Manufacturing Automation using PLCs

CHAPTER 2

Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

Chapter 2: Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL).
2.1
2.2
2.3
2.4
2.5
2.6

PLC Operation using scanning technique.

Understanding Relay Ladder Diagram (RLL).
Basic Instructions of RLL.
Motor control using PLC, two push buttons and motor starter.
Adding two indicators for the developed RLL.
PLC Programming.

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Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

Programmable Logic Controller (PLC)

And Relay Ladder Logic(RLL)
PLC stands for programmable logic controller. PLCs are electronic control devices that are
used in variety of industries, ranging from manufacturing plants to processing plants. A PLC
is a device that was invented to replace the necessary sequential relay circuits for machine
control and to replace analog controller. The PLC works by looking at its inputs (both logic
and continues types) and depending upon their state, turning on/off its outputs. Examples:
PLCs used in automotive assembly plants, automotive parts manufacturing plants, mineral
processing plants, semi-conductor manufacturing plants, steel mills .etc. The user enters a
program, usually via software, that gives the desired results.
The PLC has three components;
1) Central Processing Unit CPU,
2) Inputs,
3) Outputs.
We could consider the PLC to be a box of hundreds of separate relays, counters, timers and
data storage locations. Do these counters, timers, etc. really exist? No, they "physically"
don't exist but rather they are simulated and can be considered software counters, timers, etc.
The internal relays are simulated through bit locations in registers, as shown in Fig. 2.1.
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The functions of these modules are given as follows:

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. These inputs are called discrete or logic inputs.
INTERNAL UTILITY RELAYS-(contacts): These relays 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.

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Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

COUNTERS: These again do not physically exist. They 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. Most of the time these counters can count up, down
or up/down.
TIMERS: These also do not physically exist. They 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 1ms through 1s.
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 the 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-on
they will still have the same contents as before when power has been removed.
ANALOG MODELS: This covers analog inputs and outputs. The analog models
cover reading analog signals from sensor, provides analog signal such as thermocouples,
strain gauges, thermistor, pressure sensor.etc. The analog output signals can be used to
command external controller e.g. servomotors amplifier, solenoid amplifier etc.
USER INTERFACE INPUT: Which contains extra push-bottoms that can be
configured by the user to set/reset logic output devices e.g. relays outputs, or can be used
as a storage of messages that can be displayed on liquid crystal display. Furthermore,
some of these interfaces has led which can be configured by the user.
NETWORKING MODULES: Larger PLCs could have serial port that can be used for
networking a multiple of PLCs that are to be programmed from one main computer or
sending/receiving data between PLC network. Furthermore, some of the PLCs are
equipped with remote control module (modem) to program the PLC from long distance
computer.
The CPU of the PLC contains a microprocessor, which means that a PLC is basically a
specialized computer that has been designed to control the operation of machines and
processes within the harsh environment of the plant.
The language used to program the PLC to perform the logic required to connect the filed
input to its outputs is called Relay Ladder Logic (RLL). The RLL language is programmed by
means of special software using personal computer (connected to the PLC using serial port)
or hand-held programmer which has led or liquid-crystal display and keyboard as illustrated
in Fig. 2.2.
Hand-held programmer or PC communication

Input
Module
(logic or
continuous)
+24V DC
User
interface

CPU & Memory

Output
module
(logic or
continuous
modules)

M
S

Serial port

Power Supply
.23

Fig. 2.2 PLC structure, user communication and interfaces modules

interconnections.

Manufacturing Automation using PLCs

CHAPTER 2

Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

RAM and EPROM memory are used to store the program instructions in the PLC. The
computer or hand-held programmer can be used to load and save the RLL programs into the
PLC.
The physical input and output modules can be discrete or analog I/O modules and can be
selected and specified when purchasing the PLC, and depend on the number of the required
I/O lines.
The discrete I/O modules connects field inputs devices of the ON/OFF nature like limit
switches, push button switches, solenoids, solenoid valve or electro-mechanical relay ..etc.
Each discrete I/O module supply voltage source. Since these voltages can be of different
magnitude or types, I/O modules are available at various AC & DC voltages ratings as shown
in Table 2.1. Furthermore, the inputs and outputs are connected to LEDs to indicate the
operation of the I/O module
Table 2.1: common ratings for discrete I/O interface modules.
Interface input module

Interface output modules

24 V AC/DC

12-48 V AC

48 V AC/DC

120 V AC

230 V AC/DC

230 V DC

5 V (TTL)

5 V DC (TTL)

2.1 PLC Operation using scanning technique

A PLC works by continually scanning a program. We can think of this scan cycle as
consisting of 3 important steps, as shown in Fig. 2.3. There are typically more than three
steps but we can focus on the important parts and ignore the others. Typically the others are
checking the system and updating the current internal counter and timer values.

Fig. 2.3 Scanning technique in PLC.

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Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

Step 1: CHECK INPUT STATUS:

First the PLC takes a look at each input to determine if it is on or off. In other words, is the
sensor connected to the first input on? How about the second input? How about the third. It
records this data into its memory to be used during the next step.
Step 2: EXECUTE PROGRAM:
Next the PLC executes your program one instruction at a time. Maybe your program said
that if the first input was on then it should turn on the first output. Since it already knows
which inputs are on/off from the previous step it, will be able to decide whether the first
output should be turned on based on the state of the first input. It will store the execution
results for use later during the next step.
Step 3: UPDATE OUTPUT STATUS:
Finally the PLC updates the status of the outputs. It updates the outputs based on which
inputs were on during the first step and the results of executing your program during the
second step. Based on the example in step 2, it would now turn on the first output because
the first input was on and your program said to turn on the first output when this condition is
true.
After the third step the PLC goes back to step one and repeats the steps continuously. One
scan time is defined as the time it takes to execute the 3 steps listed above.
The total response time of the PLC is a fact that we have to consider when shopping for a
PLC. The PLC takes a certain amount of time to react to changes. In many applications
speed is not a concern, in others though. The PLC can only see an input turn on/off when it's
looking. In other words, it only looks at its inputs during the check input status part of the
scan.

Fig. 2.4 Variation of scanning time on detecting the high-speed inputs.

In Fig. 2.4 the input 1 is not seen until scan 2. This is because when input 1 turned on, scan 1
had already finished looking at the inputs. Input 2 is not seen until scan 3. This is also
because when the input turned on scan 2 had already finished looking at the inputs.
Input 3 is never seen. This is because when scan 3 was looking at the inputs, signal 3 was not

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Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

on yet. It turns off before scan 4 looks at the inputs. Therefore signal 3 is never seen by the
PLC. This illustrates the importance of scanning time of the PLC.

2.2 Understanding Relay Ladder Diagram (RLL)

To understand the programming of PLC relay ladder diagram, let us start with simple case of
relay control system. We can think of a relay as an electromagnetic switch. Apply a voltage
to the coil results in a magnetic field is generated. This magnetic field sucks the contacts of
the relay in, causing them to make a connection. These contacts can be considered to be a
switch. They allow current to flow between 2 points thereby closing the circuit.
Power circuit

Control circuit

Fig. 2.5 Simple control circuit of a bell

Let's consider the following example. Here we simply turn on a bell whenever a switch is
closed, as shown in Fig. 2.5. We have 3 real-world parts; A switch, a relay and a bell.
Whenever the switch closes we apply a current to the bell causing it to sound. The bottom
circuit indicates the DC control circuit. The top circuit indicates the AC control circuit. Here
we are using a DC relay to control an AC circuit. Thats the benefit of using relay. When the
switch is open no current can flow through the coil of the relay. As soon as the switch is
closed, however, current runs through the coil cause a magnetic field to build up. This
magnetic field causes the contacts of the relay to close. Now AC current flows through the
bell and we hear it. Fig. 2.6 shows a typical industrial relay.

Fig. 2.6 A typical industrial relay.

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Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

Next, we would like to replace the relay control system with PLC control system using relay
ladder logic. After seeing a few of these it will become obvious why its called a ladder
diagram. We have to create one of these because, unfortunately, a PLC doesn't understand a
schematic diagram. It only recognizes code. Fortunately most PLCs have software, which
convert ladder diagrams into code. This shields us from actually learning the PLC's code.
The PLC doesn't understand terms like switch, relay, bell, etc. It prefers input, output, coil,
contact, etc. It doesn't care what the actual input or output device actually is. It only cares
that its an input or an output.
First we replace the battery with a symbol. This symbol is common to all ladder diagrams.
We draw what are called bus bars. These simply look like two vertical bars. One on each side
of the diagram. Think of the left one as being + voltage and the right one as being ground.
Further think of the current (logic) flow as being from left to right. Next we give the inputs a
symbol. In this basic example we have one real world input. (i.e. the switch) We

Fig. 2.7 Contact relay symbol.

give the input that the switch will be connected to, the symbol shown below. Fig. 2.7 shows
the symbol for contact of switch or relay.
Next we give the outputs a symbol. In this example we use one output (i.e. the bell). We give
the output that the bell will be physically connected to the symbol shown below. Fig. 2.8
shows the symbol used as the output coil or relay.

Fig. 2.8 Output relay symbol.

The AC supply is an external supply so we don't put it in our ladder. The PLC only cares
about which output it turns on and not what's physically connected to it.
Second, we must tell the PLC where everything is located. In other words we have to give all
the devices an address. Where is the switch going to be physically connected to the PLC ?
How about the bell? We start with a blank road map in the PLCs town and give each item an
address. Could you find your friends if you didn't know their address? You know they live in
the same town but which house? The PLC town has a lot of houses (inputs and outputs) but
we have to figure out who lives where (what device is connected where). We'll get further
into the addressing scheme later. The PLC manufacturers each do it a different way! For now
let's say that our input will be called "0000". The output will be called "500", as shown in
Fig. 2.9.
Finally, we have to convert the schematic into a logical sequence of events. This is much
easier than it sounds. The program we're going to write tells the PLC what to do when certain
events take place. In our example we have to tell the PLC what to do when the operator turns
on the switch. Obviously we want the bell to sound but the PLC doesn't know that.

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Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

Fig. 2.9 RLL for bell control circuit.

The Fig. 2.9 shows the final converted diagram (RLL) for bell control system. Notice that we
eliminated the real world relay from needing a symbol.

2.3 Basic Instructions of RLL

Main input instructions
Normally open contact :
Normally closed contact :
Main output instructions
Normally open relay
Normally closed relay
Fig. 2.10 Main instructions in RLL.
Example 1:
Draw ladder logic for the control circuit shown in Fig. 2.11:

Fig.2.11 Control and RLL for AND Boolean operation.

The Boolean logic equation for this control circuit: Coil = SW1 . SW2

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Example 2:
Redraw the relay ladder logic of Example 1, using normally closed switch for SW2 ?
The amended RLL is shown in Fig. 2.12:

Fig. 2.12 Amended RLL using Normally closed switch for switch SW2.
The Boolean logic equation will be : Coil = SW1 . SW2

2.4 Motor control using PLC, two push buttons and motor starter
Here two push buttons switches
(Start/Stop) are used to switch
the motor on/off. These
switches are connected to the
two PLC inputs discrete type),
as shown in Fig. 2.13.
One of the output ports
(discrete outputs) of the PLC
used to switch motor starter
on/off, which will start/stop the
electric motor.
The control steps of the electric
motor using RLL is shown in
Fig. 2.14.

Motor
starter

Output

Motor

PLC

Input

Two bush bottom switches

Fig. 2.13 Motor control using

PLC, motor starter and two
push bottoms.

Fig. 2.14 Developed RLL for motor control.

4
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step 1

Manufacturing Automation using PLCs

CHAPTER 2

Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

2.5 Adding two indicators for the developed RLL

Here two indicators to be added to the developed circuits. Red color to indicates that the
motor is off, and green color to indicates that the motor is running. The amended RLL is
shown in Fig. 2.15.

Motor starter

Output

Motor
Two indicators

PLC

Input

Input

Two push bottom switches

Fig. 2.15 Amended RLL for motor control after adding two indicators.
The modified RLL is given as follows:

Fig. 2.15 (a)RLL when Start push button undressed, (b)RLL when Start push button
pressed
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Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

2.6 PLC Programming

The programming technique through serial port via PC and using special software provided
by the manufacturer, as shown in Fig. 2.16 or using hand programmer.

Fig. 2.16 PLC Programming technique using PC computer through serial port.
In case of PC program, a special software program must be installed in the PC which is
provided by the manufacturer to write and edit user Relay Ladder Logic (RLL). This also
transfers the program between PLC and PC computer and vise versa. The program
developed to be friendlier with user during RLL development, as shown in Fig. 2.17.

Fig. 2.17 Example of RLL developed using TPDS software for Toshiba PLC.
Because the PLC uses Relay Ladder Logic diagrams, the convention from any existing relay
ladder to programmed relay ladder logic is simple. Each rung is a combination of input
conditions (symbols) connected from left to right, with the symbol that represents the output
at the far right. The symbols that represent the inputs are connected in series, parallel, or
some combination to obtain the desired logic. The following examples show how PLC can
be used to carry out different control logics, as shown in Fig. 2.18. Note, any combination
logic called Boolean equation.
Example 3:
Develop a relay-ladder logic that allows four switches in a room to control a single light?
SW1
LIGHT=SW1+SW2+SW3+SW4
The RLL is shown in Fig. 2.19.Light
SW2
SW3
SW4
11
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Fig. 2.19 Developed RLL for example 3.

Manufacturing Automation using PLCs

CHAPTER 2

Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

Boolean or Logic Function

SW1
SW1

SW2

LAMP

{ Relay Ladder Diagram}

LAMP =SW1 and SW2
LAMP= SW1 . SW2

SW2
Lamp

{ Relay Ladder Logic }

LAMP

SW1
{ Relay Ladder Diagram}

SW2

LAMP =SW1 OR SW2

LAMP= SW1 + SW2

SW1
Lamp

{ Relay Ladder Logic }

SW2

SW1

SW3
Lamp

SW2

SW1

SW3
Lamp

SW2

{ Relay Ladder Logic }

LAMP =(SW1 OR SW2) AND SW3
LAMP= (SW1 + SW2) . SW3

{ Relay Ladder Logic }

LAMP= (SW1.SW3) +(SW2.SW4)+SW5

SW4

SW5

SW1

SW3
Y20

SW2
SW4

Y20=(SW1+ SW2) . SW3

LAMP= SW4 . Y20
Or
LAMP=(SW1+ SW2) . SW3 . SW4

Y20
Lamp

Fig. 2.18 Development of RLL for different control logics.

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SW1

Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

SW3
Y20

SW2
SW4

Y20=(SW1+ SW2) . SW3

LAMP= SW4 . Y20
Or
LAMP=(SW1+ SW2) . SW3 . SW4

Y20
Lamp

SW1

SW3
Y20

SW2
SW4

SW4
Y20
Lamp

SW1

SW3
Y20

Y20
SW4

Y20=(SW1.SW3)+(SW1.SW4)
+(SW2.SW3)+(SW2.SW4)
LAMP= SW4 . Y20
Or
LAMP= ((SW1.SW3)+(SW1.SW4)
+(SW2.SW3)+(SW2.SW4)) . SW4

Y20=SW1. SW3+Y20.SW3
LAMP= SW4 . Y20
Note: 1st Boolean equation is memory or
filp-flop.

Y20
Lamp

Fig. 2.18 Development of RLL for different control logics

Example 4:
Modify the developed relay-ladder logic given in example 3 such that these switches are
enabled/disabled using external supervisor through switch (SW5) ?
SW1

SW5
Light

LIGHT=(SW1+SW2+SW3+SW4) . SW5

SW2
SW3
SW4

Fig. 2.20 Modified RLL by adding external switch SW5, refer example 4.

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PROBLEMS
2.1) Develop the RLL diagrams for the following Boolean equations :
F1 = A . B + A . B
F2 = sw1 . sw2 . sw3 . sw4
F3 = ( sw1 . sw2 . sw3) + sw4
Y = (A.B.C + D ) . (E.F)
2.2) Drive the Boolean equations for the following relay ladder logics
(a)
SW1

SW3

SW4
Y20

Y20
SW4

Y20
Lamp

(b)
SW1

SW3

SW4
Y20

SW2
SW5

SW6

SW1

2.3) Develop a relay ladder logic that will switch on the motor on/off in automatic and
manual (called jog) modes?
(ans: SW1: START push bottom, SW3 STOP push bottom, SW2 JOG or Manual
operating mode, and Y20 memory that will run the relay that will switch the motor on)
SW1

SW3
Y20

Y20
SW2
Y20

Y20
motor

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Programmable Logic Controller (PLC) and Relay Ladder Logic (RLL)

2.4) Give examples of where a PLC could be used?

2.5) Why would relays be used in place of PLC?
(ans: for some cases is simple and cost effective)
2.6) List the advantages of a PLC over relay control?

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