Controls

Prof. Dr.-Ing. Dirk Nissing

1 Programmable Logic Controllers (PLC)

21
Literature

Petruzella, Frank D.
Programmable Logic Controllers
2011, McGraw-Hill
ISBN 978-0-07-351088-0

Berger, Hans
Automating with SIMATIC S7-1200
2011, Publicis
ISBN 978-3-89578-356-2

Rehg, James A.
Programmable Logic Controllers
2009, Pearson Prentice Hall
ISBN 978-0135048818

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Programmable Logic Controllers

Disadvantages of relay control

circuits:
-
-
-
-
-
-

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Programmable Logic Controllers
• Most widely used in industrial
process control technology
• Programmable controller has
eliminated much of the
hardwiring
• Designed for multiple inputs
and outputs
• Basically a digital computer
designed for use in machine
control (abbreviation PLC)
• Capable of performing
switching, timing, counting, Source: Siemens

calculating, comparing,
processing of analog signals

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Learning Outcomes

• Identify the main parts of a PLC and describe

their functions
• Understand the fundamentals of logic for AND,
OR and NOT functions
• Construct circuits from Boolean expressions
and derive logic programs
• Understand the usage of timers and counters
• Application

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PLC Hardware and Components

• Relationship between the

inputs and outputs are
determined by the user
program

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PLC Hardware and Components

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PLC Hardware and Components

• Fixed I/O configuration

• Modular/scalable I/O configuration

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Principles of Operation

Example: Process control

problem
• Mixer motor to automatically
stir the liquid
• Temperature and pressure
have to reach a preset
value before stirring
• Direct manual operation of
the motor required by
means of a separate
pushbutton

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Principles of Operation
• Relay method for motor
control
• Motor starter coil (M)
energized
a) when both pressure and
temperature switches
are closed
b) Or when the manual
button is pressed

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Principles of Operation

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Fundamentals of Logic
Binary Principle
• Refers to the idea that many things can be thoughts of as
existing in only one of two states
• States are 1 and 0
• 1 and 0 can represent ON or OFF, open or closed, true or false,
high or low, …

Logic Gate
• Circuit with several inputs but only one output activated by
particular combinations of
input conditions
• Basis for making decisions
• Example: high beam
automobile lighting circuit

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Fundamentals of
Logic

AND Function
• AND-gate output is 1 only
if all inputs are 1
• Logic gate truth tables
show each possible
combinations
• AND-truth table

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Fundamentals of Logic

AND Function
• Operates similarly to control devices connected
in series

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Fundamentals of
Logic

OR Function
• Any number of inputs
• One output
• Output is 1 if one or
more inputs are 1

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Fundamentals of Logic

OR Function
• Control devices connected in parallel

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Fundamentals of Logic

NOT Function
• Only one input
• Output is 1 if the input is 0  output is the
inverse of the input  inverter
• Small circle at the output is termed a state
indicator and indicates that an inversion has
taken place

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Fundamentals of Logic

NOT Function
• Most often used in
conjunction with AND
or OR gate

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Fundamentals of Logic

NOT Function
• NOT-symbol placed at the
output of an AND gate 
inverting the result  called
NAND gate
• NOT-symbol placed at the
output of an OR gate 
inverting the result  called
NOR gate

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Fundamentals of Logic

XOR Function
• Exclusive OR function
• Output of the circuit is HIGH
only when one input or the
other is HIGH, but not both
• Commonly used for the
comparison of two binary
numbers

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Fundamentals of Logic

Boolean Algebra
• Mathematical study of the binary number system
and logic
• Provides a simple way of writing complicated
combinations of logic statements
• Implemented in the same logic as relay ladder
logic

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Fundamentals of Logic
Boolean Algebra
• Inputs are represented by capital letters A, B, C,
…
• Output represented by the capital letter Y

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Fundamentals of Logic

Boolean Algebra - Examples

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Fundamentals of Logic

Boolean Algebra - Examples

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Fundamentals of Logic

Boolean Algebra –
Basic Laws

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Fundamentals of Logic
Distributive Law
A B C BC A+(B C) A+B A+C (A+B)
(A+C)
0 0 0 0 0 0 0 0
0 0 1 0 0 0 1 0
0 1 0 0 0 1 0 0
0 1 1 1 1 1 1 1
1 0 0 0 1 1 1 1
1 0 1 0 1 1 1 1
1 1 0 0 1 1 1 1
1 1 1 1 1 1 1 1

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PLC Programming
The term hardwired logic refers to logic control
functions that are determined by the way devices are
electrically interconnected.

Hardwired logic
is fixed and
changeable
only by altering
the way devices
are electrically
interconnected.

Hardwired motor
control program.
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PLC Programming
Programmable control is based on the basic
logic functions, which are programmable and easily
changed.

PLC programmed
motor control
program.

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PLC Programming
A common PLC programming language is ladder logic
(LAD).

• A ladder logic program consists of several rungs, each of

which controls an output.
• 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.

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 PLC Programming
Relationship between the relay ladder schematic, the
ladder logic program, and the equivalent logic gate
circuit.

Two limit switches connected in series and used to control a

solenoid valve.
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PLC Programming
Two limit switches connected in parallel and used to
control a solenoid valve.

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PLC Programming
Two limit switches connected in parallel with each other
and in series with a pressure switch to control a pilot
light.

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PLC Programming
One limit switch connected in series with a normally
closed pushbutton and used to control a solenoid valve.

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PLC Programming

The output lamp of this circuit is ON only when

pushbutton A or B is pressed, but not both.
- Truth table
- Boolean expression (usage of AND and OR only)
- Gate logic
- Relay schematic
- Ladder logic program

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PLC Programming

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PLC Programming

A motor control circuit contains two start/stop switches

each. When either start switch (NO) is pressed, the motor
runs. Either stop switch (NC) stops the motor when it is
pressed
- Relay schematic
- Ladder logic program
- Gate logic

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PLC Programming

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PLC Programming

A motor control circuit contains two start/stop buttons

each. When either start button (NO) is pressed, the motor
runs. Either stop button (NC) stops the motor when it is
pressed
- Relay schematic
- Ladder logic program
- Gate logic

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PLC Programming

Sequential Logic Systems

• Present output is influenced by the history of its
past inputs as well as by the present input
• Unlike a combinational logic system, where the
output only depends on the current input state
• Binary counter  sequential logic system
• Memory needed

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PLC Programming

Functions of memory element

• Setting the memory
• Save / maintain the state
• Reset

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PLC Programming

Example of a memory function

memory
Find the correct sequence
• Reset memory
• Setting memory
• Default setting
• Save/maintain state

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PLC Programming

Flip-Flop
• Bistable
• Can, on command, flip into one stable state of
flop back again to the other
• Basis RS-Flip-Flop using NOR-Gates

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PLC Programming

1. Default setting
2. Setting memory
3. Save/maintain memory
4. Reset memory
5. Default setting

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PLC Programming

Flip-Flop with two Outputs

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PLC Programming

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PLC Programming

Problem of Priority
• Combination R = S = 1 not allowed
• Pre-logic defines priority of either R or S

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PLC Programming
S has priority

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PLC Programming
R has priority

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PLC Programming
Locking

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PLC Programming
During each program scan cycle, the processor
reads all the inputs, takes these values, and energizes or
de-energizes the outputs according to the user program.

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PLC Programming
The time it takes to complete a scan cycle is a measure
of how fast the controller can react to changes in inputs.

If a controller has to react to an input

signal that changes states twice during
the scan time, it is possible
that the PLC will never be able to
detect this change.

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PLC Programming
Overview of the data flow during the scan process.

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PLC Programming

PLC programming language refers to the method by

which the user communicates information to the PLC.

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PLC Programming
Instruction list programming language consists of a
series of instructions that refer to the basic AND, OR, and
NOT logic gate functions.

Hardwired relay
control circuit

Equivalent instruction
list program

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PLC Programming
Structured text is a high level language primarily
used to implement more complex procedures.

Ladder diagram

Equivalent
structured text
program.

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PLC Programming
Ladder diagram language is a common used PLC
language and is designed to mimic hardwired relay logic.

Hardwired relay
control circuit

Equivalent ladder
diagram program

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PLC Programming
Functional block diagram programming uses
instructions that are programmed as blocks wired
together to accomplish certain functions.

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PLC Programming
Ladder diagram and functional block diagram
programming used to produce the same logical output.

Ladder diagram

Equivalent function
block diagram.

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PLC Programming

Sequential function
chart programming
language is similar to a
flowchart of your
process.

The program is split into steps

with multiple operations
happening in parallel branches.

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PLC Programming
Branch instructions are used to create parallel paths of
input condition instructions.

The rung will be true if

either instruction
A or B is true.

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PLC Programming
Output branching allows a true logic path to control
multiple outputs

Either A or B provides a true

logical path to all three output
instructions: C, D, and E.

Additional input instructions

can be programmed in the
output branches.

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PLC Programming
A seal-in circuit is a method of maintaining current flow
after a momentary switch has been pressed and
released.

Hardwired

Programmed

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PLC Programming

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PLC Programming

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PLC Programming

Writing a Ladder Logic

Diagram from a narrative
button
description
Drilling process that requires
the drill press to turn on only if
there is a part present and the
operator has one hand on
each of the start button.

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PLC Programming

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PLC Programming

• Enable a horn Q if the power consumption is >12kW

• Corresponding relay provide 0 if pump is activated,
1 if pump is off
1. Develop a truth table
2. Determine the Boolean equation
3. Develop a ladder or functional block diagram

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 PLC Programming
S1 S2 S3 S4 Power Q
3 kW 4 kW 5 kW 6 kW
0 0 0 0 18 kW 1
0 0 0 1 15 kW 1

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Karnaugh-Veitch (KV)-Diagram

• Tool to find optimized logical function

• Truth table in a 2D-array
• Using symmetries and fields can be summarized
(𝑆1 + 𝑆1 = 1)

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Karnaugh-Veitch (KV)-Diagram

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Karnaugh-Veitch (KV)-Diagram

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Karnaugh-Veitch (KV)-Diagram

Example
Find the optimized logic function of the expression
𝑌 = 𝐴𝐵 + 𝐴𝐵 + 𝐴𝐵
using a KV-diagram.

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Karnaugh-Veitch (KV)-Diagram

Example
Find the optimized logic function of
the expression as shown in the truth
table, using a KV-diagram.

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Karnaugh-Veitch (KV)-Diagram

E3 E3

E2
E4

E2

E4
E2

E1 E1 E1

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Karnaugh-Veitch (KV)-Diagram

E3 E3

1 0 0 1 E2
E4
1 1 0 0
E2
1 1 1 1
E4
0 1 1 1 E2

E1 E1 E1

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Karnaugh-Veitch (KV)-Diagram

Back to pump-example:

𝑌
= 𝑆1 𝑆2 𝑆3 𝑆4 + 𝑆1 𝑆2 𝑆3 𝑆4 + 𝑆1 𝑆2 𝑆3 𝑆4
+ 𝑆1 𝑆2 𝑆3 𝑆4

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Karnaugh-Veitch (KV)-Diagram

Back to pump- S3 S3
example:
S2
S4
𝑌
= 𝑆1 𝑆2 𝑆3 𝑆4 S2

+ 𝑆1 𝑆2 𝑆3 𝑆4 S4
+ 𝑆1 𝑆2 𝑆3 𝑆4 S2
+ 𝑆1 𝑆2 𝑆3 𝑆4
S1 S1 S1

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Programming Timers

Learning Objectives
• Most commonly used PLC instruction, after coils
and contacts
• Way in which they can control outputs
• Discussion of the basics PLC on-delay timer
function

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Programming Timers

Industrial Timing Tasks?

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Programming Timers
The on-delay timer is sometimes referred to as DOE, which
stands for delay on energize.

• When S1 is closed TD coil is energized and the timing

period starts.
• After the 10 s time-delay period has elapsed, TD1 contacts
close and L1 is switched on.

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Programming Timers
On-delay timer circuit that uses a normally closed, timed
open (NCTO) contact.

• When S1 is closed, TD coil is energized but TD1

contacts are delayed from opening so L1 remains on.
• After the 10 s time-delay period has elapsed, TD1
contacts open and L1 is switched off.
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Programming Timers
The off-delay timer is sometimes referred to as DOD,
which stands for delay on deenergize.

• When S1 is closed, TD coil is energized and TD1

contacts close instantly to switch light L1 on.
• When S1 is opened, TD coil is de-energized the timing
starts and after the 10 s TD1 contacts open to switch the
light off.
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Programming Timers
Off-delay timer circuit that uses a normally closed,
timed closed (NCTC) contact.

• When S1 is closed, TD coil is energized and TD1

contacts open instantly to switch light L1 off.
• When S1 is opened, TD coil is de-energized the
timing starts and after 10 s TD1 contacts close to
switch the light on.
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Programming Timers

Timer Instructions
• Provide the same functions as on-delay and off-delay timing relays
• Time setting can be easily changed
• Timer accuracy and repeatability extremely high

Most common PLC timer types

• On-delay timer (TON): Counts time-based intervals when the
instruction is true
• Off-delay timer (TOF): Counts time-based intervals when the
instruction is false
• Retentive on-delay (TONR / RTO): Counts time-based intervals
when the instruction is true and retains the accumulated value when
the instruction goes false or when the power cycle occurs

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Programming Timers

Quantities associated with the timer instructions

• Preset time (PT) represents the time duration for
the timing circuit.
• Accumulated time (ET) represents the amount of
time that has elapsed from the moment the timing
started.
• Time Base is the intervals that the timers time out
at. If a programmer entered 0.1 for the time base
and 50 for the preset time, the timer would have a 5-
s delay (50 x 0.1 s = 5 s).

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Programming Timers

On-delay TON, representation and function

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Programming Timers

Example
A conveyer belt starts
5sec after start button
is activated.

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Programming Timers

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Programming Timers

Off-delay TOF, representation and function

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Programming Timers

Example
Usage of an off-delay timer instruction to switch
motors off sequentially at 5 seconds intervals.

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Programming Timers

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Programming Timers

A retentive timer
accumulates time
whenever the device
receives power, and it
maintains the current
time should power be
• Electromechanical retentive timer.
removed from the device. • If power is removed from the motor,
the shaft stops but does not reset.

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Programming Timers

Retentive on-delay TONR / RTO, representation and function

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Programming Timers
Example: Fluid Pumping Process
• The process involves pumping fluid from tank A to tank B.
• Before starting, PS1 must be closed.
• When the start button is pushed, the pump starts.
• PS2 and PS3 must be closed within 5s after the pump
starts. If either PS2 or PS3 opens, the pump will shut off
and will not be able to start again for another 15s.
• An emergency NC stop button should immediately stop
the pump.

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Programming Counters

Learning Objectives
• List and describe the functions of PLC counter
instructions
• Analyze and interpret typical PLC counter ladder
logic programs
• Apply the PLC counter function and associated
circuitry to control systems

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Programming Counters
Programmed counters
serve the same function
as mechanical
counters.
• Every time the actuating lever is moved over, the
counter adds one number.
• Resetting to zero is done with a pushbutton
located on the side of the unit.

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Programming Counters
Electronic counters can
count up, count down, or
be combined to count up
and down.

Although the majority of counters used in industry

are up-counters, numerous applications require the
implementation of down-counters or of combination
up/down-counters.
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Programming Counters

One common counter

application is keeping
track of the number of
items moving past a given
point.

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Programming Counters
• PLC counter
The up-counter is
instructions are similar
incremented by 1 each
to timers except that time the rung containing
they do not operate on the counter is energized.
an internal clock but
are dependent on
external or program
sources for counting The down-counter
• PLC counters can be decrements by 1 each
time the rung
programmed to count containing the counter
up to a preset value or is energized.
to count down to a
preset value.

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Programming Counters

Up-counter CTU, representation and function

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Programming Counters
PLC counter program used to stop a motor from running
after 10 operations.

© 2011, The McGraw-Hill

Companies, Inc.
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Programming Counters
S7 Program

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Programming Counters

Down-counter CTD, representation and function

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Programming Counters
Up/down counter program counting diagram.

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Programming Counters
Example: Parking Garage
One application for an up/down-counter is to keep count of the cars
that enter and leave a parking garage. The operation of a program
can be summarized as follows:
• A car enters, the enter switch triggers the up-counter output
instruction and increments the accumulated count by 1.
• As a car leaves, the exit switch triggers the down-counter
output instruction and decrements the accumulated count by 1.
• Whenever the accumulated value of 150 equals the preset
value of 150, a lot full light is activated.
• A reset button has been provided to reset the accumulated
count.

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Programming Counters
S7-Program

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Summary PLC

• Fundamentals of Logic
• Memory
• Improvement of logic expression using KV-
diagram
• PLC Programming: Relay diagram  Ladder
Diagram  Functional Block Diagram
• Programming Timers
• Programming Counters

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