PLCs-3e-S 11-28/06, 06/04/07

57
Chapter 9
DISCRETE CONTROL USING PROGRAMMABLE LOGIC
CONTROLLERS AND PERSONAL COMPUTERS
REVIEW QUESTIONS
9.1 Briefly define the two categories of discrete process control?
Answer: Discrete process control can be divided into two categories: (1) logic control, which is concerned
with event-driven changes in the system; and (2) sequencing, which is concerned with time-driven changes in
the system.
9.2 What is an AND gate? How does it operate on two binary inputs?
Answer: An AND gate outputs a value of 1 if all of the inputs are 1, and 0 otherwise.
9.3 What is an OR gate? How does it operate on two binary inputs?
Answer: An OR gate outputs a value of 1 if either of the inputs has a value of 1, and 0 otherwise.
9.4 What is Boolean algebra? What was its original purpose?
Answer: Boolean algebra is a special form of algebra based on the logic elements (AND, OR, and NOT) that
was developed around 1847 by George Boole. Its original purpose was to provide a symbolic means of
testing whether complex statements of logic were TRUE or FALSE.
9.5 What is the difference between a delay-off timer and a delay-on timer?
Answer: A delay-off timer switches power on immediately in response to a start signal, and then switches
power off after a specified time delay, whereas a delay-on timer waits a specified length of time before
switching power on when it receives a start signal.
9.6 What is the difference between an up counter and a down counter?
Answer: An up counter starts at zero and increments its contents (the count total) by one in response to each
pulse. When a preset value has been reached, the up counter can be reset to zero. A down counter starts with a
preset value and decrements the total by one for each pulse received.
9.7 What is a ladder logic diagram?
Answer: A ladder logic diagram shows the various logic elements and other components along horizontal
lines or rungs connected on either end to two vertical rails. The diagram has the general configuration of a
ladder, hence its name. The elements and components are contacts (representing logical inputs) and loads,
also known as coils (representing outputs).
9.8 The two types of components in a ladder logic diagram are contacts and coils. Give two examples of each type.
Answer: Contacts include switches and relay contacts, and coils include motors, lamps, and alarms.
9.9 What is a programmable logic controller?
Answer: A programmable logic controller is a microcomputer-based controller that uses stored instructions in
programmable memory to implement logic, sequencing, timing, counting, and arithmetic functions through
digital or analog input/output (I/O) modules, for controlling machines and processes.
9.10 What are the advantages of using a PLC rather than conventional relays, timers, counters, and other hard-wired
control components?
Answer: The advantages listed in the text are (1) programming the PLC is easier than wiring the relay control
panel; (2) the PLC can be reprogrammed, whereas conventional controls must be rewired and are often
scrapped instead; (3) PLCs take less floor space than relay control panels; (4) reliability is greater, and
maintenance is easier; (5) the PLC can be connected to computer systems more easily than relays; and (6)
PLCs can perform a greater variety of control functions than can relay controls.
9.11 What are the five basic components of a PLC?
PLCs-3e-S 11-28/06, 06/04/07
58
Answer: The five basic components of a PLC are the following: (1) processor, (2) memory unit, (3) power
supply, (4) I/O module, and (5) programming device.
9.12 The typical operating cycle of the PLC, called a scan, consists of three parts: (1) input scan, (2) program scan,
and (3) output scan. Briefly describe what is accomplished in each part.
Answer: During the input scan, the inputs to the PLC are read by the processor and the status of these inputs
is stored in memory. Next, the control program is executed during the program scan. The input values stored
in memory are used in the control logic calculations to determine the values of the outputs. Finally, during the
output scan, the outputs are updated to agree with the calculated values.
9.13 Name the five PLC programming methods identified in the International Standard for Programmable
Controllers (IEC 11313).
Answer: The standard specifies three graphical languages and two text-based languages for programming
PLCs, respectively: (1) ladder logic diagrams, (2) function block diagrams, (3) sequential functions charts, (4)
instruction list, and (5) structured text.
9.14 What are three of the reasons and factors that explain why personal computers are being used with greater and
greater frequency for industrial control applications?
Answer: Some of the reasons given in the text are the following: (1) The technological evolution of PLCs has
not kept pace with the development of PCs. (2) New generations of PCs are introduced with much greater
frequency than PLCs. (3) There is much more proprietary software and architecture in PLCs than in PCs,
making it difficult to mix and match components from different vendors. (4) PLC performance lags its PC
counterpart by as much as two years, and the gap is increasing. (5) PCs are now available in more-sturdy
enclosures for the dirty and noisy plant environment. (6) PCs can be equipped with membrane-type keyboards
for protection against factory moisture, oil, and dirt. (7) PCs can be ordered with I/O cards and related
hardware to provide the necessary devices to connect to the plants equipment and processes. (8) Operating
systems designed to implement real-time control applications can be installed in addition to traditional office
software.
9.15 Name the two basic approaches used in PC-based control systems.
Answer: The two approaches are soft logic and hard real-time control. In the soft logic configuration, the
PCs operating system is Windows, and control algorithms are installed as high-priority programs under the
operating system. However, it is possible to interrupt the control tasks in order to service certain system
functions in Windows, such as network communications and disk access. When this happens, the control
function is delayed, with possible negative consequences to the process. By contrast, in a hard real-time
control system, the PCs operating system is the real-time operating system, and the control software takes
priority over all other software. Windows tasks are executed at a lower priority under the real-time operating
system. Windows cannot interrupt the execution of the real-time controller. If Windows locks up, it does not
affect the controller operation. Also, the real-time operating system resides in the PCs active memory, so a
failure of the hard disk has no effect in a hard real-time control system.
PROBLEMS
9.1 Write the Boolean logic expression for the pushbutton switch of Example 9.2 using the following symbols: X1 =
START, X2 = STOP, Y1 = MOTOR, and Y2 = POWER-TO-MOTOR.
Solution: Let X1 = start, X2 = stop, Y1 = motor, Y2 = power-to-motor.
Boolean logic expression: Y2 = ( ) X Y X 1 1 2
9.2 Construct the ladder logic diagram for the robot interlock system in Example 9.1.
Solution: Ladder logic diagram.

X1
X2
X3
Y

PLCs-3e-S 11-28/06, 06/04/07
59
9.3 In the circuit of Figure 9.1, suppose a photodetector were used to determine whether the lamp worked. If the
lamp does not light when both switches are closed, the photodetector causes a buzzer to sound. Construct the
ladder logic diagram for this system.
Solution: Ladder logic diagram.

X1
X2
Y
Y1 X1
X2
X3

9.4 Construct the ladder logic diagrams for (a) the NAND gate and (b) the NOR gate.
Solution: Ladder logic diagrams.
X1
X2
(a) NAND
C
Y
C


(b) NOR
C
Y
X1
X2
C

9.5 Construct the ladder logic diagrams for the following Boolean logic equations: (a) Y = (X1 + X2)X3, (b) Y =
(X1 + X2)(X3 + X4), and (c) Y = (X1X2) + X3.
Solution: Ladder logic diagrams.
(a)
X1
X2
Y
X3

PLCs-3e-S 11-28/06, 06/04/07
60
(b)
X1
X2
Y
X3
X4

X1 Y
(c)
X3
X2

9.6 Write the low level language statements for the robot interlock system in Example 9.1 using the instruction set in
Table 9.10.
Solution: STR X1
AND X2
AND X3
OUT Y
9.7 Write the low level language statements for the lamp and photodetector system in Problem 9.4 using the
instruction set in Table 9.10.
Solution: STR X1
AND X2
OUT Y
STR X1
AND X2
AND NOT X3
OUT Y1
9.8 Write the low level language statements for the fluid filling operation in Example 9.6 using the instruction set in
Table 9.10.
Solution: STR X1
OR C1
AND NOT FS
OUT C1
STR C1
OUT S1
STR FS
OR C2
AND NOT T2
OUT C2
STR C2
TMR T1 120 (120 specifies timer delay in sec)
STR T1
OUT S2
STR T1
TMR T2 90 (90 specifies timer delay in sec)
9.9 Write the low level language statements for the four parts of Problem 9.5 using the instruction set in Table 9.10.
PLCs-3e-S 11-28/06, 06/04/07
61
Solution: (a) STR X1 (c) STR X1
OR X2 AND X2
AND X3 OR X3
OUT Y OUT Y
(b) STR X3 (d) STR X1
OR X4 AND X2
OUT Y1 OUT Y
STR X1
OR X2
AND Y1
OUT Y
9.10 In the fluid filling operation of Example 9.6, suppose a sensor (e.g., a submerged float switch) is used to
determine whether the contents of the tank have been evacuated, rather than rely on timer T2 to empty the tank.
(a) Construct the ladder logic diagram for this revised system. (b) Write the low level language statements for the
system using the PLC instruction set in Table 9.10.
Solution: (a) Ladder logic diagram. Assume FS2 (new float switch) is open when tank is empty. FS1 is the tank
full float switch.

X1
C1
C1
FS1
C1
S1
FS1
FS2
C2
T1
120 s
C2
T1 S2
C2

(b) Low level language statements:
STR X1
OR C1
AND NOT FS1
OUT C1
STR C1
OUT S1
STR FS1
OR C2
AND NOT FS2
OUT C2
STR C2
PLCs-3e-S 11-28/06, 06/04/07
62
TMR T1 120 (120 specifies timer delay in sec)
STR T1
OUT S2
9.11 In the manual operation of a sheet metal stamping press, a two button safety interlock system is often used to
prevent the operator from inadvertently actuating the press while his hand is in the die. Both buttons must be
depressed to actuate the stamping cycle. In this system, one pressbutton is located on one side of the press while
the other button is located on the opposite side. During the work cycle the operator inserts the part into the die
and depresses both pushbuttons, using both hands. (a) Write the truth table for this interlock system. (b) Write the
Boolean logic expression for the system. (c) Construct the logic network diagram for the system. (d) Construct
the ladder logic diagram for the system.
Solution: Let X1 = button one, X2 = button 2, and Y = safety interlock
(a) Truth table X1 X2 Y
0 0 0
0 1 0
1 0 0
1 1 1
(b) Boolean logic expression: Y = X1 X2
(c) Logic network diagram

X1
X2
Y

(d) Ladder logic diagram

X1
X2
Y

9.12 An emergency stop system is to be designed for a certain automatic production machine. A single "start" button
is used to turn on the power to the machine at the beginning of the day. In addition, there are three "stop" buttons
located at different locations around the machine, any one of which can be pressed to immediately turn off power
to the machine. (a) Write the truth table for this system. (b) Write the Boolean logic expression for the system.
(c) Construct the logic network diagram for the system. (d) Construct the ladder logic diagram for the system.
Solution: Let X1 = start button, X2 = stop button 1, X3 = stop button 2, X4 = stop button 3, Y1 = machine, and
Y2 = power-to-machine.
(a) Truth table: X1 X2 X3 X4 Y1 Y2
0 0 0 0 0 0
0 0 0 0 1 1
0 0 0 1 0 0
0 0 0 1 1 0
0 0 1 0 0 0
0 0 1 0 1 0
0 0 1 1 0 0
0 1 0 0 0 0
0 1 0 0 1 0
0 1 0 1 0 0
0 1 0 1 1 0
0 1 1 0 0 0
0 1 1 0 1 0
PLCs-3e-S 11-28/06, 06/04/07
63
0 1 1 1 0 0
0 1 1 1 1 0
1 0 0 0 0 1
1 0 0 0 1 1
1 0 0 0 1 0
1 0 0 1 0 0
1 0 0 1 1 0
1 0 1 1 1 0
1 1 0 0 0 0
1 1 0 0 1 0
1 1 0 1 0 0
1 1 0 1 1 0
1 1 1 0 0 0
1 1 1 0 1 0
1 1 1 1 0 0
1 1 1 1 1 0

(b) Boolean logic expression: Y2 = (X1 + Y1) ( ) X X X 2 3 4 = (X1 + X2) X X X 2 3 4
(c) Logic network diagram

Y1
Y2
X1
X2
X3
X4

(d) Ladder logic diagram

X1
Y2
X2 X3 X4
Y2

9.13 An industrial robot performs a machine loading and unloading operation. A PLC is used as the robot cell
controller. The cell operates as follows: (1) a human worker places a workpart into a nest, (2) the robot reaches
over and picks up the part and places it into an induction heating coil, (3) a time of 10 seconds is allowed for the
heating operation, and (4) the robot reaches in and retrieves the part and places it on an outgoing conveyor. A
limit switch X1 (normally open) will be used in the nest to indicate part presence in step (1). Output contact Y1
will be used to signal the robot to execute step (2) of the work cycle. This is an output contact for the PLC, but an
input interlock for the robot controller. Timer T1 will be used to provide the 10 second delay in step (3). Output
contact Y2 will be used to signal the robot to execute step (4). (a) Construct the ladder logic diagram for the
system. (b) Write the low level language statements for the system using the PLC instruction set in Table 9.10.
Solution: (a) Ladder logic diagram
PLCs-3e-S 11-28/06, 06/04/07
64

X1
Y1
X2
T1
T1
X3 C1
C1
C1
Y2
10 s

(b) Low level language staements:
STR X1
OUT Y1
STR X2
TMR T1 10 (10 specifies timer delay in sec)
STR T1
OR C1
AND NOT X3
OUT C1
STR C1
OUT Y2
9.14 A PLC is used to control the sequence in an automatic drilling operation. A human operator loads and clamps a
raw workpart into a fixture on the drill press table and presses a start button to initiate the automatic cycle. The
drill spindle turns on, feeds down into the part to a certain depth (the depth is determined by limit switch), and
then retracts. The fixture then indexes to a second drilling position, and the drill feed-and-retract is repeated.
After the second drilling operation, the spindle turns off, and the fixture moves back to the first position. The
worker then unloads the finished part and loads another raw part. (a) Specify the input/output variables for this
system operation and define symbols for them (e.g., X1, X2, C1, Y1, etc.). (b) Construct the ladder logic diagram
for the system. (c) Write the low level language statements for the system using the PLC instruction set in Table
9.10.
Solution: (a) Let X1 = spindle up
X2 = spindle at desired depth
X3 = fixture at position 1
X4 = fixture at position 2
X5 = start button
Y1 = spindle on
Y2 = spindle down
Y3 = fixture to position 2
C1 = drill cycle permit
C2 = hole 1 drilled
C3 = hole 2 drilled.
(b) Ladder logic diagram:
PLCs-3e-S 11-28/06, 06/04/07
65

X3
C3
C1
X5 X1
C1 X1
X3 X2 Y2 C1
C2
C2
X2
Y2 X4
C2
C3
C3
C1
X3 C2 C1
Y2
Y1
X4 C3
C2
Y3
X1 C1
Y3

(c) Low level language:
STR NOT C3
OR NOT X1
OUT C10 (C10 used to facilitate parallel circuit)
STR X5
AND X1
AND X3
OR C1
AND C10
OUT C1
STR X2
AND Y2
AND X3
OR C2
AND C1
OUT C2
STR X2
AND Y2
AND X4
OR C3
AND C2
OUT C3
PLCs-3e-S 11-28/06, 06/04/07
66
STR C1
OUT Y1
STR X4
AND NOT C3
OUT C11 (C11 used to facilitate parallel circuit)
STR X3
AND NOT C2
OR C11
AND C1
OUT Y2
STR C2
AND X1
OR Y3
AND C1
OUT Y3
9.15 An industrial furnace is to be controlled as follows: The contacts of a bimetallic strip inside the furnace close if
the temperature falls below the set point, and open when the temperature is above the set point. The contacts
regulate a control relay which turns on and off the heating elements of the furnace. If the door to the furnace is
opened, the heating elements are temporarily turned off until the door is closed. (a) Specify the input/output
variables for this system operation and define symbols for them (e.g., X1, X2, C1, Y1, etc.). (b) Construct the
ladder logic diagram for the system. (c) Write the low level language statements for the system using the PLC
instruction set in Table 9.10.
Solution: (a) Let X1 = temperature below set point, X2 = door closed, Y1 = furnace on.
(b) Ladder logic diagram:

X1
X2
Y1

(c) Low level language:
STR X1
AND X2
OUT Y1