Dr: Gamal Gouda

Course Contents
 Definition of PLC & its importance to Control
 Structure and main components of PLC
 PLC Wiring diagram
 PLC Programming Languages
 Ladder Programming
 Basics of Ladder Programming
 Ladder from Relay diagram
 Function Block Diagram FBD
 Ladder diagram and equivalent FBD
 Equivalent Ladder, Function Block & Boolean Equation
 Counters in PLC
 Industrial Examples
 PLC definition & its importance to Control
PLC definition A digitally operating electronic apparatus which
uses a programming memory to store instructions to implement
specific functions such as logic, sequencing, timing, counting and
arithmetic to control an industrial process.

Importance to Control circuits

• Less wiring in control
• Wiring between devices and relay contacts are done in PLC
program.
• Easier and faster to make changes in control.
• Reliable components make these likely to operate for years
before failure
Structure and main components of PLC
 Structure and main components of PLC

 POWER SUPPLY
Provides the voltage needed to run the primary PLC components
 I/O MODULES
Provides signal conversion and isolation between the internal
logic- level signals inside the PLC and the high level signal.
 PROCESSOR
Provides logical operations to command the activities of the PLC
systems
 PROGRAMMING DEVICE
Provides the desired program which determines the sequence of
operation and control of process equipment
Input / Output connections of PLC unit
PLC Wiring Diagram
 PLC Output Wiring

• TheRelay is turned on if output 03 is true

•The Lamp is turned on if output 07 is true
 PLC Programming Languages
Structure of a PLC program
 A PLC program consists of rules that make logic relation
between inputs and outputs of the controller.
 Basically it uses logic operands: AND, OR, negation
 The structure of the rules is IF…THEN…ELSE…
•Inputs
•Outputs
• Switches and Pushbuttons
• Valves
•Limit Switches
• Motor Starters
• Photoelectric Sensors
• Solenoids
• Proximity Sensors
• Pressure Switches
• Actuators
• Level Switches • Control Relays
• Temperature Switches • Horns & Alarms
•Encoders •Indicators
 PLC Programming Languages

Text based Graphical based

•Statement List SL • Ladder Diagram LD
• Instruction List IL • Function Block Diagram FBD
• Sequential Function Chart SFC

Functions and function blocks Graphic programming language derived

are represented graphically from the circuit diagram of directly
and interconnected into wired relay controls
networks
 Ladder Programming
Basic Ladder Logic Symbols
Normally open contact Power (ON) if the contact is ON (closed)

Normally closed contact Power (OFF) if the contact is off (open)

Output or coil If any left-to-right path of inputs passes

power, output is energized

If any left-to-right path of inputs passes

Not Output or coil
power, output is de-energized
 Input-Output Wiring

Input wiring

Operation Program

Output wiring
Basic Ladder Logic Symbols
Function Block Instructions
 Power Rails, Rungs and Power
Flow

• Power Rails - Pair of Vertical

Lines
• Rungs - Horizontal Lines
• Contacts A, B, C, D… arranged on
rungs

Note in PLC Ladder Logic:

• No Real Power Flow (like in relay
ladder)
• There must be continuous path
through the contacts to energize
the output
 Ladder Diagram
Correct Current Basics
Ladder Flow
logic follows a left to
right principle. current flows
through paths started from
either X0 or X3.
Reverse Current
When a current flows from
right to left, which makes a
reverse current logic, an error
will be detected
•Y0 is energized from paths
•x0x1x2 or x0x1x5 or x3x4x2
Or x3x4x5 or x3x6 but path
x0x1x4x6 is impossible
 Ladder Diagram
Basics
•Reverse Current

•If the programmer wants to

energize Y0 by the contacts of
the path x0x1x4x6, he has to
modify the program

Correction
A correct path is now
developed such that there is
no reversed current flow
 Ladder Diagram
Current Flow
Basics
Example
Correct the circuit with reverse current flow

•To energize coil PL1

•3 paths are possible
• Path ABC
•Path ADE
• Path FE
•One path is wrong (reverse)
FDBC

Correction