PLC Fundamental Theory

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COMPONENTS & THEIR SYMBOLS
 The following are most commonly used

components.
 Control transformers.
 Fuses/MCBs.
 Switches/Sensors.
 Relays/Contactors Contnu…..
CONTROL TRANSFORMER
Transformer is a component which converts electrical voltage/current from one
circuit to the other circuits at the same frequency.
If the person were to touch any part of metal bulb the shock could be lethal.However if
the bulb is powered by 110VAC or less the resulting shock would likely be much less
severe.
In order to make large ,powerful machines effective and cost effective and reduce line
Current, most are powered by high voltages (230 VAC,440VAC).
This means line voltage must be reduce to 230VAC or less for the controls.
This is done using a Control Transformer.
Contnu…..
TRANSFORMER CIRCUIT DIAGRAM
420VAC or 230VAC
Primery winding
Secondary winding
230VAC 0VAC 24VAC 0VAC
The secondary windings are generally rated at 230VAC,110VAC,or 24VAC.

MCB
MCB (Miniature Circuit Breaker)

MCB is a device which cuts of the circuit if the current is more than predetermined
value,flows in a circuit.
Control circuits are always protected by MCB. This prevents damage to the control
components in the event of short circuit in the control circuit.
MCB must be rated at a current that is less than or equal to the rated Current of
control circuit.
MCB must be connected in series with the circuit.

USES OF SWITCHES
Switches are used to send instruction/signals to

the control logic.
Switches are installed on the moving parts

of a machine to provide automatic feedback
to the control logic.
TYPES OF SWITCH & SENSOR
 Push buttons
 Selector switches
 Limit switches
 Pressure switches
 Float switches
 Liquid Level switches
TYPES OF SWITCH & SENSOR
 Proximity sensors
 Optical sensors
 Encoders
 Transducers
 Thermocouples
 (RTD) Resistance Temperature Device
TYPES OF PUSHBUTTON & LAMP
 Momentary
 Maintained
 Mushroom Head
Contacts and Coils
Contacts have two states ,ON and OFF.In PLCs two type of
contacts.
Normally open (NO)
This type of contact does not allow current to flow through it when it is
switched OFF.
When the contact is switched ON,the circuit is completed and current flows
through the circuit.
Normally close (NC)

This type of contact allows current to flow through it when it is switched OFF.
When the contact is switched ON,the circuit is broken and stops the current
flow in the circuit.
Coils
Coils are output devices that are controlled By PLC as per the input
conditions of ladder logic is True or ON value.The coil is set to the ON status
and device performs its function.
FUNCTION OF SWITCHES
The contacts (Rear blocks ) on push button can be of
two types.
Normally Open (N/O)
Normally Close (N/C)
Description Symbol Comment
It is Normally Open (N/O).

Push Button When external force is applied it
(N/O) becomes closed.
It is used to switch ON equipments.
It is Normally Close (N/C).
Push Button When external force is applied it
(N/C) becomes open.
It is used to switch OFF equipments.
It is normally open condition, it selects

Selector the mode of operation of work.
Switch
EXAMPLE:
Selection of Manual Mode.
Selection of Auto Mode.
Limit Switch: Limit switches are not operator accessible,instead they are
Activated by moving part on the machine.
They are usually mechanical switches.
Example: Mechanically operated limit switch is the switch on the

refrigerator
Doors that turns on inside the light.
It is normally open condition when any
Limit Switch object is in contact of its CAM then it
becomes closed. Its application is to
limit the continuous signal by sensing
it.
It is normally open condition it
Pressure works on the pressure level, it
becomes on when pressure level
Switch
reaches up to preset value.
It is normally closed condition it
Float consists a long lever arm with a
float attached.
Switch As the liquid level rises,the lever
arm presses on the switch’s
actuator knob.
FUNCTION OF SENSORS
Type of Proximity Sensors.
 Inductive proximity sensor.
 Capacitive proximity sensor.
 Inductive proximity sensor

It operates on the principle that the inductance of a coil and
the power losses in the coil vary as a metallic (or inductive)
object is passed near by it.
Because of this operating principle ,inductive proximity
sensors are only used for sensing metal objects.
They will not work with non-metallic materials.
FUNCTION OF SENSORS
Inductive proximity sensors are available in both AC and DC

powered types.
Most sensors available built in LED that indicates when the

sensor output is on while the object is sensed.
Capacitive proximity sensor

The principle of operation of the sensor is that internal
oscillator will not oscillate until a target material is moved
near to the sensor face.
This will work with Non-metallic objects.
SENSORS
Proximity Output It is normally open Condition, when
Sensor any metallic object is sensed from
specified distance then it becomes on.
+VE -VE
Optical Output
It is normally open Condition, It is
Sensor capable of sensing any type of
+VE material whether it is metallic,
-VE Conductive or porous.
It operates over longer distances.
SENSORS
Output Read switch and proximity switch

are similar in function but it is
Read Switch mounted on the pneumatic
cylinders only.
+VE -VE
CONTACTORS/RELAYS
A relay or Contactor is an electromagnetic device assembled of a frame,
electromagnetic coil and contacts (Movable and Fixed).
The movable contacts are mounted via an insulator to a plunger that moves
with in a bobbin.
A coil of copper wire is wound on the bobbin to create an electromagnet.

A spring holds the plunger up and always from the electromagnet.
When the electromagnet is energized by passing an electric current through

coil,the magnetic field pulls the plunger into the core,which pulls the movable
contacts downwards.
Two fixed pairs of contacts are mounted to the relay frame on electrical
insulator so that when movable contacts are not being pulled towards the core
(The coil is de-energized) they physically touch the upper fixed pair of contacts
And,when being pulled towards the coil,touch the lower pair of fixed contacts.
CONTACTORS&RELAYS
Contactor It is a device to make and break

the circuit. It is mainly used to
control the motors and heaters etc.
on/off
Relay It is a device to make and break

the circuit. It is mainly used to
control the solenoid coils,
magnetic clutches etc.. on/off
CONTACTORS/RELAYS
Following figure shows the three most common Contactor or Relay symbols.
These are used in electrical control logic diagrams.
 Normally open contact (N/O)

%QX0.3
R1
 Normally close contact (N/C)

R1
 Coil R1
Normally open and normally closed contacts of above figures have lines
extending from both sides of the symbols.These are the connecting lines
which,on a real relay would be the connection points for wires
OVER LOAD RELAY
Over load relay is component used to break the circuit and over loaded caution
automatically if there is short circuit or power over loaded in the power circuit.
Over load relay will have NO/NC contacts to inter lock the control circuit.
Mainly it is mounted under the Power contactor (L1,L2,L3 terminals) of 3-Phase

induction motors.
Restarting of OLR is very easy ,just pressing the RESET knob.

INDICATING LAMPS
LAMPS
The lamps are used to indicate present operation status of
the machine or fault conditions.
The indicators are generally white,they generally covered

with colored lenses.
INDICATING LAMPS
The colors are usually RED,GREEN or AMBER etc.
RED LAMP
This is used for Power is ON,the machine is running.
the machine door is open or other important faults.
GREEN LAMP
This is used for safety conditions (power to the motion
controllers OFF status etc).
AMBER LAMP
This indicates that are important but not dangerous.
Fluid getting low,Machine paused,etc.
INDICATING LAMPS
Indicating All control panels provided
Lamp indicator lamps.
It is provided at important
diagnostic points to monitor.
Know the present operating status
of the machine.
FUNDAMENTALS OF BASIC DIAGRAMS
All electrical control circuit diagrams are designed using a

standard format call the Relay Logic Circuit (RLC).
Ladder diagram begin with control transformer and protective

MCB on the left side.
As mentioned earlier,From transformer and MCB combination,

horizontal lines are extended to both sides and then drawn
vertically down the page as shown in Figure in next slide.
BASIC CONTROL CIRCUIT
R 420VAC Y
Primery
Secondary
1 230VAC 0VAC
MCB
230VAC
2 0
These vertical lines are called power lines.
The voltage deference between the two vertical lines is equal to the control
transformer secondary voltage.
WIRING AND NUMBERING
Total wires in a control circuit are numbered.
In our circuit,the left line number is 2 and right line number is 0.
When the circuit is designed,the actual wires used to connect
the components will have a ferrule(Number) on each end
called a wire numbering.
Numbering makes easier to design,troubleshoot and modify the
circuitry.
By using wire ferrule numbers,all the wires in the control panel
will be identified and unnecessary to use more than one color
wire to wire the circuit (except for ground wire).
SWITCH GEAR NOMENCLATURE PREFIX
Some of the most commonly used reference nomenclature

prefixes are listed below.
 T/F ------------ Transformer

 MCB ----------- Miniature Circuit Breaker
 CR ------------ Control Relay
 PB ------------ Push Button
 LS ------------ Limit Switch
 PX ------------ Proximity Switch
 OS ------------ Optical Sensor
 SS ------------Selector Switch
 OLR ------------ Over Load Relay
 FWD ------------ Forward
 REV ------------ Reverse
 L1 ------------ Lamp1
Etc…..
The number of the nomenclature is assigned by designer beginning

with the number 1.
CIRCUIT REFERENCE NOMENCLATURE
All electrical circuits and every switch gear is given a reference

nomenclature. This is a label assigned to the switch gear so
that it can be easily located.
The reference nomenclature for each switch gear appears on
the schematic diagram.
The reference nomenclature consists of an alphabetical prefix
followed by a number.
The prefix identifies that the kind of switch gear it is (Viz Control
transformer,Relay,Pushbutton…etc).
CONVENTIONAL RLC CIRCUIT
2
From Control Transformer (230V AC) 0
3 4
CR1
PB1 PB2
Wire ferrule number
CR1 Label
5 6 7 8
FWD
PB3 CR1
Label LS1 REV
9 10 11 12
REV
PB4 CR1 LS2
FWD
RELAY LOGIC
Since the relays in a machine perform some type of control
operation,it can be set that they perform a logic function.
As with all logic functions, these control circuits must consist of
the fundamental AND,OR,and compliment logic operations.
N/O,N/C contacts and relay coils can be wired to perform these
Same fundamental logical functions.
By properly wiring relay contacts and coils together ,we can
develop any logic function as required.
AND Lamp Circuit
This slide shows the actual wiring connection for two switches
a lamp and voltage source.
PUSHBUTTON-1 PUSHBUTTON-2
LAMP-1
230V AC
The LAMP1, will glow only when PUSHBUTTON-1,PUSHBUTTON-2

are pressed while the voltage sours is there.
AND Lamp Ladder diagram
To represent the previous diagram in ladder logic form an
electrical Machine diagram,we will utilize the power from the
vertical lines and simply add the two Pushbuttons and Lamp
in series between the two vertical power lines as shown in next
slide.
The switches are on the left and lamp is on the right.
This is a standard convention when designing and drawing

machine circuits.The controlling devices are always positioned
on the left side of the power line,and the controlled devices are
always positioned on the right side of the power line
AND Lamp Ladder diagram
420VAC
R Y
Primery
Secondary
MCB
230VAC
2 0
3 4
PB-1 PB-2
L-1
OR Lamp Circuit
This circuit shown in below figure illustrates two pushbuttons
wired as an OR logic controlling a lamp.
The lamp will glow if either PUSHBUTTON-1OR PUSHBUTTON-2 is
pressed,That is depressing either of switches will cause LAMP-2
to glow while the voltage sours is there.
PUSHBUTTON-1
LAMP-2
PUSHBUTTON-2
230V AC
LADDER DIAGRAM WITH “AND,OR” LOGIC
The next slide shows the combined ladder diagram (AND,OR logic).
Note that since the pushbuttons PB-1 and PB-2 same ones used in the top
line ,they will have the same names and the same reference nomenclature
when drawn in bottom.
When two or more components in parallel,each parallel path is called
branch.
In our diagram AND,OR logic has two branches,it is possible to exchange
branches 1and 2 without changing the way the lamps operate.
The branches can be arranged in any order without changing the way the
machine operates.
It allows the designer to group and organize the control circuitry so that it is
easier to understand and troubleshoot.
420VAC
R Y
Primery
Secondary
MCB AND Lamp Ladder diagram
230VAC
2 0
3 4
PB-1 PB-2
L-1
5
PB-1
L-2
PB-2
AND-OR Lamp Circuit
PB-1 PB-2
L-3
PB-3 PB-4
230V AC
LAMP- 3 will glow if PB-1 and PB-2 are both ON, or PB-3
and PB-4 are both ON.
This circuit is called AND-OR logic.
OR-AND Lamp Circuit
PB-1 PB-3
L-4
PB-2 PB-4
230V AC
This circuit is called OR- AND logic.

OR-AND Circuit combination chart
LAMP- 4 will glow when the following combination of

pushbuttons are ON.
LAMP- 4 ON PB-1 AND PB-3 are ON

PB-1 AND PB-4 are ON
LAMP- 4 ON PB-1 OR PB-2 AND PB-3 are ON
PB-1 OR PB-2 AND PB-4 are ON
LADDER DIAGRAM WITH COMBINATION BRANCHES
230VAC
2 0
3 4
PB-1 PB-2
L-1
5
PB-3
L-2
PB-4
6 7
PB-5 PB-6
L-3
PB-7 PB-8
9 10
L-3
PB-9 PB-10
L-3
PB-11 PB-12
INCH Circuit
2 0
3
CR1
INCH
SELF LATCH Circuit
2 0
3 4
CR1
START STOP
CR-1
When power is applied to the vertical lines,CR1 is de-energized and the N/O
of CR1 contact in parallel with START pushbutton is also open.
CR1 is energized when START pushbutton is pressed and CR1 remain ON,if
release START PB because power will flow through CR1 (NO) contact.
CR1 is de-energized when STOP PB is pressed.
Since we are assuming START PB not been pressed,there is no path for
power flow through the branch and it will be OFF.
INVENTION OF PLC
 The first PLC systems evolved from conventional computers
in the early 1970 s. These first PLCs were installed in
automotive plants. Traditionally automotive plants had to be
shut down for a month to change the model .
 The PLC keyboard reprogramming procedure replaced

rewiring of panel full of wires, relays, counters and other
components. The new PLCs helped to reduce the
changeover time to a matter of few days.
PLC DEFINITION
The Programmable Logic Controller is a solid state

equipment, designed to perform the function of logic
made for industrial control applications.
INTRODUCTION OF PLC
The PLC acts as a total replacement for hardwired relay
logic with an effective reduction in wiring and panels.
 With the coming of microprocessor and associated peripheral chips

the whole process of control & automation went for a radical
change.
 Instead of achieving the desired control or automation through

physical wiring of control components, in PLC it is achieved
through a program or say software.
 As the desired logic control is achieved through a program, these

controllers are referred to a Programmable Logic Controllers (PLC).
BLOCK DIAGRAM OF PLC
PB1 I O
POWER SUPPLY FWD
N U CONT
PB2
P T
U P REV
CPU CONT
T U
LS1
USER PROGRAM T
MEMORY
R1
SERIAL PORT LAMP
Computer
PROGRAMMING DEVICE
CONNECTING CODEYSYS TO THE
NEXGEN 2000 PLC
Computer
CABLE CODE:PRG CAB 2910

DETAILS OF PLC BLOCK
DIAGRAM
INPUT MODULE
 The input module acts as an interface between the field
components (viz pushbuttons, selector switches, limit
switches, proximity switches, pressure switches etc) and
CPU.
POWER SUPPLY UNIT
 The power supply module delivers the power required for the
electronic components in the modules of the PLC.
CPU
 It is a Central Processing Unit which masterminds the
operation of PLC.
DETAILS OF PLC BLOCK
DIAGRAM
OUTPUT MODULE
 The Output Module receives commands from CPU inorder to
control various field elements like power contactors, solenoid
coils, indicating lamps etc.
SERIAL PORT
 It is a hardware device used to transfer a program from PC to
PLC and PLC to PC.
PROGRAMMING DEVICE
 Used for storing, editing, inserting, deleting of the logic
diagram and transferring the same to PLC and PC devices
like PC or Hand-Held programmer and also used to monitor
the status of inputs, outputs and flags in online mode.
PLC CONFIGURATION EXAMPLE
Slot Slot Slot-0 Slot-1 Slot-2 Slot-3
2113 2211 2616 2716 2616 2716
P C 16 16 16 16
S P I O I O
U U N U N U
P T P T
U P U P
T U T U
T T
M M
O M O M
D O D O
U D U D
L U L U
E L E L
E E
Slot Slot Slot-0 Slot-1 Slot-2 Slot-3 Slot-4 Slot-5 Slot-6 Slot-7
2113 2211 2616 2414 2416 2716 2708 2708 2712 SPARE
P C 16 8 8 16D 8D 8D 12R S
I I I O O O O
S P
N N N U U U U P
U U P P P T T T T
U U U P P P P
A
T T T U U U U R
+ + T T T T
M 6R 8D E
O O O M M M M
D U U O O O O
U T T D D D D S
L P P U U U U
E U U L L L L L
E E E E
T T
O
M M T
O O
D D
U U
L L
E E
16 Pt 24 VDC Input Module
Sr.No SPECIFICATIONS Details
1 No of inputs 16
2 Voltage rating 24 VDC (18 to 30 VDC)
3 Indication for inputs Provided on CPU module via
Multiplexed dot matrix display
4 ON voltage 18 VDC Minimum
5 OFF voltage 5 VDC Maximum
6 Current per input channel 7mA (Maximum) @24 VDC
7 Ordering code 2616
Contnu…..
16 Pt 24 VDC Output Module
1 No of outputs 16
2 Voltage rating 24 VDC (18 to 30 VDC external
supply)
3 Current rating 250 mA per output
4 Indication for inputs Provided on CPU module via
Multiplexed dot matrix LED display
5 ON voltage 22 VDC Minimum
6 OFF voltage 1.5 VDC Maximum
7 Response time OFF to ON---- 0.1ms
ON to OFF---- 0.4ms
8 Inrush Current 600mA for 700 micro second
Contnu…..
16 Pt 24 VDC Output Module
9 Protections  Reverse voltage

 Over voltage
 Output short circuit protection
10 Ordering code 2716
DETAILS OF ADDRESSING
Following slides explain the input/output/Memory

addressing.
BASICS IN DIGITAL ELECTRONICS
 Numbering Systems
 Bit, Nibble, Byte, Word
Bit: Bit means binary digit. It is smallest piece of digital information. It can
be either 0 (OFF) or 1(ON).
Nibble: Four bits grouped together form nibble.
Byte: Eight bits or two nibbles grouped together form one byte.
Word: It is the maximum number of bits that are processed or handled at a time.
Sixteen bits or four nibbles or two byes grouped together form one word.
B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 B0

1 0 1 0 1 0 1 1 0 0 1 0 1 0 1 0
Bit
Nibble
Byte
Word
NUMBERING SYSTEM
 Binary
 Hexadecimal
 Binary Coded Decimal (BCD)
Binary Numbering System:
The binary numbering systems uses a number set that consist of two digits
VIZ., numbers 0 AND 1.
Each digit in a binary number has a weightage expressed as a power of “2”.
The decimal equivalent of binary number is computed by multiplying each
binary digit by its corresponding weightage and adding these number
together.
2 2 2 2 2
Binary Number: 4 3 2 1 0
1 1 0 1 0
Decimal equivalent =
= 0 1 2 3 4
2X0 + 2X1 + 2X0 + 2X1 + 2X1
0+ 2 +0 + 8 + 16 = 26
NUMBERING SYSTEM
Hexadecimal Numbering System:

The hexadecimal numbering system has a number set of 16 digit VIZ.The
number 0-9 and the letter of A to F (Decimal number 10-15 respectively).
Each digit in a hexadecimal has a weightage expressed as a’16’.
A hexadecimal number can be converted to a decimal number by multiplying

the hexadecimal digit by its corresponding weightage,expressed as power of
’16’ and the adding these numbers together.
4 3 2 1 0
Binary Number: 16 16 16 16 16
1 0 1 0 1
Decimal equivalent =
= 2X0 + 2X1 + 2X0 + 2X1 + 2X1
0+ 2 +0 +8 + 16 = 26
ADDRESSING CODE
Hexadecimal Decimal Octal Binary
(Base 16) (Base 10) (Base 8) (Base 2)
00 00 000 00
01 01 001
02 02 002
03 03 003
04 04 004
05 05 005
06 06 006
07 07 007
08 08
09 09
0A 10
0B
0C
0D
0E
0F
INPUTS ADDRESSING RANGE
WORD BYTE BITS

%IB0 %IX0.0 %IX0.1 %IX0.2 %IX0.3 %IX0.4 %IX0.5 %IX0.6 %IX0.7
%IW0
%IB1 %IX1.0 %IX1.1 %IX1.2 %IX1.3 %X1.4 %IX1.5 %IX1.6 %IX1.7
%IW2
%IW4
%IW6
INPUTS ADDRESSING RANGE
WORD BYTE BITS

%QB0 %QX0.0 %QX0.1 %QX0.2 %QX0.3 %QX0.4 %QX0.5 %QX0.6 %QX0.7
%QW0
%QW2
%QW4
%QW6
DEFINITION OF FLAG/MEMORY BIT
Storage of intermediate results of one Rung, ( as internal
relay in PLC software)
In Relay logic it is defined as Auxiliary contactor
%IX0.0 %IX0.1 %IX0.2 %MX0.0
Motor on PB
Motor off PB Safety
input Motor on flag
input inter lock
%MX0.0
Motor on flag
%MX0.0 %QX0.6
Motor on flag Motor on output

MEMORY ADDRESSING RANGE
WORD BYTE BITS
%MB0 %MX0.0 %MX0.1 %MX0.2 %MX0.3 %MX0.4 %MX0.5 %MX0.6 %MX0.7
%MW0

%MW2
%MW4
%MW6 %MB7 %MX7.0 %MX7.1 %MX7.2 %MX7.3 %MX7.4 %MX7.5 %MX6.6 %MX7.7
%MW8
%MW12

%MW14
MEMORY ADDRESSING RANGE
WORD BYTE BITS
RANGE OF WORDS RANGE OF BYTES

%MW0 TO %MW 7678 %MB0 TO %MB7679
Slot Module Input addressing Output addressing
Slot PSU Nil Nil
Slot CPU Nil Nil
I/o Slot-0 16 Pt DC Input %IB0 & %IB1 Nil
I/o Slot-1 12Pt Relay Output NIL %QB0 & %QB1
I/o Slot-3 8Pt DC input+6Pt %IB4 %QB2
Relay Output
I/o Slot-4 8Pt Relay Output NIL %QB3
I/o Slot-6 8Pt DC input+6Pt %IB7 %QB4
Relay Output
I/o Slot-7 12Pt Relay Output NIL %QB5 & %QB6
Types of PLC
Basically PLCs are two types.
 Brick type.
 Modular type.
BRICK TYPE
PLC is housed in a single box with all power supply,CPU,Inputs and out puts
& connection terminals.
These are generally chosen according to a available program memory and

required number of I/Os to suit he application.
This type of PLC generally has an expansion port. This type of PLC will have
limited I/Os.
These ports allow the addition of Digital Inputs/outputs or analog Inputs/

Outputs. These expansion units are either plugged directly or connected it
with ribbon cable.
PLC Configurations
MODULAR TYPE
More sophisticated units,with a wider range of options,are MODULAR.
Modular type PLC can be connected consist following Modules.

 CPU (Central Processor Unit).
 I/O Rack.
 Power supply Module (PSU).
 Digital Input Module.
 Digital Output Module.
 Analog I/O Modules
 High speed counter Module.
Other type of modules may be available depending up on the manufacture of
the PLC.
Function of communication modules is transfer the data from one device to
another. One module allows the serial transfer of data to remote I/O modules
which is some feets away.
Modular Type PLC with 8 I/O Rack Figure
RACK
Slot Slot I/O I/O I/O I/O I/O I/O I/O I/O
Slot-0 Slot-1 Slot-2 Slot-3 Slot-4 Slot-5 Slot-6 Slot-7
P C
O P
W U
E
R
Supply
Expansion Port
The RACK is a framework into which the Input/outputs modules

are inserted.
The size of the Rack depends on the number of slots ,such as 3,
5,8.
(Source: MESSUNG)
Fundamentals of PLC Programming
 Symbols used in ladder logic.
 Rungs.
 Contacts and Coils.
Symbols Used in Ladder Logic
A PLC takes input from field devices and based on the programming instructions
controls output devices.
Ladder logic diagrams are used in PLCs to write programming instructions below
figure illustrates a simple ladder diagram.
Input Rung Output
As shown in above figure,a ladder logic diagram consists of three elements.

 Input
 Output
 Rung
A ladder logic diagram consists of one or more horizontal lines,called RUNGS. The
rungs contain the input and output elements.In a ladder logic diagram,the input
elements referred as the contact and output element s referred as Coil.
Rungs
The horizontal lines in a ladder logic diagram are called RUNGS.
Each Rung of a ladder logic diagram represents a condition of the input/output/
memory bits.
Each Rung ends with a coil and starts with a set of conditions.
The two vertical lines at the two end of the rungs are called rails and are
represented as L1 and L2.
These rails represents the voltage potential of the ladder diagram.
The below figure illustrates the rails and the rung of ladder logic diagram.
L1 L2
Rung
Ladder Logic Specifications
Input Conditions Arrange Inputs Ladder Logic Diagram

All conditions Series A B C D M
should be met
Any condition Parallel M

A
should be met
B
A combination of In combination A D M
conditions
B
C
FUNDAMENTAL PLC
PROGRAMMING
 Relay type instructions.
 Function Block instructions.

 How to convert a simple relay logic diagram into
PLC Ladder Program.
RELAY TYPE INSRTUCTIONS
Symbol Instruction Comment
NO This is a single Normally Opened contact.

Its results is True if the input bit is 1 and the false if the
input bit is 0.
NC This is a single Normally Closed contact.

Its results is True if the input bit is 0 and the false if the
input bit is 1.
COIL This represents the coil of output, memory bit etc.

It becomes ON if the result of ladder programmed
prior to it is 1 (true).
RELAY TYPE INSRTUCTIONS
Symbol Instruction Comment
This represents the latch type coil of the output,

S
SET
memory bit etc. It is SET to 1(true).
RESET This represents the latch type coil of the output,

R
memory bit etc. It RESETS the latched coil if the result
of the ladder programmed prior to it is 1 (true).

FUNCTION BLOCK INSTRUCTION
 TIMERS
 COUNTERS
TYPE OF TIMERS
 On delay timer
 Off delay timer
TYPE OF COUNTERS
 Up counter
 Down counter
 Up/Down counter
DETAILS OF FUNCTION BLOCKS
ON DELAY TIMER
T1
%IX0.1 TON DONE
IN Q
T# 10M PT ET T1_ET
PT- Preset time

ET- Elapsed time
When IN input becomes high , the elapsed time value increments on every rising
edge. The DONE bit becomes on when elapsed time becomes equal to preset
time. When IN input becomes low the elapsed time become 0.
Cont….
OFF DELAY TIMER
T3
%MX10.0 TOF DONE
IN Q
T# 10S PT ET T3_ET
PT- Preset time

ET- Elapsed time
When IN input becomes high , timer DONE bit also becomes high immediately.
When IN input becomes low and the elapsed time value will get incremented by
every rising edge of time base. When elapsed time becomes equal to preset time
DONE bit goes low and elapsed time becomes 0.
Cont….
BLINK/CYCLIC
B10
%IX0.1 BLINK %QX0.6
ENABLE OUT
T#5S LOW TIME
T#3S HIGH TIME
LOW TIME- Output OFF duration

HIGH TIME- Output ON duration
When the ENABLE input becomes high , BLINK begins to set OUTPUT for the
time period TIMEHIGH to ON and then afterwards TIMELOW to OFF
Cont….
UP COUNTER
C1
%MX0.1 CTU DONE
UP Q
%IX0.6 RESET
20 PV CV %MW00
PV- Preset value

CV- Current value
When the REST input becomes high , the current value of counter becomes
zero. This is resetting of counter. When reset input is OFF the current value of
the counter increments by one on every transition from OFF to ON at the UP
input. The DONE bit goes high when the current value becomes equal to preset
value. Cont….
DOWN COUNTER
C10
%MX0.1 CTD DONE
DN Q
%IX0.6 LOAD
20 PV CV %MW100
PV- Preset value

CV- Current value
DN- Down
When the LOAD input becomes high , the current value of counter becomes
equal to preset value. This is presetting of counter. When LOAD input is OFF the
current value of the counter decrements by one on every transition from OFF to
ON at the DOWN input. The DONE bit goes high when the current value
becomes equal to zero. Cont….
PLC INPUTS AND OUTPUTS WIRING OF ‘AND’ LOGIC
INPUT MODULE OUTPUT MODULE
I0 I0 PB1 PUSH BUTTON-1 Q0 Q0 L1 LAMP-1

I1 I1 PB2 PUSH BUTTON-2 Q1
I2 Wire ferrule number Q2
I3 Q3
G1 Label Q4
I4 Q5
I5 Q6
I6 Q7
I7 V1
G2 G1
I10 Q10
I11 Q11
I12 Q12
I13 Q13
G3 Q14
I14 Q15
I15 Q16
I16 Q17
I17 V2
G4 G2
24VDC P1 N1
N1
P1 24VDC N1
CONVERSION OF RELAY LOGIC
CIRCUIT TO PLC LADDER
AND Relay Logic Diagram
PB-1 PB-2
L-1
230V AC
AND PLC Logic RUNG

%IX0.0 %IX0.1 %QX0.0
PB-1 PB-2 L-1

PLC INPUTS AND OUTPUTS WIRING OF ‘OR’ LOGIC

I2 Wire ferrule number Q2
I3 Q3
G1 Label Q4
I4 Q5
I5 Q6
I6 Q7
I7 V1
G2 G1
I10 Q10
I11 Q11
I12 Q12
I13 Q13
G3 Q14
I14 Q15
I15 Q16
I16 Q17
I17 V2
G4 G2
24VDC P1 N1
N1
P1 24VDC N1
OR Relay Logic Diagram
PB-1
L-2
PB-2
230V AC
OR PLC Logic RUNG

%IX0.0 %QX0.0
PB-1 L-2
%IX0.1
PB-2
PLC INPUTS AND OUTPUTS WIRING OF ‘AND-OR’ LOGIC

G1 Wire ferrule number Q4
I4 Q5
I5 Label Q6
I6 Q7
I7 V1
G2 G1
I10 Q10
I11 Q11
I12 Q12
I13 Q13
G3 Q14
I14 Q15
I15 Q16
I16 Q17
I17 V2
G4 G2
24VDC P1 N1
N1
P1 24VDC N1
AND-OR Relay Logic Diagram
PB-1 PB-2
L-3
PB-3 PB-4
230V AC
AND-OR PLC Logic RUNG
%IX0.0 %IX0.1 %QX0.0
PB-1 PB-2 L-3
%IX0.2 %IX0.3
PB-3 PB-4
PLC INPUTS AND OUTPUTS WIRING OF ‘OR-AND’ LOGIC

G1 Wire ferrule number Q4
I4 Q5
I5 Label Q6
I6 Q7
I7 V1
G2 G1
I10 Q10
I11 Q11
I12 Q12
I13 Q13
G3 Q14
I14 Q15
I15 Q16
I16 Q17
I17 V2
G4 G2
24VDC P1 N1
N1
P1 24VDC N1
OR-AND Relay Logic Diagram
PB-1 PB-3
L-4
PB-2 PB-4
230V AC
OR-AND PLC Logic RUNG
%IX0.0 %IX0.2 %QX0.0
PB-1 PB-3 L-4
%IX0.1 %IX0.4
PB-2 PB-4
ADVANTAGES OF USING PLC OVER
CONVENTIONAL ELECTRICAL PANEL
 Solid state devices reduce failures because there is no mechanical wear and tear.
 Power consumption is less.
 Easily programmed or reprogrammed with the help of
programming device.
 PLC can be reused if no longer required in original application. Only application
program is to be changed.
 Indicating lamps are provided at important diagnostic points to simplify
troubleshooting.
 No external hardware timers and counters are required unless due to specific need.
 Unlimited NO and NC contacts of inputs, outputs and auxiliary relays (Memory Bits)
are available.
 Smallest cabinet size leading to less floor requirement.
 Easy troubleshooting.
DISADVANTAGES OF RLC
 Life of components is limited because of wear and
tear of mechanical components .
 No flexibility.
 Huge space is required.
 Required more no of Labors.
 Fault finding is very lengthy process (Some times it
may take few days to solve the problem).
 Lot of time required to complete the Job of small
logic.
THANK YOU TO ALL
PARTICIPANTS AND KEEP ON
UPDATE THE KNOWLEDGE OF
PLC
THE END

PLC Fundamental Theory

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PLC Fundamental Theory

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RANE ENGINE VALVES

 The following are most commonly used

This is done using a Control Transformer.

230VAC 0VAC 24VAC 0VAC

The secondary windings are generally rated at 230VAC,110VAC,or 24VAC.

MCB (Miniature Circuit Breaker)

MCB must be connected in series with the circuit.

Switches are used to send instruction/signals to

Switches are installed on the moving parts

Normally close (NC)

It is Normally Open (N/O).

Description Symbol Comment

It is normally open condition, it selects

Example: Mechanically operated limit switch is the switch on the

 Inductive proximity sensor

Inductive proximity sensors are available in both AC and DC

Most sensors available built in LED that indicates when the

Capacitive proximity sensor

Description Symbol Comment

Output Read switch and proximity switch

A coil of copper wire is wound on the bobbin to create an electromagnet.

When the electromagnet is energized by passing an electric current through

Contactor It is a device to make and break

Relay It is a device to make and break

These are used in electrical control logic diagrams.

 Normally open contact (N/O)

 Normally close contact (N/C)

Mainly it is mounted under the Power contactor (L1,L2,L3 terminals) of 3-Phase

Restarting of OLR is very easy ,just pressing the RESET knob.

The indicators are generally white,they generally covered

All electrical control circuit diagrams are designed using a

Ladder diagram begin with control transformer and protective

As mentioned earlier,From transformer and MCB combination,

These vertical lines are called power lines.

Some of the most commonly used reference nomenclature

 T/F ------------ Transformer

The number of the nomenclature is assigned by designer beginning

All electrical circuits and every switch gear is given a reference

The LAMP1, will glow only when PUSHBUTTON-1,PUSHBUTTON-2

The switches are on the left and lamp is on the right.

This is a standard convention when designing and drawing

MCB AND Lamp Ladder diagram

This circuit is called OR- AND logic.

LAMP- 4 will glow when the following combination of

LAMP- 4 ON PB-1 AND PB-3 are ON

 The PLC keyboard reprogramming procedure replaced

The Programmable Logic Controller is a solid state

 With the coming of microprocessor and associated peripheral chips

 Instead of achieving the desired control or automation through

 As the desired logic control is achieved through a program, these

CABLE CODE:PRG CAB 2910

9 Protections  Reverse voltage

Following slides explain the input/output/Memory

B15 B14 B13 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 B0

Hexadecimal Numbering System:

A hexadecimal number can be converted to a decimal number by multiplying

WORD BYTE BITS