Saint Louis University

SCHOOL OF ENGINEERING AND ARCHITECTURE

Department of Chemical Engineering

PROGRAMMABLE LOGIC CONTROL

Presented to the Faculty of Chemical Engineering

In Partial Fulfillment of the Requirements for the Degree

Bachelor of Science in Chemical Engineering

Submitted by:

Acnam,
Balajadia,
Gano, Perari
Cucal, Deanne L.
Grace, Cherry Mae
Mosing, Gizikuh
Tayco, Vay Ann

Submitted to:

Engr. Ronald Ringor

 PROGRAMMABLE LOGIC CONTROL (PLC)

Incorporating logic and hardwiring it into the older MCC-based controls requires a
diagram to guide electricians in the construction process. These diagrams are called ladder
diagrams. Having accurate ladder drawings was important because major modifications in
control required time-consuming and expensive rewiring. Any time a change was made to the
wiring, or the control system the ladder diagrams had to be updated for future reference and
troubleshooting purposes. This, too, was an expensive and time consuming process.

Reading Ladder Diagrams

Ladder logic diagrams derive their name from the ladder-like graphical symbolism used
to depict PLC logic. The vertical lines, which look like upright ladder support indicate power to
an electrical system. The horizontal lines, which look like the rungs of a ladder, depict the
availability of power to a device of trough a device. “Gates” in the horizontal lines indicate
whether current is actually flowing through a particular device.

Ladder logic diagrams are read from left to right and from top to bottom, just like a page
of text would be read. Generally, devices are rearranged in order of decreasing impact. Devices
that have a larger impact on the system are generally shown above devices with relatively minor
impact. Contacts, relays, and other devices are shown in their shelf position. For instance, a
normally open (NO) contact will be shown as open.

Consider the diagram on the right. Switch A is A X

considered normally open (NO) because there is no
diagonal line intersecting it. When power is applied to this
Ladder Diagram (Power On)
circuit relay, X remains de-energized because the circuit
path is broken by switch A. However, if there had been a
B X
diagonal line, like in the second diagram, the switch would
be considered normally closed (NC). When power is applied
Ladder Diagram (Power Off)
to this circuit relay, X is energized because the closed
switch A enables current to flow in the circuit.
 Listed below are some practical tips for incorporating PLCs in a system:

1. Instrument and electrical (I&E) technicians are typically quite good with PLCs and
instrumentation. However, they may lack process knowledge. Process technicians
provide a process liaison to work with the instrument technicians.
2. Should it be necessary to temporarily bypass safety systems, management or change
procedures must be strictly adhered to. A bypass, or “jumper” as it is called, should be
documented and removed immediately after the completion of work.
3. Before issuing a maintenance work permit to someone working on a PLC, plan the job
thoroughly. It is not uncommon to see an entire plant shutdown accidentally because a
PLC is being repaired or modified. Thus, process and maintenance technicians need to
work together when planning PLC modification.

Modern PLCs allow logic changes to be easily programmed using desktop personal
computers. In addition, these PLCs allow changes to ladder diagrams to be automatically
recorded during the programming process, thus saving considerable amounts of time and money.
PLCs may be stand–alone units controlling only a single operation or they may be integrated into
a broader control scheme such as modern distributed control system (DCS)

Ladder logic is the main programming method used for Programmable Logic Control
(PLC). It was a method intentionally developed to mimic relay logic. By using a familiar logic
structure, the amount of retraining needed for engineers and maintenance technicians was
significantly reduced. While modern control system do still use relays, they are seldom used for
logic.

PLCs gained their name from its ability to program logic into these controls. Some of
these examples are on application of and/or, if/then, or true/false. These are employed for
choosing decisions and the corresponding action.

Input The diagram on the left is one example of

employing logic in a control system. For a set
parameter or decision (i.e. measured level, temperature,

Decision

True False
pressure), the system will do the action that will satisfy this parameter.

On/off instructions such as these are expressed as binary code in the computer. Because
of this functionality, PLCs are commonly used for safety-related applications and make up the
heart of emergency shutdown (ESD) systems.

PLC functionality can be expressed as a three-part process:

1. Scan inputs from switches or transmitters,

2. Execute logic or control within the PLC,
3. Set outputs based upon results or logic.

Programming a PLC
Hot rail Neutral rail
There are a number of ways that a
PLC can be programmed. These include A B X
wiring diagrams, C++, Java or other
computer languages. However, ladder
C D G Y
diagrams tend to be the method most
plant personnel are familiar with and are,
therefore, the most commonly used
E F H
method for interfacing with a PLC. An
Inputs Outputs
example of ladder logic can be seen in in
figure on the right.

In the figure, the vertical lines on the left and right are the power source “rails”. In
between the left rail and the right rail are horizontal lines or “rungs”. On these rungs are a
combination of inputs and outputs. Inputs are entered into the system by sensors or switches.
Outputs exit the system and are sent to devices such as lights and motors that are outside the
PLC. If the inputs on the ladder diagram are opened or closed in the right combination, the
power can flow from the left rail, through the inputs, to the power outputs, and finally to the
right rail.
 To summarize all these information, Computer-based programmable logic controllers
(PLCs) are relatively small, stand-alone, easily programmed computers that can be used to
control various processes. Prior to the application of PLCs, logic tasks were accomplished
by hard-wired relays, switches, or contacts housed in large metal cabinets called motor
control centers (MCCs). MCCs controlled the starting, stopping, and sequencing of motors
and other devices. However, PLCs now perform these functions faster and with greater
reliability, more sophisticated control, more flexibility, less cost, and less downtime.

There are many ways to program PLCs; however, the most common method is through
the use of ladder logic. Ladder logic, which was intentionally developed to mimic relay logic,
is used because engineers and maintenance technicians were already familiar with it, and
therefore required less training.

Ladder logic functions primarily as a series of “and/or”, “if/then”, or “true/false”

statements and is represented through drawings called ladder diagrams. When reading ladder
diagrams, it is important to note which devices are listed toward the top, since devices that
have a larger impact on the system are generally shown above devices with relatively minor
impact. It is also important to note that PLC executes ladder logic one rung at a time.

Ladder diagrams show the logic of the controls but they are not used to build the system,
a wiring diagram is used for that. But the wiring diagram wouldn’t be used to trouble shoot
with or show functionality, that’s where the ladder is most useful.
L1 START L2
STOP O.L.
M
M
Figure 1: Standard motor control
2 3 circuit
When viewing the pictorial version of the controls as in standard motor control circuit,
one can see that the devices on a rung of the ladder are in series reading horizontally and in
parallel reading vertically. Control voltage is supplied to the vertical rails, L1 being hot and
L2 being common or ground. In Figure 1 we see a normally closed (N.C.) stop button and a
normally open (N.O.) start button and a motor starter. Normally open switch won't conduct
electricity until it is pressed down, and normally closed switch will conduct electricity until it
is pressed. The circle with the M represents the coil of a relay, not the actual motor. The M
contact is physically part of the starter and actuates with the coil. The contact labeled O.L.
(over load) is also part of the starter and is a circuit breaker tripped by over current in the
motor legs. The M contact is called the seal contact. Without it, the motor would run as long
as someone held down the start button and would stop when released. With it, the power is
allowed to flow through the start button to energize the coil, which closes the M contact,
maintaining the complete circuit when the start button is released. To stop the motor, any
element in series with the coil can break the circuit, in this case the stop button.
START O.L.
L1 STOP L2
M
M JOG

2 3
Figure 2: Motor circuit with jog

In figure 2 the jog button is added which closes on the very bottom rung and opens on the
middle rung when pushed.
START O.L.
L1 STOP L2
M
M

M 2 3 LAMP 1
G
M LAMP 2
R
Figure 3: Motor circuit with indicator lights

In Figure 3, the light/s tell/s if the motor has been energized or not. The M coil in the
second rung is a normally closed contact and the M coil in the third rung is a normally open
contact.

One purpose of this is to perform Boolean or digital logic. AND, OR, NOT,
EXCLUSIVE OR, NOR, and NAND circuits are common in ladder logic and parallel
designs found in digital logic circuits. Simple circuits can be combined into larger circuits to
perform very complicated tasks. PLCs use the same type of logic as does digital logic texts.
Some common digital and ladder logic equivalent circuits follow:

AND
Input A Input B Output X
0 0 0
X
A B
0 1 0
1 0 0
1 1 1
A*B=X
A
X
B

OR
Input A Input B Output X
0 0 0 X
A
0 1 1
1 0 1
1 1 1
B
A A+B=X
X
B

NAND
X
Input A Input B Output X A
0 0 1
0 1 1
B
1 0 1
A*B=X
1 1 0
 A
X
B

NOR
Input A Input B Output X
0 0 1 X
A B
0 1 0
1 0 0
1 1 0 A+B=X

A
X
B

XOR
Input A Input B Output X X
A B
0 0 0
0 1 1
1 0 1 A B
1 1 0
(A*B) + (A*B) = X
A
X
B

Input A Output X
0 1
X
1 0 A

A X A =X