Chapter 2: Basic Ladder Logic Programming. Computer Aided Manufacturing TECH 4/
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1 Chapter 2: Basic Ladder Logic Programming Computer Aided Manufacturing TECH 4/
2 Ladder Logic Learning objectives Understand basic ladder logic symbol Write ladder logic for simple applications Translate relay ladder logic into PLC ladder logic Computer Aided Manufacturing TECH 4/
3 Simple Ladder Logic Ladder Logic: Primary Programming Language for PLCs. Visual and Graphical language unlike textual high-level, such as C, C++, Java Derived from relay logic diagrams Primitive Logic Operations: OR AND NOT Computer Aided Manufacturing TECH 4/
4 Simple Ladder Logic OR Operation Control Behavior: The light should be on when either switch A is on (i.e., closed) or switch B is on (closed). Otherwise it should be off Task: Implement this behavior using Relay circuit PLC Ladder Logic Computer Aided Manufacturing TECH 4/
5 Simple Ladder Logic OR Operation Possible Combinations of the 2 Switches: (2 2 ) OR Truth Table A B Light OFF OFF OFF OFF ON ON ON OFF ON ON ON ON Computer Aided Manufacturing TECH 4/
6 OR Operation Relay Circuit V+ Com A AR L1 LR Light Com B BR Switches A and B are connected in parallel to relay coils AR & BR resp. When switch A (or switch B) is closed relay coil AR (or BR) gets energized The Normally Open (NO) contact AR (or BR) gets closed Power is transmitted to coil LR Relay coil LR gets energized The NO contact LR gets closed Power is transmitted to the Light bulb Computer Aided Manufacturing TECH 4/
7 OR Operation Relay Ladder Logic Circuit 120v Neutral A AR B BR AR LR BR LR Lamp W Computer Aided Manufacturing TECH 4/
8 OR Operation PLC Ladder Logic V+ A Light Com B Append above to the leading two rungs of relay ladder logic diagram Switch A and Switch B are connected to discrete input channels of the PLC Light is connected to discrete output channel (actuator) of the PLC When input switch A (or switch B) is on the light is on Computer Aided Manufacturing TECH 4/
9 Simple Ladder Logic AND Operation Control Behavior: The light should be on when switch A is on (i.e., closed) and switch B is on (closed). Otherwise it should be off Task: Implement this behavior using Relay circuit PLC Ladder Logic Computer Aided Manufacturing TECH 4/
10 Simple Ladder Logic AND Operation Possible Combinations of the 2 Switches: (2 2 ) AND Truth Table A B Light OFF OFF OFF OFF ON OFF ON OFF OFF ON ON ON Computer Aided Manufacturing TECH 4/
11 AND Operation Relay Circuit V+ Com A AR V+ B BR L1 LR Light Switches A and B are connected in series to relay coils AR & BR resp. When switch A is closed relay coil AR gets energized The Normally Open (NO) contact AR gets closed Power flows to Normally Open (NO) contact BR, where it terminates until BR is energized Subsequently, when BR gets energized, LR is energized, which causes the NO contact LR to close Power is transmitted to the Light bulb What happens if BR is energized before AR? Computer Aided Manufacturing TECH 4/
12 AND Operation PLC Ladder Logic Circuit V+ A B Light Com Computer Aided Manufacturing TECH 4/
13 Simple Ladder Logic NOT Operation Control Behavior: The light comes on only when switch A is on (i.e., closed) and switch B is off (open). Otherwise it should be off Task: Implement this behavior using Relay circuit PLC Ladder Logic Computer Aided Manufacturing TECH 4/
14 Simple Ladder Logic NOT Operation Possible Combinations of the 2 Switches: (2 2 ) NOT Truth Table A B Light OFF OFF OFF OFF ON OFF ON OFF ON ON ON OFF Computer Aided Manufacturing TECH 4/
15 NOT Operation Relay Circuit V+ Com A AR V+ B BR L1 LR Light Switches A and B are connected to relay coils AR & BR resp. When switch A is closed relay coil AR gets energized When switch B is off (on) relay coil BR is not energized (energized) and BR contact is normally-closed (normally-open) Computer Aided Manufacturing TECH 4/
16 NOT Operation PLC Ladder Logic V+ A B Light Com Computer Aided Manufacturing TECH 4/
17 Simple Ladder Logic NAND Operation NAND (NOT AND) Control Behavior: The light comes on only when switch A is off and switch B is off. Otherwise it should be off Task: Implement this behavior using Relay circuit PLC Ladder Logic Computer Aided Manufacturing TECH 4/
18 Simple Ladder Logic NAND Operation Possible Combinations of the 2 Switches: (2 2 ) NAND Truth Table A B Light OFF OFF ON OFF ON ON ON OFF ON ON ON OFF Computer Aided Manufacturing TECH 4/
19 NAND Operation Relay Circuit Computer Aided Manufacturing TECH 4/
20 NAND Operation Ladder Logic Circuit Computer Aided Manufacturing TECH 4/
21 Digital Logic Gates AND AB OR + A + B NAND AB NOR + A + B NOT A Light A Computer Aided Manufacturing TECH 4/
22 Basic Ladder Logic Symbol Normally open contact Passes power (ON) if coil driving the contact is ON (closed) Allen-Bradley calls it XIC - examine If Closed Normally closed contact Passes power (ON) if coil driving the contact is off (open) Allen-Bradley calls it XIO - examine If Open Output or coil If any left-to-right path of inputs passes power, output is energized Allen-Bradley calls it OTE - OuTput Energize Not Output or coil If any left-to-right path of inputs passes power, output is de-energized The IEC standards describe the complete list of ladder logic contact and coil symbols. See also section Computer Aided Manufacturing TECH 4/
23 PLC Ladder Logic Symbols The symbols are ladder logic instructions The PLC scans (executes) the symbols: = on = Closed = True = 1 = off = Open = False = 0 Every PLC manufacturer uses instruction symbols Industry trend is based on IEC Variations in symbols by Manufacturers Allen-Bradley ControlLogix symbols slightly different (Refer 2.3.3) Computer Aided Manufacturing TECH 4/
24 Ladder Logic Diagram 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 thru the contacts to energize the output Input (Condition) Instructions A B C D E F G H K Output Instruction Out1 Out2 Continuous path for logic continuity Power flows Computer Aided Manufacturing TECH 4/
25 Ladder Logic Diagram Instructions Two Classes of Ladder Logic Instructions Input (Condition) Instructions A B C Output Instruction Out1 Output: Appears on extreme RHS of rung always Out1, Out2 D E Input: Any instruction that can replace a contact F G H K Out2 Continuous path for logic continuity Power flows Can contacts appear on the RHS of a coil? Computer Aided Manufacturing TECH 4/
26 Ladder Logic Diagram Function Block Instructions Function Block Instructions Any non-contact instruction: Timer Instruction Counter Instruction Comparison Instruction E H Input Function Block Output Function Block ( ) ( ) Computer Aided Manufacturing TECH 4/
27 Ladder Logic Diagram Example 1 Task: Draw a ladder diagram that will cause the output, pilot light PL2, to be on when selector switch SS2 is closed, push button PB4 is closed and limit switch LS3 is open. (Note: no I/O addresses yet.) Thought Process Identify the output: PL2 PL2 appears on rhs of rung What is the behavior (type of connection to use): sequential operation of all switches series connection Type of contacts to implement output: SS2 closed PB4 closed LS3 open Computer Aided Manufacturing TECH 4/
28 Ladder Logic Diagram Example 1 SS2 PB4 LS3 PL2 Computer Aided Manufacturing TECH 4/
29 Ladder Logic Diagram Example 2 Task: Draw a ladder diagram that is equivalent to the following digital logic diagram A B C D E + Y Y is on when (A is on, B is on and C is off ) or D is on, or E is off What is the Boolean logic expression? Computer Aided Manufacturing TECH 4/
30 Ladder Logic Diagram Example 2 Thought Process Identify the output: Y Coil Y appears on rhs of rung What is the behavior (type of connection to use): The inputs A, B, C for AND gate will be connected in series The D, E inputs for OR gate will be connected in parallel with the output of AND gate Type of contacts to implement output (review the expected behavior again to determine contact types): A is on: B is on: C is off: D is on: E is off: Computer Aided Manufacturing TECH 4/
31 Ladder Logic Diagram Example 2 A B C Y D E What happens if the D contact refers to Y? Computer Aided Manufacturing TECH 4/
32 Ladder Logic Diagram Sealing an output A B C Y Y E Output Y is set (latched) indefinitely Computer Aided Manufacturing TECH 4/
33 Ladder Logic Diagram Dangers Repeated Output Do not repeat normal output coils that refer to the same address A B C Out1 D E Other ladder logic F G H Out1 K The coils for first and second rung refer to Out1 Second rung overrides the logic in first rung Computer Aided Manufacturing TECH 4/
34 Ladder Logic Diagram Dangers Repeated Output - Correction First consider the output Next, consider ALL the conditions that drive the output (Out1) (Implement the conditions in parallel) Computer Aided Manufacturing TECH 4/
35 Ladder Logic Diagram Dangers Use set/seal (latch) and reset (unlatch) together: If a set coil refers to an output there should be a reset coil for that output Reverse power flow in contact matrix is not allowed Power flow one way left to right (solid state relays) Computer Aided Manufacturing TECH 4/
36 Ladder Logic Diagram Dangers Reverse Power Flow This is not allowed: L1 A B C D E PL1 L2 F Reverse Power Flow L1 A B C PL1 L2 If the reverse power flow path is truly needed, then put it as a separate path, where the power flows from left to right: F F D E D B C E Computer Aided Manufacturing TECH 4/
37 Typical PLC Processor Scan Major tasks in a scan Read Inputs Execute Ladder Logic Scan Time Update Outputs Processor must read the state of the physical inputs and set the state of the Physical outputs Computer Aided Manufacturing TECH 4/
38 Typical PLC Processor Scan Order of PLC Processor Scan Read Physical Inputs Scan ladder logic program Update Outputs Start Read Inputs Write the physical outputs Scan Time Program (ladder logic) execution Time to complete above cycle Order of milliseconds What could happen if scan time exceeds more than 200 milliseconds? Computer Aided Manufacturing TECH 4/
39 Typical PLC Processor Scan Scenario 2 The state of actual input devices are copied to an area of the PLC Memory, input data table before the ladder logic program executes State of Actual Input Device Input Image (PLC Memory) Ladder Logic Program Runs Output Image (PLC Memory) State of Actual Output Device As the ladder logic program is scanned, it reads the input data table then writes to a portion of PLC memory - the output data, table as it executes The output data table is copied to the actual output devices after the ladder logic has been scanned. What is the significance of the input and output data tables? Computer Aided Manufacturing TECH 4/
40 Typical PLC Processor Scan Allen-Bradley RSLogix 5000 The execution of PLC Processor controlled by processor mode (Refer to lab 1) Run Mode: Physical Input, Physical Outputs and Ladder logic all get scanned Remote Mode Down load ladder logic to PLC Processor; and initiate scan from the remote terminal Program Mode Ladder logic not scanned Computer Aided Manufacturing TECH 4/
41 Ladder Logic Evaluation For most PLC's, the ladder scan starts at the top of the ladder and proceeds to the bottom of the ladder, examining each rung from left to right. Once a rung is examined, it is not examined again until the next scan. The rungs are not examined in reverse order. The JMP instruction may be used to jump back up the ladder and execute earlier rungs. Use of JMP not recommended Why? Computer Aided Manufacturing TECH 4/
42 Ladder Logic Evaluation Push Button (PB) Start PB: PB Scan PL4 PL1 PL1 1 0 PL3 PL2 PL2 1 0 PB PL3 PL3 1 0 PL2 PL4 PL4 1 0 Physical Input: PB Physical Outputs: PL1, PL2, PL3 and PL4 Start of PLC scans State of PLC image memory for I/O devices: Computer Aided Manufacturing TECH 4/
43 Ladder Logic Evaluation Push Button (PB) Scan 1: Only the state of PB changes to ON (1) during the scan Scan 2: The ON state of PB is copied into Input data table before Ladder logic is scanned When rung 1 is scanned PL1 is still off (o) When rung 2 is scanned PL2 is still off (o) Why? What is the value of PL4 and PL3 in Output Data table? When rung 3 is scanned the Value of PL3 in the output data table changes to 1 Why? When rung 4 is scanned, the Value of PL4 in the output data table remains at off (0). Why? At the end of scan 2 the values in Output data table are copied to the Physical Output Devices. PL 3 turns on Computer Aided Manufacturing TECH 4/
44 Ladder Logic Evaluation Push Button (PB) Scan 3: When rung 1 is scanned the value of PL4 in output data table is still 0 PL1 in output data table remains 0 When rung 2 is scanned the value of PL3 in Output Data table is currently 1 value of PL2 in Output Data table changes to 1 When rung 3 is scanned the Value of PB in the input data table is still1 Value of PL3 in Output data table remains at 1 When rung 4 is scanned Value of PL2 in the output data table is now 1 so the value of PL4 in the Output Data table changes to 1 At the end of scan 3 the values in Output data table are copied to the Physical Output Devices: PL2 and PL4 turn on simultaneously (PL3 remains on) Computer Aided Manufacturing TECH 4/
45 Ladder Logic Evaluation Push Button (PB) Scan 4: When rung 1 value of PL4 in output data table is now 1 value of PL1 in output data table changes to 1 When rung 2 is scanned the value of PL3 in Output Data table is still 1 value of PL2 in Output Data table remains at 1 When rung 3 is scanned the Value of PB in the input data table is still1 Value of PL3 in Output data table remains at 1 When rung 4 is scanned Value of PL2 in the output data table is still 1 so the value of PL4 in the Output Data table remains at 1 At the end of scan 4 the values in Output data table are copied to the Physical Output Devices: PL1 turns on (PL2, PL3 and PL4 remain on) Computer Aided Manufacturing TECH 4/
46 Ladder Logic Evaluation Push Button (PB) Scans 5 and 6: Nothing Changes Scans 7 9 : Similar to Scans 2 4 except that state changes from 1 (on) to 0 (off) Computer Aided Manufacturing TECH 4/
47 Ladder Logic Evaluation Push Button (PB) Scan Timing Diagram I/O Terminal: I/O Data Table: Computer Aided Manufacturing TECH 4/
48 Scan 1 Scan 2 Scan 4 Scan 6 Scan 8 Scan 10 Scan 12 Scan 14 Ladder Logic Evaluation Push Button (PB1) Assume rungs are scanned from top - down PB1 PB1 Int3 Int3 Int2 Int1 Int1 Int2 PB1 1 0 Int2 Int1 1 0 PB1 Int3 Int2 1 0 Int2 PL1 Int3 1 0 Physical Input: PB1 Physical Output: PL1 PL1 1 0 Computer Aided Manufacturing TECH 4/
49 Ladder Logic Evaluation Push Button (PB1) Scan 1: Only the state of PB1 changes to ON (1) during the scan, new state copied at next scan PB1 Int3 Int2 Int1 Scan 2: The ON state of PB1 is copied into Input data table before Ladder logic is scanned When rung 1 is scanned, PB1 is ON, Int3 is off so power goes to Int2, But Int2 is off Int1 is off (0) When rung 2 is scanned PB1 is ON, Power goes thru Int3 and Int1 Int2 is On When rung 3 is scanned the Value of PB1 in the input data table is now 1 so Int3 is energized and Int3 contact is ON When rung 4 is scanned, the Value of Int2 in the PLC memory is now 1 so the value of PL1 in the Output data table changes to 1 PB1 Int2 PB1 Int2 Int3 Int1 Int2 Int3 PL1 At the end of scan 2 the values in Output data table are copied to the Physical Output Devices. PL1 turns on Computer Aided Manufacturing TECH 4/
50 Ladder Logic Evaluation Push Button (PB1) Scan 3: No change in the rung output coils When rung 1 is scanned There is continuity thru PB1 and Int2 but not Int3 PB1 Int3 Int2 Int1 When rung 2 is scanned no continuity thru top branch But continuity thru lower branch Int2 remains ON PB1 Int2 Int3 Int1 Int2 PB1 Int3 Int2 PL1 At the end of scan 3 the values in Output data table are copied to the Physical Output Devices. PL1 remains on Computer Aided Manufacturing TECH 4/
51 Ladder Logic Evaluation Push Button (PB1) Scans 4-5: PB1 Int3 Int2 Int1 No change in the rung output coils because there is no change in the contacts PB1 Int3 Int1 Int2 Int2 PB1 Int3 Int2 PL1 At the end of scans 4 and 5 the values in Output data table are copied to the Physical Output Devices. PL1 remains on Computer Aided Manufacturing TECH 4/
52 Discrete Input/Output An actual PLC has connections to the real" world, and is not just ladder logic. An example hard-wired ladder circuit Computer Aided Manufacturing TECH 4/
53 Programming with NC Contacts If you want action" (turn ON) when switch is closed (relay energized), use. If you want action" (turn ON) when switch is open (relay de-energized), use. In the rungs, think of the contact as a symbol, = ON = CLOSED = TRUE = 1 = OFF = OPEN = FALSE = 0 Note: this is probably the most confusing concept in ladder logic Computer Aided Manufacturing TECH 4/
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