Industrial Training Report on

“PLC Programming With Ladder Logic”

By
NADIM MAJID DEVLEKAR
(PRN No- T2163151293508)

B.Tech Electrical

Under the Guidance of

Prof.Naik sir
Electrical Engineering Department

Holy-wood Academy’s

SANJEEVAN ENGINEERING & TECHNOLOGY INSTITUTE, PANHALA

DEPARTMENT OF ELECTRICAL ENGINEERING
2023-2024

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 CERTIFICATE

This is to certify that Mr. “Nadim Majid Devlekar” has successfully completed the
Industrial Training of “15” in “LearnVern”in partial fulfillment of the B. Tech Degree In
Electrical Engineering, Dr. Babasaheb Ambedkar Technological University Lonere during
the academic year 2023-24.

Prof.Y.RNaik Prof. V.T Metkari

(Guide in Department) Internship Coordinator

Dr.D.SBhosale Dr. Sanjeev N. Jain

(H.O.D.) Principal

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 DECLARATION

I declare that this report reflects my thoughts about the subject in my own words. I have
sufficientlycited and referenced the original sources, referred or considered in this work. I have
notmisrepresented or fabricated or falsified any idea/data/fact/source in this my submission. I understand
that any violation of the above will because for disciplinary action by the Institute.

No RollNo NameofStudent Signature

1 12 NADIM MAJID DEVLEKAR

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 ABSTRACT

Industrial training is an important phase of a student life. A well planned, properly executed
andevaluated industrial training helps a lot in developing a professional attitude. it develops an
awarenessof industrial approach to problem solving, based on a broad understanding of process and mode
ofoperation of organization. The aim and motivation of this industrial training is to receive discipline,
teamwork, skills and technical knowledge through a proper training environment, which will help me, as
astudent in the field of information technology, to develop a response of the self-disciplinary nature
ofproblemsin informationandcommunicationtechnology.

During a period of 15 days training “PLC Programming With Ladder Logic”. I wasseen the
different types of PLC Programming With Ladder Logic.Throughout thistraining we learn a new concept
related to our trade, I have learned the how to run the operations ofAn industrial PLCs system is used for
the development of the controls of machinery. This paper describes the PLCs systems in terms of their
architecture, their interface to the process hardware, the functionality and the application development
facilities they provide. Some attention is also paid to the industrial standards to which they abide their
planned evolution as well as the potential benefits ofLadder Logic is a graphical programming language,
initially programmed with simple contacts that simulates the opening and closing of relays. Ladder Logic
programming has been expanded to include functions such as Counters, Timers, shift Registers and math
operations.

Ladder logic is a method of drawing electrical logic schematics. It is now a graphical language
very popular for programming Programmable Logic Controllers (PLCs). It was originally invented to
describe logic made from relays. The name is based on the observation that programs in this language
resemble ladders, with two vertical "rails" and a series of horizontal "rungs" between them.

Thisexperience able to implement what I learn for the past few days as a B.Tech in electrical
engineering student in SANJEEVANENGINEERING&TECHNOLOGYINSTITUTE,PANHALA

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 CONTENTS

CERTIFICATE 2

DECLARATION 3

ABSTRACT 4

CONTENTS 5

CHAPTER 1 6

CHAPTER 2 7

CHAPTER 3 9

CHAPTER 4 11

CHAPTER 5 15

CONCLUSION 29

REFERANCES 30

Certificate/E-Certificate

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 CHAPTER 1

Software Used

All Control Logix and Compact Logix processors use LogixPro 500 software to program the PLCs.
Admittedly, the software is a bit pricey, but in my opinion, it is worth it.

Getting The Logix Pro 500 Software

If you don't have access to a PLC, it would be well worth the effort to download the demo version of
LogixPro 500. The demo runs for 90 days, and has some limitations, but you will be gaining experience
with the real thing. Currently, the software is here:

http://www.rockwellautomation.com/rockwellsoftware/design/logixpro500/demo.html

There are 7 sections to download, totaling slightly over 480MB. Yes, it's a big job to download and install
it, but it is essential.

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 CHAPTER 2
2.1 Automation

Automation or industrial automation is the use of control systems such as computers, controllers to
control industrial machinery and processes, to optimize productivity in the production of goods and
delivery of services. Automationis a step beyond mechanization. Whereas mechanization provides human
operators with machinery to assist them with the muscular requirements of work, automation greatly
decreases the need for human sensory and mental requirements.

Fig.1

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2.2Automation Impacts

It increases productivity and reduce cost. It gives emphasis on flexibility and convertibility of
manufacturing process. Hence gives manufacturers the ability to easily switch from manufacturing
Product A to manufacturing product B without completely rebuilt the existing system/product lines.
Automation is now often applied primarily to increase quality in the manufacturing process, where
automation can increase quality substantially. Increased consistency of output. Replacing humans in tasks
done in dangerous environments.

Fig.2

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 CHAPTER 3

Introduction to Programmable Logic Controller (PLC)

A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control system that

continuously monitors the state of input devices and make decisions based upon a custom program to
control the state of output devices.

It is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to
electrical noise, and resistance to vibration and impact.

Almost any production process can greatly enhance using this type of control system, the biggest benefit
in using a PLC is the ability to change and replicate the operation or process while collecting and
communicating vital information.

Another advantage of a PLC is that it is modular. i.e. you can mix and match the types of input and output
devices to best suit your application.

Fig. 3

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 History of PLC's

The first Programmable Logic Controllers were designed and developed by Modicon as a relay replacer
for GM and Landis.

Theprimary reason for designing such a device was eliminating the large cost involved in replacing the
complicated relay based machine control systems for major U.S. car manufacturers.

These controllers eliminated the need of rewiring and adding additional hardware for every new
configuration of logic. The first PLC, model 084, was invented by Dick Morley in 1969.

The first commercial successful PLC, the 184, was introduced in 1973 and was designed by Michel
Greenberg, Communications abilities began to appear in approximately 1973. The first such system was
Modicon's Modbus. The PLC could now talk to other PLCs and they could be far away from the actual
machine they were controlling.

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 CHAPTER 4

4.1 What is inside a PLC?

The PLC, being a microprocessor based device, has a similar internal structure to many embedded
controllers and computers.

They consist of the CPU, Memory an I/O device. These components are integral to the PLC controller.
Additionally, the PLC has a connection for the programming and Monitoring Unit or to connect PLC's in
other field.

Fig 4
The CPU is the brain of a PLC system. It consists of the microprocessor, memory integrated circuits, and
circuits necessary to store and retrieve information from memory.

PLC's or programming terminals. The job of the processor is to monitor status or state of input devices,
scan and solve the logic of a user program, and control on or off state of output devices.

RAM or Random Access Memory is a volatile memory that would loose its information if power were
removed, hence some processor units are provided with battery backup. Normally CMOS
(Complementary Metal Oxide Semiconductor) type RAM is used.
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ROM is a nonvolatile type of memory. This means it stores it's data even if no power is available. This
type of memory information can only be read, it is placed there for the internal use and operation of
processor units.

EEPROME or Electrically Erasable Programmable Read Only Memory is usually an add on memory
module that is used to back up the main program in CMOS RAM of the processor. In many cases, the
processor can be programmed to load the EEPROM'S program to RAM, if RAM is lost or corrupted.

Fig. 5

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4.2 INPUT MODULE
Input Module. Input modules interface directly to devices such as switches an temperature sensors. Input
modules convert many different types of electrical signal such as 120VAC, 24VDC, or 4-20mA, to signals
which the controller can understand Since all electrical systems are inherently noisy, electrical isolation is
provide between input and processor. The component most often used for this purpose is of coupler. Input
signal from the field devices are usually 4 to 20 ma or 0-10 V.

Fig.6

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4.3 OUTPUT MODULE
Output module interface directly to devices such as motor starters and lights Output modules take digital
signals from the PLC and convert them to electrical signals such as 24VDC and 4 mA that field devices
can understand. D to A conversion is carried out in their modules. Usually Silicon Controlled
Rectifier(SCR), trial, or dry contact relays are used for this purpose. Normally the output signal is 0-10 V
or 4-20 ma.

Fig.7

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 CHAPTER 5
5.1 Operation of PLC
PLC operates by continually scanning the program and acting upon the instructions, one at a time, to
switch on or off the various outputs. In order to do this PLC first scans all, the inputs and stores their
states in memory. Then it carries out program scan and decides which outputs should be high according to
the program logic.
Then finally it updates these values to the output table, making the required outputs go high. At his point
PLC checks its own operating system and if everything is ok, it goes back to scanning inputs all over
again.

5.2 PLC SCAN CYCLE

Whenever a program is executed in a PLC, before changing any output state, the processor scans the input
table and the entire program, which gives rise to states of the output devices according to the program
logic. These values are then updated to the output table making the device.

5.3TIME SCAN
Time taken by ple to execute these three steps (Checking Input status, Executing Program, Updating
Output Status) is denoted by its scan time.

Fig. 8

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5.4 Programming Languages used to Program a PLC

While Ladder Logic is the most commonly used PLC programming language, but it is not the only one.
Following table lists some of the Languages that are used to program a PLC.

Ladder Diagram (LD).

Functional block Diagram (FBD)

Structured Text (ST)

Instruction List (IL)

Sequential Functional Chart (SFC)

LADDER DIAGRAM

It is a graphical programming language, initially programmed with simple contacts that simulates the
opening and closing of relays. Ladder Logic programming has been expanded to include functions such as
Counters, Timers, shift Registers and math operations.

Fig.9

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Ladder logic is a method of drawing electrical logic schematics. It is now a graphical language very
popular for programming Programmable Logic Controllers (PLCs). It was originally invented to describe
logic made from relays. The name is based on the observation that programs in this language resemble
ladders, with two vertical "rails" and a series of horizontal "rungs" between them.

A program in ladder logic, also called a ladder diagram, is similar to a schematic for a set of relay circuits.
An argument that aided the initial adoption of ladder logic was that a wide variety of engineers and
technicians would be able to understand and use it without much additional training, because of the
resemblance to familiar hardware systems.

(This argument has become less relevant given that most ladder logic programmers have a software
background in more conventional programming languages, and in practice implementations of ladder
logic have characteristics such as sequential execution and support for control flow features that make the
analogy to hardware somewhat imprecise.)

Ladder logic is widely used to program PLCs, where sequential control of a process or manufacturing
operation is required. Ladder logic is useful for simple but critical control systems, or for reworking old
hardwired relay circuits. As programmable logic controllers became more sophisticated it has also been
used in very complex automation systems.

Ladder logic can be thought of as a rule-based language, rather than a procedural language. A "rung" in
the ladder represents a rule. When implemented with relays and other electromechanical devices, the
various rules "execute" simultaneously and immediately. When implemented in a programmable logic
controller, the rules are typically executed sequentially by software, in a loop.

By executing the loop fast enough, typically many times per second, the effect of simultaneous and
immediate execution is obtained. In this way it is similar to other rule-based languages, like spreadsheets
or SQL. However, proper use of programmable controllers requires understanding the limitations of the
execution order of rungs.

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Example of a simple ladder logic program

The language itself can be seen as a set of connections between logical checkers (relay contacts) and
actuators (coils). If a path can be traced between the left side of the rung and the output, through asserted
(true or "closed") contacts, the rung is true and the output coil storage bit is asserted (1) or true. If no path
can be traced, then the output is false (0) and the "coil" by analogy to electromechanical relays is
considered "de-energized". The analogy between logical propositions and relay contact status is due to
Claude Shannon,
Ladder logic has "contacts" that "make" or "break" "circuits" to control "coils." Each coil or contact
corresponds to the status of a single bit in the programmable controller's memory. Unlike
electromechanical relays, a ladder program can refer any number of times to the status of a single bit,
equivalent to a relay with an indefinitely large number of contacts.
So-called "contacts" may refer to inputs to the programmable controller from physical devices such as
pushbuttons and limit switches, or may represent the status of internal storage bits which may be
generated elsewhere in the program.
Each rung of ladder language typically has one coil at the far right. Somet manufacturers may allow more
than one output coil on a rung.

--()-- a regular coil, true when its rung is true

--(\)--a "not" coil, false when its rung is true

--[]--A regular contact, true when its coil is true (normally false)

-- [\] A "not" contact, false when its coil is true (normally true)

The "coil" (output of a rung) may represent a physical output which operates some device connected to
the programmable controller, or may represent an internal storage bit for use elsewhere in the program.

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Generally Used Instructions & symbol for PLC Programming

Input Instruction
--[]-- This Instruction is Called IXC or Examine If Closed.
If a NO switch is actuated, then only this instruction will be true. If a NC switch is actuated, then this
instruction will not be true and hence output will not be generated.
--[\]--
This Instruction is Called IXO or Examine If Open.
NC switch is actuated, then only this instruction will be true.
If a NC switch is actuated, then this instruction will not be true and hence output will not be generated.

Output Instruction
--(--This Instruction Shows the States of Output.
i.e.; If any instruction either XIO or XIC is true then output will be high. Due to high output a 24-volt
signal is generated from PLC processor.

Rung
Rung is a simple line on which instruction are placed and logies are created
Eg:----------------------------------------------------------------------------------------

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TIMER
A timer is a programmable instruction that lets you turn on or turn off bits after a preset time. The two
primary types of timers are TON for "timer on delay" and TOF for "timer off delay" Timers in RSLogix
5000 use tag names for identification.

COUNTER
A counter is a programmable instruction that lets you turn on or turn off bits after a preset count has been
reached.
There are different types of counters available in the RSLogix, but the CTU (counter up) instruction
covers everything we will talk about here.
Counters in RSLogix 5000 use tag names for identification.

BIT
An address within the PLC. It can be an input, output or internal coil, among others.

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This system allows very complex logic designs to be broken down and evaluated.
Practical Examples
Example-1
------[ ]------------------------[ ]---------------------------( )-------------
Key Switch 1 Key Switch 2 Door Motor

This circuit shows two key switches that security guards might use to activate an electric motor on a bank
vault door. When the normally open contacts of both switches close, electricity is able to flow to the
motor which opens the door. This is a logical AND.

Example-2
Often we have a little green "start" button to turn on a motor, and we want to turn it off with a big red
"Stop" button.
--+-----[]--+----[\]---( )---
| start |] stop run
| |
+----[]--+
Run
------[]---------------()-----
Run motor

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Consider the following circuit and PLC program:
------[]---------------()-----
Run motor

Fig. 10

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When the push button switch is unactuated (unpressed), no power is sent to the X1 input of the PLC.
Following the program, which shows a normally-open X1 contact in series with a Y1 coil, no “power”
will be sent to the Y1 coil. Thus, the PLC’s Y1 output remains de-energized, and the indicator lamp
connected to it remains dark.
If the pushbutton switch is pressed, however, power will be sent to the PLC’s X1 input. Any and all X1
contacts appearing in the program will assume the actuated (non-normal) state, as though they were relay
contacts actuated by the energizing of a relay coil named “X1”.
In this case, energizing the X1 input will cause the normally-open X1 contact will “close,” sending
“power” to the Y1 coil. When the Y1 coil of the program “energizes,” the real Y1 output will become
energized, lighting up the lamp connected to it:

Lamp Glows When At Input Switch Is Actuated

Fig. 11

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It must be understood that the X1 contact, Y1 coil, connecting wires, and “power” appearing in the
personal computer’s display are all virtual. They do not exist as real electrical components. They exist as
commands in a computer program—a piece of software only—that just happens to resemble a real relay
schematic diagram.

Equally important to understand is that the personal computer used to display and edit the PLC’s program
is not necessary for the PLC’s continued operation. Once a program has been loaded to the PLC from the
personal computer, the personal computer may be unplugged from the PLC, and the PLC will continue to
follow the programmed commands.

I include the personal computer display in these illustrations for your sake only, in aiding to understand
the relationship between real-life conditions (switch closure and lamp status) and the program’s status
(“power” through virtual contacts and virtual coils).

The true power and versatility of a PLC is revealed when we want to alter the behavior of a control
system. Since the PLC is a programmable device, we can alter its behavior by changing the commands we
give it, without having to reconfigure the electrical components connected to it.

For example, suppose we wanted to make this switch-and-lamp circuit function in an inverted fashion:
push the button to make the lamp turn off, and release it to make it turn on. The “hardware” solution
would require that a normally-closed pushbutton switch be substituted for the normally-open switch
currently in place. The “software” solution is much easier: just alter the program so that contact X1 is
normally-closed rather than normally-open.

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Programming For Start/Stop Of Motor By PLC

Fig.9
The pushbutton switch connected to input X1 serves as the “Start” switch, while the switch connected to
input X2 serves as the “Stop.” Another contact in the program, named Y1, uses the output coil status as a
seal-in contact, directly, so that the motor contactor will continue to be energized after the “Start”
pushbutton switch is released. You can see the normally-closed contact X2 appear in a colored block,
showing that it is in a closed (“electrically conducting”) state.

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Starting Of Motor
If we were to press the “Start” button, input X1 would energize, thus “closing” the X1 contact in the
program, sending “power” to the Y1 “coil,” energizing the Y1 output and applying 120 volt AC power to
the real motor contactor coil. The parallel Y1 contact will also “close,” thus latching the “circuit” in an
energized state:

Fig.12

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Logic For Continuous Running For Motor When Start Button Is Released
Now, if we release the “Start” pushbutton, the normally-open X1 “contact” will return to its “open” state,
but the motor will continue to run because the Y1 seal-in “contact” continues to provide “continuity” to
“power” coil Y1, thus keeping the Y1 output energized:

Fig.13

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To Stop The Motor

To stop the motor, we must momentarily press the “Stop” pushbutton, which will
energize the X2 input and “open” the normally-closed “contact,” breaking continuity to the Y1 “coil:”

Fig.14
When the “Stop” pushbutton is released, input X2 will de-energize, returning “contact” X2 to its normal,
“closed” state. The motor, however, will not start again until the “Start” pushbutton is actuated, because
the “seal-in” of Y1 has been lost:

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 CONCLUSION

Programmable Logic Circuits like an Arduino that is mainly used for industrial
automation. However the main difference between a PLC and an Arduino is their price, as the PLC
usually has 100 times the price of an Arduino, The PLC has a better processor power & memory, can
handle more current in the I/O ports, the ports are opt coupled, it is more robust, it is closed architecture, it
comes with industrial certificates, safety features etc.

The Logic made in this project is mainly used for controlling Door Open/Close Simulation; and can be
implemented in the industrial sector for managing the input and output of the computer hased products
cum raw materials transportation.

At IEC, the main work was to develop solutions based on the same, and hence the project was selected
and the simulation was done.

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 REFERENCES

The following is the reference list for any further information:

1. http://www.insalatorsindia.com/

2. http://www.hindusthanurban.com/

3. http://www.amci.com/tutorials/tutorials-what-is-programmable-logic- controller.asp

4. http://www.allaboutcircuits.com/textbook/digital cpt-6/programmable-logic- controllers-ple

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