CHAPTER - INTRODUCTION TO PLCS

Advantages of PLCs

Cost effective for controlling complex systems.

Flexible and can be reapplied to control other
systems quickly and easily.
Computational abilities allow more sophisticated
control.
Trouble shooting aids make programming easier and
reduce downtime.
Reliable components make these likely to operate for
years before failure.
PLC Origin

- Developed to replace relays in the late 1960s

- Costs dropped and became popular by 1980s
- Now used in many industrial designs
Relays and
Schematic
Symbols

in p u t c o il

O R
n o r m a lly
c lo s e d n o r m a lly
open

O R
Logical Control 115VA C
wall plug

with Relays

relay logic

output C
input A input B
(normally open) (normally open)
(normally closed)

A B C

ladder logic
 push buttons
Relay Logic
In a PLC power
supply
+24V

com.

PLC
inputs

ladder
logic
A B C

outputs

115Vac light
AC power

neut.
Reading Ladder Logic

HOT NEUTRAL
A B X

C D G Y

E F H

INPUTS OUTPUTS

Note: Power needs to flow through some combination of the inputs

(A,B,C,D,E,F,G,H) to turn on outputs (X,Y).
A Ladder Logic Example

A B

B Note: When A is pushed, the output B will turn on, and

the input B will also turn on and keep B on perma
nently - until power is removed.

Note: The line on the right is being left of f intentionally

and is implied in these diagrams.
 0 0 0 0 0 LD N A
0 0 0 0 1 LD B
0 0 0 0 2 A N D t h e m n e m o n ic c o d e is e q u iv a le n t t o
t h e la d d e r lo g ic b e lo w
Mnemonics 0
0
0
0
0
0
0
0
3
4
LD
LD
C
D
0 0 0 0 5 A N D
0 0 0 0 6 O R
0 0 0 0 7 ST X
0 0 0 0 8 EN D
A B X

C D

EN D

N o t e : T h e n o t a t io n s h o w n a b o v e is SO R
n o t s t a n d a r d A lle n - B r a d le y BST
n o t a t io n . T h e p r o g r a m t o t h e X IC A
r ig h t w o u ld b e t h e A - B e q u iv a X IO B
le n t . N X B
X IO C
X IO D
BN D
O TE X
EO R
EN D
SFCs

Start

power up Execution follows

multiple paths

flash
power down

End
Structured Text

i := 0 ;
REPEA T
i := i + 1 ;
U N T IL i > = 1 0
EN D _R EPEA T;
PLC in a Control Loop

PROCESS

Feedback from Connections to

sensors/switches actuators

PLC
The Four Stages of a PLC Scan

PLC program changes outputs

by examining inputs Set new outputs

THE Power turned on

CONTROL
LOOP
Process changes and PLC pauses
Read inputs while it checks its own operation
Ladder Logic Inputs

Normally open, an active input x will close the contact

and allow power to flow.

Normally closed, power flows when the input x is not open.

x
IIT

immediate inputs will take current values, not those from

the previous input scan. (Note: this instruction is actually
an output that will update the input table with the current
input values. Other input contacts can now be used to
examine the new values.)
Ladder Logic Outputs
When power is applied (on) the output x is activated for the left output, but turned
off for the output on the right.

x x

An input transition on will cause the output x to go on for one scan

(this is also known as a one shot relay)
x
OSR

When the L coil is energized, x will be toggled on, it will stay on until the U coil
is energized. This is like a flip-flop and stays set even when the PLC is turned of f.
x x
L
U

Some PLCs will allow immediate outputs that do not wait for the program scan to
end before setting an output. (Note: This instruction will only update the outputs using
the output table, other instruction must change the individual outputs.)

x
IOT

Note: Outputs are also commonly shown using parentheses ’-( )-’ instead
of the circle. This is because many of the programming systems are text
based and circles cannot be drawn.
Sample Problem:

Try to develop (without looking at the solution) a relay

based controller that will allow three switches in a room
to control a single light.