MT 612

Ladder Diagram
 PLC
• Present set up uses ABB make PLC model
LM043 (software version AC010), 24 VDC.
• It is an electronic control relay with built-in logic,
timer, and counter functions.
• The algorithm is designed based on control logic
required to carry out event actuation and signal
generation for a given system.
• The circuit diagram is made on AC010 software
using ladder logic.
Schematic
 PLC
• Contacts are used to modify the flow of current
in the circuit diagram.
• Every contact in the circuit diagram can be
defined as either a make or break contact.
• Make contact carry signal 1 and break contact
carry signal 0.
• There are different types of relays for wiring a
circuit diagram.
• Elements of Ladder Logic
– Contacts: Input devices
• Can be an external switch, internally set logic flags
(M) or time function (T).
– Coils: Output devices
• To operate motor, solenoid or other actuator. Also
used to operate internal timer, counter or flags.
• I/O Contacts / Coils and their symbols
used in PLC:

– I: Input
– Q: Output coil
– M: Marker flag
– T: Timer
– C: Counter
• Coil Functions:

–[ Contacter function, Output signal

follows input signal immediately
– Impulse relay,
switches (0 to 1 or 1 to 0) whenever
the input signal changes from 0 to 1
–S Set / latching: To set output on
–R Reset (unlatching): to set output off
– TT Triggering the timer
– I : Input contact
– Q: Output, coil functions provided
– M: Marker, coil functions provided
– T: Timer, coil function and time base is
provided
– C: Counter, coil function and parameter
values provided
• Ladder Diagram
• Functional interaction of a PLC
• The logic in a ladder diagram typically flows from left
to right.
• The diagram can be divided into sections called
rungs, analogous to the rungs on a ladder.
• Each rung typically consists of a combination of
input instructions.
• These instructions lead to a single output instruction
(right-most on a rung).
• Ladder diagram programming allows PLCs to
perform several different types of tasks, including
Boolean logic, timing, counting, arithmetic, and
special functions.
 Inputs
• Actual physical devices.
• Inputs are represented as Contacts.
• Two types of contacts are used, namely,
normally open (NO) and normally closed
(NC) contacts.

Contact Open Contact Closed

 Inputs
• Normally Open Type (NO): It is closed
when active.

Contact Open
Inactive

Contact Closed
Active
NO Inputs
 Inputs

• Normally Closed Type (NC): It is open

when active.

Contact Closed
Inactive

Contact Open
Active
NC Inputs
• Permanent contact: To energize a relay coil continuously, make a
connection of all contact fields. Output Q1 will remain on all the time.

• Series Connection: Output relay Qx is controlled by a series circuit

consisting of a maximum of three make or break contacts. Marker relays
can be used to raise the flag if more than three contacts are required to be
connected in series.

• AND circuit: Three make contacts in series

• NOR circuit: Three break contacts in series

• The AND circuit consists of three inputs connected in series. When all the
three inputs I1, I2 and I3 are set-on, then only the output Q1 will be
switched-on.
• The NOR circuit consists of three negated inputs connected in series. When
all the three inputs I1, I2 and I3 are set-off, only then the output Q2 will be
set-on.
AND & NOR ckt
AND & NOR ckt
• Parallel Connection: Output relay Qx is controlled by a parallel circuit
consisting of either make or break inputs connected in parallel.

• OR circuit: Three make contacts in parallel

• NAND circuit: Three break contacts in parallel

• The OR circuit consists of three inputs connected in parallel. When any of

the three inputs I1, I2 or I3 are set-on, then the output Q1 will be switched-
on. If input I2 is only on and the other two inputs are off, then the circuit will
be complete from I2 to Q1.

• The NAND circuit consists of three negated inputs connected in parallel.

When no input, any of the three or any of the two inputs are on, then the
output Q2 remains on. When all the three inputs are on, Q2 will be
switched-off. If input I1 is off and the other two inputs are on, then the circuit
will be completed from I2 or I3 to Q2.
NAND & OR Ckt
• Changover Circuit: It is made using two series connections
combined to form a parallel connection. It is called EXclusive OR
(XOR) circuit. Coil can be energized only when one contact
switches.

• The XOR circuit consists of two inputs connected in series, one

make and the other break contact and their combinations are
connected in parallel. When any of the two inputs I1 or I2 is set-on,
then the output Q1 will be set-on. If I1 is on, then the circuit will be
completed from I1 through negated I2 to Q1.
XOR Ckt
 Exercise -1
• Construct a logic gate for the following
condition:
– There has to be no output when any one of
four sensors gives an output,
– otherwise there is to be an output.
 Example
• A fire alarm detects smoke from 3 rooms
through three sensors.
• If it receives signal from any of the room, it
would switch off the mains.
 Exercise -2
• A fire alarm detects smoke from 3 rooms
through three sensors.
• If it receives signal from any of the room, it
would put-on the alarm.
 Exercise -3
• An alarm should go when any of the two
sensors attached will be on.
• To put off the alarm, press button.
 Exercise -4
• In a hall comprising of three cubicles, an
AC is providing comfort condition.
• Input signals would be received from the
cubicles if persons are not resent.
• When there is no one in any of the
cubicles, AC should be turned off, else it
will remain on.
 Timer
• Time is always a part of a control system.
• Typical examples are:
– Lift parking brake,
– drive to forward limit and stop drive,
– wait 50 second and apply parking brake,
– After n rotation, stop motor.
• A PLC system must therefore include
timers as part of its programming
language.
Timer Relay
• AC010 provides eight timer relays, T1 to T8.
• It is used
– to set the switching duration and
– make and break times of a relay contact.
• It is integrated into circuit diagram in the form of a
contact.
• The function is defined in terms of parameter display.
• The relay starts with coil function TTx (triggering timer
relay x) and can be reset via the reset coil function RTx.
• Reset coil has priority over the trigger coil.
 Timer
• On delay
• Off delay
• Single pulse
• Multiple pulses
 On Delay Timer
• A 0 to 1 transition is delayed for a preset time T.
• A 1 to 0 transition is instant with input signal.
• An input signal shorter than T is ignored.
 Off Delay Timer
• The off delay passes a 0 to 1 transition instantly but
delays the 1 to 0 transition by preset time.

• Eg.: In Xylo, the head lights remain on even after

ignition switch is put-off. It will remain on for preset
time. It is providing the driver to walk-off with ease
in the dark.
Off Delay Timer
• Single Pulse
– It is an edge-triggered pulse timer.
– It gives a fixed width pulse for every 0 to 1
transition at the timer input.
– Output pulse width is independent of input
pulse width.
 Example
• A car has arrived at the washing pit.
• Provide a preset time for positioning.
• Start washing motor.
• Allow preset time for washing.
• In case washing could not be completed in
the set time, raise sensor signal.
• When the preset time of washing is over
and sensor signal is off, switch off the
motor.
• Important points:
– Timer should not be triggered on input signal
directly, till we are sure that input signal will
remain.
– Since stopping of washing motor is
conditional, set and reset switch is used.
– In case washing could not be completed in
given time (T2), another signal has been
incorporated to be used in time of use.
– What happens if instead of on delay timer, off
delay timer T1 is used?
 Counters
• The PLC may be required to count the number of
items in a batch.
• Record the number of times some event occurs.
• Number of starts of a motor needs to be logged.
• The value of the count can be read, displayed and
used by other parts of the program.
Counter Relay
• It increments or decrements signals and switches
when the actual value is greater than the setpoint
value.
• A counter relay can be controlled via the counting
pulse CCx and reset RCx coil functions.
• The count-up instruction simply increases the value
of a counter by 1 each time an upward (OFF to ON)
transition is detected in the input.
• The reset instruction resets the value of the count to
0 or to a predetermined reset value.
 Example
• Items passing along a conveyor are to be detected
by a photocell and counted.
• When a batch is complete, the conveyor is stopped
and a batch complete light is lit for the operator to
remove the batch.
• When he does this, a restart button sets the
sequence running again.
 Algorithm
• A start button is used for conveyor
operation (I1).
• When motor is reset by completion of
batch (C1=5), it is given priority over
setting by I1.
• Till C1 is made zero by RC1.
• Restart button is actually resetting counter.
• Then motor will restart.
Designing a Control System using PLC
• Planning
• Detailed design of system generated.
• Wiring of program is done. (Ladder diag)
• Installation
– Sensors, actuators, limit switches, operator
controls are wired.
• Commissioning
– Nothing ever works first time.
– Most changes can be made quickly and relatively
cheaply, provided the designer of the control
system has built in spare memory capacity and
spare I/Os.
• Maintenance
• A plant is also subjected to many changes during its
life to speed production, to ease breakdowns or
because of changes in its requirements.
• A PLC system can be changed so easily that
modifications are simple and the PLC program will
automatically document the changes that have been
made.
 Wiring and Fail Safe operation
• Fail-safe wiring should be used so that if wires are
cut or connections fail, the equipment should turn
off.
• For example, if a normally closed stop button is
used and the connector is broken off, it will cause
the machine to stop, as if the stop button has been
pressed and broken the connection.
• Programs should be designed that checks for
problem and shut down in safe ways.
• Use redundancy in hardware.
Lab Exercise
 Practice 1

• A fire alarm detects smoke from 3 rooms

through three sensors.
• If it receives signal from any of the room, it
would switch off the mains.
 Practice 2
• In a hall comprising of three cubicles, an
AC is providing comfort condition.
• Input signals would be received from the
cubicles if persons are not present.
• When there is no one in any of the
cubicles, AC should be turned off, else it
will remain on.
 Practice 3
• Make a ladder diagram for the following
status diagram
I1

Delay

Output
 Evaluation
• Make a pulse timer with single switch
control for on and off of the circuit.
• The output should be on for 7 seconds
and off for the next 3 seconds.