PLC

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George W. Woodruff School of Mechanical Engineering, Georgia Tech

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Section Objectives:
Before the invention of the Programmable Logic Controller
(PLC), most industrial control was done using relay control
panels.
Switches and relays can be arranged in circuits to make
logical decisions. Output from these circuits can be used to
drive loads such as motors, heaters, or electromagnetic
coils. A relay control panel is comprised of a single to
thousands of these circuits.
In this Section, relay control panels will be presented.
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Relay Control Panel Components : Switch
2
2
1
1
3
3
Off: contacts 1 and 2 connected On: contacts 1 and 3 connected
Pins 1 and 2 are normally closed since they are connected when the
switch is off. T Pins 1 and 2 are not connected when the switch is on.
Pins 1 and 3 are normally open since they are not connected when the
switch is off. Pins 1 and 3 are connected when the switch is on.
(Note: Although this is a toggle switch, this switch can symbolize any type
of input source such as push button switches, sensors, power supplies,
etc. in this lecture.)
ME6405ME6405Relay Control Panel Components : Coil
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Coil off Coil on
(Note: Although this is really an electromagnetic coil, this can symbolize

any load such as a pump, dc motor, heating element, light, etc. for this
lecture.)
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Relay Control Panel Components : Relay
32
32
Off: Coil off, contacts ON: Coil on, contacts
1 and 2 connected 1 and 3 connected
A relay is a combination of coil and switch.
With coil off, the switch goes to its normal position off.
With coil on, the switch is pulled by electromagnetic force to its on

position.
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Relay Logic : NOT
Using one switch, a logical NOT operation can
be constructed. An example is given below:
NOT Switch 1 = Coil
V+ Switch 1
Coil
2
3
1
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Relay Logic : NOT (Continued)
NOT Switch 1 off = Coil on

V+ Switch
1
Coil
2
3
1
NOT Switch 1 on = Coil off
V+ Switch 1
Coil
2
3
1
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Relay Logic : AND
Using two switches, a logical AND operation can
Switch 1 AND Switch 2 = Coil
V+ Switch 1 Switch 2 Coil
2
3
1
2
3
1
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Relay Logic : AND (continued)
Switch 1 off AND Switch 2 off = Coil off
2
3
1
2
3
1
Switch 1 on AND Switch 2 off = Coil off
2
3
1
2
3
1
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Relay Logic : AND (continued)
Switch 1 off AND Switch 2 on = Coil off
2
3
1
2
3
1
Switch 1 on AND Switch 2 on = Coil on
2
3
1
2
3
1
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Relay Logic : OR
Using two switches, a logical OR operation can
Switch 1 OR Switch 2 = Coil
V+ Switch 1
2 Coil
1
3
Switch 2
2
1
3

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Relay Logic : OR
Switch 1 off OR Switch 2 off = Coil off
V+ Switch 1
2 Coil
1
3
Switch 2
2
1
3

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Relay Logic : OR
Switch 1 on OR Switch 2 off = Coil on
V+ Switch 1
2 Coil
1
3
Switch 2
2
1
3

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Relay Logic : OR
Switch 1 off OR Switch 2 on = Coil on
V+ Switch 1
2 Coil
1
3
Switch 2
2
1
3

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Relay Logic : OR
Switch 1 on OR Switch 2 on = Coil on
V+ Switch 1
2 Coil
1
3
Switch 2
2
1
3

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Relay Logic : XOR
Using two switches and four relays, a logical XOR operation can be
constructed. An example is given below:
Switch 1 XOR Switch 2 = Coil
V+
2
3
1
Switch 1
Switch 2
2
3
1
1
2
1
3 2
1 1
3 23 2
V+ V+
3
Coil
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Relay Logic : XOR (continued)
Switch 1 off XOR Switch 2 off = Coil off
V+
2
3
1
Switch 1
Switch 2
2
3
1
1
2
1
3 2
1 1
3 23 2
V+ V+
3
Coil
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Switch 1 on XOR Switch 2 off = Coil on
V+
V+
V+
2
1
2
2
2
3
1
Switch 1
Switch 2
2
3
1
1
2
1
3
1
33
3
Coil
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Switch 1 off XOR Switch 2 on = Coil on
V+
V+
V+
2
3
1
1
23
1
3 2
1
3 2
1
3 2
Switch 1
Switch 2
2
3
1
Coil
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Switch 1 on XOR Switch 2 on = Coil off
2
3
1
1
23
1
3 2
1
3 2
1
3 2
V+ Switch 1
Switch 2
2
3
1
V+ V+
Coil
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Problems with relay control panels:
Mechanical Relays and switches failed regularly (coil failure, contact

wear and contamination, etc.)
Difficult to diagnose problems and replace relays and switches
Difficult to change hardwired logic (example: changing an OR circuit
to XOR )
Consumed a lot of power
To address these problems, Richard E. Morley of Bedford
Associates invented the first PLC as a consulting project for
General Electric in 1968. Bedford Associates is currently named
Modicon and is a supplier of PLCs.

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Section Objectives:
Basic PLC Components needed to replace relay control
panels will be presented. These include:
Isolated Power Supply
Digital Input and Output pins ( DI/0)

Micro-controller
Memory
(Note: Advanced features such as Timers, Interrupts, Counters, etc.
will not be discussed in this lecture)
For this lecture, Siemens A&D S7
314C-2 PtP PLC installed in the
Mechatronics Laboratory will be used
as an example.
Siemens 314C-2 PtP

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Basic PLC: Isolated Power Supply
Every PLC has an external or internal Isolated Power Supply.

Isolated Power Supplies can have more than one isolated
output.
One isolated output is reserved for the PLC micro-controller. The
rest is reserved for other components such as DI/O.
Normally Power supplies are high voltage. Typically 24 Volts for
industrial PLCs.
The S7 314C-2 PtP PLC uses the
Siemens A&D PS307 5A power
supply. The PS307 5A can source
5
amps of current at 24 volts. The PS307
5A has 3 isolated outputs.
Siemens PS307 5A
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Basic PLC: Micro-controller
Every PLC at least one micro-controller

The S7 314C-2 PtP PLC uses a custom micro-controller.
Designed by Siemens A&D and manufactured by Infineon
Technologies AD.
Part Number:
Infineon
Siemens A&
D
IBC 16
SXA1020A-
E
S7 Controller
Specifications not given in documentation

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Basic PLC: Digital Inputs and Outputs (DI/Os)
DI/Os are electrically isolated from the micro-controller

The number of DI/Os can be increased by adding additional DI/O
modules.
Example:
The S7 314C-2 PtP PLC has 16 digital
outputs and 24 digital inputs. Can be
expanded up to 1024 DI/Os by adding
additional DI/O modules.
SM232 DI/O module

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Basic PLC: Memory
Memory on a PLC is separated into 3 main areas:
LOAD Memory
Can be RAM (dynamic) or EEPROM (retentive)

Used to store user programs
For S7 314C-2 PtP PLC : LOAD Memory located on memory card
WORK Memory
Memory is RAM
When PLC starts, Program is copied from LOAD memory to
WORK memory. The program is then executed from Work
memory.
For S7 314C-2 PtP PLC: 48K bytes of WORK memory
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Basic PLC: Memory ( Continued)
SYSTEM Memory
Memory is RAM
Is used by micro-controller to implement counters, timers, interrupt
stacks, etc..
Contains a bit for each D I/0
Contains Marker Memory . Marker memory is a free area of RAM
that can be used by the programmer. (In S7 314C-2 PtP, 258
bytes are available as Marker Memory)
Contains Process Input and Output Images. Periodically the PLC
will store the states of the inputs to the Process Input Image and
Process Output Image to the output. (In S7 314C-2 PtP, this is
limited to the first 128 bytes of input information and 128 bytes of
output information.)
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Section Objectives:
Initially PLCs were used to directly replace relay control
panels. To directly replace relay control panels based on
mechanical relays with PLCs based on a micro-controller
presented challenges. These challenges and solutions will
be discussed.
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Transition:A Simplified Programmer s Model
In the simplified programmer s model of relay logic, all inputs I1, I2, .., Im go
into each relay logic section. Each relay logic section then produces an
output Q.
Relay Logic Section 1

I1,I2, ,Im
Q1
I1,I2, ,Im
Q2
.
.
.
Relay Logic Section n

I1,I2, ,Im
Qn
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Transition: Relay control panel execution of Model
A relay control panel will execute all relay logic sections in parallel since
each switch is capable of powering many coils at a time. If any input
changes at time t0 then all the relay logic sections will update the outputs
at time t1.
Q1 changes at t1
I1,I2, ,Im changes at t0
Q2 changes at t1
.
.
.
Qn changes at t1

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Transition: PLC execution of Model
A PLC will execute all relay logic sections in series since a micro-
controller can execute only one instruction at a time. If any input changes
at time t0 then relay logic section 1 will update Q1 at t1, relay logic section
2 will update Q2 at t2, . , and relay logic section n will update Qn at tn.
Q1 changes at t1
Q2 changes at t2
.
.
.
Qn changes at tn

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Transition: Differences in Relay Control Panel vs.
PLC execution of Model
Difference 1:
Relay Control Panel The maximum time any change in input is reflected in any out
put is t1.
PLC The maximum time any change in input is reflected in any output is t1+t2+ +tN.
Difference 2:
Relay Control Panel Since this is made from analogue components. It is possible
to replace
a logic section without stopping execution of other logic sections if wired corr
ectly.
PLC This is made with a digital micro-controller. The micro-controller must be h
alted to
replace a logic section. All other logic sections will stop operation.
Difference 3:
Relay Control Panel Since parallel execution of logic sections, all outputs are
a function of
one set of inputs.
PLC Since serial execution of logic sections, all outputs may not be a function
of one set of
inputs. (example: input I2 may change as the micro-controller is processing Logi
c section
2. Therefore Q1 and Q2 are based on different inputs)
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Transition: PLC Operation
To minimize the effects of differences between the Relay Control Panel and PLC
execution of the programming model, the PLC operates in the following manner:
Warm Restart
Update Process Image Input
User Program
Update Process Image Output
PLC System Processes
scan cycle
Steps:
PLC Restarts (Warm Restart)

Reads Inputs and updates Process Input
Image
Executes User Program Once
Writes Process Output Image to Outputs
Take care of system processes ( such as
communications with other PLCs, updating
user program, etc..)
Loop Back to step 2
Steps 2 through 5 is called a scan cycle. (Note:
some people may refer to a PLC as a
Programmable Loop Controller because of
the scan cycle loop.)
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Transition: PLC Operation
To Minimize Difference 1:
Time to complete a scan cycle can be set by user. If PLC violates the scan cycle
, an interrupt
routine can be run or the PLC will halt execution. (For S7 314C-2 PtP, maximum s
can
cycle allowed is 6 sec)
If a part of the user program is replaced, the new part is written first to LOAD
memory. During
step 5, PLC System Processes, the new part is copied into WORK memory from LOAD
Memory. During the next scan cycle, the new part of the user program will be exe
cuted.
If the programmer uses the inputs stored in the Process Input Image, the user pr
ogram will
have access to the same inputs per scan cycle. Also if the programmer, writes ou
tputs to
the Process Output Image, all the outputs will be updated simultaneously during
step 4,
Update Process Output Image.
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Section Objectives:
The biggest transition from relay control panels to PLCs
was the transition from the hard wired relay logic to logic
defined by user program. In order to allow established relay
logic users to program the PLC, a visual programming
language that looks like a relay control panel was created.
This visual programming language is called Ladder Logic .
In this section, basic Ladder Logic will be presented.
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Ladder Logic: System Memory Addressing
To address a bit of memory

___ ___ . __
_
Memory Area Byte Address Bit Number
Notation
To address a byte, word, or double word
Memory Area Size of Addressed Byte Address

Notation Memory Notation
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Ladder Logic: System Memory Addressing (continued)
Memory Area Notations:

Notation Memory Area
I Process Input Image
Q Process Output Image
M Marker Memory
PI Peripheral Input ( Actual Input Pins)
PQ Peripheral Output ( Actual Output Pins)
T Timer Storage Area
C Counter Storage Area
L Local Memory of current Data Block
DB Data Block Memory
(Note: Advanced features such as Timers, Counters, Data
Blocks will not be discussed in this lecture)
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Size of Addressed Memory Notations:

Notation Size of Addressed Memory
B Byte (8 bits)
W Word (16 bits)
D Double Word (32 bits)
Byte Address:
Each Memory Area is addressed in one byte increments
starting at byte 0.
Bit Number:
MSBit is 7 and LSBit is 0
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Examples:
MB0
M1.3
(Note: only bit 3 of
MW1
Marker Area byte 1)
MD3
MD4
Marker Area
Byte 0
Byte 1
Byte 2
Byte 3
Byte 4
Byte 5
Byte 6
Byte 7
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Examples:
PIB1PI2.5
(Note: only bit 5 of
Peripherial Input Area byte 2)
PID4
Peripheral Input
Area
Byte 0
Byte 1
Byte 2
Byte 3
Byte 4
Byte 5
Byte 6
Byte 7
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Ladder Logic : The Ladder
A ladder logic program has a ladder look to it. The sides of the ladder
are the power rail on the left and ground rail on the right. The rungs of the
ladder consists of Virtual Relay Components. (Note: Rungs are called
Networks in Step 7)
Virtual Relay Components
Power RailGround Rail
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Ladder Logic : Virtual Relays
Any Marker or Function Block memory bit can be one or more virtual relays.
If memory bit is 0, the coils of virtual relays associated with the bit are off.
If
memory bit is 1, the coils of virtual relays associated with the bit are on.
Any D I/O memory bit ( Peripheral or Process Image) is a virtual relay for a
digital input or output pin of the PLC.
Mechanical Relay
1
32
Virtual Relay Components:
Normally Open Switch ( equivalent to pins 1

and 3 of Mechanical Relay. If this switch is
closed for a virtual digital output relay, the
digital output pin is high. If this switch is open
for a virtual digital output relay, the digital
output pin is low )
Normally Closed Switch ( equivalent to pins 1
and 2 of Mechanical Relay)
Coil ( equivalent to coil of Mechanical Relay.
Not available for virtual digital input relays)
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Ladder Logic: Rules for converting Relay Logic
to Ladder Logic
Each external switch must be connected to an input pin of

a
PLC.
Each external coil or load must be connected to an output pin of
a PLC.
The relay logic must be recreated using virtual input and output
relays associated with the input and output pins.
Only possible paths from power to ground though virtual relays
need to be recreated in Ladder Logic.

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Ladder Logic : NOT
NOT Switch 1 = Coil
From Relay Logic:
V+ Switch 1
Coil
2
3
1
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Ladder Logic : NOT (continued)
Relay Logic rewired to include Virtual Input and Output Relays:
V+
Coil
3
Switch 1
2
1 1
3 2
1
3 2
V+
V+
Inside PLC
Virtual Output
Relay at Q0.0
Virtual Input
Relay at I0.0
(Note: Wired to PLC
Input Pin Associated
with Virtual Input
Relay I0.0) (Note: Wired to PLC
Output Pin Associated
with Virtual Output
Relay Q0.0)
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Ladder Logic : NOT (continued)
Ladder Logic Equivalent:
Switch 1 is wired to PLC input pin associated with Virtual Input Relay
I0.0
Coil is wired to PLC output pin associated with Virtual Output Relay
Q0.0
I0.0 Q0.0

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Ladder Logic : AND

Switch 1 AND Switch 2 = Coil
From Relay Logic:
2
3
1
2
3
1
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Ladder Logic : AND (continued)
V+ Switch 1
1
(Note: Wired to PLC
with Virtual Input
Relay I0.0)
V+ Switch 2
1
(Note: Wired to PLC
with Virtual Input
Relay I0.1)
Virtual Input
Relay at I0.1
3
2
1
3 2
V+
V+
1
3 2
Inside PLC
Virtual Output
Relay at Q0.0
Virtual Input
Relay at I0.0
2
1
3 2
Coil
(Note: Wired to PLC

with Virtual Output
Relay Q0.0)
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Ladder Logic : AND (continued)
I0.0
I0.1
Q0.0
I0.0 Q0.0I0.1
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Ladder Logic : OR
From Relay Logic:
V+ Switch 1
2 Coil
1
3
Switch 2
2
1
3

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Ladder Logic : OR (continued)
V+ Switch 1
1
(Note: Wired to PLC
with Virtual Input
Relay I0.0)
V+ Switch 2
1
(Note: Wired to PLC
with Virtual Input
Relay I0.1)
Virtual Input
Relay at I0.1
3
2
1
3 2
V+
V+
1
3 2
Inside PLC
Virtual Output
Relay at Q0.0
Virtual Input
Relay at I0.0
2
1
3 2
V+
Coil
(Note: Wired to PLC

with Virtual Output
Relay Q0.0)
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I0.0
I0.1
Q0.0
I0.0
I0.1
Q0.0

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Ladder Logic : XOR

From Relay Logic:
V+
2
3
1
Switch 1
Switch 2
2
3
1
1
2
1
3 2
1 1
3 23 2
V+ V+
3
Coil
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Ladder Logic : XOR (continued)

Virtual Input
Relay at I0.1
Coil
3
Switch 1
2
1
V+
Inside PLC
Virtual Output
Relay at Q0.0
Virtual Input
Relay at I0.0
(Note: Wired to PLC
with Virtual Input
Relay I0.0)
Switch 2
2
1
V+
(Note: Wired to PLC
with Virtual Input
Relay I0.1)
(Note: Wired to
PLC Output Pin
Associated with
Virtual Output
Relay PQ0.0)
V+
1
3 2
1
3 2
V+
1
3 2
V+
1
3 2
1
3 2
Virtual Input
Relay at I0.0
Virtual Input
Relay at I0.1
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I0.0
I0.1
Q0.0
I0.0 Q0.0
I0.0
I0.1
I0.1
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Section Objectives:
A micro-controller can be used for more than relay logic
with virtual relays. Ladder logic has components that take
advantage of the micro-controller. These components can
be categorized as follows: bit logic,comparator, converter,
counter, data base calls, jumps, integer functions, floating
point functions, move, program control, shift/rotate, status
bits, timers, and word logic.
It is impossible to cover all of the components in one
lecture. This lecture will first explain formatting of
constants. Then, only a few categories and examples of
components will be shown.
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Constants

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Constants

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Constants

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Constants

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Bit Logic
Available Bit logic components:
Normally Closed Switch

Normally Open Switch
Output Coil
Midline Output
Set Coil
Reset Coil
Invert Power Flow
Save RLO into BR Memory
Bit Exclusive OR
Positive Edge Detection
Negative Edge Detection
Address Positive Edge Detection
Address Negative Edge Detection
Set-Reset Flip Flop
Reset-Set Flip Flop
Immediate Read
Immediate Write
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Bit Logic example: Set Coil and Reset Coil
Description:
Set Coil is executed only if power flows to the coil. When executed, the specifi
ed
<address> of the element is set to "1". It will remain set even if power is remo
ved
from the coil.
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Description:
Reset Coil is executed only if power flows to the coil. When executed, the
specified <address> of the element is reset to "0". No power flow to the coil ha
s
no effect and the state of the element's specified address remains unchanged.
(Note: can be used to reset timers and counters)
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Example:
Switch 1 connected to Input 0.0
Coil connected to Output 0.0
If Switch 1 turns on then turn on Coil and keep it on even if Switch 1 is

released. If Switch 2 turns on then turn off the Coil.
I0.0 Q0.0
I0.1
S
Q0.0
R
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Comparator
Available Comparator components (Note: Integer is Word, Double Integer is
Double Word)
Integer: Equal to
Double Integer: Greater than or Equal to
Integer: Greater than
Double Integer: Less than or Equal to
Integer: Less than
Real: Equal to
Integer: Greater than or Equal to
Real: Greater than
Integer: Less than or Equal to
Real: Less than
Double Integer: Equal to
Real: Greater than or Equal to
Double Integer: Greater than
Real: Less than or Equal to
Double Integer: Less than
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Comparator example: Integer Compares
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Comparator example: Integer Compares
Example:
If MW0 and MW2 are equal then turn on coil.
Q0.0
CMP
== I
MW0
MW2
IN1
IN2
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Jumps
Available Jump components (Note: called Logic control in Step 7 Help)
Label
Unconditional Jump
Conditional Jump
Not conditional Jump
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Jump example: Conditional Jump
Description Conditional Jump:

The micro-controller will goto the specified Label if power flows into the JUMP.
(Note: a label can be assigned to any Network)

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Jump example: Label and conditional Jump
Example:
If Switch 1 turns on then jump to label END
I0.0
END
I0.1
JMP
Q0.0
Components
Components
END
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Integer Math
Available Integer Math components:

(Note: Integer is Word, Double Integer is Double Word)
Integer: Add Double Integer: Subtract
Integer: Subtract Double Integer: Multiply
Integer: Multiply Double Integer: Divide
Integer: Divide Double Integer: Modulus
Double Integer: Add
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Math example: Integer Add
Description:
IN1 and IN2 are added and the result is stored in OUT when power is
applied to EN . Power flows out of EN0 when power is applied to EN unless
the addition results in overflow.
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Math example: Integer Add
Example:
Add 5 and integer stored at MW0. Store the result in MW2.
ADD_I
5
MW0
IN1
IN2
EN EN0
OUT MW2
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Move
Available Move components:
Move

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Move example:
Description:
IN is moved to Out and power flows out of EN0 when power is applied to
EN.
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Move example:
Example:
Move 5 to MW2.
MOVE
5 IN1
EN EN0
OUT MW2
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Timer
Available Timer components:
Pulse S5 Timer
Extended Pulse S5 Timer
On-Delay S5 Timer
Retentive On-Delay S5 Timer
Off-Delay S5 Timer
Pulse Timer Coil
Extended Pusle Timer Coil
On-Delay Timer Coil
Retentive On-Delay Timer Coil
Off-Delay Timer Coil
Description: Description:
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Timer example: Extended Pulse S5 Timer
A power transition from OFF to ON on S will restart the timer. Power flows
from Q while timer is running. The timer will run for a preset time TV.
(Note: 256 timers allowed in S7 314C-PtP PLC)
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Timer example:
Example:
Coil is connected to Output 0.0
Turn on coil for 10 seconds if Switch 1 is turned on.

T 0
S_EXt
S5T#10s TV
S Q
BI
R BCD
I0.0 Q0.0
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Word Logic
Available Word Logic components:
AND Word
AND Double Word

OR Word
OR Double Word
XOR Word
XOR Double Word

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Word Logic example: AND Word
Description:
IN1 AND IN2 is stored in OUT when power is applied to EN . Power flows
out of EN0 when power is applied to EN unless the addition results in
overflow.
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Word Logic example: Integer Add
Example:
AND MW0 and MW2. Store the result in MW4.
WAND W
MW0
MW2
IN1
IN2
EN EN0
OUT MW4
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Section Objectives:
In this section two example ladder logic programs will be
given.
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Example 1 :
If Switch 1 is on then turn on and off a coil at 2 second intervals

(Note: 2 second interval means a period of 4 seconds and 50% Duty
cycle).
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Example 1 (Continued)
Time: Scan cycle right before t = 0s

User Action : None
T 0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
M0.0S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
T 1
Q0.0
Q0.0M0.0
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Example 1 : Continued
Time:Scan cycle at t = 0
User Action: User turns Switch 1 on
T 0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0 Q0.0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
T 1
Q0.0 M0.0
M0.0
(Note:
Time left: 2 s)
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User Action: None
T 0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0 Q0.0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
T 1
Q0.0 M0.0
M0.0
(Note:
Time left: ~0)
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Time: Scan cycle at t = 2 s

User Action: None
(Note: There is an inconsistency in this
picture. The power is still flowing though the
normally closed contact for M0.0 on the first
rung even though the coil on the second rung
for M0.0 is on. This is due to the serial nature
of the PLC micro-controller. Since the first
rung is evaluated first, the coil was still off
when the micro-controller evaluated the
normally closed contact for M0.0)
T 0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0 Q0.0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
T 1
Q0.0 M0.0
M0.0
(Note:
Time left 0 s)
(Note:
Time left: 2 s)
ME6405
ME6405ME6405(Note: Inconsistency from the previous slide
resolved)
Time: Scan cycle right after t = 2 s

User Action: None
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0 Q0.0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
T 1
Q0.0 M0.0
M0.0
(Note:
Time left: 2 s 1
scan cycle time)
T 0
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Time: Scan cycle right before t = 4 s

User Action: None
T 0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0 Q0.0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
T 1
Q0.0 M0.0
M0.0
(Note:
Time left: ~0 s)
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Time: Scan cycle at t = 4 s

User Action: None
T 0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0 Q0.0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
T 1
Q0.0 M0.0
M0.0
(Note:
Time left: 0 s)
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Time: Scan cycle right after t = 4 s

User Action: None
(Note: A once scan cycle error has been
introduced in the timing. The reason is that
the coil of M0.0 on the second rung was
turned off during the scan cycle at t = 4s. The
normally closed switch of M0.0 is not
evaluated again until the scan cycle after the
scan cycle at t = 4 s. Therefore, Timer T0
starts one scan cycle after t = 4. This error will
propagate and similar errors will accumulate. )
T
0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0 Q0.0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
T 1
Q0.0 M0.0
M0.0
(Note:
Time left: 2 s)
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Time: Some time later

User Action: User turns Switch 1 off
T 0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0 Q0.0
S_EXt
S5T#2s TV
S Q
BI
RBCD
I0.0
T 1
Q0.0 M0.0
M0.0
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Example 1 :
Comments:
As this example illustrates, consistent timing is difficult to achieve with a
PLC due to the scan cycle. This is the reason why PLC s are not used to
control systems with very fast time constants such as CNC machines,
chemical mixers, etc .
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Example 2 :
A Hall effect switch is connected to Input 0.1
(Note: a Hall effect switch will turn on when a magnetic object comes
in close proximity)
The motor for a conveyer belt is connected to Output 0.0
(Note: As previously mentioned, a coil can be any load such as a
motor during these lectures.)
If Switch 1 is turned on, the conveyer belt will transport 1000 magnetic
SHAFTS to Georgia Tech Students. Switch 1 must be turned off then on to
send another 1000 magnetic SHAFTS. The hall affect switch is positioned
right under the conveyer belt and can be used to count the SHAFTS as
they pass by.
ME6405ME6405Example 2 (Continued)
I0.1
Actions : no part near hall effect switch
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
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Time: Scan cycle at t = 0s

Actions : Switch 1 is turned on,
no SHAFT near hall effect switch
(Note: There is an inconsistency. Power is still
flowing though normally closed contact for
M0.0 even though the coil M0.0 is on. Since
the components on a rung is evaluated from
left to right, coil for M0.0 when micro-controller
evaluated the normally closed contact for M0.0
was still off. Same for PQ0.0)
I0.1
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
(Note: Inconsistency from previous slide
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ME6405ME6405resolved. The conveyer is still moving because
of the Set coil.)
Time: Scan cycle right after t = 0s

Actions : no SHAFT near hall effect switch
I0.1
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
Time: t = t1
Actions : SHAFT approaches hall effect switch, 1 is added to MW1
(Note: Similar Inconsistency between normally
closed switch of M0.1 and coil of M0.1 as seen
with normally closed switch of M0.0 and coil of
M0.0)
I0.1
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
Time: t = t1 + 1 scan cycle
Actions : SHAFT passes over hall effect switch
resolved.)
I0.1
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
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(Note: Inconsistency between the set and
reset of M0.1. That is because coil is still set
when the third rung is evaluated.)
I0.1
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
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reset of M0.1 resolved.)
I0.1
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
Time: t = t2
Actions : the 1001th SHAFT approaches hall effect switch (so 1000 have been deli
vered)
I0.1
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
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ME6405ME6405 reset of PQ0.0. That is because coil is still
set when the first rung is evaluated.)
Time: t = t2+ 1 scan cycle

Actions : the conveyer is stopped with 1001th SHAFT over the Hall effect switch
I0.1
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
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)
Time: t = t2+ 1 scan cycle

Actions : the conveyer is stopped. Switch 1 must be turned off and on to deliver
1000 more
I0.1
Q0.0M0.0I0.0
S
I0.1
M0.1
ADD_I
IN1
IN2
EN EN0
OUTMW1
1
MW1
Move
IN1
EN EN0
OUT0 MW1
M0.1 M0.1
S
Q0.0
R
CMP
== I
IN1
IN2MW1
1001
M0.0
S
Q0.0
M0.0
R
I0.0
R
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Example 2 :
Comments:
This and the previous example illustrates that the serial nature of the PLC
micro-controller can still affect program execution.
Also, this program can be simplified using an positive edge detection coil.
This was not done because the positive edge detection coil was not an
example in Section 5.
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So far we have looked at topics applicable to all PLC s. Further Study Should focu
s
on:
Topics applicable to some but not all PLC s:
Interrupts
A/
D
Counters
Function Blocks
Communication Protocol:
Profibus
How to use communications to communicate with other PLC s,
smart actuators and sensors, etc

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ME6405

George W. Woodruff School of Mechanical Engineering, Georgia Tech

(Note: Although this is really an electromagnetic coil, this can symbolize

With coil on, the switch is pulled by electromagnetic force to its on

NOT Switch 1 off = Coil on

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

Mechanical Relays and switches failed regularly (coil failure, contact

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

Digital Input and Output pins ( DI/0)

Siemens 314C-2 PtP

Every PLC has an external or internal Isolated Power Supply.

Every PLC at least one micro-controller

Specifications not given in documentation

DI/Os are electrically isolated from the micro-controller

SM232 DI/O module

Can be RAM (dynamic) or EEPROM (retentive)

George W. Woodruff School of Mechanical Engineering, Georgia Tech

Relay Logic Section 1

Relay Logic Section n

Relay Logic Section 1

George W. Woodruff School of Mechanical Engineering, Georgia Tech

Relay Logic Section 1

George W. Woodruff School of Mechanical Engineering, Georgia Tech

PLC Restarts (Warm Restart)

George W. Woodruff School of Mechanical Engineering, Georgia Tech

To address a bit of memory

Memory Area Size of Addressed Byte Address

Memory Area Notations:

Size of Addressed Memory Notations:

Virtual Relay Components:

Normally Open Switch ( equivalent to pins 1

Each external switch must be connected to an input pin of

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

Ladder Logic : AND

(Note: Wired to PLC

George W. Woodruff School of Mechanical Engineering, Georgia Tech

(Note: Wired to PLC

George W. Woodruff School of Mechanical Engineering, Georgia Tech

Ladder Logic : XOR

Relay Logic rewired to include Virtual Input and Output Relays:

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

George W. Woodruff School of Mechanical Engineering, Georgia Tech

Normally Closed Switch

If Switch 1 turns on then turn on Coil and keep it on even if Switch 1 is

Description Conditional Jump:

(Note: a label can be assigned to any Network)

Available Integer Math components:

George W. Woodruff School of Mechanical Engineering, Georgia Tech

Turn on coil for 10 seconds if Switch 1 is turned on.

AND Double Word

XOR Double Word

George W. Woodruff School of Mechanical Engineering, Georgia Tech

If Switch 1 is on then turn on and off a coil at 2 second intervals