PICG 433 chapter 2 PLC

Introduction to
Programmable Logic Controller (PLC)
PICG 433 chapter 2 PLC

Introduction

Programmable logic controllers (PLC) were originally designed to replace relay-based

discrete state control systems ( called also relay sequencer or relay logic panel).

Relay sequencers were used in the early day for the control of industrial processes.

They are made of physical relays wired together (or programmed) to make the processes
under control executes a desired sequence of events.

If the event sequence is to be changed, it is necessary to rewire all or part of the relay
sequencer. It may even be necessary to add more relays to the system or use more
relays than in the previous wiring. Obviously, such a task is quite hard and time
consuming.

With the development of reliable computers, it was than an easy decision to replace relay
logic panels with computer-based controller, i.e. PLCs.
PICG 433 chapter 2 PLC

RELAY CONTROLLERS
Example of a small switch used to energize a relay with contact ratings that
can handle the heavy load, such as that shown in Figure below.

Use of a relay and switch to start a motor.

 PICG 433 chapter 2 PLC

RELAY SEQUENCER
When an entire control system is implemented using relays, the
system is called a relay sequencer.

A relay sequencer consists of a combination of many relays, including

special time-delay types, wired up to implement the specified
sequence of events.

Inputs are switches and push buttons that energize relays, and outputs
are closed contacts that can turn lights on or off, start motors, energize
solenoids, and so on.
PICG 433 chapter 2 PLC
Physical Ladder Diagram Elements
The ladder diagram is a symbolic and schematic way of representing
both the system hardware and the process controller.

It is called a ladder diagram because the various circuit devices

connected in parallel across the ac line form something that looks
like a ladder, with each parallel connection a “rung” on the ladder.

Ladder diagram to control two lights

 PICG 433 chapter 2 PLC

Symbols used in Ladder Diagram

Symbols of input Symbols of output

Symbols for switches devices used in devices used in ladder
used in ladder diagrams. ladder diagrams diagrams.
PICG 433 chapter 2 PLC
Example Physical Ladder Diagram Elements
 PICG 433 chapter 2 PLC
Example on Physical Ladder Diagram Elements

The following narrative description indicates the

required sequence of events for the elevator system.

1. When the START button is pushed, the platform is

driven to the down position.
2. When the STOP button is pushed, the platform is
halted at whatever position it occupies at that
time.
3. When the UP button is pushed, the platform, if it
is not in downward motion, is driven to the up
position.
4. When the DOWN button is pushed, the platform,
if it is not in upward motion, is driven to the down
position.

Prepare a ladder diagram to implement this control

function.
PICG 433 chapter 2 PLC
Physical Ladder Diagram Elements

Elevator system

The complete ladder diagram

PICG 433 chapter 2 PLC
Physical Ladder Diagram Elements

Elevator system
A simplified ladder diagram
 PICG 433 chapter 2 PLC
Programmable Logic Controller (PLC)
Replacement of relay logic controllers by computer-based controllers called
programmable logic controller (PLC) in modern industries:

1. The input and output variables of discrete state control systems are binary in
nature, just as with a digital computer.

2. Many of the “control relays” of the panel can be replaced by software, which
means less hardware failure.

3. It is easy to make changes in a programmed sequence since it is only change

in software.

4. Special functions, such as time delay actions and counters, are easy to
produce in software.

5. The semiconductor industry developed solid-state devices that can control

high-power ac/dc in response to low-level commands from a computer,
including SCR and TRIACs.
 PICG 433 chapter 2 PLC
Basic Component of PLC
Regardless of size, cost, or complexity, all programmable logic controllers
(PLC) share the same basic components and functional characteristics

1. Processor,
2. Memory,
3. Input/Output modules,
4. Programming language
5. Power Supply.
 Processor

The processor is a computer that executes a program to perform the operationsspecified

in a ladder diagram.

The processor performs arithmetic and logic operations on input

variable data as determined by the user program and determine the
proper state of the output variables.

The processor functions under a permanent supervisory operating

system that direct the overall operation from data input and output to
execution of user program.
 Processor
The microprocessors used in PLCs are categorized according to their
word size, or the number of bits that they use simultaneously to perform
operations.
Standard word lengths are 8, 16, and 32 bits. This word length affects
the speed at which the processor performs most operations.

For example, a 32- bit microprocessor can manipulate data faster than
a 16-bit micro, since it manipulates twice as much data in one
operation.
Word length correlates with the capability and degree of sophistication
of the controller (i.e., the larger the word length, the more sophisticated
the controller).
 PICG 433 chapter 2 PLC

The input modules

• The input modules examine the status of physical switches and other input devices
and put their state into a form suitable for the processor.
• The PLC is able to accommodate a number of inputs, called channels.
• Many input modules can also be used in a networked environment wherein the input
signal arrives as serial digital data encoded with the input device address and state.

If the input switch is closed an electronic

circuit in the input module senses the
supplied voltage.

To indicate the status of that device it then

converts this into a logic-level signal that is
accepted by the processor.

A logic 1 indicates “ON” or “CLOSED”, and

a logic 0 indicates “OFF” or “OPENED” for
the field input device or switch.

Most input modules will contain light-emitting

diode (LED) to indicate the status of each
input.
 Input modules

In smaller PLCs the inputs are normally built in and are specified when
purchasing the PLC.

For larger PLCs the inputs are purchased as modules, or cards, with 8 or 16
inputs of the same type on each card. The list below shows typical ranges
for input voltages, and is roughly in order of popularity.
12-24 Vdc,100-120 Vac, 10-60 Vdc, 12-24 Vac/dc, 5 Vdc (TTL), 200-240
Vac, 48 Vdc, 24 Vac

PLC input cards rarely supply power, this means that an external
power supply is needed to supply power for the inputs and sensors.
Typical Discrete Input Module wiring circuit
 Output Module
The output modules supply power to an external device such as a motor, light,
solenoid, and so on, as required by the ladder diagram.

The output module is designed to input the processor digital output and use this to
activate relays, SCRs, TRIACs, BJTs, and other solid-state switches that can handle
the high-power ac requirements

If the device, such as the motor in Figure, requires a

current that exceeds the module output capability, then
external relays or solid-state switches can be used.

Output modules can now provide many other kinds

of outputs such as dc voltages, pulse outputs, and
even serial digital outputs that can be transmitted to
the output device over a network.
 Output modules
As with input modules, output modules rarely supply any power, but
instead act as switches.
External power supplies are connected to the output card and the card will
switch the power on or off for each output. Typical output voltages are listed
below, and roughly ordered by popularity.
120 Vac, 24 Vdc, 12-48 Vac, 12-48 Vdc, 5Vdc (TTL), 230 Vac
PLC output module wiring circuit

The AC switch is normally

protected by an RC circuit and/or a
metal oxide varistor (MOV),
which limits the peak voltage to
some value below the maximum
rating.
The configuration of the PLC refers to the packaging of the components. Typical
configurations are listed below from largest to smallest as shown in Figures.
 PLC configuration

Rack - A rack is often large (up to 18” by 30” by 10”) and can hold
multiple cards. When necessary, multiple racks can be connected
together. These tend to be the highest cost, but also the most flexible
and easy to maintain.

Mini - These are similar in function to PLC racks, but about half the
size.

Shoebox - A compact, all-in-one unit (about the size of a shoebox) that

has limited expansion capabilities. Lower cost, and compactness make
these ideal for small applications.

Micro - These units can be as small as a deck of cards. They tend to

have fixed quantities of I/O and limited abilities, but costs will be the
lowest.
These families consist of a product line that ranges from very small
“microcontrollers,” with as few as 10 I/O points, to very large and sophisticated
PLCs, with as many as 8,000 I/O points and 128,000 words of memory.
Input/Output Rack enclosure

Typical I/O modular housings

PICG 433 chapter 2 PLC

Power supply
The power supply converts ac line voltages to dc voltages to power the electronic circuits
in PLC.

These power supplies rectify, filter, and regulate voltages and currents to supply the
correct amounts of current and voltage to the system.

The power supply for PLC may be integrated with the processor, memory and I/O
modules into a single housing or it might be separated unit connected to the system
through a cable.
PICG 433 chapter 2 PLC

Power supply circuit

 PLC operation
PLC operation cycle is made up of four separate parts:
1. Input Scan,
2. Program Scan, and
3. Output Scan.
This cycle is made sequentially and repeatedly.
 Details the scan process

During the input scan, the PLC examines the external input devices to see if a
signal is present or absent, that is, if the input devices are in ON or OFF state.

The status of these inputs is temporarily stored in an input image table or memory
file.

During the program scan, the processor scans the instruction in the control program,
uses the inputs from the input image file, and determines if an output will or will not
be energized.

The resulting status of the outputs is written to the output image table or memory file.

Based on the data in the output image table, the PLC energize or deenergize its
associated output circuits, which control external devices.
 Scan time
An important characteristic of the PLC is how much time is required for one
complete cycle of I/O scan and execution.

Scan time depends on how many input and output channels are involved and
on the length of the ladder diagram program.

A typical maximum scan/execution time is 5 to 20 ms.

The speed of the controller depends on the clock frequency of the processor.
The higher the clock frequency, the greater the speed, and the faster the
scan/execution time.

The length of time for one scan consists of three parts: (1) input time, (2)
execution time, and (3) output time. Most of the scan time comes from the
execution phase.
 Assignment

Assignment on PLC

1) Show that the answer is

66.7 m/s.
2) What will happen if the
conveyor speed is higher than
66.7 m/s ? Disadvantage
Assignment
PICG 433 chapter 2 PLC

Programming Unit
The programming unit are used to enter, store, and monitor the programmable
controller software.
They can be hand held systems or personal computer based systems.

The programming device is connected to the PLC only while programming or

troubleshooting.

Once the program has downloaded in the memory of the PLC, the program unit can be
disconnected and the PLC operate the process according to the program downloaded
by user.

There is danger of loss of the program because of power failure, but this can be
prevented by placing the program into the permanent memory.

The additional feature of computer based programming units is that they can be
connected to Ethernet type local area network (LAN) or dedicated control networks such
as Foundation Fieldbus or Profibus.

This network give the programmer or engineer access to any PLC in the network, so it is
possible to monitor and control any PLC in the network.
 Hand Held Programming Units

Hand held programming units are inexpensive and portable; they are normally used to
program small PLCs.

Most of these devices resemble portable calculators but with larger displays and
somewhat different keyboard.
 Desktop Programming Unit

The personal computer based systems employ keyboard and mouse; color
graphic display; personal computer; printer; communication interface and cable.
 Programming Languages
The programming language allows the user to communicate with the programmable logic
controller via a programming device.

PLC manufacturers use several different programming languages, but they all use
instructions to convey a basic control program to the system.
Five common types of languages encountered in PLC systems are as follows
Graphical languages
 Ladder Logic (LAD)
 Function Block Diagram (FBD)
Text-based languages
 STatement List (STL)
 Structured text (ST)
Flow chart-type
• Sequential Function Charts (SFC) - Grafcet
All these programming languages are part of the IEC 61131 standard.

The IEC Standard allows some ground rules that standardize PLC's and
their languages.
 PICG 433 chapter 2 PLC

Ladder diagram

The logic function shown is an AND function, that is, if pushbutton (PB1) is closed and
pushbutton (PB2) is closed then the GO light is on.

The ladder diagram is the most common language used in PLC applications. This is
because ladder diagrams have already been used by technicians and engineers in the
design of the relay sequencers.
 PICG 433 chapter 2 PLC

Statement list
Statement list is a textual programming language that can be used to create the code for
a PLC control program.

Its syntax for statement is similar to microprocessor assembly language and consists of
instructions followed addresses on which instructions act.
 Structured Text

If you know how to program in any high level

language, such as Basic or C, you will be
comfortable with Structured Text (ST)
programming.

ST has been designed to work with the other

PLC programming languages. For example, a
ladder logic program can call a structured text
subroutine.
PICG 433 chapter 2 PLC

Functional block diagram

Functional block diagram is graphical programming language.

It allows the programmer to build complex control procedures by taking existing functions
from the FBD library and wiring them in graphic diagram area.

An FBD describes a relationship or function between input and output variables.

LAD, FBD, ST, & IS
 SFC (Sequential Function Charts )- Grafcet

The SFC structure is much like a flowchart-type of programming framework,

utilizing different languages for different control tasks and also routing control
program actions.
 The Basic Elements of an SFC diagram

Basic Elements in SFCs flowlines - connects steps and transitions (these

basically indicate sequence) transition - causes a shift between steps, acts as a
point of coordination
 Example using SFC
for control of a two door security system.

One door requires a two digit entry code, the

second door requires a three digit entry code.

The execution of the system starts at the top of

the diagram at the Start block when the power is
turned on.

There is an action associated with the Start

block that locks the doors.

After the start block the diagram immediately

splits the execution into two processes and both
steps 1 and 6 are active

(Note: in practice the SFC uses ladder

logic for inputs and outputs, but this is not
shown on the diagram.)
 Video Show
Five common types of languages
encountered in PLC systems
 PICG 433 chapter 2 PLC

LAD program

In this chapter, we discuss only ladder diagram applications. Before, we have to put in
mind that the PLC has no “real” relay or relay contacts.

The only real devices are those that are actually part of the process being controlled- that
is, limit switches, motors, solenoids, and so on.

In the LAD program addresses are used to identify both the physical and software
devices according to the following categories:

• Physical input devices

• Physical output devices
• Programmed control relay coils and contacts
• Programmed time delay relay coils or contacts
• Programmed counters or contacts
• Special functions
 Ladder Diagram Interpretation
In a programmed diagram rung, the ON or OFF state of the output of the rung is
determined by testing the elements of the rung for a TRUE or FALSE condition.
If a complete TRUE element path to the output exists in the rung, then the output will be
made TRUE or ON.
PICG 433 chapter 2 PLC

Programmed Ladder Diagram Interpretation

In programmed ladder diagram, the symbol for a NO contact indicates

that the device should be interpreted as FALSE if the contact is tested
and found to be open, and TRUE if it is found to be closed.

We often say it is to be “examined ON”, and if ON, it is TRUE.

For a NC symbol, if the contact is tested and found to be closed, then

it is FALSE, and if tested and found open, it is ON (This is not like the
physical contact).

We often say this is an “examine OFF”, and if it is OFF, it isTRUE.

Ladder relay instructions are the most basic instructions in the ladder diagram
instruction set. These instructions represent the ON/OFF status of connected inputs and
outputs.
Ladder relay instructions use two types of symbols: contacts and coils. Contacts
represent the input conditions that must be evaluated in a given rung to determine the
control of the output. Coils represent a rung’s outputs. Table 9-2 lists common ladder
relay instructions.
 Example on ladder relay contact status

EXAMINE-
ON/NORMALLY OPEN

EXAMINE-
OFF/NORMALLY
CLOSED
Example on ladder relay coil status
Example on relay instruction
Reading of LAD diagram
PICG 433 chapter 2 PLC

Addressing terms in PLC

The address designation depends on the type of PLC.

Some PLC may reserve certain address for physical I/O devices, other addresses for
software control relays, and for special functions.

For some examples to be considered in this chapter, we will use the following addresses
PICG 433 chapter 2 PLC

Some common PLC Software functions

Control Relay

Counter
Timers

Accumulating Timers

One-shot

Shift register

Modern PLCs are able to handle multi-digit numbers as well as single-bit, binary numbers.
Thus, it is possible for a PLC to accept input from an 8-bit ADC and store the result in a
known memory location or register. These PLCs have the ability to perform a variety of
math operations on this data, from simple addition, subtraction, multiplication, and
division, to exponential and trigonometric operations. In this way, the PLC can be made to
process continuous plant data such as PID control.
PICG 433 chapter 2 PLC

Example
Implementation of latch to turn on and off a motor using two NO push-button switches.
PICG 433 chapter 2 PLC

Example

The objective of the system shown is as follows:

• If PB1 alone is pushed, the red light turns on.
• If PB2 alone is pushed, the green light turns on.
• If both buttons are pushed at once, neither light turns on
PICG 433 chapter 2 PLC
 Importance of Push Button (PB) programming
for Start up and Shut down

Figure 9-39a shows an example of a

normally closed stop push button
used to stop the power to a motor.
During operation, when the start PB
has been pressed and sealed by the
internal motor contact (100), the
motor turns ON (see Figure 9-39b).
The normally closed stop PB
interrupts the power continuity to the
motor output coil contact. The
pressing of this stop push button is
the only way the motor can be
stopped (see Figure 9-39c). However,
if the wire connection for the stop PB
is accidentally cut, the motor circuit
will disengage (see Figure 9-39d).
 Importance of Push Button (PB) Programming

This same logic operation can also be

achieved using a normally open stop PB
instead of a normally closed one and
implementing it as a normally closed
circuit in the PLC program (see Figure 9-
40a). When the start button is pushed,
the motor turns ON (see Figure 9-40b); if
the stop PB is pressed, the motor turns
OFF (see Figure 9-40c). However, there
is no way to stop the motor from running
if the normally open stop PB wire is cut
(see Figure 9- 40d). The programmed
examine-OFF instruction corresponding
to the stop PB will never disrupt
continuity in this situation. The only way
to stop the motor is to shut down power
to the whole PLC system. This type of
PLC system configuration is dangerous
and should be avoided at all times.
 TIMERS AND COUNTERS
PLC timers and counters are internal instructions that provide the same
functions as hardware timers and counters. They activate or deactivate a
device after a time interval has expired or a count has reached a preset value.
Timer and counter instructions are generally considered internal outputs. Like
relay-type instructions, timer and counter instructions are fundamental to the
ladder diagram instruction set.

Timer instructions may have one or more time bases (TB) which they use to
time an event. The time base is the resolution, or accuracy, of the timer. For
instance, if a timer must time a 10 second event, the user must choose the
number of times the time base must be counted to get to 10 seconds.

Counter instructions are used to count events, such as parts passing on a conveyor, the
number of times a solenoid is turned ON, etc. Counters, along with timers, must have two
values, a preset value and an accumulated value.
Timer instructions
Counters instructions
 PICG 433 chapter 2 PLC

Counter (Text Book chapter 8, examples)

A counter is programmed function that counts (increments) every time the input
changes from False or True.

This means that, if in one scan the input is False and in the next scan is True,
the counter increments.

No further counts will occur until the input goes False again and then True.
 PICG 433 chapter 2 PLC

Example

• A counter is to be used to count objects in the conveyor delivery system of figure

below. Show how a counter can be set up to count 200 objects and then turn off the
conveyor motor. What is the maximum conveyor speed to assure that no objects will
be missed in the count if the objects are at least 1 cm apart? The object width is 2 cm
and the PLC scan time is 30 ms.
PICG 433 chapter 2 PLC

Solution
Figure 36 shows the conveyor with multiple objects and
how a counter can be connected to the object detector
so that the conveyor is turned off after counting 200
objects. The object detector is connected to input
channel 01, and the conveyor motor to output channel
08. The counter is assigned address 32, and the count is
preset to 200.
This means that, when a count of 200 occurs, the
counter will become true. When it becomes true, the
EXAMINE OFF contact 32 in the third rung will become
false, and the conveyor motor will turn off.
Input channel 02 is unspecified but would be used to
reset the counter to start another count of 200.
PICG 433 chapter 2 PLC

Figure 36 also shows a timing diagram of the PLC

scan cycles and the pulses coming
in from detected objects.

Remember that there must be a return to zero

(false) before the next object can be detected.

This means that even the shortest time, which is the

1 cm between objects, must last one full scan to
assure a return to zero.
PICG 433 chapter 2 PLC

Timers (Text Book chapter 8, examples)

The programmed timer function when activated by true path (its input is true), it
begins to accumulate time in the form of “ticks”.

Each tick is worth a certain amount of time. Typical of tick time is 10 ms and
100 ms.

The timer is pre-loaded with a specified number of these ticks. When the
accumulated time ticks equals the pre-load value, the timer itself becomes true.
If the input becomes False and then True again, the timer will reset to zero and
start to count again.
PICG 433 chapter 2 PLC

Example

Show how a timer can be used to turn a red light on for 2500 ms when a NO
start push button is pushed. The PLC timer tick is 10 ms. An NC stop button
resets the system.
PICG 433 chapter 2 PLC

We need a preset tick count of 2500 ms/l0 ms = 250. Let’s use address 33 for the timer,
01 for the push button, and 08 for the red light. We need to latch the effect of the start
push button, since it will likely not be held for the full 2500 ms. Figure 8.38 shows the
programmed ladder diagram. The stop button is used to reset the process. Without the
latch, the timer would only count while the push button is held down.
PICG 433 chapter 2 PLC

Accumulating Timers
The accumulator timers retain a tick count when its input goes false.

When the input goes true again, the tick count will pick up where the previous
one left off.

It is necessary to have a reset input to this

timer so that, when desired, the timer can
reset back to zero.
 PICG 433 chapter 2 PLC

Example
Figure shows a P&ID of a chemical vat in which a mixture must be cooked at a
temperature greater than 100°C for 10 minutes. Due to external influences, the
temperature might fall below 100°C periodically, and this should not be counted in the
cooking time. After the vat is filled, a Start push button (NC) starts the cooking. It is
terminated by an NC Stop push button. A thermal switch goes high when the temperature
is above 100°C. When the mixture has been cooked for 10 minutes at 100°C, the heater
should be turned off and the drain valve opened. The PLC tick time is 10 ms.
PICG 433 chapter 2 PLC

Solution
Since the tick marks are 10 ms, the required count is (60 s/min)(lO min)/(10 ms) = 6000
counts. A start/stop latch is used with a programmed control relay to start the process
with the NC switches addressed at 01 and 02. The accumulating timer (address 32) will
count long as the start is latched and the temperature is above 100°C as indicated by
the thermal switch, address 03. As long as the timer has not timed out, the heater is on
and the valve closed. When the timer times out, the heater is turned off and the valve is
opened. The timer is reset by pressing the stop button. Figure shows the programmed
ladder diagram for this system.
PICG 433 chapter 2 PLC

Example

Prepare the physical and programmed ladder diagram for the control
problem shown in Figure 8.41. The global objective is to heat a liquid to
a specified temperature and keep it there with stirring for 30 min.
The hardware has the following characteristics:
• 1. START push button is NO, STOP is NC.
• 2. NO and NC are available for the limit switches.
• The event sequence is
• 1. Fill the tank.
• 2. Heat and stir the liquid for 30 min.
• 3. Empty the tank.
• 4. Repeat from step 1.
PICG 433 chapter 2 PLC

Inputs:
01 = NO Start switch
02 = NC Stop switch
03 = Full level switch (opens
on rising
level)
04 = Temperature switch
(opens on rising
temperature)
05 = Empty switch
(closes on rising
level)
Outputs:
08 = Input valve
09= Stir motor
10 = Heater
11 = Output valve
Timer tick = 1 second
 PICG 433 chapter 2 PLC
Solution
• The solution is provided by first constructing the physical ladder diagram.
Once this is done, addresses are assigned to all the elements, and the
ladder diagram program prepared.
• Figure below shows the six-rung physical ladder diagram.
• Rung 2 opens the input valve, provided the output valve is not open, until
the full level is reached.
• When the full level is reached, rung 3 turns on the stir, provided the output
valve is not open.
• Rung 4 starts a 30-min timer.
• The heater is controlled by rung 5. The rung is energized and de-energized
as the temperature goes below and above the limit.
• When the timer times out, the rung is de-energized, and rung 6 is energized
to open the output valve. The output valve remains open until the empty
limit switch opens.
• The output valve cannot be opened as long as the input valve is open.
• The programmed ladder diagram is shown in Figure below. Addresses for
the input, output, and internal devices have been assigned. Notes indicate
how the physical contacts change in response to the control variable. The
timer becomes True after 1800 ticks or 30 minutes, so we use an EXAMINE
OFF for the timer in rung 5 to assure that the heater can be on only during
the 30 minutes the timer is not True. Since the empty valve closes on a
rising level, it will be closed until the tank empties. Therefore, we use an
EXAMINE ON to assure that the output valve stays open until the tank is
empty.
 PICG 433 chapter 2 PLC

Inputs:
01 = NO Start switch
02 = NC Stop switch
03 = Full level switch
(opens on rising
level)
04 = Temperature
switch
(opens on rising
temperature)
05 = Empty switch
(closes on rising
level)
Outputs:
08 = Input valve
09= Stir motor
10 = Heater
11 = Output valve
Timer tick = 1 second

➢ Figure above shows the six-rung physical ladder diagram.

➢ Rung 2 opens the input valve, provided the output valve is not open, until the full level is
reached.
➢ When the full level is reached, rung 3 turns on the stir, provided the output valve is not
open.
➢ Rung 4 starts a 30-min timer.
➢ The heater is controlled by rung 5. The rung is energized and de-energized as the
temperature goes below and above the limit.
➢ When the timer times out, the rung is de-energized, and rung 6 is energized to open the
output valve. The output valve remains open until the empty limit switch opens.
➢ The output valve cannot be opened as long as the input valve is open.
 PICG 433 chapter 2 PLC
Inputs:
01 = NO Start switch
02 = NC Stop switch
03 = Full level switch
(opens on rising
level)
04 = Temperature
switch
(opens on rising
temperature)
05 = Empty switch
(closes on rising
level)
Outputs:
08 = Input valve
09= Stir motor
10 = Heater
11 = Output valve
Timer tick = 1 second

➢ The programmed ladder diagram is shown in Figure above.

➢ Addresses for the input, output, and internal devices have been assigned.
➢ Notes indicate how the physical contacts change in response to the control
variable. The timer becomes True after 1800 ticks (i.e. 30 minutes), so we use an
EXAMINE OFF for the timer in rung 5 to assure that the heater can be ‘ON’ only
during the 30 minutes the timer is not True.
➢ Since the empty valve closes on a rising level, it will be closed until the tank
empties. Therefore, we use an EXAMINE ON to assure that the output valve stays
open until the tank is empty.
1. START push button is NO, STOP is NC.
2. NO and NC are available for the limit switches.
The event sequence is
1. Fill the tank.
2. Heat and stir the liquid for 30 min.
3. Empty the tank.
4. Repeat from step 1.

Inputs:
01 = NO Start switch
02 = NC Stop switch
03 = Full level switch
(opens on rising
level)
04 = Temperature
switch
(opens on rising
temperature)
05 = Empty switch
(closes on rising
level)
Outputs:
08 = Input valve
09= Stir motor
10 = Heater
11 = Output valve
Timer tick = 1 second
PICG 433 chapter 2 PLC

Other functions

The one-shot is an output that will go true for only one scan when its
input path is True.
This device is used for initialization and other instances when an event
is to occur only once, even though the conditions that make it True may
occur again.
A shift-register is used to remember a certain number of previous
states of a rung. A four-event shift register could be used to remember
the state of a rung for the latest four scans..
PICG 433 chapter 2 PLC

Other functions

PLCs are able to handle multi-digit numbers (AI/AO)as well as single-

bit (DI/DO), binary numbers.
Thus, it is possible for a PLC to accept input from an 8-bit ADC (AI)
and store the result in a known memory location or register in a
known memory location or register.
They are able to perform variety of mathematical operations. In this
way, the PLC can be made to control discrete process (batch
process) as well as continuous process ( using e.g. PID controller).
Example: Using S7 300 Siemens PLC &
STEP 7 Software
Part 1: Programming using Siemens PLC S7 300 &
STEP 7 Software
Part 2: Programming using Siemens PLC S7 300
STEP 7 Software