Basics of PLC Programming

Industrial Control Systems

Fall 2006

Lecture PLC Programming Basics

MME 486 Fall 2006

1 of 62

PLC Architecture

Lecture PLC Programming Basics

MME 486 Fall 2006

2 of 62

PLC System

Lecture PLC Programming Basics

MME 486 Fall 2006

3 of 62

Processor Memory Organization

The memory of a PLC is organized by types.
The memory space can be divided into two broad
categories:
program and data memory.
Advanced ladder logic functions allow controllers to
perform calculations, make decisions and do other
complex tasks. Timers and counters are examples of
ladder logic functions. They are more complex than
basic inputs contacts and output coils and rely
heavily upon data stored in the memory of the PLC.
Lecture PLC Programming Basics

MME 486 Fall 2006

4 of 62

Memory Map
A memory map can be used to show how memory is
organized in a PLC.
Input/output locations
Internal relay and
timer/counter locations

Data table

User program

The user program causes

the controller to operate
in a particular manner

Housekeeping memory

Used to carry out

functions needed to make
the processor operate
(no access by user)

Lecture PLC Programming Basics

MME 486 Fall 2006

5 of 62

Program Files
The user program will
account for most of the
memory of a PLC system.

Program files contain

the logic controlling
machine operation.

Program file organization

for SLC-500 controller.
Lecture PLC Programming Basics

This logic consists of

instructions that are
programmed in a
ladder logic format.
MME 486 Fall 2006

6 of 62

Data Files
Data file organization
for SLC-500 controller.

The data file portion of memory

stores input and output status,
processor status, the status of
various bits and numerical data.

Lecture PLC Programming Basics

MME 486 Fall 2006

7 of 62

Data Files
Data files are organized by the type of data they contain

Lecture PLC Programming Basics

MME 486 Fall 2006

8 of 62

Input Table File Operation

Input module
Switch Open

Binary 0 stored
0

Lecture PLC Programming Basics

MME 486 Fall 2006

9 of 62

Input Table File Operation

Input module
Processor continually
reads current input
status and updates
input image table file

Switch Closed

Binary 1 stored
1

Lecture PLC Programming Basics

MME 486 Fall 2006

10 of 62

Output Table File Operation

Output module
Output
OFF

Processor continually
activates or deactivates
output status according
to output image table
file status
0
Status 0

Lecture PLC Programming Basics

MME 486 Fall 2006

11 of 62

Output Table File Operation

Output module
Processor continually
activates or deactivates
output status according
to output image table
file status

Output
ON
1

Status 1

Lecture PLC Programming Basics

MME 486 Fall 2006

12 of 62

Program Scan
During each operating cycle, the processor reads all
inputs, takes these values, and energizes or de-energizes
the outputs according to the user program. This
process is known as a scan.
I/O scan records status data of input
devices. Energizes output devices that
have their associated status bits set to
ON (1)

Program scan instructions are

executed sequentially

Because the inputs can change at any time, the PLC must
carry on this process continuously.
Lecture PLC Programming Basics

MME 486 Fall 2006

13 of 62

Scan Process
The scan time indicates how fast the controller can react
to changes in inputs. Scan times vary with computer
model and program content, and length. If a controller
has to react to an input signal that changes states twice
during the scan time, it is is possible that the PLC will
never be able to detect this change.

Scan time may be a concern

in high speed operations

Lecture PLC Programming Basics

MME 486 Fall 2006

14 of 62

Scan Process
Read inputs

The scan is a
a continuous
and sequential
process
Adjusts
outputs

Lecture PLC Programming Basics

Run
program

MME 486 Fall 2006

15 of 62

Data Flow Overview

Input
modules

Input
data

Input
image
table file

Output
image
table file

Examine data

Output
data

Output
modules

Return results
Program

Check/compare/examine
specific conditions
Lecture PLC Programming Basics

MME 486 Fall 2006

Take some
action
16 of 62

Scan Process
Output
Module

Input
Module
Input
device

Input
file

Output
file

I:3/6

O:4/7

Output
device

O:4/7

I:3/6
Program
When the input is
closed, the input
module senses a
voltage and an ON
condition (1) is
entered into the
input table bit I:3/6

I:3/6

O:4/7

During the program scan the

processor sets instructions
I:3/6 and O:4/7 to ON (1)

Lecture PLC Programming Basics

MME 486 Fall 2006

The processor turns

light output O:4/7
ON during the next
I/O scan

17 of 62

Scan Patterns
Horizontal Scanning
Order
The processor examines
input and output
instructions from the
first command, top left
in the program,
horizontally, rung by
rung.

End of ladder

In addition to the program itself, the scan time is also dependent on

the clock frequency of the processor!
Lecture PLC Programming Basics

MME 486 Fall 2006

18 of 62

Scan Patterns
Vertical Scanning
Order
The processor examines
input and output
instructions from the
first command, vertically,
column by column and
page by page. Pages are
executed in sequence.

End of ladder
Misunderstanding the way the PLC scans can cause programming
bugs!
Lecture PLC Programming Basics

MME 486 Fall 2006

19 of 62

PLC Programming Languages

The term PLC programming language refers to the method
by which the user communicates information to the PLC.

The three most common

language structures are:
ladder diagram language, Ladder diagram language
Boolean language, and
functional chart.
Functional
chart
Boolean language
Lecture PLC Programming Basics

MME 486 Fall 2006

20 of 62

Comparing Programming Language

PB1

CR1

CR2

SOL

Relay Schematic

LS1
PB1 CR1

CR2

SOL

Equivalent ladder
diagram language
LS1

Equivalent Boolean language

Lecture PLC Programming Basics

MME 486 Fall 2006

21 of 62

Relay-Type Instructions
The ladder diagram language is basically a
symbolic set of instructions used to create the
controller program.
These ladder instructions symbols are
arranged to obtain the desired control logic.

Lecture PLC Programming Basics

MME 486 Fall 2006

22 of 62

Examine If Closed (XIC) Instruction

Symbol

Analogous to the normally open relay

contact. For this instruction we ask
the processor to EXAMINE IF (the
contact is) CLOSED (XIC)

Typically represents any input. Can be a switch

or pushbutton, a contact from a connected output,
or a contact from an internal output.
Has a bit-level address which is examined for an
ON condition.
The status bit will be either 1 (ON) or 0 (OFF).
Lecture PLC Programming Basics

MME 486 Fall 2006

23 of 62

Examine If Closed (XIC) Instruction

I:012
I:012
04

Lecture PLC Programming Basics

MME 486 Fall 2006

24 of 62

Examine If Closed (XIC) Instruction

I:012
I:012
04
If the status bit is 0 (OFF), then the instruction
is FALSE.
Lecture PLC Programming Basics

MME 486 Fall 2006

25 of 62

Examine If Closed (XIC) Instruction

I:012
I:012
04
If the status bit is 1 (ON), then the instruction is TRUE.

Lecture PLC Programming Basics

MME 486 Fall 2006

26 of 62

Examine If Open (XIO) Instruction

Symbol

Analogous to the normally closed

relay contact. For this instruction we
ask the processor to EXAMINE IF (the
contact is) OPEN (XIO).

Typically represents any input. Can be a switch or

pushbutton, a contact from a connected output,
or a contact from an internal output.
Has a bit-level address which is examined for an OFF
condition.

The status bit will be either 1 (ON) or 0 (OFF).

Lecture PLC Programming Basics

MME 486 Fall 2006

27 of 62

Examine If Open (XIO) Instruction

I:012
I:012
04
If the status bit is 0 (OFF), then the instruction is TRUE.

Lecture PLC Programming Basics

MME 486 Fall 2006

28 of 62

Examine If Open (XIO) Instruction

I:012
I:012
04
If the status bit is 1 (ON), then the instruction is FALSE.

Lecture PLC Programming Basics

MME 486 Fall 2006

29 of 62

Output Energize (OTE) Instruction

Symbol

Analogous to the relay coil. The

processor makes this instruction true
(analogous to energizing a coil) when
there is path of true XIC and XIO
instructions in the rung.

Typically represents any output that is controlled by

some combination of input logic. Can be a connected
device or an internal output (internal relay).
If any left-to-right path of input conditions is TRUE,
the output is energized (turned ON).
Lecture PLC Programming Basics

MME 486 Fall 2006

30 of 62

Output Energize (OTE) Instruction

O:013

I:012
I:012

I:012

11

15

O:013

01

OUTPUT ENERGIZE instruction - TRUE

Lecture PLC Programming Basics

MME 486 Fall 2006

31 of 62

Output Energize (OTE) Instruction

O:013

I:012
I:012

I:012

11

15

O:013

01

OUTPUT ENERGIZE instruction - FALSE

Lecture PLC Programming Basics

MME 486 Fall 2006

32 of 62

Status Bit Examples

Input module

Bit status

Button not actuated

Output

OFF

False
A

Output
ON

True
Lecture PLC Programming Basics

MME 486 Fall 2006

33 of 62

Status Bit Examples

Input module

Bit status

Button actuated
Output

ON

True
Output

OFF

False
Lecture PLC Programming Basics

MME 486 Fall 2006

34 of 62

Ladder Rung
A

Output
instruction

Input conditions
D

A ladder rung consists of a set of input conditions,

represented by contact instructions, and an output
instruction at the end of the rung, represented by the
coil symbol.
Lecture PLC Programming Basics

MME 486 Fall 2006

35 of 62

Ladder Rung
A

Output
instruction

Input conditions
D

For an output to be activated or energized, at least one

left-to-right path of contacts most be closed. A complete
path is referred to as having logic continuity. When logic
exists the rung condition is said to be TRUE.
Lecture PLC Programming Basics

MME 486 Fall 2006

36 of 62

Rung Continuity
Bit in memory

Bit in memory

1
LS_1

SOL_5

The Examine If Closed instruction is TRUE

making the rung TRUE
Lecture PLC Programming Basics

MME 486 Fall 2006

37 of 62

Rung Continuity
Bit in memory

Bit in memory

0
LS_1

SOL_5

The Examine If Closed instruction is FALSE

making the rung False
Lecture PLC Programming Basics

MME 486 Fall 2006

38 of 62

Allen-Bradley SLC-500 Controller Addressing

Output image table
file 0

Address
output
terminal
O0:4/6

O:0:4/6
Bit address
Address
input
terminal
I1:3/12

Input image table

file 1

Energized
output

I:3/12
Bit address
Closed input

I1:3

O:0:4

User-programmed rung

12
Lecture PLC Programming Basics

MME 486 Fall 2006

6
39 of 62

Structure of A 16-Bit Word

Bit

OFF ON

Word
(16 bits)

0 1
15 14 13 12 11 10 9

I/O Connection Diagram

L1

L2

L1

L2

PB1

SOL 1
O:2/3

I:4/5

PL 1
LS1

O:3/6

I:4/6

Lecture PLC Programming Basics

MME 486 Fall 2006

40 of 62

Parallel Input Branch Instructions

A

Lecture PLC Programming Basics

Branch instructions are used

to create parallel paths of
input condition instructions.
If at least one of these parallel
branches forms a true logic
path, the logic is enabled.

MME 486 Fall 2006

41 of 62

Parallel Output Branching

A

C
D

E
On most PLC models, branches can be established at
both the input and output portion of the rung.
With output branching, you can program parallel outputs
on a rung to allow a true logic path to control multiple
outputs.
Lecture PLC Programming Basics

MME 486 Fall 2006

42 of 62

Nested Input and Output Branches

Input and output branches can be nested to avoid

redundant instructions and to speed up the processor
scan time.
A nested branch starts or ends within another branch.
Lecture PLC Programming Basics

MME 486 Fall 2006

43 of 62

Nested Contact Program

A

Nested
contact

On some PLC models,

the programming of a
nested branch circuit
cannot be done directly.

E
A

Contact
instruction
C repeated

Reprogrammed to
obtain the required
logic.

E
Lecture PLC Programming Basics

MME 486 Fall 2006

44 of 62

PLC Matrix Limitation Diagram

Max series
contacts

No. outputs
per rung and
location of the
output in the rung

Max parallel
lines

There may be limitations to the number of series contacts

instructions, number of parallel lines, and the number of outputs and
their location on the rung.
Lecture PLC Programming Basics

MME 486 Fall 2006

45 of 62

Programming of Vertical Contacts

A

Original program

C
E
D

B
A
B

D
E

Y = (AD) + (BCD) + (BE) + (ACE)

Reprogrammed to obtain the

required logic

Lecture PLC Programming Basics

MME 486 Fall 2006

46 of 62

Programming for Different Scan Patterns

B

Original program

Y = (ABC) + (ADE) + (FE) + (FDBC)

Reprogrammed to obtain the

required logic
B C

Lecture PLC Programming Basics

MME 486 Fall 2006

47 of 62

Internal Control Relay

The internal output operates just as any other output
that is controlled by programmed logic; however, the
output is used strictly for internal purposes.
The internal output does not directly control an
output device.
The advantage of using internal outputs is that there
are many situations where an output instruction is
required in a program, but no physical connection to
a field device is needed. Their use in this type of
instance can minimize output card requirements.

Lecture PLC Programming Basics

MME 486 Fall 2006

48 of 62

Extending the Number of Series Contacts Using

an Internal Control Relay
Internal
relay coil
Rung 1

Rung 2
Internal
relay
contact

Lecture PLC Programming Basics

Discrete output (requires

one physical connection
on the output module)

MME 486 Fall 2006

49 of 62

Programming The XIC Instruction

PB1

PB2

Hardwired Circuit
PL

PB1

PB2

PL

User program
providing the
same results

Note that both pushbuttons are represented by the XIC symbol. This
is because the normal state of an input (NO or NC) does not matter!
What does matter is that if contacts need to close to energize the
output, then the XIC instruction is used. Since both PB1 and PB2
must close to energize the PL, the XIC instruction is used for both.

Lecture PLC Programming Basics

MME 486 Fall 2006

50 of 62

Programming The XIO Instruction

PB1

PB1
CR

PL

CR1
PL

User program providing

the same results

Hardwired Circuit
When the pushbutton is open in the hardwired circuit, relay coil CR is deenergized and contacts CR1 close to switch the PL on. When the
pushbutton is closed, relay coil CR is energized and contacts CR1 open
to switch the PL off. The pushbutton is represented in the user program
by an XIO instruction. This is because the rung must be true when the
external pushbutton is open, and false when the pushbutton is closed.

Lecture PLC Programming Basics

MME 486 Fall 2006

51 of 62

Operation of The XIC and XIO Instructions

Summary of status conditions
The status of the instruction is:
XIC
Examine If Closed

XIO
Examine If Open

Logic 0

False

True

False

Logic 1

True

False

True

If the data
table bit is:

Lecture PLC Programming Basics

MME 486 Fall 2006

OTE
Output Energize

52 of 62

Operation of The XIC and XIO Instructions

State of the output as determined by the changing
state of the inputs in the rung
Inputs

Time

XIC

XIO

OTE

Goes true

False

Goes false

False

Remains false

XIC

XIO

t1 (initial)

False

True

t2

True

True

t3

True
False

t4

Input instructions
XIC

XIO

Bit status

Output
OTE
False

Output instruction
OTE

Lecture PLC Programming Basics

MME 486 Fall 2006

53 of 62

Entering the Ladder Diagram

A personal computer is most often used to enter the
ladder diagram.

The computer is adapted

to the particular PLC
model using the relevant
programmable controller
software.

Lecture PLC Programming Basics

MME 486 Fall 2006

54 of 62

RSLogix Main Screen

Different screens, toolbars and windows dialog boxes are
used to navigate through the Windows environment

Lecture PLC Programming Basics

MME 486 Fall 2006

55 of 62

Bit Instructions Tool Bar

To place an instruction on a rung, click its icon

on the toolbar and simply drag the instruction
straight off the toolbar onto the rung of the
ladder.

Lecture PLC Programming Basics

MME 486 Fall 2006

56 of 62

Select Processor Type Screen

The programming software needs to know what
processor is being used in conjunction with the program.
1747-L40E

You simply
scroll down
the list until
you find the
processor you
are using and
select it.

Lecture PLC Programming Basics

MME 486 Fall 2006

57 of 62

I/O Configuration Screen

The I/O screen
lets you click or
drag-and-drop a
module from an
all inclusive list to
assign it to a slot
in your
configuration.

Lecture PLC Programming Basics

MME 486 Fall 2006

58 of 62

Data File Screen

Data file screens
contain data that
is used in
conjunction with
ladder program
instructions. These
include:
Input
Output
Timer
Counter
Integer
Bit

Lecture PLC Programming Basics

MME 486 Fall 2006

59 of 62

Monitoring a Ladder Logic Program

Operation of the logic is apparent from the highlighting
of rungs of the various instructions on screen, which
identifies the logic state in real time and has logic
continuity.

Highlighted rungs indicate the instruction is true

Lecture PLC Programming Basics

MME 486 Fall 2006

60 of 62

Modes of Operation
A processor has basically two modes of operation:
the program mode or some variation of the run mode.
Program Mode may be used to
enter a new program
edit or update an existing program
upload files
download files
document programs
change software configurations
When the PLC is switched into the
program mode, all outputs from the PLC
are forced off regardless of their rung
logic status, and the ladder I/O scan
sequence is halted.

Lecture PLC Programming Basics

MME 486 Fall 2006

61 of 62

Variations of the Run Mode

Run Mode is used to execute the
user program. Input devices are monitored
and output devices are energized
accordingly.
Test Mode is used to operate, or monitor,
the user program without energizing any
outputs.

Remote Mode allows the PLC to be

remotely changed between program and run
mode by a personnel computer connected
to the PLC processor.

Lecture PLC Programming Basics

MME 486 Fall 2006

62 of 62