Experiment (3)

Introduction to PLC and Ladder Logic Programming (1)

Introduction
A PLC (Programmable Logic Controller) is an industrial computer used for automation of
electromechanical processes, such as control of machinery on factory assembly lines, amusement
rides, or light fixtures. PLCs are expected to work flawlessly for years in industrial environments
that are hazardous to the very microelectronic components that give modern PLCs their excellent
flexibility and precision.
Prior to PLCs, many of these control tasks were 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. Electricians would then wire the
components necessary to perform a specific task. If an error was made the wires had to be
reconnected correctly. A change in function or system expansion required extensive component
changes and rewiring.
Objectives
This experiment aims to:
1- Learn the basics of ladder logic programming.
2- Familiarize the students with SIMATIC S7 software to program Siemens S7-400 PLC.
3- Implement different logic functions using PLC.
4- Understand the function of each Siemens S7-400 PLC modules.

Theory

PLC (Programmable Logic Controller)

Before you start using PLC, it is convenient to know and understand its architecture. See figure
1.
As shown in figure 1, PLC consists of the following parts:
1) POWER SUPPLY: Provides the voltage needed to run the primary PLC components.
2) I/O MODULES: Provides signal conversion and isolation between the internal logic-level
signals inside the PLC and the field’s high level signal.
3) PROCESSOR SYSTEM: Provides intelligence to command and govern the activities of
the entire PLC systems.
4) PROGRAMMING DEVICE: Used to enter the desired program that will determine the
sequence of operation.
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Figure 1: PLC architecture

The following are some advantages of PLC over other microcontrollers:
1) Cost effective for controlling complex systems.
2) Flexible and can be reapplied to control other systems.
3) Computational abilities allow more sophisticated control.
4) Trouble shooting aids making programming easier and reduce downtime.
5) Small physical size, so shorter project time.
In this experiment Siemens S7-400 PLC will be used, table 1 presents the main components of
this model.

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Table 1: Siemens S7-400 PLC main components

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You can notice from figure 2 that the common of the digital input module is connected to the
ground of the circuit while the common of the digital output module is connected to the power
source.

Figure 2: Simple Connection using Siemens S7-400 PLC

The last figure shows a switch connected to the input I0.0 in the digital input module, and an
LED connected to the output Q0.0 in the output module.
Ladder Logic Programming
Figure 3 shows electrical continuity, when SW1 is closed, the current will flow from L-1 to L-2
and energize the load.

Figure 3: Hardwire switch-lamp circuit

Even though PLC ladder logic was modeled after the conventional relay ladder, there is no
electrical continuity in PLC ladder logic. PLC ladder rungs should have logical continuity in
order for the output to be energized. PLC ladder program uses familiar terms like “rungs”,
“normally open” and “normally closed” contacts, as illustrated in table 2.

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Table 2: Fundamental contacts and coils instructions of PLC ladder logic programming

In a ladder logic program, there is no physical conductor that carries the input signal through to
the output. Each rung in the ladder diagram is a program statement. This program statement
consists of a condition or sometimes conditions, along with some type of action.
Inputs are the conditions, and the action, or output, is the result of the conditions. As in case of
physical wiring hardware devices connected in series or parallel, PLC also combines ladder
program instructions in series or parallel. However, rather than working in series or parallel, the
PLC combines instructions logically using logic operators like: AND, OR, and NOT. These
operators are used to combine the instructions on a PLC rung to make the outcome of each rung
either true or false.
1. AND-logic function:
A series circuit of two switches can be regarded as AND logic function. In figure 4, both
switches (SW1 AND SW2) must be closed to have electrical continuity to energize the
output (Light-1). Hence the keyword here is AND.

Figure 4: AND-logic function

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The circuit shown in figure 5 represents a schematic ladder logic rung for the circuit
shown in figure 4. When switch 1 and switch 2 are closed the output coil will be
energized.

Figure 5: Ladder logic diagram for AND function

2. OR-logic function:
A parallel circuit of two switches can be regarded as OR logic function. In figure 6, one
of the switches (SW1 OR SW2) must be closed to have electrical continuity to energize
the output (Light-1). Hence the keyword here is OR.

Figure 6: OR-logic function

The circuit shown in figure 7 represents a schematic ladder logic rung for the circuit
shown in figure 6. If switch 1 or switch 2 is closed the output coil will be energized.

Figure 7: Ladder logic diagram for OR function

3. The PARALLEL NOT logic function:
Figure 8 shows ladder diagram for the parallel NOT logic function and its truth table is
illustrated in table 3.

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Figure 8: Ladder logic diagram for parallel NOT function

Table 3: Parallel NOT logic function truth table

Equipment
1) Computer with SIMATIC software.
2) Siemens S7-400 PLC.
3) LEDs.
4) Switches.
5) Connecting wires.
6) Motor.
7) Limit switches.

Procedures
To write and download a ladder diagram using SIMATIC Manager software, do the following
steps:
1. Run SIMATIC Manager software.
2. Start a new project wizard, then click on “Next”.
3. Select the appropriate CPU type, then click on “Next”. You can check the type and order
no. from the hardware.
4. Choose “LAD” since we are going to use ladder diagram programming, then click on
“Next”.
5. Write a name for your project, then click on “Finish”.

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6. Click in the left half of the project window on the box containing a plus sign to display
the full tree structure of the project. The resulting structure will look something like
figure 9. Double click on “SIMATIC 400 Station” then choose “Hardware”.

Figure 9: Project window

7. Configure the station hardware (Power supplay (PS), CPU, Digital Input (DI), … etc.)
according to their order in the racks, see figure 10. You can check the type and order no.
from the hardware.

Figure 10: Basic steps for configuring a station

8. Save the configurations.

9. STOP the PLC station from the switch and download the configurations.
10. Click in the left half of the project window on the box containing a plus sign to display
the full tree structure of the project, see figure 9.
11. Double click on “Blocks” then choose “OB1”, it will open a new window where you
have to write your ladder logic diagram.
12. After you finish the ladder diagram, download it to the PLC station.

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Part 1: Logic functions implementation

1- Connect two switches to the digital input module.
2- Connect one LED to the digital output module.
3- Write down the ladder diagram to implement AND-logic function using SIMATIC
Manager software.
4- Download the program to the PLC.
5- Repeat steps 1 through 4 to implement OR-logic function.
6- Repeat steps 1 through 4 to implement Parallel NOT-logic function.

Part 2: NOR-logic function implementation

1- Write down the Boolean sum-of-product expression for NOR logic function, see table 4.

Table 4: NOR-logic function truth table

2- Connect two switches to the digital input module.

3- Connect one LED to the digital output module.
4- Write down the ladder diagram to implement NOR-logic function using SIMATIC
Manager software.
5- Download the program to the PLC.

Part 3: Alarm system implementation using 2 LEDs

Assume that we have 3 signals (Inputs) that we get from the field that warn us about some kind
of fire danger. The system works as follows:
Any 1 signal, turn the green light on.
Any 2 signals will turn the orange light on.
All 3 signals, will turn the two lights simultaneously.
1- Connect three switches to the digital input module.
2- Connect two LEDs to the digital output module.
3- Write down the ladder diagram to implement the previous system using SIMATIC
Manager software.
4- Download the program to the PLC.

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Part 4: The sealed in coil pattern implementation

This pattern is the basis for remembering state in a PLC. The pattern consists of a trigger
condition and a coil, where a contact from the coil branches around the trigger condition to “seal
itself in” once the coil is energized, see figure 11.

Figure 11: The sealed in coil pattern

1- Connect one switch to the digital input.

2- Connect one LED to the digital output.
3- Write down the ladder diagram to implement this function using SIMATIC Manager
software.
4- Download the program to the PLC.

Part 5: The state coil pattern implementation

This pattern is an extension to the Sealed in Coil pattern. The pattern consists of a trigger
condition, a coil, with a contact from the coil branching around the trigger condition to “seal
itself in”, and then some other condition to “break the seal”, see figure 12.

1- Connect one switch to the digital input.

2- Connect one LED to the digital output.
3- Write down the ladder diagram to implement this function using SIMATIC Manager
software,
4- Download the program to the PLC.

Figure 12: The state coil pattern

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Part 6: The start/stop circuit pattern implementation

A very useful Ladder Logic Programming Pattern is the Start/Stop Circuit. This pattern is an
extension to the Sealed in Coil pattern and is similar to the State Coil, see figure 13.

Figure 13: The start/stop circuit pattern

1- Connect one switch to the digital input.

2- Connect one LED to the digital output.
3- Write down the ladder diagram to implement this function using SIMATIC Manager
software,
4- Download the program to the PLC.

Part 7: DC motor direction control

1- Connect three switches to the digital input, as follows:

Forward pushbutton, Backward pushbutton, and Overall system switch.
2- Connect forward motor and backward motor connections to the digital output.
3- Write a ladder diagram to control the direction of the motor using the pushbuttons.

Hints:
1) Use the idea of an interlock (electrical and mechanical); to prevent the situation of
pressing the backward and forward pushbuttons at the same time, and stop the motor
when it reaches its maximum limits.
2) Use the idea of state coil pattern since we are using pushbuttons to control the direction
of motion.
Discussion and Conclusions
1- Discuss the advantages of PLC controllers in comparison with general purpose
computers.
2- Illustrate the operation of sealed in coil pattern? How it can be de-energized?
3- Illustrate the operation of state coil pattern? How it can be de-energized?
4- Illustrate the operation of start/stop circuit pattern?
5- What is the main difference between state coil pattern and start/stop circuit pattern?
6- Mention four different applications where the PLC can be used?
7- Illustrate the mechanical and electrical interlocks?

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