PLC Programming Techniques 1

PLC Programming 
Techniques   – Part 1

1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 1
PLC Programming Techniques 1
Lesson Objectives

• Introduction regarding basic PLC Texts and their

advantages and limitations.
• Take a look at basic hardware configurations for
moving equipment
• Build a simple program covering Automatic and Manual
Modes
• Include ideas for Cycle Start and End of Cycle
• Discuss various Faults, their meaning and possible
application.

1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 2
PLC Programming Techniques 1
PLC Texts

• Many pages devoted to introduction to Binary Logic

operations including AND, NAND, NOR and XOR gates
(to name a few).
• Conversion and Binary Logic Simplification exercises
• Boolean Logic to Ladder Conversion

• Although good basic and introduction to Logical Systems,

most of this has very little to do with Programming
Machines or Automation on a Factory Floor.
• Some exercise are still very basic and do little to
explain systematic approaches to controls.

1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 3
PLC Programming Techniques 1
Challenge

To discuss system programming, we must start by

defining the system being controlled and make some
assumptions regarding its operation.

Example:
• Simple machine with a cylinder that must advance and
return.
• Could be some events that precede the cylinder motion
• A Process is started once the Cylinder is the Advanced
and held in Position.
• Solenoid type must be defined (see next slide).

1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 4
PLC Programming Techniques 1
+ Vdc Auto PB Input Card

• Begin by defining some standard

Manual PB PLC inputs.
• All N.O. for simplicity (although there is
typically a mixture of N.O. and N.C.
Hand/Auto • Could be Physical PB or even inputs from
Reset HMI

Cycle
Start PB For this example, addressing is not necessary
and will not be discussed

Cycle
Stop PB
N.O. = Normally Open
N.C. = Normally Closed
1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 5
PLC Programming Techniques 1
Complication Factors not Addressed:

Programming Techniques is a very difficult subject to discuss since

how the program is written will depend heavily on many other
mitigating factors such as:

• Safety Issues related to valves (Estop energy release, moving a

pneumatic cylinder without first being pressurized, need to hold in a
position, speed and response of mechanical systems etc.).
• Pneumatic versus Hydraulic
• Single Sided Spring Return
• Double Sided - Detent versus Spring Return
• 3 Position versus 2 Position
• 3 Position Center Blocked
• 3 Position Center Vented or Return to Tank

1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 6
PLC Programming Techniques 1
+ Vdc
Input Card
Adv’d LS
• Outputs move a pneumatic cylinder
to an Advanced Position and then
Return it (Home) again.
Ret’d LS • Double sided, electrically held, spring return
to center.
• Center position vents all energy but could
also be blocked if necessary.

Output Card Adv. Sol. 0 Vdc

Supply Advance

Ret. Sol.

Exhaust
Return

1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 7
PLC Programming Techniques 1

Machine at Communication Permission

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
I/O Power Home Interlock Okay To Start Cycle
‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐‐

• A typical machine, system or process will have conditions that are required
for starting of the cycle.
• Permissions are particular to each machine, system or process with a few
suggestions noted here.
• The next few slides show some samples of simple machine programming.
• For these examples, Latches --- (L) --- will not be used. Seals, it can be
argued, are a better choice.

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PLC Programming Techniques 1
Auto Mode Manual Hand / Auto * Cat 0 Auto

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Auto P.B. Conditions Mode Reset Fault Mode

‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Auto
Mode
‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Auto Hand / Auto Manual

Manual P.B. Mode Reset Mode
‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Manual
Mode
‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
• Mode selection is best handled by Sealing Circuits and a Reset that
is required to switch Modes.
• There may be some additional conditions for Auto. Typically less
conditions for Manual Mode.
*Cat 0 Fault:  See last slide
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PLC Programming Techniques 1
Auto Cycle Permission Machine Cycle Cat 0 In
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Mode Start P.B. to Cycle Start Complete Fault Cycle

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐
In End of Cycle
Cycle Request
‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐

End of Cycle In End of Cycle
Request P.B. Cycle Request
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

* Cat 2
Fault • Once in Auto Mode, a cycle can be initiated.
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐ • Stop at the End of a Complete Cycle.
End of Cycle -- OR --
Request • End of Cycle Request allows continuous
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐ operation or stop once current cycle is complete.

*Cat 2 Fault:  See last slide
1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 10
PLC Programming Techniques 1
Auto Return Advance
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Step F Mode Cylinder Cylinder

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Advance
Complete
‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐
Manual Advance Return
Mode Cyl P.B. Cyl P.B.
‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐
Advanced Stabilization  Advance
Limit Sw. Timer Complete
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ TON ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐
0.200s

• In Automatic Mode the cylinder advances when Step 7 Activates.

• In this example Step 7 contains the necessary permissions to Advance.
• A 200ms debounce or stabilization time is used.

1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 11
PLC Programming Techniques 1

Auto Advance Return Start

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Cycle Complete Cylinder Process

‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Start
Process
‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐

• Advance Complete is not mode dependent so Auto Cycle is required for the
Process to Start.
• Start Process is used to seal around Advance Complete.
• Seal may not be required but if the Advance Proximity “flickers” due to the
Process (ie: Press moving the part slightly), the Operation will not be interrupted.
• Fault logic should hand abnormal conditions.

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PLC Programming Techniques 1
Process Auto Return Return
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Complete Mode Complete Cylinder

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Return
Cylinder
‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐
Manual Return Advance
Mode Cyl P.B. Cyl P.B.
‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐
Returned Stabilization  Return
Limit Sw. Timer Complete
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ TON ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐
0.200s

• In Automatic Mode the Cylinder returns after the Process is complete.

• A 200ms debounce or stabilization time is used to ensure the cylinder
has Returned Completely.
• The Return Seal is broken once Stabilization is complete.

1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 13
PLC Programming Techniques 1
Stabilization 
Returned Advanced Return
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Timer
Limit Sw. Limit Sw. Complete
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐ ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐
TON
‐ 0.200s

• Resist the temptation to add additional conditions.

• Use fault logic to detect and act on anomalies.
• If, in this case, the Advance Switch were to stick Closed, the program
would now fail to detect that the Cylinder has Returned possibly creating
erroneous fault states and limit recovery options

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PLC Programming Techniques 1
Returned Advanced Switch

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Limit Sw. Limit Sw. Fault

‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Switch Fault
Fault Reset
‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐
Advance Advanced Motion 
Timeout
Cylinder Limit Sw. Fault
‐‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ TON ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Motion Fault 10.0s
Fault Reset
‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐

• Fault logic can be tricky without a clearly defined fault detection strategy.
For example, will the machine execute an Immediate or End of Cycle Stop?
• It is a good practice to hold Fault Bits on until Explicitly Reset to aid in
Diagnosing the Root Cause.
• Note that resetting may seem to clear a motion fault but then see a
reoccurrence at the next cycle.

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PLC Programming Techniques 1
Switch General

‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Fault Reset Fault

‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐

‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Motion 
Fault
‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
General Acknowledge 
Fault Oneshot or Silence Alarm
‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐[ / ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐(    )‐‐‐‐‐‐‐

Alarm ‐‐‐‐‐‐‐‐‐‐‐‐‐‐
‐‐‐‐‐‐‐‐‐‐‐‐‐[   ]‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
• Some simple logic to trigger a Fault Bit and also an Alarm Bit for Annunciation.
• In this example, Alarms can be Acknowledged or Silenced; however, if a Fault
still exists when the Reset Button is Pressed, the Alarm Annunciation will be
re-triggered.
• Depending on the number of expected faults, this method might not be
optimal.

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PLC Programming Techniques 1
Category Definitions

Cat 0: Stopping by immediate removal of power to the machine

actuators (i.e., an uncontrolled stop). Traditional E-stop.

Cat 1: A controlled stop with power available to the machine actuators

to achieve the stop and then removal of power when the stop is
achieved.

Cat 2: A controlled stop with power left available to the machine

actuators. Traditional End of Cycle Stop

Wording varies depending on the specification

(IEC 60204-1, NFPA 79, CSA C22.2 No. 301)

1Feb2020 PLC Programming Techniques 1 © 2020 Wayne Schaefer All rights reserved 17