

2.11 PLC choice

After establishing the specifications, it is up to the user to look on the market for the PLC best
suited to their needs, considering a certain number of important criteria such as:

- The Number of inputs/outputs: the number of cards can have an impact on the number of
racks as soon as the number of necessary inputs/outputs becomes high.
- Processor type: memory size, processing speed and special functions offered by the
processor.
- Special functions or modules: certain cards (axis control, weighing, etc.) will “relieve” the
processor.
- Communication functions: the PLC must be able to communicate with other control
systems (PLC, supervision, etc.) and offer communication possibilities with standardized
standards (Profibus, etc.).

2.12 Required hardware and software

1 Engineering station: requirements include hardware and operating system
(for additional information, see Readme on the TIA Portal Installation DVDs)
2 SIMATIC STEP 7 Professional software in TIA Portal – as of V13
3 SIMATIC S7-300 controller, e.g. CPU 314C-2 PN/DP – Firmware as of V3.3 with
MMC memory card
4 Ethernet connection between engineering station and controller.

Figure 2.22: Required hardware and software.

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Course 2 Programmable Logic Controller (PLC)

2.13 Memory areas of the CPU and the SIMATIC memory card
The memory of the S7-300 CPU can be divided into three areas:

Figure 2.23: Memory areas of the CPU and the SIMATIC memory card.

Note: Loading of user programs and thus operation of the CPU 31xC is possible only with
inserted MMC.

 Load memory
The load memory is on a SIMATIC Micro Memory Card (MMC). It is used to store code
blocks, data blocks and system data (configuration, connections, module parameters, etc.).
Blocks that are identified as not runtime-relevant are stored exclusively in the load memory.
You can also store all the configuration data for your project on the MMC.
 Work memory
The work memory is integrated in the CPU and cannot be expanded. It is used to execute the
code and process user program data. Program processing takes place exclusively in the work
memory and system memory areas. The work memory of the CPU is retentive with inserted
MMC.
 System memory
The system memory is integrated in the CPU and cannot be extended. It contains:
- The bit memory, timer and counter operand areas
- The process image of the inputs and outputs
- The local data

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Course 2 Programmable Logic Controller (PLC)

2.14 STEP 7 Professional (TIA Portal) programming software

STEP 7 Professional V13 (TIA Portal V13) software is the programming tool for the
following automation systems:
- SIMATIC S7-1500
- SIMATIC S7-1200
- SIMATIC S7-300
- SIMATIC S7-400
STEP 7 Professional V13 provides the following functions for plant automation:
- Configuration and parameter assignment of the hardware
- Specification of the communication
- Programming
- Testing, commissioning and servicing with operational/diagnostic functions
- Documentation
- Creation of visualizations for SIMATIC Basic Panels using the integrated WinCC
Basic software
- Visualization solutions for PCs and other panels can also be created with other WinCC
software packages.

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