PROGRAMMABLE LOGIC CONTROLLERS AND LADDER LOGIC

Programmable Logic Controllers control most of the mechanical processes in many areas of production Very simple in operation, complex in design

Overview

1. 2. 3. 4.

PLC and Controls History PLC Components Ladder Logic Programming of Ladder Logic

1. PLC and Controls History

Large amount of work required connecting wires Difficulty with changes or replacements Difficulty in finding errors; requiring skillful/experienced work force When a problem occurs, hold-up time is indefinite, usually long Too many moving parts

Advantages of PLCs
Number of wires reduced by approximately 80% Fast and easy error detection. No change in wiring to change program Needs fewer spare parts Cheaper when large number of I/O instruments are needed Less moving parts Compact Cost effective for installation/maintenance

2. PLC Components

Definition Components PLC Operation

Definition
A Programmable controller is a solid state user programmable control system with functions to control logic, sequencing, timing, arithmetic data manipulation and counting capabilities.

Components
CPU Memory Areas Circuits to input or output data

Basically, a big box of math

Specific Components
Input Relays (contacts) Internal Utility Relays

Output Relays (coils)

Counters

Data Storage

Timers

PLC Operation
Continually scans ladder diagram Consists of 3 important steps

Rung Scanning

3. Ladder Logic
Definition Introduction Comparison to Relay Logic

Definition
One form of drawing electrical logic schematics Very popular for PLCs Originally invented for use with relays

Comparison to Relay Logic

First used for technicians, electricians & engineers Still first choice for most technicians, electricians, etc.

Relay Logic
Ladder Logic

Relay Logic

 Jog function added to previous relay circuit 1 component added 3 wires added

 Two status indicators added 6 additional wires

 Most widely used program Shown here as a very small program

4. Ladder Logic Programming

Introduction Basics NO/NC Contacts/Coils AND & OR Gates Timers and Counters Building a PLC Ladder Logic Programming

Introduction
First PLC programming system used Borrowed heavily from relay diagrams plant electricians already knew Each rung solved left to right

Basics
NO Contact NO Coil (Output) NC Contact NC Coil (Output)

AND Gate

OR Gate

Timers
Very simple concept, it times 2 basic types, ondelay and off-delay Still sends logic as its output

Counters
Counts number of times a lever is pulled, a button is pushed, etc. 3 types Up Counter Down Counter Up-Down Counter

Building a PLC/Ladder Logic Program

To illustrate, will start in relay logic, convert to ladder logic at end Will need to remove/replace some components

 Overload Device Removed All components in relay diagram because wires are run to them Is not addressed in ladder logic Motor relay is not a physical entity in ladder logic as in relay logic

 Jog Function added Usually added for ease in troubleshooting purposes only. Now two ways to run motor press start, or press and hold Jog button

 Status Indicators added Green for output on Red for output off

 Relay Logic converted to Ladder Logic Diagram Much fewer hard wired components Double Pole Pushbutton for Jog switched to Single Pole Instead of motor relays, PLC just checks state of motor output