Ladder logic program

Internal
Inputs Start Stop relay Output
L1 I:3/0 I:3/1 B3:1/0 L2
Jog

I:3/2 B3:1/0
Start OL
O:2/2 M
I:3/0 Jog Stop M
I:3/2 I:3/1 O:2/2
Stop
I:3/1
B3:1/0

Figure 6-69 PLC program equivalent of the hardwired relay jog circuit.

6.12 Writing a Ladder Logic Program
Directly from a Narrative Description
In most cases, it is possible to prepare a ladder logic program
directly from the narrative description of a control process.
Some of the steps in planning a program are as follows:
• Define the process to be controlled.
• Draw a sketch of the process, including all sensors
and manual controls needed to carry out the control
sequence.
• List the sequence of operational steps in as much
detail as possible.
• Write the ladder logic program to be used as a basis
for the PLC program.
• Consider different scenarios where the process se-
quence may go astray and make adjustments as needed.
• Consider the safety of operating personnel and
make adjustments as needed.
The following are examples of ladder logic programs
derived from narrative descriptions of control processes.

EXAMPLE 6-1

Figure 6-70 shows the sketch of a drilling process that PB1 PB2
requires the drill press to turn on only if there is a part Drill
motor
present and the operator has one hand on each of the
start switches. This precaution will ensure that the opera- Switches
tor’s hands are not in the way of the drill.
The sequence of operation requires that switches
1 and 2 and the part sensor all be activated to make the
drill motor operate. Figure 6-71 shows the ladder logic
program required for the process implemented using an
SLC 500 controller.

Part sensor

Figure 6-70 Sketch of the drilling process.

Inputs Ladder logic program Output
L1 L2
PB1 Motor
PB1 PB2 Sensor contactor Motor
I:3/4 I:3/5 I:3/6 O:4/0 contactor
I:3/4
O:4/0 M
PB2

I:3/5
Sensor

I:3/6

Figure 6-71 Drilling process PLC program.

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EXAMPLE 6-2

A motorized overhead garage door is to be operated au-
tomatically to preset open and closed positions. The field
devices include one of each of the following:
• Reversing motor contactor for the up and down
directions.
• Normally open down limit switch to sense when the
door is fully closed.
• Normally open-held closed up limit switch to sense
when the door is fully opened.
• Normally open door up button for the up direction.
• Normally open door down button for the down
direction.
• Normally closed door stop button for stopping the
door.
• Red door ajar light to signal when the door is partially
open.
• Green door open light to signal when the door is fully
open.
• Yellow door closed light to signal when the door is fully
closed.
The sequence of operation requires that:
• When the up button is pushed, the up motor contac-
tor energizes and the door travels upward until the up
limit switch is actuated.
• When the down button is pushed, the down motor
contactor energizes and the door travels down until
the down limit switch is actuated.
• When the stop button is pushed, the motor stops.
The motor must be stopped before it can change
direction.
Figure 6-72 shows the ladder logic program required for
the operation implemented using an SLC 500 controller.

Input devices Program Output devices

(shown in unactuated
condition) L2
L1
Down Door ajar
Up limit Stop Up Down Intrlock Up limit Motor up
I:3/0 I:3/7 I:3/4 I:3/5 O:4/4 I:3/0 O:4/3 O:4/0 R

Motor up
Down limit O:4/3
I:3/1
Up
Door open
Stop Down Up intrlock Down limit Motor down
I:3/7 I:3/5 I:3/4 O:4/3 I:3/1 O:4/4 O:4/1 G
Door up

I:3/4
Motor down Door
O:4/4
closed

Door down O:4/2 Y

Up limit Down limit Door ajar
I:3/5 I:3/0 I:3/1 O:4/0

Motor
contactor
Stop door
I:3/7 Up limit O:4/3 UP
Door open
I:3/0 O:4/1

Down limit Door closed

Motor
I:3/1 O:4/2 contactor
O:4/4 DN

Figure 6-72 Motorized overhead garage door PLC program.

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 EXAMPLE 6-3

Figure 6-73 shows the sketch of a continuous filling opera- Hopper

tion. This process requires that boxes moving on a con- PL Run
veyor be automatically positioned and filled.
The sequence of operation for the continuous filling
operation is as follows: PL Standby

• Start the conveyor when the start button is momen-

tarily pressed. Solenoid
PL Full
Level
• Stop the conveyor when the stop button is momen-
switch
tarily pressed.
• Energize the run status light when the process is
operating.
• Energize the standby status light when the process is
stopped.
• Stop the conveyor when the right edge of the box is Photo
first sensed by the photosensor. switch
• With the box in position and the conveyor stopped, Motor
open the solenoid valve and allow the box to fill. Filling
should stop when the level sensor goes true.
Start
• Energize the full light when the box is full. The full light Stop
should remain energized until the box is moved clear
of the photosensor. Figure 6-73 Sketch of the continuous filling operation.
Figure 6-74 shows the ladder logic program required for
the operation.

Inputs Ladder logic program Outputs

Stop Start Run
L1 L2
Stop Motor
Run

Start Run Solenoid

Standby

Photo Level Photo Full Run

Full Standby

Level
Photo Run Motor
Full

Full

Run Level Full Photo Solenoid

Figure 6-74 Continuous filling operation PLC program.

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