Abhinav Srivastav

EE-3rd year
Overview

1. PLC and Controls History

2. PLC Components
3. Ladder Logic
4. Programming of Ladder Logic
Definition
A Programmable
controller is a solid
state user
programmable control
system with functions
to control logic,
sequencing, timing,
arithmetic data
manipulation and
counting capabilities.
 •Programming
•Device

•Input •User •Output

•Table •Program •Table

•Data
•Storage

•Input •Input/Output •Output

•Devices •System •Devices
 1. PLC and Controls History
 Large amount of work required connecting wires
 Difficulty with changes or replacements
 Difficulty in finding errors; requiring
skillful/experienced work force
 When a problem occurs, hold-up time is indefinite,
usually long
 Too many moving parts
Programmable Logic Controllers control most of
the mechanical processes in many areas of
production
Very simple in operation, complex in design
Basically it is used for automation in industries.
2. PLC Components

Components

PLC Operation
Components
 CPU
 Memory Areas
 Circuits to input or output data
 We can actually consider the
PLC to be a box full of hundreds
or thousands of separate relays,
counters, timers and data
storage locations that don't
physically exist but rather they
are simulated and can be
considered software counters,
timers, etc.

 Basically, a big box of math

Specific Components
Input Relays (contacts)
Internal Utility Relays

Output Relays (coils)

Counters

Data Storage
Timers
•Input Relays (contacts) - These are connected to the outside
world. They physically exist and receive signals from switches, sensors, etc.
Typically they are not relays but rather they are transistors.
•Internal Utility Relays - These do not receive signals from the
outside world nor do they physically exist. They are simulated relays and
are what enables a PLC to eliminate external relays. There are also some
special relays that are dedicated to performing only one task. Some are
always on while some are always off. Some are on only once during power-
on and are typically used for initializing data that was stored.
•Counters - These are simulated counters and they can be programmed
to count pulses. Typically these counters can count up, down or both up
and down. Since they are simulated they are limited in their counting speed.
Some manufacturers also include high-speed counters that are hardware
based. We can think of these as physically existing.
•Timers - These come in many varieties and increments. The most
common type is an on-delay type. Others include off-delay and both
retentive and non-retentive types. Increments vary from 1 millisecond
through 1 second.
•Output Relays (coils) - These are connected to the outside world.
They physically exist and send on/off signals to solenoids, lights, etc. They
can be transistors, relays, or triacs depending upon the model chosen.
•Data Storage - Typically there are registers assigned to simply store
data. They are usually used as temporary storage for math or data
manipulation. They can also typically be used to store data when power is
removed from the PLC. Upon power-up they will still have the same
contents as before power was removed.
PLC Operation
A PLC works by continually
scanning a program. We
can think of this scan cycle
as consisting of 3 important
steps. There are typically
more than 3 but we can
focus on the important parts
and not worry about the
others. Typically the others
are checking the system
and updating the current
internal counter and timer
values
What' happens in an operating cycle
•START
•1Input
•3. Output
•Scan •-
Scan
•- • •- PLC
•OPERATING
•
•During the input scan PLC
• CYCLE
•TYPICALLY
•examines the external input
•Based on the data in devices -On or Off.
• 1 to 25 ms.
•the output image file • The status
•- of the inputs is
•the PLC energises or •temporarily stored in an input
• de-energises it’s output image memory file.
•circuits,controlling
•external devices.

•The PLC scans the instructions in the ladder

• logic program,uses the input status from the
•2. Program• input image file & determines if an output will
•be energised.The resulting status of the outputs
•Scan •is written to the output image memory file.
RUNG SCANNING- A new style of scanning has been
implemented in the more recent years, called “rung scanning”. This type basically
scans each ladder rung individually in the entire ladder logic program, updating the
outputs on that rung after scanning through the inputs. This changes the type of
programming that will be used as well. If an output is in a rung above the inputs it
depends on, you will not get the output updated until the next scan, as the program
will keep scanning down until the last rung, then start over. This style is very
advantageous in certain situations. If you want your outputs updated at the soonest
possible moment, this is the style of scanning that you want to use.
3. Ladder Logic
Definition

Comparison to Relay
Logic
Definition:-
 Ladder logic is one form of
drawing electrical logic
schematics, and is a graphical
language very popular for
programming Programmable
Logic Controllers. Ladder logic
was originally invented to
describe logic made from
relays. The name is based on
the observation that programs
in this language resemble
ladders, with two vertical "rails"
and a series of horizontal
"rungs" between them.
Relay Logic
Ladder Logic 

Relay Logic
Comparison to Relay Logic
 A ladder diagram is similar to a schematic for a set of relay circuits. An argument that aided the initial
adoption of ladder logic was that a wide variety of engineers and technicians would be able to
understand and use it without much additional training, because of the resemblance to familiar
hardware systems.
 This argument has become less relevant lately given that most ladder logic programmers have a
software background in more conventional programming languages, and in practice implementations of
ladder logic have characteristics such as sequential execution that make the analogy to hardware
somewhat imperfect.
 Electricians and data cabling or control technicians still argue that this is the best graphical interface as
they generally do not have any computer science or digital systems background, and are therefore
taught with this interface in sequence with relay logic.

 Relay logic is the precursor to ladder logic, and is a method of controlling industrial electronic circuits
by using relays and contacts.

 . The schematic diagrams for relay logic circuits are often called line diagrams, because the inputs and
outputs are essentially drawn in a series of lines, with the lines representing actual wires run in the
circuit. A relay logic circuit is an electrical network consisting of lines, in which each input/output group
must have electrical continuity with all components in that group of devices to enable the output device.
The Relay logic diagrams represent the physical interconnection of devices, while the relay logic circuit
forms an electrical schematic diagram for the control of input and output devices. This is why
electricians and control technicians can easily understand and interpret relay logic and ladder logic
diagrams
Most widely used
program
Shown here as a very
small program
4. Ladder Logic Programming
Introduction
Basics – NO/NC Contacts/Coils
AND & OR Gates
Timers and Counters
Building a PLC Ladder Logic Programming
Introduction
 Ladder logic was one of the first programming approaches used in
PLCs because it borrowed heavily from the relay diagrams that plant
electricians already knew.

 The symbols used in relay ladder logic consist of a power rail to the
left, a second power rail to the right, and individual circuits that connect
the left power rail to the right.

 The logic of each circuit (or rung) is solved from left to right. ----
Technicians think of it as “reading” the diagram
 One line of instruction is called Rung.
 as the following is the example of the rung
Basics
NO Contact

NO Coil (Output)

NC Contact

NC Coil (Output)

Timers & Counters-
Very simple concept, it
times
2 basic types, on-delay and
off-delay
Still sends logic as its
output
•Counts number of times a lever
is pulled, a button is pushed, etc.
•3 types
•Up Counter
•Down Counter
•Up-Down Counter
Building a PLC/Ladder Logic Program
To illustrate, will start in relay logic, convert to
ladder logic at end
Will need to remove/replace some components
Overload Device Removed
All components in relay diagram because wires are
run to them
Is not addressed in ladder logic
Motor relay is not a physical entity in ladder logic
as in relay logic
Relay Logic converted to Ladder Logic Diagram
Much fewer hard wired components
Instead of motor relays, PLC just checks state of
motor output
Advantages of PLCs
 Number of wires reduced by
approximately 80%
 Fast and easy error detection.
 No change in wiring to change
program
 Needs fewer spare parts
 Cheaper when large number
of I/O instruments are
needed
 Less moving parts
 Compact
 Cost effective for
installation/maintenance
PLC IN INDUSTRIES
 This control system is used in so many industries and in so many applications that it is
practically impossible to predict its use. Although at the first stage of the development the
PLC’s were used for only BATCH PROCESS but with the rapid development of the
technology and software the PLC is being used in the complex continuous processes and
machines as well .
 The general use of PLC in industries is listed below-
1.Petrochemical industries
2.Steel rolling mills
3.cement mills
4.paper mills
5. Fertilizer plants
6.Machine tools manufacturing plants
7.Chemical industries
8.Automobile industries
9.Food processing industries
10.Security system
11.Power generation plant
12.Research institute and organizations
This list is ever increasing with the need of the process and the machine requirement.
Truly whenever the plan of the automation comes in the mind of automation people the
first best option is always a PLC now a days…
Conclusion
1. Programmable Logic History- This section
discussed the history and advancement of
controls technology, with a comparison of
programmable logic controllers and hard-wired
relays.
2. PLC Components-This section defined what
programmable logic is and described all
hardware associated with it.
3. Ladder Logic-This section covered ladder logic
and its general progression from relay logic.
4. Ladder Logic Programming-This section covered
basic programming techniques and their
implementation.
Thank you