ME6405

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ME6405

Section Objectives:
Before the invention of the Programmable Logic Controller
(PLC), most industrial control was done using relay control
panels.
Switches and relays can be arranged in circuits to make
logical decisions. Output from these circuits can be used to
drive “loads” such as motors, heaters, or electromagnetic
coils. A relay control panel is comprised of a single to
thousands of these circuits.
In this Section, relay control panels will be presented.

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Relay Control Panel Components : Switch

2 2
1 1

3 3

Off: contacts 1 and 2 connected On: contacts 1 and 3 connected

Pins 1 and 2 are “normally closed” since they are connected when the
switch is off. T Pins 1 and 2 are not connected when the switch is on.

Pins 1 and 3 are “normally open” since they are not connected when the
switch is off. Pins 1 and 3 are connected when the switch is on.

(Note: Although this is a toggle switch, this switch can symbolize any type
of input source such as push button switches, sensors, power supplies,
etc. in this lecture.)

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Relay Control Panel Components : Coil

Coil off Coil on

(Note: Although this is really an electromagnetic coil, this can symbolize

any “load” such as a pump, dc motor, heating element, light, etc. for this
lecture.)

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Relay Control Panel Components : Relay

1
1

3 2
3 2
Off: Coil off, contacts ON: Coil on, contacts
1 and 2 connected 1 and 3 connected
A relay is a combination of coil and switch.

With coil off, the switch goes to its normal position off.

With coil on, the switch is pulled by electromagnetic force to its on

position.

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ME6405

Relay Logic : NOT

Using one switch, a logical “NOT” operation can
be constructed. An example is given below:

“NOT” Switch 1 = Coil

V+ Switch 1 Coil
2
1

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Relay Logic : NOT (Continued)

“NOT” Switch 1 off = Coil on
V+ Switch 1 Coil
2
1

“NOT” Switch 1 on = Coil off

V+ Switch 1 Coil
2
1

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Relay Logic : AND

Using two switches, a logical “AND” operation can
be constructed. An example is given below:

Switch 1 “AND” Switch 2 = Coil

V+ Switch 1 Switch 2 Coil

2
2
1
1
3
3

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Relay Logic : AND (continued)

Switch 1 off “AND” Switch 2 off = Coil off
V+ Switch 1 Switch 2 Coil
2
2
1
1
3
3

Switch 1 on “AND” Switch 2 off = Coil off

V+ Switch 1 Switch 2 Coil
2
2
1
1
3
3

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Relay Logic : AND (continued)

Switch 1 off “AND” Switch 2 on = Coil off
V+ Switch 1 Switch 2 Coil
2
2
1
1
3
3

Switch 1 on “AND” Switch 2 on = Coil on

V+ Switch 1 Switch 2 Coil
2
2
1
1
3
3

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ME6405

Relay Logic : OR
Using two switches, a logical “OR” operation can
be constructed. An example is given below:

Switch 1 “OR” Switch 2 = Coil

V+ Switch 1
2 Coil
1

Switch 2
2
1

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Relay Logic : OR
Switch 1 off “OR” Switch 2 off = Coil off

V+ Switch 1
2 Coil
1

Switch 2
2
1

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Relay Logic : OR
Switch 1 on “OR” Switch 2 off = Coil on

V+ Switch 1
2 Coil
1

Switch 2
2
1

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ME6405

Relay Logic : OR
Switch 1 off “OR” Switch 2 on = Coil on

V+ Switch 1
2 Coil
1

Switch 2
2
1

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ME6405

Relay Logic : OR
Switch 1 on “OR” Switch 2 on = Coil on

V+ Switch 1
2 Coil
1

Switch 2
2
1

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Relay Logic : XOR

Using two switches and four relays, a logical “XOR” operation can be
constructed. An example is given below:

Switch 1 “XOR” Switch 2 = Coil

V+ V+
V+ Switch 1
1 1
2
1 Coil
3
3 2 3 2

Switch 2
1 1
2
1

3
3 2 3 2

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Relay Logic : XOR (continued)

Switch 1 off “XOR” Switch 2 off = Coil off

V+ V+
V+ Switch 1
1 1
2
1 Coil
3
3 2 3 2

Switch 2
1 1
2
1

3
3 2 3 2

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Relay Logic : XOR (continued)

Switch 1 on “XOR” Switch 2 off = Coil on

V+ V+
V+ Switch 1
1 1
2
1 Coil
3
3 2 3 2

Switch 2
1 1
2
1

3
3 2 3 2

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Relay Logic : XOR (continued)

Switch 1 off “XOR” Switch 2 on = Coil on

V+ V+
V+ Switch 1
1 1
2
1 Coil
3
3 2 3 2

Switch 2
1 1
2
1

3
3 2 3 2

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Relay Logic : XOR (continued)

Switch 1 on “XOR” Switch 2 on = Coil off

V+ V+
V+ Switch 1
1 1
2
1 Coil
3
3 2 3 2

Switch 2
1 1
2
1

3
3 2 3 2

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ME6405

Problems with relay control panels:

Mechanical Relays and switches failed regularly (coil failure, contact
wear and contamination, etc.)
Difficult to diagnose problems and replace relays and switches
Difficult to change hardwired logic (example: changing an “OR” circuit
to “XOR”)
Consumed a lot of power

To address these problems, Richard E. Morley of Bedford

Associates invented the first PLC as a consulting project for
General Electric in 1968. Bedford Associates is currently named
Modicon and is a supplier of PLCs.

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ME6405

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ME6405

Section Objectives:
Basic PLC Components needed to replace relay control
panels will be presented. These include:
Isolated Power Supply Digital Input and Output pins ( DI/0)
Micro-controller Memory
(Note: Advanced features such as Timers, Interrupts, Counters, etc.
will not be discussed in this lecture)

For this lecture, Siemens A&D S7

314C-2 PtP PLC installed in the
Mechatronics Laboratory will be used
as an example.
Siemens 314C-2 PtP

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ME6405

Basic PLC: Isolated Power Supply

Every PLC has an external or internal Isolated Power Supply.
Isolated Power Supplies can have more than one isolated
output.
One isolated output is reserved for the PLC micro-controller. The
rest is reserved for other components such as DI/O.
Normally Power supplies are high voltage. Typically 24 Volts for
industrial PLCs.

The S7 314C-2 PtP PLC uses the

Siemens A&D PS307 5A power
supply. The PS307 5A can source 5
amps of current at 24 volts. The PS307
5A has 3 isolated outputs.
Siemens PS307 5A

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Basic PLC: Micro-controller

Every PLC at least one micro-controller

The S7 314C-2 PtP PLC uses a custom micro-controller.

Designed by Siemens A&D and manufactured by Infineon
Technologies AD.
Part Number:
Infineon
Siemens A&D
IBC 16
SXA1020A-E
S7 Controller
Specifications not given in documentation

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Basic PLC: Digital Inputs and Outputs (DI/Os)

DI/Os are electrically isolated from the micro-controller

The number of DI/Os can be increased by adding additional DI/O
modules.

Example:
The S7 314C-2 PtP PLC has 16 digital
outputs and 24 digital inputs. Can be
expanded up to 1024 DI/Os by adding
additional DI/O modules.

SM232 DI/O module

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Basic PLC: Memory

Memory on a PLC is separated into 3 main areas:

LOAD Memory
• Can be RAM (dynamic) or EEPROM (retentive)
• Used to store user programs
• For S7 314C-2 PtP PLC : LOAD Memory located on memory card
WORK Memory
• Memory is RAM
• When PLC starts, Program is copied from LOAD memory to
WORK memory. The program is then executed from Work
memory.
• For S7 314C-2 PtP PLC: 48K bytes of WORK memory

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Basic PLC: Memory ( Continued)

SYSTEM Memory
ƒ Memory is RAM
ƒ Is used by micro-controller to implement counters, timers, interrupt
stacks, etc..
ƒ Contains a bit for each D I/0
ƒ Contains “Marker Memory”. Marker memory is a free area of RAM
that can be used by the programmer. (In S7 314C-2 PtP, 258
bytes are available as Marker Memory)
ƒ Contains “Process Input and Output Images.” Periodically the PLC
will store the states of the inputs to the Process Input Image and
Process Output Image to the output. (In S7 314C-2 PtP, this is
limited to the first 128 bytes of input information and 128 bytes of
output information.)

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ME6405

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ME6405

Section Objectives:
Initially PLCs were used to directly replace relay control
panels. To directly replace relay control panels based on
mechanical relays with PLCs based on a micro-controller
presented challenges. These challenges and solutions will
be discussed.

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Transition:A Simplified Programmer’s Model

In the simplified programmer’s model of relay logic, all inputs I1, I2, .., Im go
into each relay logic section. Each relay logic section then produces an
output Q.

I1,I2, … ,Im Relay Logic Section 1 Q1

I1,I2, … ,Im Relay Logic Section 2 Q2

.
.
.

I1,I2, … ,Im Relay Logic Section n Qn

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Transition: Relay control panel execution of Model

A relay control panel will execute all relay logic sections in parallel since
each switch is capable of powering many coils at a time. If any input
changes at time t0 then all the relay logic sections will update the outputs
at time t1.

I1,I2, … ,Im changes at t0 Relay Logic Section 1 Q1 changes at t1

I1,I2, … ,Im changes at t0 Relay Logic Section 2 Q2 changes at t1

.
.
.

I1,I2, … ,Im changes at t0 Relay Logic Section n Qn changes at t1

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Transition: PLC execution of Model

A PLC will execute all relay logic sections in series since a micro-
controller can execute only one instruction at a time. If any input changes
at time t0 then relay logic section 1 will update Q1 at t1, relay logic section
2 will update Q2 at t2, …. , and relay logic section n will update Qn at tn.

I1,I2, … ,Im changes at t0 Relay Logic Section 1 Q1 changes at t1

I1,I2, … ,Im changes at t0 Relay Logic Section 2 Q2 changes at t2

.
.
.

I1,I2, … ,Im changes at t0 Relay Logic Section n Qn changes at tn

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Transition: Differences in Relay Control Panel vs.

PLC execution of Model
Difference 1:
Relay Control Panel – The maximum time any change in input is reflected in any output is t1.
PLC – The maximum time any change in input is reflected in any output is t1+t2+…+tN.

Difference 2:
Relay Control Panel – Since this is made from analogue components. It is possible to replace
a logic section without stopping execution of other logic sections if wired correctly.
PLC – This is made with a digital micro-controller. The micro-controller must be halted to
replace a logic section. All other logic sections will stop operation.

Difference 3:
Relay Control Panel – Since parallel execution of logic sections, all outputs are a function of
one set of inputs.
PLC – Since serial execution of logic sections, all outputs may not be a function of one set of
inputs. (example: input I2 may change as the micro-controller is processing Logic section
George
2. Therefore
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inputs)
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 ME6405

Transition: PLC Operation

To minimize the effects of differences between the Relay Control Panel and PLC
execution of the programming model, the PLC operates in the following manner:
Steps:
• PLC Restarts (Warm Restart)
Warm Restart
• Reads Inputs and updates Process Input
Image
Update Process Image Input
• Executes User Program Once

• Writes Process Output Image to Outputs

scan cycle

User Program

• Take care of system processes ( such as

communications with other PLCs, updating
Update Process Image Output
user program, etc..)

PLC System Processes

• Loop Back to step 2

Steps 2 through 5 is called a scan cycle. (Note:

some people may refer to a PLC as a
Programmable “Loop” Controller because of
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 ME6405

Transition: PLC Operation

To Minimize Difference 1:
Time to complete a scan cycle can be set by user. If PLC violates the scan cycle, an interrupt
routine can be run or the PLC will halt execution. (For S7 314C-2 PtP, maximum scan
cycle allowed is 6 sec)

To Minimize Difference 2:
If a part of the user program is replaced, the new part is written first to LOAD memory. During
step 5, PLC System Processes, the new part is copied into WORK memory from LOAD
Memory. During the next scan cycle, the new part of the user program will be executed.

To Minimize Difference 3:
If the programmer uses the inputs stored in the Process Input Image, the user program will
have access to the same inputs per scan cycle. Also if the programmer, writes outputs to
the Process Output Image, all the outputs will be updated simultaneously during step 4,
Update Process Output Image.
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ME6405

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Section Objectives:
The biggest transition from relay control panels to PLCs
was the transition from the hard wired relay logic to logic
defined by user program. In order to allow established relay
logic users to program the PLC, a visual programming
language that looks like a relay control panel was created.
This visual programming language is called “Ladder Logic”.
In this section, basic Ladder Logic will be presented.

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Ladder Logic: System Memory Addressing

To address a bit of memory

___ ___ . ___

Memory Area Byte Address Bit Number

Notation

To address a byte, word, or double word

___ ___ ___

Memory Area Size of Addressed Byte Address

Notation Memory Notation

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Ladder Logic: System Memory Addressing (continued)

Memory Area Notations:
Notation Memory Area
I Process Input Image

Q Process Output Image

M Marker Memory

PI Peripheral Input ( Actual Input Pins)

PQ Peripheral Output ( Actual Output Pins)

T Timer Storage Area

C Counter Storage Area

L Local Memory of current Data Block

DB Data Block Memory

(Note: Advanced features such as Timers, Counters, Data

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Ladder Logic: System Memory Addressing (continued)

Size of Addressed Memory Notations:
Notation Size of Addressed Memory
B Byte (8 bits)

W Word (16 bits)

D Double Word (32 bits)

Byte Address:
Each Memory Area is addressed in one byte increments
starting at byte 0.

Bit Number:
MSBit is 7 and LSBit is 0

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Ladder Logic: System Memory Addressing (continued)

Examples:

Marker Area

Byte 0 MB0
M1.3
(Note: only bit 3 of Byte 1
Marker Area byte 1) MW1
Byte 2

Byte 3

Byte 4
MD3
Byte 5

Byte 6 MD4

Byte 7

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Ladder Logic: System Memory Addressing (continued)

Examples:

Peripheral Input
Area
Byte 0

Byte 1 PIB1
PI2.5
(Note: only bit 5 of Byte 2
Peripherial Input Area byte 2)
Byte 3

Byte 4

Byte 5
PID4
Byte 6

Byte 7

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Ladder Logic : The Ladder

A ladder logic program has a “ladder” look to it. The sides of the ladder
are the power rail on the left and ground rail on the right. The rungs of the
ladder consists of Virtual Relay Components. (Note: Rungs are called
“Networks” in Step 7)

Virtual Relay Components

Power Rail

Ground Rail
Virtual Relay Components

Virtual Relay Components

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Ladder Logic : Virtual Relays

Any Marker or Function Block memory bit can be one or more virtual relays.
If memory bit is 0, the coils of virtual relays associated with the bit are off. If
memory bit is 1, the coils of virtual relays associated with the bit are on.

Any D I/O memory bit ( Peripheral or Process Image) is a virtual relay for a
digital input or output pin of the PLC.

Virtual Relay Components:

Mechanical Relay Normally Open Switch ( equivalent to pins 1

and 3 of Mechanical Relay. If this switch is
1 closed for a virtual digital output relay, the
digital output pin is high. If this switch is open
for a virtual digital output relay, the digital
output pin is low )
3 2

Normally Closed Switch ( equivalent to pins 1

and 2 of Mechanical Relay)

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Not available for virtual digital input relays)
ME6405

Ladder Logic: Rules for converting Relay Logic

to Ladder Logic

Each external switch must be connected to an input pin of a

PLC.
Each external coil or load must be connected to an output pin of
a PLC.
The relay logic must be recreated using virtual input and output
relays associated with the input and output pins.
Only possible paths from power to ground though virtual relays
need to be recreated in Ladder Logic.

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Ladder Logic : NOT

“NOT” Switch 1 = Coil

From Relay Logic:

V+ Switch 1 Coil
2
1

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Ladder Logic : NOT (continued)

Relay Logic rewired to include Virtual Input and Output Relays:

Inside PLC

V+ Switch 1
2
V+ V+
Coil
1 1 1

3
(Note: Wired to PLC
Input Pin Associated
3 2 3 2
with Virtual Input
Relay I0.0) (Note: Wired to PLC
Output Pin Associated
Virtual Input Virtual Output with Virtual Output
Relay Q0.0)
Relay at I0.0 Relay at Q0.0

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Ladder Logic : NOT (continued)

Ladder Logic Equivalent:

Switch 1 is wired to PLC input pin associated with Virtual Input Relay
I0.0
Coil is wired to PLC output pin associated with Virtual Output Relay
Q0.0

I0.0 Q0.0

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Ladder Logic : AND

Switch 1 “AND” Switch 2 = Coil

From Relay Logic:

V+ Switch 1 Switch 2 Coil

2
2
1
1
3
3

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Ladder Logic : AND (continued)

Relay Logic rewired to include Virtual Input and Output Relays:

V+ Switch 1 Inside PLC

2
V+
1 1

3
(Note: Wired to PLC V+
Input Pin Associated Coil
3 2
with Virtual Input 1
Relay I0.0) Virtual Input
Relay at I0.0

V+ Switch 2 3 2

2 (Note: Wired to PLC

Output Pin Associated
1 1
Virtual Output with Virtual Output
Relay at Q0.0 Relay Q0.0)
(Note: Wired to PLC
Input Pin Associated
3 2
with Virtual Input
Relay I0.1) George Virtual Input
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Ladder Logic : AND (continued)

Ladder Logic Equivalent:

Switch 1 is wired to PLC input pin associated with Virtual Input Relay
I0.0
Switch 2 is wired to PLC input pin associated with Virtual Input Relay
I0.1
Coil is wired to PLC output pin associated with Virtual Output Relay
Q0.0

I0.0 I0.1 Q0.0

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Ladder Logic : OR

Switch 1 “OR” Switch 2 = Coil

From Relay Logic:

V+ Switch 1
2 Coil
1

Switch 2
2
1

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Ladder Logic : OR (continued)

Relay Logic rewired to include Virtual Input and Output Relays:

V+ Switch 1 Inside PLC

2
V+
1 1

3
(Note: Wired to PLC V+
Input Pin Associated Coil
3 2
with Virtual Input 1
Relay I0.0) Virtual Input
Relay at I0.0

V+ Switch 2 3 2
V+
2 (Note: Wired to PLC
Output Pin Associated
1 1
Virtual Output with Virtual Output
Relay at Q0.0 Relay Q0.0)
(Note: Wired to PLC
Input Pin Associated
3 2
with Virtual Input
Relay I0.1) George Virtual Input
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 ME6405

Ladder Logic : OR (continued)

Ladder Logic Equivalent:

Switch 1 is wired to PLC input pin associated with Virtual Input Relay
I0.0
Switch 2 is wired to PLC input pin associated with Virtual Input Relay
I0.1
Coil is wired to PLC output pin associated with Virtual Output Relay
Q0.0

I0.0 Q0.0

I0.1

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 ME6405

Ladder Logic : XOR

Switch 1 “OR” Switch 2 = Coil

From Relay Logic:

V+ V+
V+ Switch 1
1 1
2
1 Coil
3
3 2 3 2

Switch 2
1 1
2
1

3
3 2 3 2

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 ME6405

Ladder Logic : XOR (continued)

Relay Logic rewired to include Virtual Input and Output Relays:
Inside PLC
Virtual Input Virtual Input
V+ Switch 1 Relay at I0.0 Relay at I0.0
2 V+ V+
1 1 1

3 Virtual Output
(Note: Wired to PLC Relay at Q0.0 Coil
Input Pin Associated V+
3 2 3 2
with Virtual Input
1
Relay I0.0)
V+ Switch 2
2

1 1 3 2
1 (Note: Wired to
PLC Output Pin
Associated with
(Note: Wired to PLC Virtual Output
Input Pin Associated Relay PQ0.0)
3 2 3 2
with Virtual Input
Relay I0.1)
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Relay at I0.1 Engineering, Georgia Tech
 ME6405

Ladder Logic : OR (continued)

Ladder Logic Equivalent:

Switch 1 is wired to PLC input pin associated with Virtual Input Relay
I0.0
Switch 2 is wired to PLC input pin associated with Virtual Input Relay
I0.1
Coil is wired to PLC output pin associated with Virtual Output Relay
Q0.0

I0.0 I0.1 Q0.0

I0.0 I0.1

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ME6405

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ME6405

Section Objectives:
A micro-controller can be used for more than relay logic
with virtual relays. Ladder logic has components that take
advantage of the micro-controller. These components can
be categorized as follows: bit logic,comparator, converter,
counter, data base calls, jumps, integer functions, floating
point functions, move, program control, shift/rotate, status
bits, timers, and word logic.
It is impossible to cover all of the components in one
lecture. This lecture will first explain formatting of
constants. Then, only a few categories and examples of
components will be shown.

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ME6405

Constants

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ME6405

Constants

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ME6405

Constants

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ME6405

Constants

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 ME6405

Bit Logic

Available Bit logic components:

Normally Closed Switch Positive Edge Detection

Normally Open Switch Negative Edge Detection
Output Coil Address Positive Edge Detection
Midline Output Address Negative Edge Detection
Set Coil Set-Reset Flip Flop
Reset Coil Reset-Set Flip Flop
Invert Power Flow Immediate Read
Save RLO into BR Memory Immediate Write
Bit Exclusive OR

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ME6405

Bit Logic example: Set Coil and Reset Coil

Description:
Set Coil is executed only if power flows to the coil. When executed, the specified
<address> of the element is set to "1". It will remain set even if power is removed
from the coil.

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ME6405

Bit Logic example: Set Coil and Reset Coil

Description:
Reset Coil is executed only if power flows to the coil. When executed, the
specified <address> of the element is reset to "0". No power flow to the coil has
no effect and the state of the element's specified address remains unchanged.
(Note: can be used to reset timers and counters)

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ME6405

Bit Logic example: Set Coil and Reset Coil

Example:
Switch 1 connected to Input 0.0
Switch 2 connected to Input 0.1
Coil connected to Output 0.0

If Switch 1 turns on then turn on Coil and keep it on even if Switch 1 is

released. If Switch 2 turns on then turn off the Coil.

I0.0 Q0.0

I0.1 Q0.0

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 ME6405

Comparator

Available Comparator components (Note: Integer is Word, Double Integer is

Double Word)
Integer: Equal to
Integer: Greater than
Integer: Less than
Integer: Greater than or Equal to
Integer: Less than or Equal to
Double Integer: Equal to
Double Integer: Greater than
Double Integer: Less than
Double Integer: Greater than or Equal to
Double Integer: Less than or Equal to
Real: Equal to
Real: Greater than
Real: Less than
Real: Greater than or Equal to
Real: Less than or Equal to

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ME6405

Comparator example: Integer Compares

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ME6405

Comparator example: Integer Compares

Example:
Coil connected to Output 0.0

If MW0 and MW2 are equal then turn on coil.

Q0.0
CMP
== I
MW0 IN1

MW2 IN2

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 ME6405

Jumps

Available Jump components (Note: called Logic control in Step 7 Help)

Label
Unconditional Jump
Conditional Jump
Not conditional Jump

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 ME6405

Jump example: Conditional Jump

Description Conditional Jump:

The micro-controller will goto the specified Label if power flows into the JUMP.
(Note: a label can be assigned to any Network)

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ME6405

Jump example: Label and conditional Jump

Example:
Switch 1 connected to Input 0.0

If Switch 1 turns on then jump to label “END”

I0.0 “END”

JMP

Components

Components

END

I0.1 Q0.0
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 ME6405

Integer Math

Available Integer Math components:

(Note: Integer is Word, Double Integer is Double Word)

Integer: Add Double Integer: Subtract

Integer: Subtract Double Integer: Multiply
Integer: Multiply Double Integer: Divide
Integer: Divide Double Integer: Modulus
Double Integer: Add

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 ME6405

Math example: Integer Add

Description:
IN1 and IN2 are added and the result is stored in OUT when power is
applied to EN . Power flows out of EN0 when power is applied to EN unless
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the addition results in overflow. of Mechanical Engineering, Georgia Tech
ME6405

Math example: Integer Add

Example:
Add 5 and integer stored at MW0. Store the result in MW2.

ADD_I

EN EN0
5 IN1

MW0 IN2 OUT MW2

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 ME6405

Move

Available Move components:

Move

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 ME6405

Move example:

Description:
IN is moved to Out and power flows out of EN0 when power is applied to
EN.
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ME6405

Move example:
Example:
Move 5 to MW2.

MOVE

EN EN0
5 IN1 OUT MW2

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 ME6405

Timer

Available Timer components:

Pulse S5 Timer Pulse Timer Coil

Extended Pulse S5 Timer Extended Pusle Timer Coil
On-Delay S5 Timer On-Delay Timer Coil
Retentive On-Delay S5 Timer Retentive On-Delay Timer Coil
Off-Delay S5 Timer Off-Delay Timer Coil

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 ME6405

Timer example: Extended Pulse S5 Timer

Description:
A power transition from OFF to ON on S will restart the timer. Power flows
from Q while timer is running. The timer will run for a preset time TV.
(Note: 256 timers
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ME6405

Timer example:
Example:
Switch 1 connected to Input 0.0
Coil is connected to Output 0.0

Turn on coil for 10 seconds if Switch 1 is turned on.

T0
I0.0 Q0.0
S_EXt
S Q
S5T#10s TV BI
R BCD

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 ME6405

Word Logic

Available Word Logic components:

“AND” Word “AND” Double Word

“OR” Word “OR” Double Word
“XOR” Word “XOR” Double Word

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ME6405

Word Logic example: “AND” Word

Description:
IN1 “AND” IN2 is stored in OUT when power is applied to EN . Power flows
out of EN0 when power is applied to EN unless the addition results in
overflow.
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ME6405

Word Logic example: Integer Add

Example:
“AND” MW0 and MW2. Store the result in MW4.

WAND W

EN EN0
MW0 IN1

MW2 IN2 OUT MW4

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ME6405

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ME6405

Section Objectives:
In this section two example ladder logic programs will be
given.

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ME6405

Example 1 :

Switch 1 connected to Input 0.0

Coil connected to Output 0.0

If Switch 1 is on then turn on and off a coil at 2 second intervals

(Note: 2 second interval means a period of 4 seconds and 50% Duty
cycle).

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ME6405

Example 1 (Continued)
Time: Scan cycle right before t = 0s
User Action : None

T0
I0.0 M0.0 Q0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

T1
I0.0 Q0.0 M0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

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ME6405

Example 1 : Continued
Time:Scan cycle at t = 0
User Action: User turns Switch 1 on

T0
I0.0 M0.0 Q0.0
S_EXt
S Q
S5T#2s TV BI (Note:
R BCD Time left: 2 s)

T1
I0.0 Q0.0 M0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

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ME6405

Example 1 : Continued
Time: Scan cycle right before t = 2s
User Action: None

T0
I0.0 M0.0 Q0.0
S_EXt
S Q
S5T#2s TV BI (Note:
R BCD Time left: ~0)

T1
I0.0 Q0.0 M0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

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 (Note: There is an inconsistency in this
ME6405 picture. The power is still flowing though the
normally closed contact for M0.0 on the first
Example 1 : Continued rung even though the coil on the second rung
for M0.0 is on. This is due to the serial nature
Time: Scan cycle at t = 2 s of the PLC micro-controller. Since the first
User Action: None rung is evaluated first, the coil was still off
when the micro-controller evaluated the
normally closed contact for M0.0)
T0
I0.0 M0.0 Q0.0
S_EXt
S Q
S5T#2s TV BI (Note:
Time left 0 s)
R BCD

T1
I0.0 Q0.0 M0.0
S_EXt
S Q
S5T#2s TV BI (Note:
R BCD Time left: 2 s)

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ME6405 (Note: Inconsistency from the previous slide
resolved)
Example 1 : Continued
Time: Scan cycle right after t = 2 s
User Action: None

T0
I0.0 M0.0 Q0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

T1
I0.0 Q0.0 M0.0
S_EXt
S Q
S5T#2s TV BI (Note:
R BCD Time left: 2 s – 1
scan cycle time)
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ME6405

Example 1 : Continued
Time: Scan cycle right before t = 4 s
User Action: None

T0
I0.0 M0.0 Q0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

T1
I0.0 Q0.0 M0.0
S_EXt
S Q
S5T#2s TV BI (Note:
R BCD Time left: ~0 s)

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ME6405

Example 1 : Continued
Time: Scan cycle at t = 4 s
User Action: None

T0
I0.0 M0.0 Q0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

T1
I0.0 Q0.0 M0.0
S_EXt
S Q
S5T#2s TV BI (Note:
R BCD Time left: 0 s)

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 (Note: A once scan cycle error has been
ME6405
introduced in the timing. The reason is that
the coil of M0.0 on the second rung was
Example 1 : Continued turned off during the scan cycle at t = 4s. The
normally closed switch of M0.0 is not
Time: Scan cycle right after t = 4 s evaluated again until the scan cycle after the
User Action: None scan cycle at t = 4 s. Therefore, Timer T0
starts one scan cycle after t = 4. This error will
propagate and similar errors will accumulate. )
T0
I0.0 M0.0 Q0.0
S_EXt
S Q
S5T#2s TV BI (Note:
R BCD Time left: 2 s)

T1
I0.0 Q0.0 M0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

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ME6405

Example 1 : Continued
Time: Some time later
User Action: User turns Switch 1 off

T0
I0.0 M0.0 Q0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

T1
I0.0 Q0.0 M0.0
S_EXt
S Q
S5T#2s TV BI
R BCD

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ME6405

Example 1 :

Comments:

As this example illustrates, consistent timing is difficult to achieve with a

PLC due to the scan cycle. This is the reason why PLC’s are not used to
control systems with very fast time constants such as CNC machines,
chemical mixers, etc….

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ME6405

Example 2 :

Switch 1 connected to Input 0.0

A Hall effect switch is connected to Input 0.1
(Note: a Hall effect switch will turn on when a magnetic object comes
in close proximity)
The motor for a conveyer belt is connected to Output 0.0
(Note: As previously mentioned, a coil can be any “load” such as a
motor during these lectures.)

If Switch 1 is turned on, the conveyer belt will transport 1000 magnetic
SHAFTS to Georgia Tech Students. Switch 1 must be turned off then on to
send another 1000 magnetic SHAFTS. The hall affect switch is positioned
right under the conveyer belt and can be used to count the SHAFTS as
they pass by.

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ME6405

Example 2 (Continued)
Time: Scan cycle right before t = 0s
Actions : no part near hall effect switch

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S

I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
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R

ME6405
Example 2 (Continued)
Time: Scan cycle at t = 0s
Actions : Switch 1 is turned on,
no SHAFT near hall effect switch
(Note: There is an inconsistency. Power is still
flowing though normally closed contact for
M0.0 even though the coil M0.0 is on. Since
the components on a rung is evaluated from
left to right, coil for M0.0 when micro-controller
evaluated the normally closed contact for M0.0
was still off. Same for PQ0.0)

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S

I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
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 (Note: Inconsistency from previous slide
ME6405 resolved. The conveyer is still moving because
of the “Set” coil.)
Example 2 (Continued)
Time: Scan cycle right after t = 0s
Actions : no SHAFT near hall effect switch

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S

I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
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 (Note: Similar Inconsistency between normally
ME6405 closed switch of M0.1 and coil of M0.1 as seen
with normally closed switch of M0.0 and coil of
Example 2 (Continued) M0.0)
Time: t = t1
Actions : SHAFT approaches hall effect switch, 1 is added to MW1

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S

I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
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 (Note: Inconsistency from previous slide
ME6405 resolved.)
Example 2 (Continued)
Time: t = t1 + 1 scan cycle
Actions : SHAFT passes over hall effect switch

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S

I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
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 (Note: Inconsistency between the “set” and
ME6405 “reset” of M0.1. That is because coil is still set
when the third rung is evaluated.)
Example 2 (Continued)
Time: t = t1 + 2 scan cycle
Actions : no SHAFT near hall effect switch

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S

I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
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 (Note: Inconsistency between the “set” and
ME6405 “reset” of M0.1 resolved.)
Example 2 (Continued)
Time: t = t1 + 3 scan cycle
Actions : no SHAFT near hall effect switch

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S

I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
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ME6405

Example 2 (Continued)
Time: t = t2
Actions : the 1001th SHAFT approaches hall effect switch (so 1000 have been delivered)

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S

I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
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 (Note: Inconsistency between the “set” and
ME6405 “reset” of PQ0.0. That is because coil is still
set when the first rung is evaluated.)
Example 2 (Continued)
Time: t = t2+ 1 scan cycle
Actions : the conveyer is stopped with 1001th SHAFT over the Hall effect switch

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S
I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
GeorgeW.
George W.Woodruff
WoodruffSchool
SchoolofofMechanical
MechanicalEngineering,
Engineering,Georgia
GeorgiaTech
Tech
R
 (Note: Inconsistency from previous slide
ME6405 resolved.)
Example 2 (Continued)
Time: t = t2+ 1 scan cycle
Actions : the conveyer is stopped. Switch 1 must be turned off and on to deliver 1000 more

I0.0 M0.0 Q0.0 Move Q0.0

EN EN0 S
0 IN1 OUT MW1
M0.0
S

I0.0 M0.0
R

CMP Q0.0
== I R
1001 IN1
MW1 IN2
I0.1 M0.1 ADD_I M0.1
EN EN0 S
1 IN1
MW1 IN2 OUT MW1
I0.1 M0.1
GeorgeW.
George W.Woodruff
WoodruffSchool
SchoolofofMechanical
MechanicalEngineering,
Engineering,Georgia
GeorgiaTech
Tech
R
ME6405

Example 2 :

Comments:

This and the previous example illustrates that the serial nature of the PLC
micro-controller can still affect program execution.

Also, this program can be simplified using an positive edge detection coil.
This was not done because the positive edge detection coil was not an
example in Section 5.

GeorgeW.
George W.Woodruff
WoodruffSchool
SchoolofofMechanical
MechanicalEngineering,
Engineering,Georgia
GeorgiaTech
Tech
 ME6405

So far we have looked at topics applicable to all PLC’s. Further Study Should focus
on:

Topics applicable to some but not all PLC’s:

Interrupts A/D
Counters Function Blocks

Communication Protocol:
Profibus
How to use communications to communicate with other PLC’s,
smart actuators and sensors, etc…

GeorgeW.
George W.Woodruff
WoodruffSchool
SchoolofofMechanical
MechanicalEngineering,
Engineering,Georgia
GeorgiaTech
Tech