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Basic PLC Programming – How to Program

a PLC using Ladder Logic (for Beginners)
Last Updated on: April 29, 2020 by Rick Phillips

How do you program a PLC? PLC Programming starts by identifying the

problem, creating a sequence of operations based on binary logic, entering
a program using a language, and simulating the program in your software.

This guide assumes that, because you know about the existence of
Programmable Logic Controllers, you already know the most basic electrical

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 principles that govern the actual PLC operations. The knowledge of Input
Devices helps to imagine a multitude of solutions to a common problem, as
well as knowing the different Output Devices that are controlled by the PLC
to solve the problem in the first place.

Table of Contents [show]

Identifying the Problem

Before you start programming your PLC, or in fact any controller, you must
begin with the end in mind. This means that the final outcomes must be
determined clearly along with the conditions that determine the outcome.

Also, the input and output devices must be clearly identified.

For instance, you want a control system for your water tank. You want the
tank to fill up until it is full and then automatically refill one the water level is
near empty just to maintain the pressure. What do you do?

Because you have clearly identified what outcomes you want along with the
conditions, you now have to think the appropriate types of sensors and
output devices that you must use.

In this case, because there are water levels involved, you must use level
sensors: One for the Full level and one for the Near Empty level. Lastly, you
would want to control an input valve to regulate the flow of water into your
tank.

I found this helpful video that actually shows a control problem to solve:

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 PLC Programming
Programming Tutorial for Beginners_
Beginners_ Part 1
RealPars

Watch on

The next step is actually designing a program for your controller to execute
the steps required to perform your automated control system.

But first, you have to know some logical fundamentals that will allow your
system to create decisions on its own.

Fundamentals of Logic

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 PLC Programming was based on Relay Logic, and Relay Logic was based on
—well, the fundamentals of logic. Logic circuits are digital, so they produce
outputs that are discrete in nature. This means that it’s either “True or
False”, “High or Low”, “Yes or No”, “0 or 1”. Nothing in between. This
simplifies input-output relationships as compared to the analog side of
things.

In analog, we consider an INFINITE number of values. Instead of 0 or 1 only,

we have values in between. The “Maybe” in between the “Yes or No”, or the
“Medium” in between “High or Low”.

The result may also vary by the tiniest amount and it is already considered a
different output. Therefore, it is much simpler to use the Binary concept in
Number Systems to represent the outputs.

What is Binary?
Binary is part of the M-ary system of representation when M is the total

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 number of results. Confused? For a single digit, BI (two)-nary means two
possible outputs. Quarter(four)nary means four possible outputs. The
Decimal number system—which we are familiar with, has 10 (prefix Deci-)
representations: 0, 1, 2, 3, up to 9.

Because you are an intelligent human being, you may have guessed that
more digits can represent more values. In decimal, you use 10 if you have
exceeded counting through all representations (0 to 9) once. You use 20 if
you have exceeded twice, and so on.

Binary numbers are quite the same. 0, 1, 10, 11, 100, 101, 110, 111, 1000—you
see the pattern? One digit is added to the mix every time you have “used up”
all the possible representations.

How is this important in PLC programming? Well, because as I have

mentioned earlier, PLC programs were based on Relay Logic which operates
on Binary Logic. It’s either ON or OFF for them.

Using the proper sequence and arrangement of the Relays, the early
programmers were able to set conditions for switching their output devices.
The way they did this is by using the binary logical operations: NOT, AND,
OR, XOR, NAND, NOR, and XNOR.

Since the invention of transistors, manufacturers are now able to produce

Integrated Circuits that readily perform these logical operations. Such chips
are called “Logic Gates”.

Whether you have relays or logic gates, these are the fundamental logical
operations that you must know.

Note: For the examples that I will discuss below, the assumption is an output
of 1 “Turns the circuit ON” and an output of 0 is a “Circuit OFF condition”.

NOT

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 The NOT operation performs negation of input. If you have “0” as an input,
performing the NOT operation will output a “1”. Let’s look at how this is
performed using Relays.

Relays can either be “Normally Open (NO)” or “Normally Closed (NC)”.

Normally Open relays do not allow current to pass unless it is energized.

Normally Closed relays do not allow current to pass ONCE energized.

Hence, the Normally Closed relays served as the primitive versions of NOT
gates.

As an example, if you want a motor to turn off (Output: 0) when a button is

pressed (Input: 1), then you should use a Normally Closed Relay. The table
below summarizes the input-output relationship. By the way, that table is
called a truth table.

PLC programming NOT table

This is the only logical operation that requires only 1 INPUT. The logical
operators that I will discuss next require 2 inputs. Basically, they now
COMPARE the inputs that you provide.

AND

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 PLC Programming AND table

The AND gate outputs a “1” whenever BOTH inputs are “1”.

In everyday language, the AND operation requires that input 1 AND input 2 is
ON.

How did they do it for Relays? By placing normally open relays in series.

Connecting the normally open relays in series would not allow current to
pass through unless BOTH relays are energized. Simple as that.

The AND operation is commonly used in drilling machines where, for safety
reasons, the operator must use two hands to turn on the drill. This
decreases the possibility that the operator has his hand placed on the
drilling platform while the drilling operation starts.

OR

PLC Programming OR table

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 The OR operation outputs a “1” whenever ONE of the inputs is a “1”.

Basically, both Input 1 and Input 2 can control the switching of the circuit. In
comparison with the AND operation, you can only turn on a circuit by turning
BOTH switches ON.

In the AND operation, the relays were placed in series. In the OR operation,
relays are connected in PARALLEL to each other.

XOR

PLC Programming XOR table

XOR stands for “Exclusive OR”. This means that the input must be different
from each other, hence the term exclusive.

Using XOR, only one input at a time can control the circuit switching.

XOR can be used as comparators. Comparators, as implied, compares two

input signals and sends an output signal based on predetermined criteria or
functions. In this case, the comparator outputs a HIGH signal when the
inputs become different.

NAND

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 PLC Programming NAND table

The NAND gate is basically the equivalent of a NOT AND gate.

The gate will turn OFF when BOTH inputs are ON. Hence, you can expect
the truth table to be an inverted version of the AND truth table in terms of
the output.

In practical applications, the NAND operation may be used for temperature

regulation in a freezer, for example.

When a thermistor is connected to BOTH inputs of a NAND setup, it can act

as a feedback sensor to turn a heat exchanger OFF.

The resistance of the thermistor decreases when it gets colder, hence

decreasing the voltage drop to a low enough level to be detected as two
LOW signals by the NAND operation.

NOR

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 PLC Programming NOR table

The NOR gate is the equivalent of NOT OR.

The gate will turn OFF when at least 1 input is ON.

XNOR

PLC Programming XNOR table

Lastly, XNOR is the equivalent of NOT XOR.

When you want to turn on a circuit when the states of both inputs are the
same, XNOR is used.

This means that when both inputs are OFF or both inputs are ON, the XNOR
operation turns the circuit ON.

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 Boolean Algebra

Usually, the inverted versions of logical operations are not used in practical
circuits as you can easily change inputs into a Normally Closed one instead
of a Normally Open one (more on that later). But, it is still helpful to have a
basic understanding of them.

In studying these logical operations, Boolean algebra is used. Boolean

Algebra provides a way to simplify even the most complex series of logical
operations imaginable.

What this means for us is a shorter program that performs the same
operation, and that is highly desirable.

There are different laws that consist Boolean Algebra, and most of them are
similar to the mathematical laws that we have studied in elementary school.
The three basic rules are:

Commutative Law

This law states that two inputs are added (OR) or multiplied (AND), the order
is not important. This means that the result is the same for A+B and B+A.

Note: In A+B, when both inputs are 1, the equation turns

into 1+1. The answer is equivalent to 1, not 2 because we
still follow the Binary number system.

For A*B, the result is the same for B*A. Both are similar to Mathematical
rules.

Hence, in PLC programming, A OR B is the same as B OR A, and A AND B is

the same as B AND A.

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 Associative Law

Again, this law is just similar to the associative law in Mathematics. Either
adding or multiplying three variables together in a grouped fashion does not
affect the result.

To put it in simple terms, below are the equations:

(A+B)+C=A+(B+C)

(A*B)*C=A*(B*C)

This means that when the result of ( A OR B ) is OR’ed to C, the logical

output is the same even if A is OR’ed to the result of (B OR C). Makes sense?

Same goes for the AND. When the result of A AND B is applied with C using
the AND operation, the logical output is the same as that of A coupled with
the result of B AND C.

Distributive Law

The distributive law is critical in simplifying logical equations in Boolean

Algebra. Long equations that use 3 logic operations can be simplified into 2,
as evident in the equations below.

A*(B+C)=(A*B)+(A*C)

A + (B * C ) = ( A + B ) * ( A + C )

So, when you see an equation that resembles the one on the right, it is

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 actually more practical to use the equivalent equation on the left because
that ultimately results in the same output using a shorter program.

How to convert Boolean Equation to Logic Gate (and

vice versa)
Converting a Boolean Equation to a Logic Gate is simple as you only have to
know the equivalent of each gate’s boolean equations.

As stated earlier, the AND gate is simply a “multiplication” and the OR gate is
simply “addition”.

The NOT gate is noted as an apostrophe or a bar at the top of the

variable(s).

PLC Programming: Boolean Equation

The equation above summarizes it all, and it is read as [NOT (A AND B )] OR

C.

We can further simplify this using the NAND gate, because we have learned
earlier that the NAND gate is the equivalent of ‘NOT AND’.

Hence, the equation is simplified as:

(A NAND B) OR C

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 Now, if you wanted to take this logic gate representation back into a boolean
equation, you would have to turn EVERY operation into a representation
using just three operations:

NOT
OR
AND

This makes it easier to determine if the variables are added or multiplied or

negated.

Further Reading:
Logic Gates by Electronics Tutorials
Boolean Algebra by Electronics Tutorials
Short Guide on Boolean Algebra

IEC61131-3 Standard: PLC programming

languages
The IEC or the International Electrotechnical Commission is the international
standards and conformity assessment body for all fields of
electrotechnology, which essentially covers Programmable Logic
Controllers.

The IEC has published the IEC 61131 standard for PLCs which should be
followed by all users worldwide, and it has a section specifically for PLC
programming languages, the IEC 61131-3.

What is a PLC programming language?

PLC programming language refers to the set of semantics
or methods that allow the user to communicate information

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 to the PLC. The IEC 61131-3 standard defined the five
standard languages that are used in PLC programming.

The standard divides these 5 PLC programming languages into two

categories, based on the nature of the language: Textural and
Graphical/Visual.

PLC Programming: IEC61131-3 Programming Languages

Textural Programming Languages

Textural programming languages are those in the form of text and consists
of commands that the user must all be familiar with in order to create a
program.

Structured text

The structured text is a high-level language developed for industrial control

and is usually in C or PASCAL language. If you have a background in C
programming, you will closely see its resemblance.

The structured text language are written as a series of statements

terminated by semicolons (like in C). These statements are defined by the
language libraries and makes it easier to set input-output relationships in the
program.

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 Example:

Buzzer:=PushA OR ( PushB AND (NOT PushC) );

The example above directly shows the relationship between the variables for
the input and the output.

Structured text, similar to the PEMDAS (Parenthesis Exponent Multiplication-

Division Addition-Subtraction) principle in Mathematics, also have
commands that are higher in priority.

For example, in the structured text above, all variables within the
parentheses will be executed first. In that case, the most inner set of
parentheses should be evaluated, and that contains “NOT PushC”.

The program negates PushC first, and then evaluating the logical value of
PushB AND *the result* before evaluating it with PushA using the OR
operation.

Further Reading:

Structured Text Programming Tutorial by PLC Academy

Instruction List

The instruction list is a more complicated one, as it uses lower level

language.

In programming, lower level language means that it gets closer to machine

language (the 1’s and 0’s) and the commands closely resemble that of the
microprocessor’s programs. Higher level language is “closer” to the user
because it is easier to understand due to the function names or graphics, for

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 example.

Instruction lists are also considered a way of entering ladder programs,

except by using text. It gives a series of instructions for each new line and
uses mnemonics for each one.

Since different manufacturers use different mnemonics, I will only give the
IEC61131-3 as an example.

LD A

AND B

ST Q

This series of commands will create an equivalent ladder diagram as shown

below:

PLC Programming: Instruction List Ladder Logic Equivalent

Further Reading:

Instruction List Programming Tutorial by Wisdom Jobs

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 A Brief Instruction List Programming Tutorial

Visual Programming Languages

PLC programming languages that are visual are also high-level languages.
They are easily understood by humans because of the symbols and can
already represent a more specific component of the program/system.

Functional Blocks

PLC Programming: Functional blocks

The function block diagram is a simple way of PLC programming where

there are “Function blocks” (hence the name) are available in the
programming software.

The image above shows a diagram that is interpreted as “[Pump AND

Pressure] OR Test”.

Basically, when the Pump and Pressure inputs give a HIGH reading, the end
output will be 1. OR it could be that only the Test input gave a HIGH reading.

Further Reading:

Functional Block Diagram Programming by PLC Academy

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 Functional Block Programming by Wisdom Jobs

Sequential Function Charts

PLC Programming Sequential Function Charts

Sequential Function charts, on the other hand, are just that–charts that
represent each function in a PLC control system in a sequential fashion.

A sequential function chart is a visual representation of the system’s

operation to display the sequence of actions involved in the operation.

Further Reading:

Comprehensive SFC Tutorial by Omron

Sequential Function Charts for All by PLC Dev

Ladder Logic Diagram

The most commonly used PLC programming language is the Ladder Logic
Diagram.

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 The reason for its popularity is that Relay Logic Diagrams were closely
resembled by the Ladder Logic Diagrams.

When the PLC was invented, designers found a way to use the existing
knowledge of the Relay Control System designers for programming the PLC.

Another reason is that the PLC programmers usually prefer to define the
actions in terms of contacts, which again was the most commonly used
control system before the PLC.

Since this is the most commonly used PLC programming language, this is
the one that you will learn in this mini-course.

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 Ladder Logic Programming
PLC Programming has never been easier for the original Relay Control
System designers, thanks to Ladder Logic.

Ladder Logic was derived from the Relay Logic Diagrams and hence uses
almost the same context.

PLC Programming: Relay Logic Diagrams

The only difference is that because the PLC was very flexible in terms of the
Input and Output Devices, the symbols for the electrical devices are now
exempted from the actual program.

For Ladder Logic Programming, Inputs are Inputs, and Outputs are Outputs.
No need to memorize all the standard symbols for each separate device.

Parts of a ladder logic diagram and how it works

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 PLC Programming: Ladder Logic Diagram (Photo from PLCacademy)

The ladder logic diagram consists of two fundamental parts, which you can
see as the vertical and the horizontal lines. They are called, respectively,
the rails and the rungs.

Now, you may have noticed in the ladder logic diagram example above, there
are multiple inputs in the same rung. EXCEPT, they are not in series but
rather connected in a parallel fashion.

The number on the left represents a new rung. In the

example above, there are 4 rungs present. It may seem for
total beginners that there should be 7 rungs, but each
parallel connection only shows an OR relationship between
the two inputs.

Back to the example, the two vertical rails represent the 24 Vdc source and
the other one the 0 Vdc terminal. They are power rails. What this means is

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 that for an output element (more on that later) to become powered up, you
have to connect the two rails together by finding a way to connect them via
your inputs.

To scan the program for continuity of rungs, the PLC uses a top to bottom,
left to right sequence, thus checking continuity between the two rails for
each scan.

PLC Programming: How Ladder Logic Works

Simply put, the devices on a rung must provide continuity from the left rail to
the right rail.

Notations

In PLC Programming there are some fundamental notations that you must

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 remember to create programs, and they are very simple. In fact, you have
already seen them in the example above but this time, you are going to learn
what those actually mean.

Normally open and Normally Closed Inputs

Two vertical bars represent an input device. It could be any input device
connected to a PLC hence the symbol does not change for ALL PLC devices
as it is the standard set by the IEC 61131.

There are two types of input device notations: one is the Normally Open
(NO) inputs, and one is the Normally Closed (NC) inputs. They are classified
that way because the Relay Logic has used the same principle in the Relay
Logic Diagrams. In fact, this was inspired by electromechanical relays
because they, too, can also be normally open or normally closed.

PLC Programming Normally Open Input

Normally open inputs are the ones that have the two vertical lines separated
by a space in between. In PLC ladder logic programs, they are usually
termed as “Make” inputs.

Normally open inputs, like normally open relays, do not by default create a
connection between the two rails when connected. When activated, only
then it will create the connection.

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 These inputs could be any input device or sensor that is used to
conditionally activate an output device.

PLC Programming Normally Closed Input

Normally closed inputs are the ones that have the two vertical lines with a
forward slash that connects the two opposite ends.

In PLC ladder logic programs, they are usually termed as “Break” inputs and
are an equivalent of the NOT operation.

Normally closed inputs, like normally closed relays, ALREADY creates a

connection between the two rails when connected. When activated, only
then it will BREAK the connection.

Normally closed inputs are most commonly used for STOP buttons or
emergency shut down devices.

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 PLC Programming: Output Device

Shown above is the notation for an output device in a PLC ladder logic
diagram. Again, this could be ANY output device that can be controlled by
the PLC: Motor starters, Lamps, Buzzers, Solenoid Valves.

Different PLC Relays

PLCs have solved the problem brought by relays, and it was thanks to the
software-based relays that were designed for the PLC.

These relays now only rely on the memory component of the PLC so instead
of actually using relays to create a connection point, the memory of the PLC
now only stores the states of the supposed relays.

Internal Relays
Internal relays are elements that hold data to serve as relays for the system.
This is what makes the PLC more cost-effective than the conventional relay
systems that were used before.

These internal relays rely in bits on the memory of the PLC but can be
treated the same way as an external relay (as what I’ve been saying since
earlier).

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 For example, using an internal relay in conjunction with a push button allows
you to turn on a solenoid valve in one rung and a motor in another rung using
the same push button.

Furthermore, conditions for logical operations such as AND, OR, or NOT may
be made using that same internal relay in a different rung.

Battery-Backed Relays
When the PLC is suddenly turned off, whether due to a power outage or
some connection breaks, the states of the internal relays become erased
automatically.

Because of this, when you start the PLC after that scenario, the states of the
internal relay will go back to the initial stage of the program rather than the
LAST state that it had before the power outage happened.

This is where battery backed relays come into play. They retain their state of
activation even when the power supply of the PLC is entirely off. Hence, they
are also called retentive coils.

Set and Reset

PLC Programming: Set and Reset

Internal relays only retain their state if the input devices that are placed to

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 activate them are also retaining their activation states.

For set and reset relays, however, you can actually retain their state
indefinitely and then remove the state using another condition from an input
device.

This type of internal relay is practically applied to a “set” condition with

multiple input conditions and a “reset” condition ALSO with multiple input
conditions (more on that later).

Applications of Internal Relays

The internal relays were designed for a specific purpose which is (obviously)
to eliminate the need of external relays. This is desirable because not only
you would not worry anymore about a relay getting some wear and tear, but
also you would not have to worry about spending money on them.

Internal relays also make the PLC highly flexible because of the different
applications that extend the PLC’s capabilities.

Multiple Input Conditions

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 PLC Programming: Multiple Input Conditions

In designing control systems, there are times when you would want more
than one condition to turn something ON or OFF.

In this situation, using the input device notation over and over again would
be impractical and messy as a ladder logic program. The rung would have
too many things on it!

Thus, the program above shows that there are two conditions that are
represented by an internal relay EACH.

Latching Programs

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 PLC Programming: Latching Programs

In practical applications, sometimes an output must be held ON for an

indefinite amount of time until power is cut.

Input devices are usually momentary in nature, hence, for that scenario to
happen, Latching programs are required to be set up in the PLC
programming software.

One-Shot Operation

PLC Programming: One Shot Operation

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 So far, we have talked about retaining the states of relays and actually doing
it even without power supplied to the PLC.

Now, this type of operation is used when you want just an output pulse that
does not retain its state all throughout the program. This function is termed
as one-shot.

One shot operation is momentary, hence pushing the trigger button will only
cause an impulse to the output device.

Master-Slave Operation

PLC Programming: Master Slave

Master inputs are used when you want the whole program to be dependent
on a Master Control condition.

For instance, if you want the system to run ONLY when authorized personnel
has already examined the machine, a Master ON button must be switched
ON first.

It does not matter if the Slave START buttons were pushed over and over
again, because the system will not start without the Master ON button being
in an energized state.

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 Equivalent Ladder Diagrams for Logical Functions
AND

PLC Programming AND

The AND condition is basically just two inputs in series with each other.
Because the inputs are in series, the two inputs must BOTH have continuity
in order for the output to turn on.

OR

PLC Programming OR

The OR condition is a parallel connection between the two inputs. Because

the inputs are in parallel to each other, ANY of them may create continuity
between the two power rails thus turning the output ON.

NOR

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 PLC Programming NOR

The NOR condition, simply put, is an OR condition using negated inputs.

Negating inputs is as simple as turning a Normally Open input to a Normally
Closed one.

NAND

PLC Programming NAND

Similar to the NOR condition, the NAND condition is just a negated version
of the AND condition. Normally Open inputs are inverted.

XOR

PLC Programming XOR

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 The XOR condition has a different story than the rest of the logical
conditions. If you look at the Boolean equation for the XOR condition:

A XOR B = A’B + AB’

Therefore, to XOR the two variables A and B, you would have to perform
NOT, AND, and OR conditions to your ladder logic programs. This way, only
ONE input variable is allowed to control the output AT A TIME.

XNOR

PLC Programming XNOR

XNOR is rarely used as a logical statement, but it is actually best applied

when simplifying logical expressions that have a negated output for XOR.

For this one, notice that the ladder logic diagram has an internal relay
connected in a “break” manner in order to negate the result.

Remember, because the XOR is a combination of the AND and the OR

operations, negation would apply in a different manner. The safest way is to
apply it to the output.

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 Before you start: PLC Safety Systems
In applying the PLC programming skills that you have learned throughout
this mini programming course, make sure that you familiarize yourself with
the different safety techniques that are most commonly used in control
systems!

Emergency Stop Button

PLC Programming Emergency Stop

Emergency stop buttons are essential in every control system because when
the output devices start malfunctioning, you can have control of the power
using the PLC by setting an emergency stop button.

This button can even be replaced by a sensor for further automaticity.

Two-handed Start

PLC Programming Two hand start

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 The two handed start is a basic practice for machines that are hazardous to
operate due to the actuators’ short distance to the user. Usually, drilling
machines are controlled using this type of setup.

A sensor input is also used to ensure that an object that was expected to be
in the drilling platform is actually on the platform before the operator can
even start the drilling.

Proximity Detection

PLC Programming Proximity Sensing

Lastly, proximity sensing is used as a safety measure when there are huge
machines that may impose risks because of some produced tiny projectiles
or even being caught by the machine itself.

This is used to ensure that the controlled machines would not cause any
harm when accidentally approached (if that is even a thing).

Conclusion
In doing PLC programming, there are plenty more combinations of programs
that you may be able to design using the knowledge that you have acquired
in this post. Your imagination is the limit!

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 Check out one of my other posts if you want more!

What Is The Difference Between PLC and SCADA?

9 reasons why PLC is used over Microcontrollers
8 Steps to PLC Commissioning
What are the different types of PLC?
PLC Actuators and Output Devices (Alarms and Indicators, too)
PLC Basic Sensors and Input Devices – A Beginner’s Guide
PLC Basics: Introduction to Programmable Logic Controllers

 What Is The Difference Between PLC and SCADA?

 PLC vs Microcontrollers – 9 Reasons Why PLC is used over
Microcontrollers

Search …

About This Site

Hi, We’re BASIC PLC, the owners of this website.

We’re a Group of PLC Techs & Engineers who have a Passion of

Automation and want to spread the knowledge we’ve gained over the last
20 yrs with other Techs & Engineers!

We created this website with the goal of helping YOU learn about the
basics of the Programmable Logic Controller.

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 Featured Posts

PLC Programming 101: Everything You Need to Know

Introduction to PLC: PLC for Dummies

PLC Input Devices and Sensors

PLC Output Devices and Actuators

What are the different types of PLC?

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