®

Because learning changes everything.

Programmable
Logic
Controllers
Frank D.
Petruzella

Sixth Edition

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 Chapter 5
Basics of PLC
Programming

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 Section 5.1

Processor Memory Organization

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 Rack-based memory
Rack-based memory addresses are derived
using the rack number, the I/O module slot
number and the screw terminal number
where the I/O device is wired.

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 Tag-based memory
Tag-based memory use a tag to identify a memory
location. There are no fixed areas of memory
allocated for I/O addresses or other types of data.

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 Memory space

The Logix 500

memory space is
divided into two:
Program files
and Data files.

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 Program Files
Program files are the part of
the processor memory that
stores the user ladder logic
program. The program
accounts for most of the total
memory of a given PLC system.

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 Data Files
The Data file portion stores input and output
status, processor status, the status of various
bits, and numerical data.

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 Type of Data

Data files are

organized by
the type of data
they contain.

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 SLC address format
I/O address format for the SLC family of PLCs.

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 Data tables
The SLC 500 stores data in data tables that
are based on 16-bit words.
You access these data by specifying the address of
the data you want.

The addresses in the output data file and the input

data file are potential locations for I/O modules
mounted in the chassis.
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 Input image table
The input image table
is allocated to storing
the on/off status of
connected discrete
inputs.
If the input is on (switch
closed), its corresponding
bit in the table is set to 1.
If the input is off (switch
open), the corresponding
bit is cleared, or reset to 0.
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 Output image table
The output image table is
allocated to storing the
on/off status of connected
discrete outputs.
If the program calls for
an output to be ON, its
corresponding bit in the
table is set to 1.
If the program calls for
an output to be OFF, its
corresponding bit in the
table is set to 0.
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 Micro PLC connections
Typically, micro PLCs have a fixed number of
inputs and outputs.

This controller has 20 discrete inputs with addresses I/0 through

I/19 and 12 discrete outputs with addresses O/1 through O/11.
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 Section 5.2

Program Scan

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 Program scan cycle
During each program scan cycle, the processor
reads all the inputs, takes these values, and
energizes or de-energizes the outputs according
to the user program.

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 Speed of scan
The time it takes to complete a scan cycle is a
measure of how fast the controller can react to
changes in inputs.
If a controller has
to react to an input
signal that changes
states twice during
the scan time, it is
possible that the
PLC will never be
able to detect this
change.
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 Scan time
The scan time is a function of:
• The speed of the processor module.
• The length of the ladder program.
• The type of instructions executed.
• The actual ladder true/false conditions.

The PLC computes the scan time each time

the END instruction is executed.

Typical scan time data include the

maximum scan time and the last scan time.

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 Electrical Continuity
In a rung of a hardwired circuit there must
be electrical continuity in order for the load
to energize.

The rung has electrical continuity only when the

current flows is established in a path from one
side of the power rail to the other.
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 A PLC ladder logic rung is evaluated
in terms of logical continuity.

When there is a continuous path of true conditional

instructions in a rung, logical continuity exists;
accordingly the output instruction is true and the
status bit will be set 1 (ON).
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 Overview of the data flow during
the scan process.

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 Scan process
applied to a
multiple rung
program.

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 Vertical versus horizontal scan patterns.

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 Section 5.3

PLC Programming Languages

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 PLC programming language refers to the method
by which the user communicates information to
the PLC.

Standard PLC programming languages

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 Ladder Diagram programming
Ladder Diagram programming is a symbolic
depiction of instructions arranged in rungs
similar to ladder-formatted schematic diagrams.

Hardwired relay
control circuit

Equivalent ladder
diagram program
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 Instruction List programming
Instruction list programming language consists
of a series of instructions that refer to the basic
AND, OR, and NOT logic functions.

Hardwired relay
control circuit

Equivalent instruction
list program
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 Functional block diagram
Functional block diagram programming uses
instructions that are programmed as blocks
wired together to accomplish certain functions.

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 Ladder and functional block
Ladder diagram and functional block diagram
programming used to produce the same logical
output.

Ladder diagram

Equivalent
function block
diagram.
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 Sequential function chart
Sequential
function chart
programming
language is
similar to a
flowchart of
your process.
The program is
split into steps with
multiple operations
happening in
parallel branches.
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 Structured text
Structured text is a high level language primarily
used to implement more complex procedures.

Ladder diagram

Equivalent
structured text
program.
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 Section 5.4

Bit-Level Logic Instructions

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 Ladder diagram – symbolic set
The ladder diagram language is a symbolic set
of instructions used to create the controller
program.

Representations of contacts and coils are the basic

symbols of the logic ladder diagram instruction set.
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 Symbolic instruction - command
Each symbolic instruction is a command
to perform a specific operation.

The symbols are arranged to obtain the

desired control logic that is to be entered
into the memory of the PLC.
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 The Examine If Closed (XIC) instruction
looks and operates like a normally open
relay contact.

Examine if closed (XIC)

Examine-on

Associated with each XIC instruction is a memory

bit linked to the status of an input device or an
internal logical condition in a rung.

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 The memory bit is set to 1 or 0 depending
on the status of the input.
A 1 corresponds to a true status or on condition.

If the instruction memory bit is a 1 (true) this

instruction will allow rung continuity through itself,
like a closed relay contact.
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 A 0 corresponds to a false status or off condition.

If the instruction memory bit is a 0 (false) this

instruction will not allow rung continuity through
itself and will assume a normally open state just
like an open relay contact.
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 The Examine If Open (XIO)
instruction looks and operates like
a normally closed relay contact.

Examine if open (XIO)

Examine-off

This instruction asks the PLC’s processor to examine

if the contact is open.

It does this by examining the bit at the memory

location specified by the address for a 0 or 1.

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 Normally closed input
As with any other input the memory bit is set to 1 or 0
depending on the status of the input. A 1 corresponds to
a true status or on condition.

The instruction is interpreted as false when the bit is

1 and will not allow rung continuity through itself.
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 Normally open input
A 0 corresponds to a off condition.

The instruction is interpreted as true when the bit is

0 and will not allow rung continuity through itself.
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 Truth table
Examine-on (XIC) instructions always
interpret a 1 status as true and a 0
status as false.

Examine-off (XIO) instructions

interpret a 1 status as false and a 0
status as true.
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 OTE instruction
The Output Energize (OTE) instruction looks
and operates like a relay coil.

This instruction signals the PLC to energize

(switch on) or de-energize (switch off ) the output.
The instruction is associated with a memory bit that
energizes the output when set to 1 and de-energizes
the output when reset to 0.
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 OTE logic
OTE instruction
is set to 1 to
energize the
output.

A true logic
path is
established by
the input
instructions in
the rung.
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 Action of the field device and PLC bit.

A signal
present
makes the
NO bit (1)
true; a signal
absent makes
the NO bit
(0) false. The
reverse is
true for an
NC bit.
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 The main function of the ladder logic
The main function of the ladder logic diagram
program is to control outputs based on input
conditions.
Each contact or coil symbol is referenced with an
address that identifies what is being evaluated and
what is being controlled.

The same contact

instruction can be
used throughout the
program whenever
that condition needs
to be evaluated.
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 For an output to be activated or energized,
at least one left-to-right true logical path
must exist.

A complete closed
path is referred to
as having logical
continuity.

When logical continuity exists in at least one path, the

rung condition and Output Energize instruction are
said to be true.
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 Section 5.5

Instruction Addressing

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 Each instruction is assigned an address.

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 Allen-Bradley Logix 5000 controllers use tags
for assigning and referencing memory spaces.

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 The assignment of an I/O address can be
included in the I/O connection diagram.

Inputs and outputs are typically represented by

squares and diamonds, respectively.
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 Section 5.6

Branch Instructions

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 Branch instructions are used to create parallel
paths of input condition instructions.

The rung will be

true if either
instruction A or
B is true.

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 Parallel branches can be used to allow more
than one combination of input conditions.

Either A and not B, or C provides logical

continuity and energizes output D.

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 Output branching allows a true logic path to
control multiple outputs.

Either A or B provides a
true logical path to all
three output instructions:
C, D, and E.

Additional input
instructions can be
programmed in the
output branches.
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 Input and output branches can be nested to
avoid redundant instructions and to speed up
processor scan time.

A nested branch starts or ends within another branch.

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 Nested branch
In some PLC models, the
programming of a nested
branch cannot be done
directly.

It is possible, however,
to program a logically
equivalent branching
condition.

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 The PLC will not
allow for
programming of
vertical contacts.

Boolean equation: Y = (AD) + (BCD) + (BE) + (ACE)

Reprogrammed to eliminate
vertical contact.

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 Right to left logic
The processor examines the ladder logic rung
for logic continuity from left to right.
If programmed as shown,
contact combination
FDBC would be ignored.

Boolean equation: Y = (ABC) + (ADE) + (FE) + (FDBC)

Reprogrammed circuit.

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 Section 5.7

Internal Relay Instructions

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 Internal relay used for a program that
requires more series contacts than the
rung allows.

This PLC allows for only 7 series contacts when 12

are actually required for the programmed logic.
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 Section 5.8

Programming
Examine If Closed and
Examine If Open
Instructions
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 Examine If Closed (XIC) instruction

Both the NO and the NC pushbuttons are represented

in the program by the Examine If Closed instruction.

The normal state of the field input device (NO or NC)

does not matter to the controller.

What matters is that contacts need to be closed to

energize the output.
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 Examine If Open (XIO) instruction

The pushbutton is represented in the user program

by an Examine If Open instruction.

This is because the rung must be true when the

external pushbutton is open and false when the
pushbutton is closed.
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 OTE Truth Table

The logic states (0 or 1) indicate whether an instruction

is true or false and is the basis of controller operation.

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 OTE Timed Truth Table

The time aspect relates to the repeated scans of the

program, wherein the input table is updated with
the most current status bits.

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 Section 5.9

Entering the Ladder Diagram

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 Allen-Bradley’s RSLogix
Rockwell’s RSLogix software packages are
windows programming packages used to
develop ladder logic programs.
Software, in various versions, can be used to program
the SLC 500, ControlLogix, CompactLogix and
MicroLogic family of processors.

A personal computer is most often used and is adapted

to the particular PLC model through the use of the
relevant programmable controller software.

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 RSLogix 500 main window.

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 Instruction toolbar with bit instructions selected.

To place an instruction on a rung, click its

icon on the toolbar and simply drag the
instruction straight off the toolbar onto
the rung of the ladder.

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 Select Processor Type
The programming
software needs to
know what
processor is being
used in conjunction
with the user
program.

The Select Processor Type screen contains a list of the

different processors that the RSLogix software can
program.
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 I/O Configuration
The I/O Configuration screen lets you double
click or drag-and-drop a module from an all-
inclusive list to assign it to a slot in your
configuration.

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 Data File B3
Data File screens contain data that are used in
conjunction with ladder program instructions
and include input and output files as well as
timer, counter, integer, and bit files.

The bit file B3 is used for internal relays.

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 Relay ladder logic
Relay ladder logic is a graphical programming
language designed to closely represent the
appearance of a wired relay system.
The logic is apparent
from the
highlighting which
identifies the logic
state of contacts in
real time and which
rungs have logic
continuity.

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 Section 5.10

Modes of Operation

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 Processor modes
A processor has basically two modes of
operation: the program mode and some
variation of the run mode.

A three-position key switch may be used to

select different processor modes of operation.
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 List of processor modes
The program mode is used to enter a new program,
edit or update an existing program, upload files and
download files.

The run mode is used to execute the user program.

The test mode is used to operate or monitor the user

program without energizing any outputs.

The remote position allows the PLC to be remotely

changed between program and run mode by a
personal computer connected to the PLC processor.

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 Section 5.11

Connecting with Analog Devices

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 Digital vs Analog
Digital devices operate using, discrete ON or
OFF signals, that have only two possible values.

Analog signals can take any shape and represent

an infinite number of possible values.

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 Analog-to-Digital Converter
Analog signals must be coded into digital signals
before they can be processed by the PLC.
An analog-to-digital converter (ADC) converts the
analog input signals to digital signals.

A digital-to-analog converter (DAC) converts the

digital output signals back to analog signals.
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 Analog Control For A Tank-Filling Process

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