AUTOMATION IN PROCESS CONTROL 18EI71

MODULE-2
2.1PLC Instructions
2.1.1 What is logic? PLC programming languages
2.1.2 Ladder programming-Conventional ladder Vs. PLCladder

2.2 Series and Parallel function

2.2.1 AND
2.2.2 OR
2.2.3 NOT
2.2.4 XOR logic

2.3 The basic relay instructions

2.3.1 Normally open
2.3.2 Normally closed

2.4 Output and latching instructions Analysis of rung

2.5 Understanding relay instructions and the PLC input modules

2.6 Interfacing start stop pushbutton and motor to PLC,

developing ladder diagrams with analytical problems.

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

MODULE 2
PLC INSTRUCTIONS
2.1 Introduction
• Conventional hardwired relay ladder diagrams represent actual hardwired control
circuit.
• In a hardwired circuit there must be electrical continuity before the load will energize.
• PLC ladder logic was modelled after the conventional relay ladder there is no
electrical continuity in PLC ladder logic.
• PLC ladder rungs must have a logical continuity before the output will energize.

2.1.1 Conventional ladder versus PLC ladder logic.

• The familiar electrical ladder diagram is the traditional method of representing an
electrical sequence of operation in hardwired relay circuits.
• Ladder diagrams are used to represent the interconnection of field devices.
• Each rung of the ladder clearly the relationship of turning on one field device and
shows how it interacts with the next field device.
• With the advent of the programmable controller, one of the specifications for this new
control device was that it had to be easily programmed.
• The difference between a PLC ladder program and relay ladder rungs involves
continuity.
• An electrical schematic rung has electrical continuity when current flows
uninterrupted from the left power rail to the right power rail.
• Electrical continuity, as illustrated in Figure 2.1, is required to energize the load. An
electrical current flows from L-1 through SW 1 and onto the load, returning by way of
L-2. When current flows, there is electrical continuity to the status table, where it is
stored.

Fig: 2.1 Hardwired Relay circuit

• Even though a PLC ladder program closely resembles an electrical schematic, PLC
ladder symbols represent ladder program instructions.
• A PLC program is a set of instructions that is stored in memory. These instructions
tell the PLC what to do with input signals and then, as a result of following the
instructions, where to send the signals.

PLC input signal follows these six steps:

1. The input signal is seen by the input module.

2. The input module isolates and converts the input signal to a low-voltage signal with
which the PLC can work.
3. The ON or OFF signal from the input section is sent via the backplane to the input
status file where it is stored.
4. The processor will look at each input's ON or OFF level as it solves the user program.

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

5. The resulting ON or OFF action, as a result of solving each rung, is sent to the output
status file for storage.
6. During the output update portion of the scan, the processor will send the ON or OFF
signal from each bit in the output status file to the associated output screw terminal by
way of the output module.
Individual ladder-programming symbols are represented as instructions in the CPU section of
Figure 2-2. The notations I: 01, I:02, and O:01 represent the instructions and their addresses.
When programming the PLC, these instructions are entered one by one and stored
sequentially in the user program portion of the processor's memory. When the PLC is in run
mode, these instructions are combined to arrive at the resulting ON or OFF state of each
rung's output.

Figure 2-2 Signal flow into and out of a PLC. Notice that there is no electrical continuity
between the inputs and the controlled output.

The PLC follows, or executes, the instructions stored in its memory. For example a packaged
grape drink. The package instructions instruct you to do the following:

1. Get one cup of sugar.

2. Put two quarts of water and the sugar into a container.
3. Add the contents of the package.
4. Mix until uniform.
5. Grape drink is ready to -serve.
Following this procedure will provide an end product (grape drink). Likewise, the
PLC follows the instructions programmed in its memory to achieve an end product.

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

2.1.2 WHAT IS LOGIC?

Devices in an electrical schematic diagram are described as being open or closed. PLC ladder
instructions are typically referred to as either true or false. When a PLC solves the user
program, it is said to be solving the ladder logic.

Figure 2-3 for a look at a PLC ladder program

Fig 2-3

• Each rung is a program. Statement.

• A program statement consists of a condition, or conditions along with some type of
action. Inputs are the conditions, and the action, or output, is the result of the
conditions.
• The PLC combines ladder program instructions similar to the physical wiring
hardware devices in series or parallel.
• The PLC combines instructions logically using logical operators such as AND, OR,
and NOT. These operators are used to combine the instructions on a PLC rung so as
to make the outcome of each rung either true or false.
• The symbol that represents the result of solving the input logic on a particular rung is
the output.

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

2.2 SERIES AND PARALLEL LOGIC FUNCTION

2.2.1 AND Logic Function
• In the series circuit (Figures 2-4 and 2-5), switch 1 AND switch 2 must be closed to
have electrical continuity. When there is electrical continuity, output (light 1) will
energize. The key word here is AND.

Fig 2-4 Conventional series circuit

Fig 2-5 series circuit represented as a conventional ladder rung

Closing switch 1 and switch 2 will provide power, or electrical continuity, to L-1. This is illustrated in
Figure 2-6.

Fig 2-6

Possible combinations that switch 1 (SW1) and switch2 (SW2), and the resulting output signals. (Fig
2-7 Truth table for AND logic)

Possible Switch Conditions AND Resulting Output

SW1 SW2 Light1
OFF OFF OFF
OFF ON OFF
ON OFF OFF
ON ON ON
Fig 2-7 Truth table for AND logic

From the truth table, you can see that only when switch 1 AND switch 2 are ON will the
output (light 1) energize.Figure 2-8 is an example of the ladder program instructions that
would be entered using a handheld programmer and an Allen-Bradley MicroLogix 1000. The

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

ladder rung in Figure 2-8 is identical to that in Figure 2-6 except that the symbols have been
changed to PLC ladder format.

Fig 2-8

Here is the program listing for the MicroLogix 1000 if you are entering the program with a
handheld programmer:
LOAD I1
AND I2
OUT 05
• The instructions tell the processor to load input 1(I1) into memory, AND it with input
2 (I2), and then output the result to output 5 (O5). The resulting output will be
determined by the truth table (Figure 2-7).
• The truth table in Figure 2-9 can also be represented as shown in Figure 2-10.

Fig 2-9 Fig 2-10

Three - Input And Logic

Figure 2-11 has three switches in series controlling the load L-1. The conventional series
circuit is shown in Figure 2-12. Figures 2-11 and 2-12 state that switch 1 AND switch 2 AND
switch 3 must be energized before output L-1 Will occur.

Fig 2-11 Three Input series circuit Fig 2-12 Three Input AND circuit

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

Fig 2-13 PLC three Input AND logic

The following is the program

LOAD I1
AND I2
AND 13
OUT O1

The instructions tell the processor to load input 1 (I1) into memory, AND it with input 2 (I2), AND
the result of the previous logical operation with input 3 (I3), and OUTPUT the result to output 1 (O1).
If all three inputs are false. If Il, which is false, is loaded into memory and then ANDed with 12,
which is also false, the result of this logical AND operation is false. Now we AND I3, which is false,
to the result of I1 and 12, which was false. ANDed with 13, the output is also false.

Three-Input AND Logic

Switch1 Switch2 Switch3 Switch4

Fig 2-14 Three Input AND logic truth table

2.2.2 Parallel Circuits - The OR logic Function

The rule of OR logic is that if any input is true, the output will also be true. OR logic also states that if
all inputs are true, the output will be true. In Figure 2-15, if switch 1 OR switch 2 is energized, light 1
will energize. If both SW 1 and SW 2 are true, the output will also be true.

Fig: 2-15

Figure 2-16 illustrates Figure 2-15 converted to a PLC ladder rung. A PLC rung of logic will
have normally open or normally closed contacts instead of normally open or closed switch
symbols. Addresses and instructions are included.

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

Fig : 2-16

A two-Input OR truth table shown in fig 2-17

Fig:2-17
In case of the OR circuit, if either switch is ON, the output will be true. In addition, if both
switches are ON, the output will be true. Figure 2-18 shows a three-input parallel circuit,
using three-input OR logic. The following is a PLC program listing from

LOAD I1
OR I2
OR I3
OUT 02
The instructions tell the processor to load input 1 (I1) into memory, OR it with input 2 (I2),
then OR the resultant of the previous logic operation with input 3 (I3), and then output the
result to output 2 (O2).

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

Fig:2-18 Three Input OR Logic Fig:2-19 Truth Table

Let's assume that inputs II and I3 are false, and input I2 is true. If Il, which is false, is loaded
into memory and then ORed with I2, which is true, the result of this logical OR operation is
true. Now OR I3, which is false, with the result of II and 12. That resultant was true; OR ed
with I3, which is false, its output is true. If any or all inputs are true, the output is true.

2.2.3 NOT LOGIC

A normally closed hardwire relay contact passes power any time the relay coil is not
energized. Likewise, the normally closed PLC ladder logic instruction will pass power any
time the input status .file bit is not a 1. This means that the physical hardware input is not
sending an input signal into the PLC's input module.
NOT logic is the opposite of a normally open PLC instruction or contact. It can be used in
conjunction with AND or OR logic when a logical 0 in the status file is expected to activate
some output device.
The NOT logic function is used when an input must not be energized for an output to be
energized.
The truth table in Figure 2-20 simply states that a normally closed instruction on a PLC
ladder rung will be the inverse, or opposite, of the input status table bit associated with the
specific instruction.
If the input status table bit is a 1, or true, the normally closed instruction will be false. In
comparison, when the input table status bit is false, or a 0, the associated normally closed
instruction will be true.
Figure 2-21 illustrates two rungs, the first with a normally open instruction and the second
with a normally closed instruction.

Fig 2-20 Truth Table

Fig 2-21 Conventional ladder diagram illustrating normally open and normally closed relay
contacts controlling load, L-1.

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

ANALYSIS OF RUNG #1

• Instruction I1 will energize the output only when there is a logical 1 in its associated
input status file bit. A 1 in this bit position will cause the normally open instruction to
become true and change state.
• In changing state, the instruction will allow logical continuity to pass on to the output
instruction and make it true.
• Instruction I1 is considered true when it passes logical continuity. If there is no valid
input signal from the field device attached to I1 screw terminal on the input module, a
logical 0 will be placed in the input status file.
• A logical 0 in the input status file will result in .this normally open input instruction
becoming false. Being false, the instruction will not pass logical continuity.

ANALYSIS OF RUNG #2
• The normally closed instruction works much like the normally closed contacts on a
hard-ware relay. Being normally closed, instruction I2 will energize the output only
when there is a logical 0 in its associated input status file bit.
• Even though there is a logical 0, or false input signal, in the status file, the normally
closed instruction is true and passes logical continuity on to the output instruction. If
there is a valid ON input signal from the field device attached to I2's input module
screw terminal, a logical 1 will be placed in the input status file.
• A logical 1 in the input status file will cause the normally closed instruction to
change state. The normally closed instruction will change from true (closed) to false
(open).
• Being false, the normally closed instruction will not pass logical continuity to the
output instruction. Without logical continuity, the output instruction will become
false.

Parallel NOT Logic

A parallel ladder rung with normally closed inputs is a rung containing OR NOT logic.
Figure 2-22, a PLC ladder rung, has two input instructions, one normally open and one
normally closed. This circuit contains parallel NOT logic. This conventional schematic
rung will be true under the conditions shown in Figure 2-23. Input I must be true OR
input 2 must NOT be true to make this rung true and energize output L-1.

Fig 2-22 Parallel NOT logic

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

Fig:2-23 Truth Table

Let's look at the following ladder and program for an Allen7Bradley MicroLogix 1000 (Fig
2-24).Notice that the normally closed instruction is referred to as "OR invert" (ORI).
LOAD
OR I2
ORI I3
OUT O2

Fig 2-24

The instructions tell the processor to load input 1 (I1) into memory, OR it with input 2 (I2),
then OR invert (OR a normally closed instruction), with the resultant of the previous logic
with input 3 (I3) then being output to output 2 (O2).OR logic states that when any or all
inputs are true, the associated output will be true.

2.2.4 EXCLUSIVE OR LOGIC

Looking at a truth table for a two-input OR logic function, we see that there are three input
conditions that will give us an output signal (see Figures 2-25and 2-26)
1. If input 01 is off and input 02 is on.
2. If input 01 is on and input 02 is off.
3. If input 01 is on and input 02 is on.

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

Fig:2-25 Fig:2-26

The exclusive OR logic function will allow either input 01 OR input 02, but not both
together, to control the output (Fig 2-27).

Fig:2-27

The logic for exclusive OR (X-OR) would look as follows (Fig 2-28).

Fig 2-28 Ex-OR logic

ANALYSIS OF EXCLUSIVE OR LOGIC

• If normally closed input I1 is true and input I2 is left as is, the logic on the main rung
will become true, thus energizing the output. As for the state of the normally closed I1
instruction on the parallel branch, with the normally open input instruction true or
closed, the normally closed contacts for input I1 on the parallel branch will open.

• With the normally closed contacts from input I1open on the parallel branch, input I2
cannot control the output.

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

• Input I2's logic will operate in the same manner. If 12's normally open instruction
becomes true while I1's instructions remain in their normal state, the parallel branch
will become true. With the parallel branch true, the rung will be true.

• The rung output will become true as there is logical continuity on the parallel branch.
With the normally open I2 closed on the parallel branch, the normally closed I2 on the
main rung will open and prevent I1 from controlling the output.

• If, by chance, both input 1 and input 2 are energized their normally closed
counterparts will both open. With an open on the main rung and the parallel branch,
there is no way for the rung to become true.

2.3 The Basic Relay Instruction

A PLC processor's collection of instructions is called its instruction set. While different
processors have different instruction sets, there are basic instructions shared by all PLC
processors.

Bit or Relay Instructions

• Contacts and coils are the basic symbols found on a ladder diagram. Normally open or
normally closed contact symbols are programmed on a given rung to represent input
conditions that are to be evaluated by the processor as it solves the user ladder
program.
• Rung contacts are evaluated to determine how output, instructions are to be controlled
by the PLC.
• Each output is represented by a coil symbol.
• Contacts and coils are also referred to as bit or relay instructions.
• Each input or output is represented by a separate bit in the input or output Status file.
Figure 2-29 presents a generalized overview of the basic instructions available in most
PLC processors.
• Instructions direct the PLC as to how to respond to bits found in its memory.
• Bits in PLC memory are typically input status file bits representing ON or OFF
signals input into the status file from an input module.

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

BIT Instructions
Instruction Symbol Use this Instruction
Normally open or As a normally open, or examine if ON, input
Examine ON instruction on your ladder rung
Normally closed or As a normally closed, or examine if OFF, input
Examine OFF instruction on your ladder rung
One-shot --[OSR]-- To input a single digital pulse from a maintained
input signal
To latch an output ON. Output stays ON until the
Latch Output coil unlatch instruction becomes true

Unlatch Output coil To unlatch a latched ON instruction with the

same address
Output coil As an output instruction that becomes true when
all inputs on the rung are true
As an output instruction that passes power at all
Negated Output times except when all rung inputs are true
Fig: 2-29

2.3.1 The Normally Open Instruction

The normally open instruction is used by all PLCs.The SLC 500 and MicroLogix use
the term "examine if closed" (XIC) to represent the normally open instruction. Other PLC
manufacturers might use "examine if ON- to identify the normally open instruction. We
are focussing on Allen Bradley SLC 500 family of PLCs.
Fig 2-30 shows how the normally open instruction is evaluated by the PLC processor’s
CPU.

Fig:2-30

The examine if closed instruction tells the processor to test for an ON condition from
the reference address bit. The reference address bit could be an input device in the
input status file, an output bit from the output status file, or an internal bit used as
either an output or a status bit from other instructions.

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

2.3.2 Normally Closed Instruction

• The normally closed instruction is also called the examine off, or examine if open, instruction,
depending on the particular PLC manufacturer.
• The SLC 500 and MicroLogix use the term "examine ifopen”, (XIO) to identify this
instruction.
• The normally closed instruction is programmed whenever the processor is to test the
instruction for an OFF, or open, condition. The instruction will normally be represented as
a 0 in the input status file.
• With the field input device OFF the normally closed instruction will remain closed.
• –A normally closed instruction that is evaluated as closed ".is a true instruction. Finding the
normally closed instruction true, the instruction will continue to provide continuity through
the instruction on the rung.
• If the status table bit is found to be a 0, the device controlling this bit is in its ON state. Figure
2-31 is a ladder rung with a normally closed, or examine if open, instruction.

Fig: 2-31

Explanation of the Rung

• If the field hardware input device connected to the. SLC 500 input module residing in slot
one, screw terminal one, is not energized, the input status bit will remain a zero.
• With the input status bit a zero, the XIO instruction will remain closed and pass logical
continuity.
• As long as XIO instruction I:1/1 is passing logical continuity, the OTE instruction with the
address of 0:2/0 will be true. Being true, the field hardware output device attached to the
output module screw terminal zero in SLC 500 chassis slot two will either be turned ON or
remain ON.
• Fig 2-32 shows the physical input device condition, input status table bit condition and
how the processor will evaluate the normally closed instruction.

Fig 2-32

• The normally closed, or examine if open, instruction is addressed in the same manner
as the normally open instruction.

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

2.4 The Output Latching Instruction

• An output-latching instruction is an output instruction used to maintain, or latch, an

output ON even if the status of the input logic that caused the output to energize
changes.
• When any logical path on the ladder rung containing the latching instruction has
continuity the output referenced the latching instruction is turned ON and remains
ON even if the rungs logical continuity or PLC system power lost.
• Since the latch instruction retains its state through a system power loss, the latching
instruction is called a retentive instruction.
• The latched instruction will remain in a latched ON condition until an unlatch
instruction with the same reference address is energized.
• Latch and unlatch instructions are always used in pairs. Each instruction is typically
located on a separate rung.
• Figure 2-33 illustrates two ladder rungs. The first rung contains the latching
instruction, while the second rung contains the unlatching instruction.

Fig:2-33 Latching and Unlatching ladder logic

Rung Operation
• When input 1:1/2 on the first rung is energized, the output-latch instruction, address 0:2/3,
is energized. The output-latch instruction will remain latched ON and will be unaffected,if
input 1:1/2 changes.
• Use the output-unlatch instruction to turn OFF, or unlatch, the output that was turned on by
the latching instruction. The unlatch instruction with the same address must energized to
unlatch the output address that was latched ON.

The following rules pertain to most latch and unlatch instructions:

1. Latch and unlatch instructions are used in pairs.

2. Latch and unlatch pairs of instructions must have the same reference address.
3. The latch and unlatch ladder rungs do not need to be grouped together in the ladder
program.
4. Latching and unlatching instructions are retentive, provided your PLC system battery is
installed and in good condition.
5. Not all PLCs allow internal bits to be latched.
6. Use an unlatch instruction to unlatch, or clear, status bits.
7. Figure 2-34 illustrates an, unlatch instruction unlatching an overflow trap status bit. This
status bit is unlatched in applications where a math overflow or divide by zero operation
occurs and could otherwise fault the processor:
8. If an unlatch instruction is left energized, the associated latching output cannot be latched.

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

9. Output latch instructions are retentive.

Fig 2-34 unlatch instruction used alone to unlatch an addition instructions overflow status bit

Programming consideration

• Figure 2-35 illustrates a latching instruction programmed before the unlatch

instruction. If both instructions are true, the last instruction programmed on the rung
will take precedence over the other instruction. In this example, the output instruction
will always be unlatched.

Fig 2-36 Latching instruction programmed before the unlatch instruction

• Figure 2-37 has the unlatch instruction programmed after the unlatch instruction. In this
case, the last instruction—the latch instruction—will take precedence and keep the output
latched, provided both the latch and unlatch rungs are true.

Fig 2-37 Latching instruction programmed after the unlatch instruction

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

2.5 Understanding Relay Instructions and the PLC Input Modules

• When a programmable control system is compared to relay control system, the PLC
operation as a function of input signals read by the CPU rather than the physical wiring
configuration of field input devices.
• For example if a normally open push button is connected to a PLC as an input device. The
PLC cannot determine if the push button is normally open or normally closed. The
processor can only see the ON or OFF incoming signals as a bit in the input status file.
• A programmer must develop a user program based on the status of input signals received
and stored in the input status file in addition to the physical status of the field input
devices. Figure 2-38 illustrates a common hardwired start-stop latching circuit.

Fig: 2-38

• A PLC program could be developed directly from this ladder rung, as illustrated in Figure
2-39.

Fig 2-39

• A PLC was designed to simulate relay ladder logic, relay operation is a key building block
in understanding, and how input signals from hardware input devices must interact with
programming instructions.
• When the relay is at rest, the normally open push-button input is not actuated and the
relay coil is not energized. The relay's normally closed contacts will remain closed and
Light A will be lit in Figure 2-40.
• When the push button is closed, the relay coil will be energized and its associated
contacts will switch. The normally open contacts, now closed, will pass power. Light A
will turn off as its contacts are open, and Light B will energized. (Fig 2-41).
• Fig 2-42 illustrates a normally closed push button, which allows power to flow
continuously to the relay coil. With the relay coil energized, Pilot Light B will remain on
as long as the normally closed push button allows power to flow to the relay coil.
• When the normally closed push button is depressed (Fig 2-43) power will be interrupted
to the relay's coil. As the coil loses power, the normally open contacts, which have been
held closed, will open. Normally closed contacts will pass power as they return to their
normal state. Pilot Light A will then energize.

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

Fig 2-40 Fig 2-41

Fig 2-42 Fig 2-43

Fig 2-44 summarizes the relay status in conjunction with the input status buttons.

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

Fig 2-44

2.6 Interfacing a start stop push button station to a PLC

• Start stop push buttons are sometimes built in to a small enclosure called a start stop
station.
• The start stop push button has one momentary, normally open, start push button and
one momentary, normally closed, stop push button.
• When depressed, the stop push button will open the circuit and shut off the controlled
device, If a wire was broken in the control circuit, the output device would be de-
energized, thus avoiding a potentially dangerous situation.
• If a normally open stop push button was used for a stop circuit, the stop circuit could
not fail safely if there was bad connection or broken wire because manual intervention
would have to take, place to kill power to the circuit.

Circuit operation

• To interface a start-stop push button station to a PLC, we need to evaluate the

conventional schematic and convert it to ladder logic for PLC control. The first step in
schematic conversion to PLC management is to determine inputs and outputs from the
conventional ladder symbols.
• Figure 2-38 is being converted to a PLC ladder rung in Figure 2-45
• .

Fig 2-45 Input and Output separation

• When converting to PLC ladder logic, the CR-1 coil and its associated contacts become
internal to the PLC and are not represented on the PLC ladder program. Because CR1-I

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Asst. Prof
AUTOMATION IN PROCESS CONTROL 18EI71

and its associated contacts no longer exist, the PLC output instruction will be used to
latch the ladder logic.
• To receive maximum flexibility from a PLC, connect each input to the PLC input
module separately so that the PLC ladder program can be used to combine each input as
required to satisfy any control problem.
• Fig 2-46 shows separated inputs wired to a PLC input module.

Fig 2-46 separated inputs connected to PLC input screw terminals

Typical PLC Input module wiring

• In fig 2-46 the start push button will be input zero on the input module in slot one, address
I: 1/0. The stop push button will be input four on the input module in slot one, address I:
1/4. Latching instruction is referenced to O: 2/1.
• The normally open start push button is open; no ON signal will be input to the CPU when
it scans this input address. A binary zero signal level will be placed in the input status file
(Fig 2-47).
• The stop button provides a constant ON, signal to, the input module (input address I:1/4), A
binary one will be placed in the input status file reflecting this ON condition (Fig 2-48).

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AUTOMATION IN PROCESS CONTROL 18EI71

Fig 2-47 Start Push button status reflected in the input status table. The OFF signal will be reflected
as a 0 in the input status table

Fig 2-48 start-stop input bit status from input hardware in a nonenergized state

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Asst. Prof
 AUTOMATION IN PROCESS CONTROL 18EI71

Motor Starter Circuits and the Overload contacts

The typical motor starter circuit has a set of normally closed hardware overload contacts that
are part of the starter's overload relay. Figure 2-49 shows the overload contacts as they are
represented in a typical start-stop rung.

Fig 2-49 A conventional motor starter schematic diagram

Many conventional schematics place the normally closed overload contact after the starter coil on the
rung. Because most PLCs require that all input instructions be programmed before the output
instruction, the conventional schematic must be converted.
• The first step in converting a conventional schematic to PLC management is to determine
inputs and outputs. The overload relay's normally closed contacts will be a physical
hardwired input.
• After they have been determined, separate inputs from outputs.
• While separating inputs and outputs, move the overload contacts to the input side of the
output.
• Assign inputs their addresses and enter the proper instructions on the ladder.
The overload contacts in a motor starter are closed during normal operation. Being a normally
closed set of contacts like the normally closed stop push button, the proper instruction on a PLC
ladder rung will be normally open. (Fig 2-50)

Fig 2-50 conventional motor starter circuit converted for PLC system management

Overload relay contacts are programmed as normally open, as the normally closed stop push
button. This input will always pass power except when the motor starter is in an Overload
condition. In an overload condition, the normally closed overload contacts will open and de-
energize the start-stop control circuit.

S J SAVITA, Dept of EIE, RNSIT

Asst. Prof
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