Chapter 5ladderlogic

ME262
Introduction to Microprocessor &

Digital Logic
(PLC and PLC Programming)
Summer 2010
William W. Melek: Introduction to Microprocessor and Digital Logic, ME262, University of Waterloo, S'10
Electrical Circuits
A simple Electric Circuit is a closed connection of Power Supplies ,
Switches/Sensors and Wires. An Electric Circuit consist of voltage loops and current
nodes
The Electrical Circuits can be presented by ladder diagram.

diagram
Sensors/ Switches
Switches
A switch is a mechanical device that either opens or closes sets of contacts inside
th body
the
b d off the
th switch.
it h
There are also multiple contact switches

utilized in electrical circuits. The contacts
in the switch change states from either
open to closed or vice versa, when the
switch is being operated.
operated
Proximity Switches
The proximity switch can be either magnetic, inductive or capacitive. Magnetic
switches are usually adjustable, in that they can be moved along the length of
cylinder body to any desired position.
A magnetic strip attached to the piston gives a magnetic field which is sensed by the
reed switch when it is in its proximity.
Courtesy of Parker
Optical Sensor
The optical switch, as its name implies, uses light to establish the position of objects
that are required to be sensed. The beam type has a sender, light sources and a
receiver. The light source shines a light beam into the receiver. When the light beam
i broken
is
b k by
b an object
bj t the
th state
t t off the
th electrical
l t i l output
t t from
f
he
h receiver
i
changers.
h
Courtesy of Festo
Relays
The relay is widely used in electrical circuits. Applications range from classical
panel built control systems to modern interfaces between the microprocessor and
their power circuits or any applications where reliable galvanic separation is
required between different circuits.
Relay coil
Relay contact
Timer, Counter
These two device are widely used in Electrical Circuits.
Timer contains of coil and contacts. When the timer coil is activated, the timer
mechanism starts working, and as soon as the time reaches the desired pre-set time,
the timer contacts switch over.
The counter also acts as the timer.
Timer contact
Counter contact
Symbols
General normally open toggle switch
General normally close toggle switch

Alternative
Alternative
Pushbutton
Limit switch NO
Temperature sensor
Limit switch NC
Proximity limit switch
Pressure switch
Time delay
Indicator lamp
PLC as a brain in automation and control lines
PLC
Sensors
Actuators
Why PLC?
Increased Reliability
Increased Flexibility
C
Communication
i ti Feature
F t
Better real-time Performance
Lower Cost
Why not PC?
Electric Noise
Operating System
Computing Power
Input/output Connections and Wiring
Software
Shock
D st
Dust
Cost
10
PLC Hardware
Power Supply
Digital
Input
Module
Central Processing Unit

(CPU)
Digital
Output
Module
Memory
Program Data
Analog
Input
Module
Analog
Output
Module
Ethernet
Interface
Profibus
Programming
Device
11
PLC Architecture Block Diagram
12
PLC Size
Nano PLCs
Fitted in shirt pocket and handles up to 16 I/O
Micro
Mi
PLC
PLCs
connected
d up to 32 I/O
/O ddevices
i
Small PLCs
Connected up to 960 I/O in a single Rack
Medium PLCs
Large PLCs
More features such as Analogues modules

Connected to several thousands I/O devices
13
Power Supply Module

Typically, this module takes 110/220 V and provides the low
Typically
voltage (5/12/24 V DC) for the other modules.
CPU Module
The most important PLC-hardware is the central processing
unit (CPU), which corresponds to a computer in structure.
The processes take place in the central control unit. The data,
processedd andd storedd in
i the
h CPU are in
i the
h form
f
off binary
bi
signals. The CPU can usually manage many timers and
counters.
Memory
Communication
C
i ti Port
P t
Serial/parallel, 486 IEEE,..
14
I/O Module
The input/output modules are connected to sensors/actuators to obtain the binary
information from the system and implement the requested logics.
Wiring diagram
for Input
Module with 16
inputs
+
DC
To PLC
Two typical opto-isolators for

AC & DC inputs
AC
To PLC
15
I/O Module
16
Wiring diagram
for output
Module with 16
outputs
Out 1
Out Com
PLC
TTL Output Unit
Out 1
Out 1
Out Com
Out Com
Out 1
Out Com
PLC
PLC
Transistor Sinking
Output (NPN)
Transistor Sourcing
Output (PNP)
PLC
Triac Output
Unit (AC)
17
I/O Module
18
Analogue Input/output Module

The analogue input/output modules are connected to analogue sensors/actuators to
obtain the continuous information (0-10 DC V or 4-20 mA current) from the system
and implement the requested logics. There are different form of analogue input/output
modules in terms of number of inputs/outputs.
inputs/outputs However,
However any module comes with
many ports which can be connected to the sensors or actuators based on the shown
diagrams.
Wiring diagram for

Analogue Input Module
with 8 inputs
19
Wiring
Wi
i diagram
di
for
f
Analogue Output Module
with 8 outputs
20
Interface Module
This module is used to communicate with other PLCs or control systems through
Serial/Parallel, Ethernet, Profibus FMS,VME, etc. A number of standard protocols are
implemented and allow data transfer with a wide variety of stations.
Courtesy of Siemens
21
PLC Programming
g
g
PLC program languages are categorized into three classes:
1.
Statement list program (STL)
2.
Ladder Diagram (LAD)
3.
Function Chart (FUC)
Processor memory structure and organization

Housekeeping
p g memory
y
Used to carry out functions

required for processor operate
(No access by user)
User program
Programs that operate the

PLC in for a particular task
Data table
Input/output , flags, timer,

counter locations
22
Program Files
System
S
fil
files
Reserved
Main ladder/STL/FUC pprogram
g
Data Files
Output
O
t t
Input
Status
Bit
Timer
Counter
Integer
Reserved
Net ork Comm
Network
Communication
nication
User-defined
23
Input/Output Imaging
M
0
I
N
P
U
T
1 IInputt
0 Image
0
MEMORY
Output
O
t t 1
Image
0
1
Data bus
C.P.U.
A.L.U.
O
U
T
P
U
T
K.B.,
Port,
H/D,
Etc.
24
Operating Cycle
Initialization
Set Output
Output
Set
Self-Test
PLC
SCAN
CYCLE
Solve Logic
Solve
Logic
Read Input
Input
Read
25
Read Inputs and Outputs

and copy into memory.
Do the overhead work

required to keep the
process working
properly.
l
1
Service
S
i
Comm
etc.
Input
Scan
Output
Scan
Program
Scan
3
Update Outputs based

on the values in
memory.
Execute PLC program with

Input variable being read
from the memory and the
Output being updated in
memory
memory.
26
Response time
1
IN
RUN
Scan 1
Pulse Stretch
OUT
IN
RUN
OUT
IN
Scan 2
RUN
OUT
Scan 3
Interrupt Function
Scan
IN
RUN
OUT
IN
Scan
IN
RUN
OUT
Pulse Stretch
Interrupt
27
PLC addresses
The following letters are used for the modules (For Siemenss PLCs):
I= Input
C= Counter
C
O= Output
F= Flag
RI= Analogue Input

RI
T= Timer
RO=Analogue
RO
Analogue Output
How to realize the address in a general fashion?
ZXX.YY
bit address or desired I/O
number on module
Type of Module
assigned address of module in PLC rack

I0
O1
O2
0
1
2
Power
supply
3
4
5
6
7
I0.6
28
Ladder Diagram Elements
NO Switch: Normally Open Switch
NC Switch: Normally Closed Switch
NO Output
NC Output
Function Block
FUN (name)
Parameter 1
Parameter 2 (opt)
.
.
Parameter N (opt)
29
Rung
30
Example
Sink
Rung
Output 1
Output_1
Output 2
Output_2
Conditions In
Results Out
Source
31
Digital Logic and Ladder Diagram

AND
X
X
0
0
1
1
Z
X
Y
0
1
0
1
Truth Table
Z
0
0
0
1
Z=XY
OR
X
0
0
1
1
0
1
0
1
0
1
1
1
Truth Table
Z=X+Y
32
NOT
X
Y
X
Truth Table
Y=X
XOR
Z
X
Z
Y
X
0
0
1
1
Y
0
1
0
1
Z
0
1
1
0
Truth Table
Z=X Y
33
Example 1: Program the following Boolean expression by ladder diagram
Z (X Y)
34
General Programming Rules

(Utilized in OMRON PLCs)
Switches can be reused in a ladder diagram:

SW_C
SW_C
SW_D
Output_E
SW_D
END (01)
Any number of switches can be used to generate the rung

condition:
SW_A
SW_B
SW_N
Output_A
SW_A2
SW_AN
END (01)
35
Common Errors
SW_1
Output_1
END (01)
SW_1
Output_1
SW_N
Output_1
Output_NoGood
TIM
000
#0020
END ((01))
Problem:
Causing
g Logical
g
Error !!!
END (01)
36
Important Functions
(OMRON)
SET andd RESET functions

f ti
Set
Button
SET
Set
Button
Output
Reset
Button
Reset
Button
RESET
Output
Output
INC function
Start Count
INC
Start
Count
DMxxxx
DMxxxx
37
TIM and TIMH Functions

Start Time
TIM
xxx
Start
Time
Set Value
Present
V l
Value
TIMxxx
TIMxxx
Output
Output
TIM interval= 0.1 second

TIMH interval= 0.01 second
CNT Function
Start Count
CNT
Reset Count
xxx
Set Value
Start
Count
Reset
Count
Present
Value
CNTxxx
Output
Output
38
CNTR Function
Count UP
Count
Up
CNTR
Count Down
Count
Down
xxx
Reset
Count
Count Down
Set Value
Present
Value
CNTxxx
Output
Output
DIFU Function
Input
p _SW
DIFU
Input_SW
OneShotOut
O Sh tO t
OneShotOut
39
DIFD Function
Input_SW
Input_SW
DIFD
OneShotOut
OneShotOut
MOV Function
Input_SW
MOV
Input_SW
Source
Destination
Source
Destination
2918
0000
2918
40
Status Monitoring
41
The Procedure for writing a PLC program

Control Task
Understanding the required Logic

Allocation List
LAD, STL, FUC programming
Transmission to the PLC
RUN
42
Example
Q: A lamp (H1) is to remain switched on as long as push button S1 and either one
or both of the push buttons S2 and S3 are actuated.
I0
S1
S2
S3
H1
0
0
0
1
0
1
1
0
1
0
1
0
0
0
0
0
1
1
1
0
1
1
1
0
1
Truth table
0
1
1
1
S1
S2
O0
0
1
0
1
H1
S3
-Circuit diagram
43
Allocation List
Designation
Abbrev.
Push button S1
S1
I0.0
Push button S2
S2
I0.1
P h bbutton S3
Push
S3
I0 2
I0.2
H1
O0.0
Light H1
S2S3
S1
S3
00
S3
01
S3
10
11
0
S1
Address
Function
I0.0, I0.1, I0.2 carry 1, as long
as push button actuated
Light is lit when O0.0 carries 1
I0.0
I0.1
O0.0
S1
S2
I0.2
S2
S1S 3
S1S 2
H1 S1 ( S 2 S3 )
44
Example 2:
A conveyor is run by a motor that can move in either direction. The

conveyor moves in the forward direction when output F is turned ON, and moves in the
backward direction if output B is ON.
ON There are two start buttons (one for each direction)
called SF and SB, and a single stop button called STOP. The user has to push STOP before
being able to change the direction of motion of the conveyor. There is also an overload
sensor OL that stops the conveyor if the motor overheats. Write a LAD program (Using CX
Programmer Command of OMRON) for:
a) The conveyor starts moving when SF or SB is depressed (and is not yet moving)
b) The conveyor stops moving when STOP is depressed or OL is ON
45
State Diagram
g
A state diagram is used to show a sequential logic graphically.
Definition of Sequential Logic
The output (s) of a sequential circuit depends on the current

and past states of the inputs
inputs.
State Diagram Elements

A state diagram consists of inputs, outputs, and states. A state of a logic system is a
unique configuration that the system can take.
Combinational Logic that causes
a transition from one state to the
next state
State
Number
Transition
Outputs
STATE
46
State Diagram Elements in a Digital Fashion

Based on the number of states a binary number is given to each state.
state
All combinational logics that
don't cause a transition
Inputs requires for transition

from state 0 to state 1
000
001
Outputs (0)
Outputs (1)
0 to 2
3 to 2
011
Outputs (3)
010
Outputs (2)
4 to 0
2 to 6
110
100
1 to 3
Outputs (6)
4 tto 5
p ((4))
Outputs
6 to 4
7 to 6
101
111
Outputs (5)
Outputs (7)
5 to 7
47
The governed logic can be simplified using the state diagram drawn for the desired system.
This simplification is possible if transitions occur from one state to the other state in which
only
l one bit
bi is
i changed
h
d (e.g.,
(
from
f
state 010 to 011),
011) otherwise
h
i we cannot simplified
i lifi d the
h
equation.
How to write a ladder pprogram

g
from a state diagram
g
Number each state uniquely and allocate enough bits for a state identifier.
For the number of state identifier bits consider SET and RESET functions.
For each output variable, create a rung ORing the states in which it is active.
For each state transition, create a rung as follows:
1.
2.
3.
4.
SET
F2F1F0
F2F1F0
101
F2
F1
100
TIM001
F2
RESET
Stop
TIM001, A, D
X+, Z+, TIM001
F0
F1
Z-, Gr, TIM002

RESET
Stop
Current
State
Transition
C diti
Conditions
New
State
F0
48
Example
A conveyer iis controlled

t ll d by
b a pushbutton
hb tt switch.
it h When
Wh the
th switch
it h is
i depressed
d
d
the conveyer:
Moves forward if it is moving backward,
Moves backward if it is moving forward.

forward
Backward Motion
Motor (M)
Forward Motion
Pushbutton Switch (I)
49
IInputs:
t
Pushbutton Switch (I)
Output:
Motor forward (MF)
Motor backward (MB)
M=0
M=1
MF: ON
MB: ON
States:
State 1 (0)- Conveyer moves forward
State 2 (1)- Conveyer moves backward
50
1. Number each state uniquely and allocate enough bits for a state variable. For
the example, we have two states and hence, one bit is sufficient.
M: State variable
M = 0,
State 1: Conveyer moves forward
M = 11, State 2: Conveyer

Con e er moves
mo es backward
back ard
2. For the number of state variable bits consider SET and RESET functions, (if you
use OMRON PLC
PLCs);
) otherwise
th
i a virtual
i t l relay
l (FLAG) can bbe used.
d
3. For each output variable, create a rung ORing the states in which it is active,
4. Use SET and RESET functions by ANDing the bits of the previous state and the
condition for the transition from the previous state to the new state.
51
MB
MF
I
SET
M
I
RESET
M
52
How to find a simplified expression for states bits

State diagram can be used in deriving simplified expressions for states bits.
bits This
is possible if there is no any double transition from one state to the other state; in
fact only one change in the bits combination from one state to the other state. In
this approach, we try to find the ON and OFF statuses of each bit not the State.
If thats a case, the expression for each bit can be found by:
M X (Y memory)
where X is the turn off signal and Y is the turn on signal for State M.
In order to study the state diagram approach, the following example is solved step
step-byby
step.
53

Chapter 5ladderlogic

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ME262

Introduction to Microprocessor &

The Electrical Circuits can be presented by ladder diagram.

There are also multiple contact switches

General normally close toggle switch

Proximity limit switch

PLC as a brain in automation and control lines

Why not PC?

Central Processing Unit

PLC Architecture Block Diagram

Fitted in shirt pocket and handles up to 16 I/O

Connected up to 960 I/O in a single Rack

More features such as Analogues modules

Power Supply Module

Two typical opto-isolators for

TTL Output Unit

Analogue Input/output Module

Wiring diagram for

Statement list program (STL)

Ladder Diagram (LAD)

Function Chart (FUC)

Processor memory structure and organization

Used to carry out functions

Programs that operate the

Input/output , flags, timer,

Read Inputs and Outputs

Do the overhead work

Update Outputs based

Execute PLC program with

RI= Analogue Input

How to realize the address in a general fashion?

assigned address of module in PLC rack

Ladder Diagram Elements

NO Switch: Normally Open Switch

NC Switch: Normally Closed Switch

Digital Logic and Ladder Diagram

Example 1: Program the following Boolean expression by ladder diagram

General Programming Rules

Switches can be reused in a ladder diagram:

Any number of switches can be used to generate the rung

SET andd RESET functions

TIM and TIMH Functions

TIM interval= 0.1 second

The Procedure for writing a PLC program

Understanding the required Logic

Light is lit when O0.0 carries 1

A conveyor is run by a motor that can move in either direction. The

A state diagram is used to show a sequential logic graphically.

Definition of Sequential Logic

The output (s) of a sequential circuit depends on the current

State Diagram Elements

State Diagram Elements in a Digital Fashion

Inputs requires for transition

How to write a ladder pprogram

Z-, Gr, TIM002

A conveyer iis controlled

Moves forward if it is moving backward,

Moves backward if it is moving forward.

Pushbutton Switch (I)

State 1: Conveyer moves forward

M = 11, State 2: Conveyer

How to find a simplified expression for states bits

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