Programmable Logic Controller Basics

Introduction to PLCs
The ‘PLC’ is the key element behind today’s Industrial

automation
The acronym ‘PLC’ stands for Programmable Logic

Controller.
A PLC is an industrialized computer that includes the hardware and

software required to automatically control production equipment
machinery processes, and other types of mechanical, electrical and
electronic devices typically found in industry.
It also includes the flexibility to reprogram its decision making behavior

through the software as often as needed.
1
PLCs are primarily used in automating factories and processes.
PLCs are also used in simple applications, such as car washes,

elevators, even amusement parks, etc.
2
More complex applications of PLCs include

water and waste water treatment plants,
manufacturing assembly lines, machinery
and bottling lines, etc.
3
History of PLC
PLC is recognized as first being introduced by Bedford Associates in 1968.
PLCs evolved concurrently by different organizations, such as GM’s Hydra-matic

Division’s specifications as a replacement for traditional relay-based machine control
systems.
PLC reduces wiring and troubleshooting time.
Because it is programmable, the PLC also allows quicker changes to the equipment’s
control behavior.
4
It may make more sense to look at the words in reverse order.

CONTROLLER
CONTROLLER – this is the key word. A PLC monitors various
conditions, and based on these conditions, it determines an
outcome. In other words it has the ability to ‘control’ the outcome
based on the status of different inputs such as sensors, switches
and numeric values from analog signals, etc.
LOGIC – How the PLC determines an outcome is based on the

logical rules it has been taught. A simple example: it is class time,
AND the door is open, then turn on the light.
PROGRAMMABLE – The PLC is taught the rules to how it should use LOGIC
the input conditions to create an outcome through its programming
software. Being programmable makes it versatile, so if needs or conditions
change, the PLC can be reprogrammed to meet the changes.
PROGRAMMABLE
5
Internals of PLC
FOUR INTERNAL AREAS
 CPU– Decision making, controls
other areas.
 Memory – User’s control

program stored in non-volatile
section of memory. Also I/O status
and data are kept in memory.
 Communication Ports –
load user’s program from PC, also
exchange data with external Working of PLC – The input and
devices, including other PLCs. output connections interface to the real
 Input/Output – handles world devices. Conditions and status of the
interface of signals to real world inputs are monitored, decisions made by
devices the user’s control program loaded into the
memory through the communication
ports and executed by the CPU, and
6
outputs activated based on the outcome.
Internals of PLC
7
Siemen’s LOGO PLC
8
Wiring of PLC
9
Ladder Diagrams for PLCs
A PLC is programmed using application software running on a PC. The most
widely used programming method, carried over from relay-based control
system, is Ladder Logic Diagram.
A Ladder Logic Diagram is made up of contacts, coils and other functions that
are arranged as rungs on a ladder.
In the ladder shown above, the Output Q1 is driven by three Inputs I1, I2, I3 in
series. Input I1 is Normally Open (NO) and I2 and I3 are Normally Closed (NC).
When I1 is energized(on), it closes, completes the path and Q1 is energized(on). On
the other hand, if I2 or I3 is energized, they open and breaks the path, output Q1
becomes de-energized (off). The parallel line below the first rung showing Q1 as the
input is called a ‘Latch’ which will be explained later slides.
10
Although Ladder Diagram is the primary programming language and supported

by all the PLCs by default, there exist other programming methods as well.
11
12
13
14
15
A Ladder Diagram
Output X is driven by four Inputs A,
B, C and D.
A is Normally Closed (NC).
Output X is on when Input B is

energized (on). But if input A is
energized (on), then A opens, Output
X becomes de-energized.
The parallel line below the first rung

which connects to the same rung
represents OR function, i.e., even if
Input B is off, or Input A is on, but
both Inputs C and D are on, then
Output X will be energized (on).
16
Program Scan
It is helpful when programming a PLC to
understand how the Ladder Logic program is
‘scanned’. Once the PLC is in RUN mode, the CPU
executes in the order shown in the flow diagram.
1. Status of the input devices are read and stored

in PLC’s internal data registers.
2. Housekeeping of any peripheral devices.
3. ‘Scan’ the user’s Ladder Logic Diagram from

left to right, sequencing through the ‘rungs’
4. Compute the results and write updates to the

outputs.
5. Do diagnostics and if all is well, repeat the

scan.
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Conventions followed in Drawing Ladder
Diagrams for PLCs
18
Conventions followed in Drawing Ladder
Diagrams for PLCs
19
20
Symbols used in Working of LADDER

LADDER Diagram Diagram
PLC Wiring PLC Logic 21

INTERLOCKING
• Interlocking means to interlock something by placing NC of coil or input in

front. The concept of interlocking reduces the complexity in PLC programming
• Interlocking in ladder programming means whenever we want to off some
output by input or any type coil, then we have to place NC of that input or a coil
in front of output which we want to off.
Latching:
Operating a circuit even after de-
energizing the main input.
A Latch circuit preserves states.
A Latch circuit is un-clocked.
First, the main input I1 (NO) is

A Latch Circuit
energized, it closes and output Q1 is
energized. Once Q1 is on, it acts as
the alternative input to first rung.
Even if I1 is de-energized, the Q1
remains on, until I2 (NC) is energized,
which breaks the path and Q1
becomes off.
23
Motor Latching: The ladder on the right

shows a motor with two lamps, one
indicating ‘motor off’ condition, another
indicating ‘motor on’ condition.
In the first rung, once the motor ‘Start’
switch (NO) is energized, it closes and
‘Motor’ is energized (on). Once ‘Motor’ is
on, it remains on due to latching.
In the second rung, the ‘Motor’ (NC)
switch is energized, it opens and the ‘Off
lamp’ is de-energized (off).
In the third rung, the ‘Motor’ (NO) switch Motor Latching
is energized, it closes and the ‘On lamp’ is
energized (on). 24
Timer: A timing function can be used in the ladder to start or
stop events/devices at a certain time delay or time interval.
The ladder on the left shows a circuit with a

‘delay on’ timer. When Input is energized, the
timer unit becomes energized. Then upon the
completion of the preset time delay in the
timer, it energizes the output in the second
rung.
When more delay is required, then one timer can

be connected with another timer in a cascading
fashion to increase the delay time. The ladder on
the right shows such cascading delay timer.
25
TIMER
Timer is basically used add some

delay in the programming circuit
by adding a particular time to each
circuit.
Types of timers :
• ON delay timer
• OFF delay timer
Counter: A counter function can be used in the ladder to up-count
(zero up to some set value) or down-count (some set value down
to zero) and then reset the output device/event.
The ladder on the right shows a

rectangular counter function.
It has a RESET line to reset to (the
set value) using Input 1.
K10 indicates the set value (10) to

be used to energize Input 2.
After the set value (10) count,

Input 2 closes, output is energized
and counter is reset.
27
Level Controller
Input (High Level)
Level
Controller
Input Here, we want the fill

(Low Level) motor to pump the
fluid into the tank
until the high level
sensor turns on. At
that point we want to
turn off the motor
until the level falls
below the low level
sensor. Then we
should turn on the fill
Output (Motor) motor and repeat the
process.
WGA_PLC_0209201
Ladder program
Low High
Level Internal PLC Coil
Level
Internal PLC Relay
Motor Contact
Internal PLC Relay
END
Exercises
Practise the examples of the following three websites:
https://www.sanfoundry.com/100-plc-programming-examples/
http://plc-scada-dcs.blogspot.com/2013/12/basic-plc-ladder-
programming-training.html#axzz5Jz5HikJd
http://www.plcacademy.com/ladder-logic-examples/
30

Programmable Logic Controller Basics

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Introduction to PLCs

The ‘PLC’ is the key element behind today’s Industrial

The acronym ‘PLC’ stands for Programmable Logic

A PLC is an industrialized computer that includes the hardware and

It also includes the flexibility to reprogram its decision making behavior

PLCs are primarily used in automating factories and processes.

PLCs are also used in simple applications, such as car washes,

More complex applications of PLCs include

PLCs evolved concurrently by different organizations, such as GM’s Hydra-matic

PLC reduces wiring and troubleshooting time.

It may make more sense to look at the words in reverse order.

LOGIC – How the PLC determines an outcome is based on the

 Memory – User’s control

Although Ladder Diagram is the primary programming language and supported

A is Normally Closed (NC).

Output X is on when Input B is

The parallel line below the first rung

1. Status of the input devices are read and stored

2. Housekeeping of any peripheral devices.

3. ‘Scan’ the user’s Ladder Logic Diagram from

4. Compute the results and write updates to the

5. Do diagnostics and if all is well, repeat the

Symbols used in Working of LADDER

PLC Wiring PLC Logic 21

• Interlocking means to interlock something by placing NC of coil or input in

First, the main input I1 (NO) is

Motor Latching: The ladder on the right

The ladder on the left shows a circuit with a

When more delay is required, then one timer can

Timer is basically used add some

The ladder on the right shows a

K10 indicates the set value (10) to

After the set value (10) count,

Input Here, we want the fill

Internal PLC Relay

Practise the examples of the following three websites:

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