Chapter (5) PLC Programming

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Chapter (5) PLC Programming

 Course Syllabus
 Pneumatics actuators, gripper technology, control valves and pneumatic circuit
representation.
 Sequential Control Systems.
o Programmable Logic Controllers (PLC). Sequential control system representation,
logic analysis and PLC programming. Relay logic ladder diagram, Timers,
Counters, shift registers.
 Sensor technology for sequence control, optical, capacitive, inductive and
magnetic.
o Computer simulation of a programmable pneumatic positioning system.

 Chapter Outlines
Programmable Logic Controllers (PLC). Sequential control system representation,
logic analysis and PLC programming. Relay logic ladder diagram, Timers, Counters,
shift registers.

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Chapter (5) PLC Programming Relay logic ladder diagram

 Relay ladder logic, the standard

programming language, is based on electromagnetic relay control.
 A relay: showing normally closed (NC) and normally open (NO) contacts.

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Chapter (5) PLC Programming Relay logic ladder diagram

 Logic functions from relays.

A B op
0 0 0
0 1 0
1 0 0
1 1 1

A B op
0 0 0
0 1 1
1 0 1
1 1 1

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Chapter (5) PLC Programming Relay logic ladder diagram

 A relay logic ladder diagram

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Chapter (5) PLC Programming Relay logic ladder diagram

Example
In a certain bank, each of three bank officers has a unique key to the vault. The bank rules
require that two out of the three officers be present when the vault is opened. Draw the
ladder diagram for a relay logic circuit that will unlatch the door and turn on the light when
two of the three keys are inserted.

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Chapter (5) PLC Programming

 The three most common types of languages encountered in programmable controller

systems are as follows

1. Ladder diagram (LAD)

2. Statement list (STL)
3. Function block diagram (FBD)
 The ladder diagram (LAD) is the most common programmable controller
language
 Basic ladder diagram instructions

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Chapter (5) PLC Programming

 The three most common types of languages encountered in programmable controller

systems are as follows

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Chapter (5) PLC Programming

 Symbols
o Contacts
 Normally Open Contacts (NO)

 Normally Closed Contacts (NC)

o Coils

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Chapter (5) PLC Programming

 Symbols

o Boxes
 Timers
 Counters
 Math Operations

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Chapter (5) PLC Programming

 Symbols

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Chapter (5) PLC Programming

 Symbols

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Chapter (5) PLC Programming

 The ladder diagram consists of two vertical lines representing the power rails.
 Circuits (rung) are connected as horizontal lines

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Chapter (5) PLC Programming

 Ladder diagram language is the most commonly used PLC language and is designed
to mimic hardwired relay logic.

Hardwired relay control

circuit

Equivalent ladder diagram

program

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Chapter (5) PLC Programming

 Typical Input / Output addresses

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Chapter (5) PLC Programming

 Typical Input / Output addresses

Siemens Allen Bradley
XXX.X
X:XXX/XX

I= input Bite I=input Module

Q=output number O=output number

Rack Terminal
Byte number number
number
Example I:012/03

Example:
Example: The Allen-Bradley PLC-5
I0.1 is an input at bit 1 in byte 0
has I: 012/03 to indicate an
Q2.0 is an output at bit 0 in byte 2
input in rack 01 at module 2
and terminal 03
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Chapter (5) PLC Programming

 Basic Instructions
LOAD (LD)
LD → normally open contact

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Chapter (5) PLC Programming

 Basic Instructions
LDI LOAD Inverse
LDI → Normally Closed Contact

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Chapter (5) PLC Programming

 Basic Instructions
o OUT Relay

I Input
Q Output
M Memory
T Timer
C counter
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Chapter (5) PLC Programming

 Relay-Type Instructions
Normally Open Instruction

Logic flow for normally open contact instruction

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Chapter (5) PLC Programming

 Relay-Type Instructions
Normally Closed Instruction

Logic flow for normally closed instruction

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Chapter (5) PLC Programming

 Output Coil Instruction

the output instruction O:0/01 is energized or TRUE if either input A or input B is TRUE
or if both inputs are TRUE.

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Chapter (5) PLC Programming

 Ladder programming
The form of programming commonly use with PLC is ladder programming. Each
program task is specified as though a rung of a ladder. Thus a rung could specify
that the state of switches A and B be examined and if both A and B are closed then a
solenoid, the output is energized.

(a), (b) Alternative ways of drawing an electric circuit,

(c) comparable rung in a ladder program.

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Chapter (5) PLC Programming

 Ladder program
Figure below shows a basic standard symbols that are used and rung, Inputs must
always precede outputs and there must be at least one output on each line Each
rung must start with an input or series of inputs and end with an output

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Chapter (5) PLC Programming

 Switch controlling a solenoid.

The output from the PLC is to energize a solenoid when a normally open start
switch connected to the input is activated by being closed

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Chapter (5) PLC Programming

 Logic functions
o The logic Functions can be obtained by combinations of switches
o AND

A B O/P
0 0 0
0 1 0
1 0 0
1 1 1
o OR

A B O/P
0 0 0
0 1 1
1 0 1
1 1 1
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Chapter (5) PLC Programming

 Logic functions
o The logic Functions can be obtained by combinations of switches
o NOR

A B O/P
0 0 1
0 1 0
1 0 0
1 1 0
o NAND

A B O/P
0 0 1
0 1 1
1 0 1
1 1 0
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Chapter (5) PLC Programming

 Logic functions

o XOR

A B O/P
0 0 0
0 1 1
1 0 1
1 1 0

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Chapter (5) PLC Programming

 Switches controlling a solenoid.

o The basic logic functions can be used to obtained more complicated combinations of
switches.
o Consider a situation where a normally open switch A must be activated and either of two
other, normally open switches B and C must be activated for a coil to be energized.

A B C O
0 0 0 0
0 0 1 0
0 1 0 0
0 1 1 0
1 0 0 0
1 0 1 1
1 1 0 1
1 1 1 1

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Chapter (5) PLC Programming

 Switches controlling a solenoid.

Shop door system

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Chapter (5) PLC Programming

 Instruction lists
o Each horizontal rung on the ladder represents a line in the program and the entire
ladder gives the complete program in the ladder language.
o Using a graphic interface, a programmer can build his program, then translate these
symbols into machine language that can be stored in the PLC memory.
o Alternatively, the ladder program can be translated into an instruction list and entered
into the programming panel or computer.
o Instruction lists consist of a series of instruction with each instruction being on a
separate line.
o An instruction consists of an operator followed by one or more operand

LD A (*load input A*)

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Chapter (5) PLC Programming

 Instruction lists

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Chapter (5) PLC Programming

 Instruction lists and logic functions

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Chapter (5) PLC Programming

 Instruction lists and branching

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Chapter (5) PLC Programming

 Example: PLC Control of AC Motor

PLC Control: ( Phase Motor in OFF position)

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Chapter (5) PLC Programming

 Example: PLC Control of AC Motor

PLC Control: (Phase Motor in START position)

PLC Control: (Phase Motor in RUNNING position)

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Chapter (5) PLC Programming

 Example: PLC Control of AC Motor

Stop pushbutton

PLC Control: (Phase Motor in switch OFF position)

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Chapter (5) PLC Programming

 Example: PLC Control of AC Motor

Stop pushbutton

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Chapter (5) PLC Programming

 Example: PLC Control of AC Motor

Start pushbutton

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Chapter (5) PLC Programming

 Data in memory, showing the relationship between memory position and the I/O
terminals.

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Chapter (5) PLC Programming

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Chapter (5) PLC Programming

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Chapter (5) PLC Programming

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Chapter (5) PLC Programming

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Chapter (5) PLC Programming

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Chapter (5) PLC Programming

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Chapter (5) PLC Programming

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Chapter (5) PLC Programming

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Chapter (5) PLC Programming

 Boolean Logic Design

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Chapter (5) PLC Programming

 Boolean Logic Design

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Chapter (5) PLC Programming

 Boolean Logic Design

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Chapter (5) PLC Programming

 Boolean Logic Design

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Chapter (5) PLC Programming

 Boolean Logic Design

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Chapter (5) PLC Programming

 Logic Design

o Process Description:

A heating oven with two bays can heat one ingot in each bay. When the heater is on it
provides enough heat for two ingots. But, if only one ingot is present the oven may
become too hot, so a fan is used to cool the oven when it passes a set temperature.

o Control Description:

If the temperature is too high and there is an ingot in only one bay then turn on fan.

o Define Inputs and Outputs:

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Chapter (5) PLC Programming

 Logic Design

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Chapter (5) PLC Programming

 Digital circuits Design.

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Chapter (5) PLC Programming

 Digital circuits Design.

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 The Simplified Form of the Example

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 Complex Gate Forms

 Multiplexers

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Chapter (5) PLC Programming

 Design Cases
o Problem: Develop a program that will cause output D to go true when switch A and
switch B are closed or when switch C is closed.

o Problem: Develop a program that will cause output D to be on when push button A is
on, or either B or C are on.

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Chapter (5) PLC Programming

 Car Safety System

o Problem: Develop Ladder Logic for a car door/seat belt safety system. When the car
door is open, and the seatbelt is not done up, the ignition power must not be applied. If
all is safe then the key will start the engine.

 Motor Forward/Reverse
o Problem: Design a motor controller that has a forward and a reverse button. The motor
forward and reverse outputs will only be on when one of the buttons is pushed.

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Chapter (5) PLC Programming

 A Burglar Alarm
o Consider the design of a burglar alarm for a house. When activated an alarm and lights
will be activated to encourage the unwanted guest to leave. This alarm be activated if an
unauthorized intruder is detected by window sensor and a motion detector. The window
sensor is effectively a loop of wire that is a piece of thin metal foil that encircles the
window. If the window is broken, the foil breaks breaking the conductor. This behaves
like a normally closed switch. The motion sensor is designed so that when a person is
detected the output will go on. As with any alarm an activate/deactivate switch is also
needed. The basic operation of the alarm system, and the inputs and outputs of the
controller are itemized

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Chapter (5) PLC Programming

 A Burglar Alarm

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Chapter (5) PLC Programming

 A Burglar Alarm

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