Programmable Logic Controllers
40.1
Programmable Logic Controllers ________________ of RLL
Relay Ladder Logic (RLL) is "hard-wired" by the interconnection of the relays, limit switches, timers, counters, etc. Changing the program requires _______________________________ the wires from the relays and limit switches.
not terribly easy or convenient!
Programmable Controllers
Programmable Logic Controllers (PLC) were developed in the early 60's to overcome the deficiencies of RLL
uses ________________________________
Programming can still be done in ladder logic, just like hard-wired RLL Electricians and technicians can readily adapt to this familiar type of programming.
PLC Station
Operator Interface Panel PLC Solenoid Valves X1 (NO)
PLC Direct DL205
DL 250 CPU Input Module (X0 to X7, X10 to X17)
Fan output Y11 Controlled by Y0
X0 (NO) Controlled by Y1
X7 (NC)
X6 (NC)
X3 (NO) Controlled by Y2
Controlled by Y3
X2 (NO)
Output Module (Y0 to Y7)
Simple Hydraulic System
120 VAC PB-1 CR-1
PLC physical wiring diagram
+24VDC PB-1 Inputs X1 Outputs Y2 Sol-A +24VDC
LS-1 Sol. A
CR-1A
LS-1
LS-1
SOL-A
CR-1B
X2
Hydraulic System
Relay Ladder Logic (RLL) Control System
Programmable Logic Controllers
40.2
Simple Pneumatic System
X1 C5 C5 Y2 LS-1 C5 Y2 Pneumatic System PLC Ladder Logic X2
Simple Pneumatic System
External pushbutton switch connected to bit X1 X1 C5 Reads internal coil (bit) C5 C5 C5 Y2 PLC Ladder Logic X2 Writes external (bit) Y2 Writes internal coil (bit) C5
Start-up StartConfiguration
LS-1
X1 C5 C5 X2
Opposite of X2
Press the PB-1 pushbutton Contacts X1 turn ON
X1 C5 C5 X2
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON Y2
Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
PLC Wiring Diagram
PLC Wiring Diagram
Output relay C5 turned ON Inputs C5 read as ON
X1 C5 C5 X2
Output relay Y2 turned ON Valve solenoid shifts spool
X1 C5 C5 X2
Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
PLC Wiring Diagram
PLC Wiring Diagram
Programmable Logic Controllers
X1 C5 C5 X2 X1
40.3
Pushbutton released Contact X1 turned OFF
LS-1 is activated Contact X2 turned ON
C5 C5 X2
Opposite of X2
Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
PLC Wiring Diagram
PLC Wiring Diagram
Hold is broken Output relay C5 turned OFF
X1 C5 C5 X2
Contacts C5 turned OFF
X1 C5 C5 X2
Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
PLC Wiring Diagram
PLC Wiring Diagram
Output Y2 turned OFF Solenoid Y2 turned OFF
X1 C5 C5 X2
Valve spool shifts to left Cylinder begins to retract
X1 C5 C5 X2
Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
PLC Wiring Diagram
PLC Wiring Diagram
Programmable Logic Controllers
X1 C5 C5 X2
Opposite of X2
40.4
X1 C5 C5 X2
Limit switch LS-1 released Input X2 goes OFF
Cylinder fully retracts to initial start configuration
Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON Y2
LS-1
C5 Y2 PLC Ladder Logic +24VDC Sol-A OFF ON
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
Pneumatic System +24VDC PB-1 LS-1 X2 Inputs Outputs X1 Y2
PLC Wiring Diagram
PLC Wiring Diagram
PLC Memory
Digital memory consists of indvidual bits (either on or off, 1 or 0) Bits can be written to or read from Organized in groups of 8 bits = 1 byte
C17 C16 C15 C14 C13 C12 C11 C10 1 0 0 1 0 1 0 1
PLC External Output - NPN
PLC Output (simplified) 0 = off 1 = on External VDC Typically +24V External Load (solenoid coil)
PLC Building Blocks
Internal N.O. Contacts (C0 - C1777) External N.O. Inputs (X0 - X17)
PLC Building Blocks
Internal Control Relays (C0 - C1777) External Outputs (Y0 - Y17)
Internal N.C. Contacts (C0 - C1777)
External N.C. Outputs (X0 - X17)
Programmable Logic Controllers
40.5
Control circuit for a one shot
X1
Simplified control circuit for a one shot
X1
X1 C5 C5 X2
X1 Y2 Y2
X2
X2
Sol-A (Y2)
X2 Wired N.O.
C5 Y2 PLC Ladder Logic
Sol-A (Y2)
Wired N.O. PLC Ladder Logic
Timers (T0 - T377)
When contacts C6 close, timer T1 will count for 2.5 seconds (K25 = 25 tenths) After 2.5 sec, contacts T1 will close (and stay closed until C6 opens and turns timer off)
C6 TMR T1 K25 T1 Y2
Simplified control circuit for a one shot
X1 Y2 PLC Ladder Logic Y2 X2
IF (X1 is true) OR { (Y2 is true) AND (not X2 is true) } THEN (Y2 will be set true) ELSE (Y2 will be set false)
Counters (CT0 - CT177)
Each time contacts X0 close, counter increments by 1 When counter reaches 6 (K6 = 6 counts), counter output CT2 closes
X0 C9 CT2 Y2 CNT CT2 K6
Counters (CT0 - CT177)
When contacts C9 close, counter will reset to zero (and the contacts CT2 will open)
X0 C9 CT2 Y2 CNT CT2 K6
