CHAPTER 1Process control system

Introduction

Generally speaking, process control system is made up of a group of electronic devices and equipment that provide stability, accuracy and eliminate harmful

transition statuses in production processes. Operating system can have different form and implementation, from energy supply units to machines. As a result of fast

progress in technology, many complex operational tasks have been solved by connecting programmable logic controllers and possibly a central computer. Beside

connections with instruments like operating panels, motors, sensors, switches, valves and such, possibilities for communication among instruments are so great that they allow high level of exploitation and process coordination, as well as greater flexibility in realizing an process control system. Each component of an process control system

plays an important role, regardless of its size. For example, without a sensor, PLC wouldn’t know what exactly goes on in the process. In automated system, PLC

controller is usually the central part of an process control system. With execution of a program stored in program memory, PLC continuously monitors status of the system through signals from input devices. Based on the logic implemented in the program, PLC determines which actions need to be executed with output instruments. To run more complex processes it is possible to connect more PLC controllers to a central

computer. A real system could look like the one pictured below:

1.1 Conventional control panel

At the outset of industrial revolution, especially during sixties and seventies, relays were used to operate automated machines, and these were interconnected using wires inside the control panel. In some cases a control panel covered an entire wall. To discover an error in the system much time was needed especially with more complex process control systems. On top of everything, a lifetime of relay contacts was limited, so some relays had to be replaced. If replacement was required, machine had to be stopped and production too. Also, it could happen that there was not enough room for necessary changes. control panel was used only for one particular process, and it wasn’t easy to adapt to the requirements of a new system. As far as maintenance, electricians had to be very skillful in finding errors. In short, conventional control panels proved to be very inflexible. Typical example of

conventional control panel is given in the following picture.  

In this photo you can notice a large number of electrical wires, time relays, timers and other elements of automation typical for that period. Pictured control panel is not one of the more “complicated” ones, so you can imagine what complex ones looked like.

Most frequently mentioned disadvantages of a classic control panel are:

- Too much work required in connecting wires- Difficulty with changes or replacements- Difficulty in finding errors; requiring skillful work force- When a problem occurs, hold-up time is indefinite, usually long.

1.2 Control panel with a PLC controller

With invention of programmable controllers, much has changed in how an process control system is designed. Many advantages appeared. Typical example of control panel with a PLC controller is given in the following picture.

Advantages of control panel that is based on a PLC controller can be presented in few basic points:

1. Compared to a conventional process control system, number of wires needed for connections is reduced by 80%2. Consumption is greatly reduced because a PLC consumes less than a bunch of relays3. Diagnostic functions of a PLC controller allow for fast and easy error detection.4. Change in operating sequence or application of a PLC controller to a different operating process can easily be accomplished by replacing a program through a console or using a PC software (not requiring changes in wiring, unless addition of some input or output device is required).5. Needs fewer spare parts6. It is much cheaper compared to a conventional system, especially in cases where a large number of I/O instruments are needed and when operational functions are complex.7. Reliability of a PLC is greater than that of an electro-mechanical relay or a timer.

1.3  Systematic approach in designing an process control system

First, you need to select an instrument or a system that you wish to control. Automated system can be a machine or a process and can also be called an process control system. Function of an process control system is constantly watched by input devices (sensors) that give signals to a PLC controller. In response to this, PLC controller sends a signal to external output devices (operative instruments) that actually control how system functions in an assigned manner (for simplification it is recommended that you draw a block diagram of operations’ flow).

Secondly, you need to specify all input and output instruments that will be connected to a PLC controller. Input devices are various switches, sensors and such. Output devices can be solenoids, electromagnetic valves, motors, relays, magnetic starters as well as instruments for sound and light signalization. Following an identification of all input and output instruments, corresponding designations are assigned to input and output lines of a PLC controller. Allotment of

these designations is in fact an allocation of inputs and outputs on a PLC controller which correspond to inputs and outputs of a system being designed.

Third, make a ladder diagram for a program by following the sequence of operations that was determined in the first step.Finally, program is entered into the PLC controller memory. When finished with programming, checkup is done for any existing errors in a program code (using functions for diagnostics) and, if possible, an entire operation is simulated. Before this system is started, you need to check once again whether all input and output instruments are connected to correct inputs or outputs. By bringing supply in, system starts working.

CHAPTER 2  Introduction to PLC controllers

Introduction2.1 First programmed controllers2.2 PLC controller parts2.3 Central Processing unit -CPU2.4 Memory2.5 How to program a PLC controller2.6 Power supply2.7 Input to a PLC controller2.8 Input adjustable interface 2.9 Output from a PLC controller2.10 Output adjustable interface2.11 Extension lines

Introduction

Industry has begun to recognize the need for quality improvement and increase in productivity in the sixties and seventies. Flexibility also became a major concern (ability to change a process quickly became very important in order to satisfy consumer needs).

Try to imagine automated industrial production line in the sixties and seventies. There was always a huge electrical board for system controls, and not infrequently it covered an entire wall! Within this board there was a great number of interconnected electromechanical relays to make the whole system work. By word "connected" it was understood that electrician had to connect all relays manually using wires! An engineer would design logic for a system, and electricians would receive a schematic outline of logic that they had to implement with relays. These relay schemas often contained hundreds of relays. The plan that electrician was given was called "ladder schematic". Ladder displayed all switches, sensors, motors, valves, relays, etc. found in the system. Electrician's job was to connect them all together. One of the problems with this type of control was that it was based on mechanical relays. Mechanical instruments were usually the weakest connection in the system due to their moveable parts that could wear out. If one relay stopped working, electrician would have to examine an entire system (system would be out until a cause of the problem was found and corrected).

The other problem with this type of control was in the system's break period when a system had to be turned off, so connections could be made on the electrical board. If

a firm decided to change the order of operations (make even a small change), it would turn out to be a major expense and a loss of production time until a system was functional again.

It's not hard to imagine an engineer who makes a few small errors during his project. It is also conceivable that electrician has made a few mistakes in connecting the system. Finally, you can also imagine having a few bad components. The only way to see if everything is all right is to run the system. As systems are usually not perfect with a first try, finding errors was an arduous process. You should also keep in mind that a product could not be made during these corrections and changes in connections. System had to be literally disabled before changes were to be performed. That meant that the entire production staff in that line of production was out of work until the system was fixed up again. Only when electrician was done finding errors and repairing,, the system was ready for production. Expenditures for this kind of work were too great even for well-to-do companies.

2.1 First programmable controllers

"General Motors" is among the first who recognized a need to replace the system's "wired" control board. Increased competition forced auto-makers to improve production quality and productivity. Flexibility and fast and easy change of automated lines of production became crucial! General Motors' idea was to use for system logic one of the microcomputers (these microcomputers were as far as their strength beneath today's eight-bit microcontrollers) instead of wired relays. Computer could take place of huge, expensive, inflexible wired control boards. If changes were needed in system logic or in order of operations, program in a microcomputer could be changed instead of rewiring of relays. Imagine only what elimination of the entire period needed for changes in wiring meant then. Today, such thinking is but common, then it was revolutionary!

Everything was well thought out, but then a new problem came up of how to make electricians accept and use a new device. Systems are often quite complex and require complex programming. It was out of question to ask electricians to learn and use computer language in addition to other job duties. General Motors Hidromatic Division of this big company recognized a need and wrote out project criteria for first programmable logic controller ( there were companies which sold instruments that performed industrial control, but those were simple sequential controllers û not PLC controllers as we know them today). Specifications required that a new device be based on electronic instead of mechanical parts, to have flexibility of a computer, to function in industrial environment (vibrations, heat, dust, etc.) and have a capability of being reprogrammed and used for other tasks. The last criteria was also the most important, and a new device had to be programmed easily and maintained by electricians and technicians. When the specification was done, General Motors looked for interested companies, and encouraged them to develop a device that would meet the specifications for this project.

"Gould Modicon" developed a first device which met these specifications. The key to success with a new device was that for its programming you didn't have to learn a new programming language. It was programmed so that same language ûa ladder diagram, already known to technicians was used. Electricians and technicians could very easily understand these new devices because the logic looked similar to old logic that they were used to working with. Thus they didn't have to learn a new programming language which (obviously) proved to be a good move. PLC controllers were initially called PC controllers (programmable controllers). This caused a small confusion when Personal Computers appeared. To avoid confusion, a designation PC

was left to computers, and programmable controllers became programmable logic controllers. First PLC controllers were simple devices. They connected inputs such as switches, digital sensors, etc., and based on internal logic they turned output devices on or off. When they first came up, they were not quite suitable for complicated controls such as temperature, position, pressure, etc. However, throughout years, makers of PLC controllers added numerous features and improvements. Today's PLC controller can handle highly complex tasks such as position control, various regulations and other complex applications. The speed of work and easiness of programming were also improved. Also, modules for special purposes were developed, like communication modules for connecting several PLC controllers to the net. Today it is difficult to imagine a task that could not be handled by a PLC.

2.2 PLC controller components

PLC is actually an industrial microcontroller system (in more recent times we meet processors instead of microcontrollers) where you have hardware and software specifically adapted to industrial environment. Block schema with typical components which PLC consists of is found in the following picture. Special attention needs to be given to input and output, because in these blocks you find protection needed in isolating a CPU blocks from damaging influences that industrial environment can bring to a CPU via input lines. Program unit is usually a computer used for writing a program (often in ladder diagram).

2.3 Central Processing Unit - CPU

Central Processing Unit (CPU) is the brain of a PLC controller. CPU itself is usually one of the microcontrollers. Aforetime these were 8-bit microcontrollers such as 8051, and now these are 16- and 32-bit microcontrollers. Unspoken rule is that you'll find mostly Hitachi and Fujicu microcontrollers in PLC controllers by Japanese makers, Siemens in European controllers, and Motorola microcontrollers in American ones. CPU also takes care of communication, interconnectedness among other parts of PLC controller, program execution, memory operation, overseeing input and setting up of an output. PLC controllers have complex routines for memory checkup in order to ensure that PLC memory was not damaged (memory checkup is done for safety reasons). Generally speaking, CPU unit makes a great number of check-ups of the PLC controller itself so eventual errors would be discovered early. You can simply look at any PLC controller and see that there are several indicators in the form of light diodes for error signalization.  

2.4 Memory

System memory (today mostly implemented in FLASH technology) is used by a PLC for an process control system. Aside from this operating system it also contains a user program translated from a ladder diagram to a binary form. FLASH memory contents can be changed only in case where user program is being changed. PLC controllers were used earlier instead of FLASH memory and have had EPROM memory instead of FLASH memory which had to be erased with UV lamp and programmed on programmers. With the use of FLASH technology this process was greatly shortened. Reprogramming a program memory is done through a serial cable in a program for application development.

User memory is divided into blocks having special functions. Some parts of a memory are used for storing input and output status. The real status of an input is stored either as "1" or as "0" in a specific memory bit. Each input or output has one corresponding bit in memory. Other parts of memory are used to store variable contents for variables used in user program. For example, timer value, or counter value would be stored in this part of the memory.

2.5 Programming a PLC controller

PLC controller can be reprogrammed through a computer (usual way), but also through manual programmers (consoles). This practically means that each PLC controller can programmed through a computer if you have the software needed for programming. Today's transmission computers are ideal for reprogramming a PLC controller in factory itself. This is of great importance to industry. Once the system is corrected, it is also important to read the right program into a PLC again. It is also

good to check from time to time whether program in a PLC has not changed. This helps to avoid hazardous situations in factory rooms (some automakers have established communication networks which regularly check programs in PLC controllers to ensure execution only of good programs).

Almost every program for programming a PLC controller possesses various useful options such as: forced switching on and off of the system inputs/ouputs (I/O lines), program follow up in real time as well as documenting a diagram. This documenting is necessary to understand and define failures and malfunctions. Programmer can add remarks, names of input or output devices, and comments that can be useful when finding errors, or with system maintenance. Adding comments and remarks enables any technician (and not just a person who developed the system) to understand a ladder diagram right away. Comments and remarks can even quote precisely part numbers if replacements would be needed. This would speed up a repair of any problems that come up due to bad parts. The old way was such that a person who developed a system had protection on the program, so nobody aside from this person could understand how it was done. Correctly documented ladder diagram allows any technician to understand thoroughly how system functions.

2.6. Power supply

Electrical supply is used in bringing electrical energy to central processing unit. Most PLC controllers work either at 24 VDC or 220 VAC. On some PLC controllers you'll find electrical supply as a separate module. Those are usually bigger PLC controllers, while small and medium series already contain the supply module. User has to determine how much current to take from I/O module to ensure that electrical supply provides appropriate amount of current. Different types of modules use different amounts of electrical current.

This electrical supply is usually not used to start external inputs or outputs. User has to provide separate supplies in starting PLC controller inputs or outputs because then you can ensure so called "pure" supply for the PLC controller. With pure supply we mean supply where industrial environment can not affect it damagingly. Some of the smaller PLC controllers supply their inputs with voltage from a small supply source already incorporated into a PLC.

2.7 PLC controller inputs

Intelligence of an automated system depends largely on the ability of a PLC controller to read signals from different types of sensors and input devices. Keys, keyboards and by functional switches are a basis for man versus machine relationship. On the other hand, in order to detect a working piece, view a mechanism in motion, check pressure or fluid level you need specific automatic devices such as proximity sensors, marginal switches, photoelectric sensors, level sensors, etc. Thus, input signals can be logical (on/off) or analogue. Smaller PLC controllers usually have only digital input lines while larger also accept analogue inputs through special units attached to PLC controller. One of the most frequent analogue signals are a current signal of 4 to 20 mA and milivolt voltage signal generated by various sensors. Sensors are usually used as inputs for PLCs. You can obtain sensors for different purposes. They can sense presence of some parts, measure temperature, pressure, or some other physical dimension, etc. (ex. inductive sensors can register metal objects).

Other devices also can serve as inputs to PLC controller. Intelligent devices such as robots, video systems, etc. often are capable of sending signals to PLC controller input modules (robot, for instance, can send a signal to PLC controller input as

information when it has finished moving an object from one place to the other.)

2.8 Input adjustment interface

Adjustment interface also called an interface is placed between input lines and a CPU unit. The purpose of adjustment interface to protect a CPU from disproportionate signals from an outside world. Input adjustment module turns a level of real logic to a level that suits CPU unit (ex. input from a sensor which works on 24 VDC must be converted to a signal of 5 VDC in order for a CPU to be able to process it). This is typically done through opto-isolation, and this function you can view in the following picture. Opto-isolation means that there is no electrical connection between external world and CPU unit. They are "optically" separated, or in other words, signal is transmitted through light. The way this works is simple. External device brings a signal which turns LED on, whose light in turn incites photo transistor which in turn starts conducting, and a CPU sees this as logic zero (supply between collector and transmitter falls under 1V). When input signal stops LED diode turns off, transistor stops conducting, collector voltage increases, and CPU receives logic 1 as information. 

2.9 PLC controller output

Automated system is incomplete if it is not connected with some output devices. Some of the most frequently used devices are motors, solenoids, relays, indicators, sound signalization and similar. By starting a motor, or a relay, PLC can manage or control a simple system such as system for sorting products all the way up to complex systems such as service system for positioning head of CNC machine. Output can be of analogue or digital type. Digital output signal works as a switch; it connects and disconnects line. Analogue output is used to generate the analogue signal (ex. motor whose speed is controlled by a voltage that corresponds to a desired speed).

2.10 Output adjustment interface

Output interface is similar to input interface. CPU brings a signal to LED diode and turns it on. Light incites a photo transistor which begins to conduct electricity, and thus the voltage between collector and emmiter falls to 0.7V , and a device attached to this output sees this as a logic zero. Inversely it means that a signal at the output exists and is interpreted as logic one. Photo transistor is not directly connected to a

PLC controller output. Between photo transistor and an output usually there is a relay or a stronger transistor capable of interrupting stronger signals.

2.11 Extension lines

Every PLC controller has a limited number of input/output lines. If needed this number can be increased through certain additional modules by system extension through extension lines. Each module can contain extension both of input and output lines. Also, extension modules can have inputs and outputs of a different nature from those on the PLC controller (ex. in case relay outputs are on a controller, transistor outputs can be on an extension module).

CHAPTER 3 Connecting sensors and execution devices

Introduction3.1 Sinking-sourcing concept3.2 Input lines3.3 Output lines

Introduction

Connecting external devices to a PLC controller regardless whether they are input or output is a special subject matter for industry. If it stands alone, PLC controller itself is nothing. In order to function it needs sensors to obtain information from environment, and it also needs execution devices so it could turn the programmed change into a reality. Similar concept is seen in how human being functions. Having a brain is simply not enough. Humans achieve full activity only with processing of information from a sensor (eyes, ears, touch, smell) and by taking action through hands, legs or some tools. Unlike human being who receives his sensors automatically, when dealing with controllers, sensors have to be subsequently connected to a PLC. How to connect input and output parts is the topic of this chapter.

3.1 Sinking-Sourcing Concept

PLC has input and output lines through which it is connected to a system it directs. Input can be keys, switches, sensors while outputs are led to different devices from simple signalization lights to complex communication modules.

This is a very important part of the story about PLC controllers because it directly influences what can be connected and how it can be connected to controller inputs or outputs. Two terms most frequently mentioned when discussing connections to inputs or outputs are "sinking" and "sourcing". These two concepts are very important in connecting a PLC correctly with external environment. The most brief definition of these two concepts would be:

SINKING = Common GND line (-)SOURCING = Common VCC line (+)

First thing that catches one's eye are "+" and "-" supply, DC supply. Inputs and outputs which are either sinking or sourcing can conduct electricity only in one direction, so they are only supplied with direct current.

According to what we've said thus far, each input or output has its own return line, so 5 inputs would need 10 screw terminals on PLC controller housing. Instead, we use a system of connecting several inputs to one return line as in the following picture. These common lines are usually marked "COMM" on the PLC controller housing.

 

3.2 Input lines

Explanation of PLC controller input and output lines has up to now been given only theoretically. In order to apply this knowledge, we need to make it a little more specific. Example can be connection of external device such as proximity sensor. Sensor outputs can be different depending on a sensor itself and also on a particular application. Following pictures display some examples of sensor outputs and their connection with a PLC controller. Sensor output actually marks the size of a signal

given by a sensor at its output when this sensor is active. In one case this is +V (supply voltage, usually 12 or 24V) and in other case a GND (0V). Another thing worth mentioning is that sinking-sourcing and sourcing - sinking pairing is always used, and not sourcing-sourcing or sinking-sinking pairing.

 

 

If we were to make type of connection more specific, we'd get combinations as in following pictures (for more specific connection schemas we need to know the exact sensor model and a PLC controller model). 

 

3.3 Output lines

PLC controller output lines usually can be:

-transistors in PNP connection-transistors in NPN connection-relays

The following two pictures display a realistic way how a PLC manages external devices. It ought to be noted that a main difference between these two pictures is a position of "output load device". By "output load device" we mean some relay, signalization light or similar.

 

How something is connected with a PLC output depends on the element being connected. In short, it depends on whether this element of output load device is activated by a positive supply pole or a negative supply pole.

CHAPTER 4  Architecture of specific PLC controller

Introduction4.1 Why OMRON?4.2 CPM1A PLC controller4.3 PLC controller input lines4.4 PLC controller output lines4.5 How PLC controller works4.6 CPM1A PLC controller memory map4.7 Timers and counters

Introduction

This book could deal with a general overview of some supposed PLC controller. Author has had an opportunity to look over plenty of books published up till now, and this approach is not the most suitable to the purposes of this book in his opinion. Idea of this book is to work through one specific PLC controller where someone can get a real feeling on this subject and its weight. Our desire was to write a book based on whose reading you can earn some money. After all, money is the end goal of every business!

4.1 Why OMRON?

Why not? It is a huge company which has high quality and by our standards inexpensive controllers. Today we can say almost with surety that PLC controllers by manufacturers round the world are excellent devices, and altogether similar. Nevertheless, for specific application we need to know specific information about a PLC controller being used. Therefore, the choice fell on OMRON company and its PLC of micro class CPM1A. Adjective "micro" itself implies the smallest models from the viewpoint of a number of attached lines or possible options. Still, this PLC controller is ideal for the purposes of this book, and that is to introduce a PLC controller philosophy to its readers.

4.2 CPM1A PLC controller

Each PLC is basically a microcontroller system (CPU of PLC controller is based on one of the microcontrollers, and in more recent times on one of the PC processors) with peripherals that can be digital inputs, digital outputs or relays as in our case. However, this is not an "ordinary" microcontroller system. Large teams have worked on it, and a checkup of its function has been performed in real world under all possible circumstances. Software itself is entirely different from assemblers used thus far, such as BASIC or C. This specialized software is called "ladder" (name came about by an association of program's configuration which resembles a ladder, and from the way program is written out).

Specific look of CPM1A PLC controller can be seen in the following picture. On the upper surface, there are 4 LED indicators and a connection port with an RS232 module which is interface to a PC computer. Aside from this, screw terminals and light indicators of activity of each input or output are visible on upper and lower sides. Screw terminals serve to manually connect to a real system. Hookups L1 and L2 serve as supply which is 220V~ in this case. PLC controllers that work on power grid voltage usually have a source of direct supply of 24 VDC for supplying sensors and such (with a CPM1A source of direct supply is found on the bottom left hand side and is represented with two screw terminals. Controller can be mounted to industrial "track" along with other automated elements, but also by a screw to the machine wall or control panel.

 

Controller is 8cm high and divided vertically into two areas: a lower one with a converter of 220V~ at 24VDC and other voltages needed for running a CPU unit; and, upper area with a CPU and memory, relays and digital inputs.

When you lift the small plastic cover you'll see a connector to which an RS232 module is hooked up for serial interface with a computer. This module is used when programming a PLC controller to change programs or execution follow-up. When installing a PLC it isn't necessary to install this module, but it is recommended because of possible changes in software during operation.

To better inform programmers on PLC controller status, maker has provided for four light indicators in the form of LED's. Beside these indicators, there are status indicators for each individual input and output. These LED's are found by the screw terminals and with their status are showing input or output state. If input/output is active, diode is lit and vice versa.

4.3 PLC controller output lines

Aside from transistor outputs in PNP and NPN connections, PLC can also have relays as outputs. Existence of relays as outputs makes it easier to connect with external devices. Model CPM1A contains exactly these relays as outputs. There a 4 relays whose functional contacts are taken out on a PLC controller housing in the form of screw terminals. In reality this looks as in picture below.

With activation of phototransistor, relay comes under voltage and activates a contact between points A and B. Contacts A and B can in our case be either in connection or interrupted. What state these contacts are in is determined by a CPU through appropriate bits in memory location IR010. One example of relay status is shown in a picture below. A true state of devices attached to these relays is displayed.

 

4.4 PLC controller input lines

Different sensors, keys, switches and other elements that can change status of a joined bit at PLC input can be hooked up to the PLC controller inputs. In order to realize a change, we need a voltage source to incite an input. The simplest possible

input would be a common key. As CPM1A PLC has a source of direct voltage of 24V, the same source can be used to incite input (problem with this source is its maximum current which it can give continually and which in our case amounts to 0.2A). Since inputs to a PLC are not big consumers (unlike some sensor where a stronger external supply must be used) it is possible to take advantage of the existing source of direct supply to incite all six keys.

4.5 How PLC controller works

Basis of a PLC function is continual scanning of a program. Under scanning we mean running through all conditions within a guaranteed period. Scanning process has three basic steps:

Step 1.Testing input status. First, a PLC checks each of the inputs with intention to see which one of them has status ON or OFF. In other words, it checks whether a sensor, or a

switch etc. connected with an input is activated or not. Information that processor thus obtains through this step is stored in memory in order to be used in the following step.

Step 2.Program execution. Here a PLC executes a program, instruction by instruction. Based on a program and based on the status of that input as obtained in the preceding step, an appropriate action is taken. This reaction can be defined as activation of a certain output, or results can be put off and stored in memory to be retrieved later in the following step.

Step 3. Checkup and correction of output status. Finally, a PLC checks up output status and adjusts it as needed. Change is performed based on the input status that had been read during the first step, and based on the results of program execution in step two. Following the execution of step 3 PLC returns to the beginning of this cycle and continually repeats these steps. Scanning time is defined by the time needed to perform these three steps, and sometimes it is an important program feature.

 

4.6 CPM1A PLC controller memory map

By memory map we mean memory structure for a PLC controller. Simply said, certain parts of memory have specific roles. If you look at the picture below, you can see that memory for CPM1A is structured into 16-bit words. A cluster of several such words makes up a region. All the regions make up the memory for a PLC controller.

Unlike microcontroller systems where only some memory locations have had their purpose clearly defined (ex. register that contains counter value), a memory of PLC controller is completely defined, and more importantly almost entire memory is addressable in bits. Addressability in bits means that it is enough to write the address of the memory location and a number of bits after it in order to manipulate with it. In short, that would mean that something like this could be written: "201.7=1" which would clearly indicate a word 201 and its bit 7 which is set to one.

IR region

Memory locations intended for PLC input and output. Some bits are directly connected to PLC controller inputs and outputs (screw terminal). In our case, we have 6 input lines at address IR000. One bit corresponds to each line, so the first line has the address IR000.0, and the sixth IR000.5. When you obtain a signal at the input, this immediately affects the status of a corresponding bit. There are also words with work bits in this region, and these work bits are used in a program as flags or certain conditional bits.

SR region

Special memory region for control bits and flags. It is intended first and foremost for counters and interrupts. For example, SR250 is memory location which contains an adjustable value, adjusted by potentiometer no.0 (in other words, value of this location can be adjusted manually by turning a potentiometer no.0.

TR region

When you move to a subprogram during program execution, all relevant data is stored in this region up to the return from a subprogram.

HR region

It is of great importance to keep certain information even when supply stops. This part of the memory is battery supported, so even when supply has stopped it will keep all data found therein before supply stopped.

AR region

This is one more region with control bits and flags. This region contains information on PLC status, errors, system time, and the like. Like HR region, this one is also battery supported.

LR region

In case of connection with another PLC, this region is used for exchange of data.

Timer and counter region

This region contains timer and counter values. There are 128 values. Since we will consider examples with timers and counters, we will discus this region more later on.

DM region

Contains data related to setting up communication with a PC computer, and data on errors.

Each region can be broken down to single words and meanings of its bits. In order to keep the clarity of the book, this part is dealt with in Attachments and we will deal with those regions here whose bits are mostly used for writing.

Note: 1. IR and LR bits that are not used for their allocated functions can be used as work bits.2. The contents of the HR area, LR area, Counter area, and read/write DM area are backed up by a capacitor. At

25 oC, the capacitor will back up memory for 20 days.3. When accessing a PV, TC numbers are used as word data; when accessing Completing Flags, they are used as bit data.4. Data in DM6144 to DM6655 cannot be overwritten from the program, but they can be changed from a Peripheral Device

4.7 Timers and counters

Timers and counters are indispensable in PLC programming. Industry has to number its products, determine a needed action in time, etc. Timing functions is very important, and cycle periods are critical in many processes.

There are two types of timers delay-off and delay-on. First is late with turn off and the other runs late in turning on in relation to a signal that activated timers. Example of a delay-off timer would be staircase lighting. Following its activation, it simply turns off after few minutes.

Each timer has a time basis, or more precisely has several timer basis. Typical values are: 1 second, 0.1 second, and 0,01 second. If programmer has entered .1 as time basis and 50 as a number for delay increase, timer will have a delay of 5 seconds (50 x 0.1 second = 5 seconds).

Timers also have to have value SV set in advance. Value set in advance or ahead of time is a number of increments that timer has to calculate before it changes the output status. Values set in advance can be constants or variables. If a variable is used, timer will use a real time value of the variable to determine a delay. This enables delays to vary depending on the conditions during function. Example is a system that has produced two different products, each requiring different timing during process itself. Product A requires a period of 10 seconds, so number 10 would be assigned to the variable. When product B appears, a variable can change value to what is required by product B.

Typically, timers have two inputs. First is timer enable, or conditional input (when this input is activated, timer will start counting). Second input is a reset input. This input has to be in OFF status in order for a timer to be active, or the whole function would be repeated over again. Some PLC models require this input to be low for a timer to be active, other makers require high status (all of them function in the same way basically). However, if reset line changes status, timer erases accumulated value.

With a PLC controller by Omron there are two types of timers: TIM and TIMH. TIM timer measures in increments of 0.1 seconds. It can measure from 0 to 999.9 seconds with precision of 0.1 seconds more or less.

Quick timer (TIMH) measures in increments of 0.01 seconds. Both timers are "delay-on" timers of a lessening-style. They require assignment of a timer number and a set value (SV). When SV runs out, timer output turns on. Numbers of a timing counter refer to specific address in memory and must not be duplicated (same number can not be used for a timer and a counter).

CHAPTER 5  Ladder diagram

Introduction5.1 Ladder diagram

5.2 Normally open and normally closed contacts5.3 Brief example

Introduction

Programmable controllers are generally programmed in ladder diagram (or "relay diagram") which is nothing but a symbolic representation of electric circuits. Symbols were selected that actually looked similar to schematic symbols of electric devices, and this has made it much easier for electricians to switch to programming PLC controllers. Electrician who has never seen a PLC can understand a ladder diagram.

5.1 Ladder diagram

There are several languages designed for user communication with a PLC, among which ladder diagram is the most popular. Ladder diagram consists of one vertical line found on the left hand side, and lines which branch off to the right. Line on the left is called a "bus bar", and lines that branch off to the right are instruction lines. Conditions which lead to instructions positioned at the right edge of a diagram are stored along instruction lines. Logical combination of these conditions determines when and in what way instruction on the right will execute. Basic elements of a relay diagram can be seen in the following picture.

 

Most instructions require at least one operand, and often more than one. Operand can be some memory location, one memory location bit, or some numeric value -number. In the example above, operand is bit 0 of memory location IR000. In a case when we wish to proclaim a constant as an operand, designation # is used beneath the numeric writing (for a compiler to know it is a constant and not an address.)

Based on the picture above, one should note that a ladder diagram consists of two

basic parts: left section also called conditional, and a right section which has instructions. When a condition is fulfilled, instruction is executed, and that's all!

 

Picture above represents a example of a ladder diagram where relay is activated in PLC controller when signal appears at input line 00. Vertical line pairs are called conditions. Each condition in a ladder diagram has a value ON or OFF, depending on a bit status assigned to it. In this case, this bit is also physically present as an input line (screw terminal) to a PLC controller. If a key is attached to a corresponding screw terminal, you can change bit status from a logic one status to a logic zero status, and vice versa. Status of logic one is usually designated as "ON", and status of logic zero as "OFF".

Right section of a ladder diagram is an instruction which is executed if left condition is fulfilled. There are several types of instructions that could easily be divided into simple and complex. Example of a simple instruction is activation of some bit in memory location. In the example above, this bit has physical connotation because it is connected with a relay inside a PLC controller. When a CPU activates one of the leading four bits in a word IR010, relay contacts move and connect lines attached to it. In this case, these are the lines connected to a screw terminal marked as 00 and to one of COM screw terminals.

5.2 Normally open and normally closed contacts

Since we frequently meet with concepts "normally open" and "normally closed" in industrial environment, it's important to know them. Both terms apply to words such as contacts, input, output, etc. (all combinations have the same meaning whether we are talking about input, output, contact or something else).

Principle is quite simple, normally open switch won't conduct electricity until it is pressed down, and normally closed switch will conduct electricity until it is pressed. Good examples for both situations are the doorbell and a house alarm.

If a normally closed switch is selected, bell will work continually until someone pushes the switch. By pushing a switch, contacts are opened and the flow of electricity towards the bell is interrupted. Of course, system so designed would not in any case suit the owner of the house. A better choice would certainly be a normally open switch. This way bell wouldn't work until someone pushed the switch button and thus informed of his or her presence at the entrance.

Home alarm system is an example of an application of a normally closed switch. Let's

suppose that alarm system is intended for surveillance of the front door to the house. One of the ways to "wire" the house would be to install a normally open switch from each door to the alarm itself (precisely as with a bell switch). Then, if the door was opened, this would close the switch, and an alarm would be activated. This system could work, but there would be some problems with this, too. Let's suppose that switch is not working, that a wire is somehow disconnected, or a switch is broken, etc. (there are many ways in which this system could become dysfunctional). The real trouble is that a homeowner would not know that a system was out of order. A burglar could open the door, a switch would not work, and the alarm would not be activated. Obviously, this isn't a good way to set up this system. System should be set up in such a way so the alarm is activated by a burglar, but also by its own dysfunction, or if any of the components stopped working. (A homeowner would certainly want to know if a system was dysfunctional). Having these things in mind, it is far better to use a switch with normally closed contacts which will detect an unauthorized entrance (opened door interrupts the flow of electricity, and this signal is used to activate a sound signal), or a failure on the system such as a disconnected wire. These considerations are even more important in industrial environment where a failure could cause injury at work. One such example where outputs with normally closed contacts are used is a safety wall with trimming machines. If the wall doors open, switch affects the output with normally closed contacts and interrupts a supply circuit. This stops the machine and prevents an injury.

Concepts normally open and normally closed can apply to sensors as well. Sensors are used to sense the presence of physical objects, measure some dimension or some amount. For instance, one type of sensors can be used to detect presence of a box on an industry transfer belt. Other types can be used to measure physical dimensions such as heat, etc. Still, most sensors are of a switch type. Their output is in status ON or OFF depending on what the sensor "feels". Let's take for instance a sensor made to feel metal when a metal object passes by the sensor. For this purpose, a sensor with a normally open or a normally closed contact at the output could be used. If it were necessary to inform a PLC each time an object passed by the sensor, a sensor with a normally open output should be selected. Sensor output would set off only if a metal object were placed right before the sensor. A sensor would turn off after the object has passed. PLC could then calculate how many times a normally open contact was set off at the sensor output, and would thus know how many metal objects passed by the sensor.

Concepts normally open and normally closed contact ought to be clarified and explained in detail in the example of a PLC controller input and output. The easiest way to explain them is in the example of a relay.  

Normally open contacts would represent relay contacts that would perform a connection upon receipt of a signal. Unlike open contacts, with normally closed contacts signal will interrupt a contact, or turn a relay off. Previous picture shows what this looks like in practice. First two relays are defined as normally open , and the other two as normally closed. All relays react to a signal! First relay (00) has a signal and closes its contacts. Second relay (01) does not have a signal and remains opened. Third relay (02) has a signal and opens its contacts considering it is defined as a closed contact. Fourth relay (03) does not have a signal and remains closed because it is so defined.

Concepts "normally open" and "normally closed" can also refer to inputs of a PLC controller. Let's use a key as an example of an input to a PLC controller. Input where a key is connected can be defined as an input with open or closed contacts. If it is defined as an input with normally open contact, pushing a key will set off an instruction found after the condition. In this case it will be an activation of a relay 00.

If input is defined as an input with normally closed contact, pushing the key will interrupt instruction found after the condition. In this case, this will cause deactivation of relay 00 (relay is active until the key is pressed). You can see in picture below how keys are connected, and view the relay diagrams in both cases.

Normally open/closed conditions differ in a ladder diagram by a diagonal line across a symbol. What determines an execution condition for instruction is a bit status marked beneath each condition on instruction line. Normally open condition is ON if its operand bit has ON status, or its status is OFF if that is the status of its operand bit. Normally closed condition is ON when its operand bit is OFF, or it has OFF status when the status of its operand bit is ON.

When programming with a ladder diagram, logical combination of ON and OFF conditions set before the instruction determines the eventual condition under which the instruction will be, or will not be executed. This condition, which can have only ON or OFF values is called instruction execution condition. Operand assigned to any instruction in a relay diagram can be any bit from IR, SR, HR, AR, LR or TC sector. This means that conditions in a relay diagram can be determined by a status of I/O bits, or of flags, operational bits, timers/counters, etc.

5.3 Brief example

Example below represents a basic program. Example consists of one input device and one output device linked to the PLC controller output. Key is an input device, and a bell is an output supplied through a relay 00 contact at the PLC controller output. Input 000.00 represents a condition in executing an instruction over 010.00 bit. Pushing the key sets off a 000.00 bit and satisfies a condition for activation of a 010.00 bit which in turn activates the bell. For correct program function another line of program is needed with END instruction, and this ends the program.  

The following picture depicts the connection scheme for this example.

 

CHAPTER 6  SYSWIN program for programming a PLC controller

Introduction6.1 Connecting a PLC controller with a PC computer6.2 SYSWIN program installation6.3 Writing your first program6.4 Saving a project6.5 Program transfer to PLC controller6.6 Testing program function6.7 Interpretation of "Tools" icons6.8 PLC controller working modes6.9 Run mode6.10 Monitor mode6.11 Program-Stop mode6.12 Program execution and monitoring6.13 Impact on the program during monitoring6.14 Graphic representation of dimension changes in a program

Introduction

SYSWIN is a software designed for OMRON programmable controllers class C and CV. It is designed for creating and maintaining a program, as well as for testing PLC controller function, in off-line and controller's operational regime. Necessary conditions for starting SYSWIN are Microsoft Windows environment on a standard IBM or 386/486 compatible or Pentium computer, with 8MB RAM at least, and 10MB free disc space.

6.1 Connecting a PLC controller with a PC computer

PLC controller is linked with a PC computer through an RS-232 cable. One end of the cable is connected to a serial PC port (9-pin or 25-pin connector), while the other end is connected to an RS-232C connector on RS232 module of a CPM1A controller. In order to establish a connection with a PC, DIP switch on the connector must be set in "Host" position.  

6.2 SYSWIN program installation

Instruction package for CPM1A is covered by three SYSWIN installation diskettes. It can be installed in Windows 3.1, 3.11, 95, 98 or NT 4.0. In order to start the installation you need to select RUN option from a START menu.

A window will come up like the one below where you need to write in the file command "setup.exe". Mentioned file can be found in the installation directory of Syswin program. Following a brief installation procedure you will get a program group Syswin 3.4.Double-click on Syswin icon starts a Syswin program which opens as in the following picture.  

6.3 Writing your first program

Writing a program begins with New Project option from a File menu. In a message window that appears you need to select options as in picture below.

Select a PLC controller by clicking on OK, and a program is ready to be used. It is recommended when you begin working that you write in a header a title of a program, author's name and inputs/outputs used. This may seem as a waste of time, but really isn't because this habit of writing comments will pay off in the future.

Program written here is just a basic program made for learning Syswin. Program can detect when a key has been pressed and can activate a relay at the PLC controller output. As long as the key is pressed down, a relay is active. Operation of a relay and a key can be followed via LED diodes on PLC controller housing. Writing a program begins with a click on the first icon to the left, recognized by two vertical lines. Icon beneath this one is similar to the first but for a slash. These two icons correspond with concepts normally open and normally closed contact which all instruction lines start with. You can select an option with an open contact by clicking on the first icon. When you click on the black rectangle to the right, a small window will appear where you need to write in the address of a bit a contact relates to.

It is very important to use addresses in a regular way when programming with SYSWIN. Addresses can have two parts, first refers to the word address, and the second to bit address in that word (both numbers must be separated by a period). For example, if address 200 is used, SYSWIN will interpret this as 2.00, and a zero bit whose word address is 2 will be called for. If you wish to access word 200 or its zero bit, you must use a call 20000, or better even 200.00. In this example address 000.00 is assigned for input address (key). This address represents a zero bit for word 000 from memory region IR. Simply said, it is an input screw terminal

designated as 00 input. By connecting a key to it, and to one of the COMM terminal screws, a needed connection between PLC controller and keys is established.

Address dialogue box for a bit that contact refers to

When you have written in 000.00, select OK, and first segment of the program will come up. Bit address will appear above the symbol with two vertical lines which refers to this bit, and a black rectangle will move one space to the right.

First element of a program myprog.swp

First instructions up to the bus bar are called conditions because their execution activates instructions found to the right of the condition instructions. When a condition is entered, you also need to enter a corresponding instruction that is set off by an execution of the condition. In this example it is a relay controlled by a 00 bit in a word 010 of memory region IR. Output instructions are represented by a circle, or a circle and a line if we are dealing with a normally closed contact. By clicking on the icon with a circle, you select an output option with normally open contacts. Click on a black rectangle, and a contact window will come up where you need to write in the address for the output bit 010.00. Output of the IR region is found at address IR010,

and first four bits of this word represent a relay within a PLC controller (if we are talking about a model CPM1A with relay outputs). Program done so far looks as in picture below.

    

Second element of myprog.swp program  

The basic functional entirety of some program is Network. Program consists of several networks found one below the other. Operations with these are found in Block option of the menu. Of all options, two basic ones, Insert network and Delete network are used the most. Other makers for PLC controllers use different concepts such as Rung instead of the term Network. Simply said, we are talking about a PLC program sequence which has one or more executing instructions, and along with END instruction can make up one correct PLC program. As the first network in a program is already in use, the next one has to be added. Adding a Network is done with Insert network command from a Block menu.  

When selecting this option, a small window appears where you need to select whether a new network will appear above or below the existing one.

In our case you should choose the second option and click on OK. Following this, a new network appears as in picture below.

Last network in every program must contain END instruction. Since this is a simple example, second network is also the last. End instruction is found among the functions. In order to come to it, you need to click on FUN icon following which a window as in picture below will come up.

Selecting a function by clicking on FUN icon.

END instruction can be obtained either by writing in "END" in newly obtained window or by clicking on Select which gives all PLC controller instructions sorted by the regions as in the following picture.

Selecting END instruction from a set of instructions sorted in regions.

By entering the END instruction your writing of a program is finished. Finished program looks as in the following picture.

Finished myprog.swp program

6.4 Saving a project

Since you've finished writing a program, you need to save a project. Select Save Project option from a File menu, and write in the file name in a message window (myprog.swp in this case). After you click on OK, project will be saved. You can access SYSWIN file contents only from SYSWIN; file type is identified by extension:

Project.swp - SYSWIN program

Project.swl- SYSWIN library

Project.swt - SYSWIN pattern

Project.swb - SYSWIN back-up file

Project.prg - PMD program

6.5 Program transfer to PLC controller

First you need to check whether PLC is connected with a PC correctly, and you'll do this by checking physical connection through a serial cable. Following this you need to select a Communication option from Project menu in order to set parameters for serial communication. Of all the parameters, the most important one to be selected is

a serial port of a computer that PLC is connected to. Default settings for CPM1A are: COM1, 9600 Baud, Unit 00, protocol ASCII 7 bit Even Parity 2 stop and they need to be left so. To check how communication functions, you can click on Test PLC to test link with a PLC controller.

When a connection has been established, program transfer begins with a click on download from Online menu. Select expansion function or memory allocation. Before you program a PLC, it's good to erase program's memory contents. Finally, after a successful program transfer to a PLC, a message window will come up to inform us of this.

6.6 Testing program function

Program check option from a Project menu allows testing of program function. Message that appears following a command has several options that can be selected before you run a test. Once these options have been selected, click on Execute, and a report on testing and errors will be displayed. You can further check for errors, and there is also a 'Go to Network' command which transfers you to a segment where the error was found.

SYSWIN has classic editorial capabilities, such as Edit/Find or Edit/Replace commands. Searching through a program for assigned values or symbols is quick and offers a large number of optional filters. We can search through an entire program or its segments, and this is defined with option call. Also, there are possibilities for defining a search path, as well as for different actions when looking for a desired element.

Beside this, SYSWIN provides various advantages in situations where we need permanent archiving of user program. It is especially important to periodically print projects that are made quick and easy by SYSWIN. Projects can be printed in many different formats, and printing can include specific sections of a project.

6.7 Meaning of "Tools" icons

SYSWIN has several types of editors among whom a relay diagram also known as relay editor, or first editor that awaits us upon starting a SYSWIN program is the most frequently used editor.

First we need to explain tools palette (Drawing Tools) and the meaning of each icon.

Aside through the usual mouse click, you can access the specific elements of this palette from a keyboard. You'll find a corresponding key of the keyboard by each icon, and you can accomplish the same action with it as you would using a mouse.

By clicking on the icon, we have selected a desired tool, and with a click on network section this symbol will be stored in a program. Explanation for each of the icons is given as follows:

Open contact icon. By clicking on this icon (or using a key '"') we enter an open contact into Network. We need to position the element we have entered at a specified place (black space). Following this, a message window where data can be entered (open contact address-number of words, bit position) is activated automatically.

Closed contact icon. By clicking on this icon (or '/' on keyboard) we enter a closed contact or inverted condition into network.

Horizontal line. By clicking on this icon (or using '-' on a keyboard), horizontal line is lengthened out from left to right. SYSWIN, however, retains a right to make drawn lines optimal in terms of length, or to point out possible errors. This option is used when you need to add another condition before an instruction contingent upon this condition, or when something simply can not fit.

Vertical line. With a click on this icon, or use of '?', we draw vertical lines from top to bottom. This option is necessary to realize parallel connections between contacts.

Output instruction. This represents an instruction that is executed if condition instruction preceding it is executed. With the help of this instruction we advance a result of logical expression with output variables (bits). We can arrive to this instruction with the help of keyboard ('O' key).

Inverted output instruction (shortcut-key 'Q'). Similarly to the previous case, with this executing instruction we advance a result of logical expression to an output bit, and the only difference is that this bit is turned on if a condition is not executed and vice versa.

PLC functions (shortcut-key 'F'). Click on this icon accomplishes possibility of installment of complex PLC instructions into a program. Window that appears following a click on the icon contains all instructions sorted by sections. Some of these instructions are given separately as icons, and some can be accessed only through this option. One such instruction is END instruction which is used in each program. Window that comes up is displayed in the following picture.

When this window pops up, select an instruction and click on OK.

Click on this icon (or using 'T' key) will give you an option to enter a timer into the program. Using a mouse, click on the bright area of the monitor, and a message window comes up where you can enter needed information relating to a timer (timer designation and duration in milliseconds). This way, we get a classic timer or timer with a delay when turned on. If some other version of a timer is needed, preceding FUN icon should be used, and option Timers and counters (see picture above) selected.

Counter icon. Click on this icon (or 'C' key), and this will install a classic counter into a PLC program. Prior to this we enter needed information in message window: designation of the counter (CNT001 for instance) and counter value. Change of counter status (decrementing by 1) is done when an input signal (CP) changes from OFF to ON status.

With this icon we can invert previously entered contact, output or input. Inversion is

done so that we first click on this icon, and then on a variable whose inversion we wish to perform.

Erase icon. Click on this icon and a shaded area of network erases the shaded part of the program.

Mouse plays an important part in the SYSWIN program. Each double-click on any PLC instruction results in a corresponding editor where necessary changes can be entered. This principle is accordingly installed into SYSWIN, so double-click on block or network heading (BLOCK HEADER BAR or NETWORK HEADER BAR) gives the same results.

6.8 PLC controller working modes

There are several ways to find out the present working mode, for example from an Online Mode menu or its display in a Toolbar. This option is accessible if communication was successfully established with a PLC controller.

If we choose a mode that differs from a present one, change of mode will be momentary. In order to avoid an accidental change of PLC controller mode, there is an option that obliges a computer to ask a question before each mode change, whether that is the option a user really wants (this option is included as default). PLC controller has three modes in class C, MONITOR, RUN and PROGRAM/STOP mode.

6.9 RUN MODE

This PLC mode enables program to be executed as basic operation. It is used in final testing, after a program has been tested in detail, and errors have been eliminated. SYSWIN can not change memory contents of PLC controller in this mode, neither is the change of a program being executed possible. Of course, when program is finished and tested, PLC begins its new life in command closet, being first set to RUN mode.

6.10 Monitor mode

In this mode, program execution is possible, as well as editing and monitoring during operation. This is the most frequently used mode in program development. When this mode has been selected, controller has an obligation to supply a PC with information which relates to program itself, or more precisely to status of variables in the program. If we additionally confirm Monitoring option from an Online menu, we can follow current values of variables on the monitor itself, in real time.

All changes in inputs and outputs can be viewed on the monitor, and status of variables and program locations used in the program are registered and memorized.

6.11 Program-Stop mode

Choosing this mode simply stops a PLC controller if PLC was in RUN or MONITOR mode. It is used for data and program transfer to PLC controller.

6.12 Program execution and monitoring

Program transferred from a PC to a PLC starts executing at the moment when you

move from a Stop/Program mode to a Monitor or Run mode. When Monitoring function starts executing, some sections of the monitor will be shaded (see picture above), and this way you can follow program execution. Monitoring is active during editing of some program segment, and is stopped at the moment when a changed section of the program is transferred into a PLC controller.

6.13 Impact on the program during monitoring

During monitoring, you can use the right button on the mouse to call up a menu of some elements of ladder diagram. Menu that appears when we click on location where address of some bit is positioned, contains the following elements:

Force Set - used for permanent forced set up of bit status to ONForce Reset - used for permanent forced set up of bit status to OFFCancel - cancels out the forced statusSet (1) - used for a brief change of bit status from OFF to ON statusReset (0) - used for a brief change of bit status from ON to OFF statusCancel All - cancels out forced status of all bits

With the help of these options, status of bits can be changed, word contents in controller memory can also be changed, and all or some of the earlier forced settings can be cancelled out. The concept of forcing entails forced set up of some input/output to ON or OFF status for program reevaluation. At the moment when PLC leaves monitoring regime, data on forced bits and words is lost. Simultaneous forcing and evaluation of contents of a greater number of dimensions, and Data Set Bar is used for this, usually found at the bottom of the monitor (see previous picture). Editing as well as defining an area in Data Set Bar is accomplished with a double click following which a corresponding message window appears, and we write here address for the bit whose status we are following.

6.14 Graphic representation of dimension changes in a program

SYSWIN allows graphic representation of dimensions with time as abscissa. When a monitoring mode is in use, monitor display changes through time, showing changes in values of monitored dimensions. Monitor refreshment is done after a reception of each sample where sample intervals are 0,1-65.5 seconds. Graphics saved in this way can be stored for later analysis as a file, or read in an already saved file.

Procedure for starting graphic monitoring is following:

- from Editors menu select Time chart monitoring option- from a new tools palette select Trace Configure (pictured as a key).- Fill out message box Configure Time Chart Monitor (see next picture)- From Online menu choose Tracing.

With Trace/Configure command adjust parameters for monitoring. Necessary parameters are Trigger or an event where saving will begin, sampling period and bits and/or words whose values we are monitoring. Mapping of a time diagram for dimensions previously specified begins after the last command.

Quitting is done with a click on a black square icon, and restarting is performed by clicking on an a red circle icon. Return to the editor with a ladder diagram by clicking on Editors menu and Program editor submenu.

CHAPTER 7  EXAMPLES

Introduction7.1 Self-maintenance7.2 Making large time intervals7.3 Delays of ON and OFF status 7.4 Counter over 99997.5 Alternate ON-OFF output7.6 Automation of parking garage 7.7 Operating a charge and discharge process7.8 Automation of product packaging7.9 Automation of storage door

Introduction

Programming only related examples make up the first group of examples. They are given as separate small programs that can later be incorporated into larger ones. Second group consists of examples which can be applied to some real problems.

7.1 Self-maintenance

Program allows input to remain at ON status even when the condition that brought it to that status stops. Example in picture below illustrates how use of a key connected to the input IR000.00 changes IR010.01 output status to ON. By letting the key go, output IR010.01 is not reset. This is because IR010.01 output keeps itself at status ON through OR circuit (having IR000.00), and it stays in this status until key at input IR000.01 is pressed. Input IR000.01 is in I connection with the output pin IR010.01 which cancels out a condition, and resets an IR010.01 bit. Example of self-maintenance is quite frequent in specific applications. If a user was connected to IR010.01 output, START and STOP functions could be realized from two keys (without the use of switches). Specifically, input IR000.00 would be a START key, and IR000.01 would be a STOP key. 

 

7.2 Making large time intervals

If it's necessary to make a bigger time interval of 999.9 seconds (9999x0.1s) two linked timers, or a timer and a counter can be used as in this example. Counter is set to count to 2000, and timer is set to 5 seconds which gives a time interval of 10.000 seconds or 2.77 hours. By executing a condition at IR000.00 input, timer begins to count. When it reaches the limit, it sets a flag TIM001 which interrupts the link and simultaneously resets a timer. Once 5 seconds have run out, flag TIM001 changes its status to ON and executes a condition at the counter input CNT002. When a counter numbers 2000 such changes in timer flag status, TIM001 sets its flag CNT002 which in turn executes a condition for IR010.00 to change status to ON. Time that has elapsed from the change of IR000.00 input status to ON and a change of IR010.00 input status to ON comes to 10.000 seconds.

Ladder Diagram:

7.3 Delays of ON and OFF status

Example shows how to make output (IR010.00) delay as opposed to ?(in relation to ?? unclear meaning) input (IR000.00). By executing a condition at IR000.00 input, timer TIM000 begins counting a set value 10 in steps of 0.1 seconds each. After one second has elapsed, it set its flag TIM000 which is a condition in changing output status IR010.00 to ON. Thus we accomplish a delay of one second between ON status of IR000.00 input and ON status IR010.00 input. By changing IR010.00 output status to ON, half of the condition for activation of the second timer is executed. Second half of the timer is executed when IR000.00 input changes status to OFF (normally closed contact). Timer TIM001 sets its flag TIM001 after one second, and interrupts a condition for keeping an output in ON status.

 

 

Ladder Diagram:

7.4 Counter over 9999

If you need to count over 9999 (maximum value for a counter), you can use two connected timers. First counter counts up to certain value, and the other one counts flag status changes of the first counter. Thus you get the possibility of counting up to a value which is a result of set values of the first and second counter. In an example at the bottom, first counter counts up to 1000, and second up to 20 which allows you to count to 20000. By executing a condition at IR000.00 input (line whose changes are followed is brought to it), first counter decreases its value by one. This is repeated until counter arrives at zero when it sets its flag CNT001 and simultaneously resets itself (is made ready for a new cycle of counting from 1000 to 0). Each setting of CNT001 influences the other counter which sets its flag after twenty settings of the first counter's flag. By setting CNT002 flag of the second counter, a condition is executed for an IR010.00 output to be activated and to stay in that status through self-maintenance.

Ladder Diagram:

Same effect can be achieved with a modified program below. First change is that there is a "switch" for the whole program, and this is IR000.00 input (program can accomplish its function only while this switch is active). Second change is that the line whose status is followed is brought to IR000.01 input. The rest is the same as in the previous version of the program. Counter CNT002 counts status changes of the CNT001 counter flag. When it numbers them, it changes the status of its flag CNT002 which executes the condition for status change of IR010.00 output. This changes IR010.00 output status after 20000 changes of input IR000.01.

Ladder Diagram:

7.5 Alternate ON-OFF output

Example makes a certain number of impulses of desired duration at PLC controller IR010.00 output. Number of impulses is given in instruction of the counter (here it is a constant #0010 or ten impulses) impulse duration in two timer instructions. First timer defines duration of ON status, and second one duration of OFF status of IR010.00 output bit. In the example these two durations are the same, but through assigning them different parameters they can differ so that duration of ON status can be different from duration of OFF status.

 

Program starts executing a condition at IR000.00 bit. Since a normally closed contact which refers to counter flag (that isn't set ) is linked with this IR000.00 bit in "I" circuit, this status of IR200.00 bit will change to ON. Bit IR200.00 keeps its status through self-maintenance until counter flag is not set and a condition interrupted.

When an IR200.00 bit is set, timers TIM001 and TIM002 start counting a set interval number at 0.1 s ( in the example, this number is 10 for the first timer, or 20 for the second timer, and this sets the period of one or two seconds). With both timers, a normally closed contact which refers to TIM002 timer flag is connected with IR200.00 bit. When this flag is set which happens every two seconds, both timers are reset. Timer TIM002 resets timer TIM001 and itself, and this starts a new cycle.

At the start of a program, IR010.00 output bit changes status to ON and stays in this status until TIM001 flag changes status to ON (after one second). By changing TIM001 flag status to ON, condition is broken (because it is represented as normally closed contact) and IR010.00 bit changes status to OFF.

IR010.00 output status changes to ON again when time has run out on TIM002 timer. This resets TIM001 timer and its flag which in turn executes a condition for status change of the IR010.00 output. Cycle is thus repeated until a counter numbers 10 changes of TIM001 flag status. With the change of status of CNT000 counter flag, a condition for an assisting bit IR200.00 is broken, and program stops working.

Ladder Diagram: 

 

APPENDIX A   Expanding the number of input/output lines

 INTRODUCTION

 A.1 Differences and similarities

 A.2 Marking the PLC controller

 A.3 Specific case

Introduction

This appendix is an answer to the question “What if more input or output lines are needed ?”. Model detailed in the book carries the mark CPM1A-10CDR-A and is taken as an optimal for it’s price and features. Alternative models with greater number of lines include CPM1A-20CDR-A, CPM1A-30CDR-A or CPM1A-40CDR-A. The last two can be expanded with three additional modules with 20 extra I/O lines each, totaling 100 I/O lines as a maximum (if this is still insufficient, maybe it is time for you to start using some of more powerful PLC controllers).

If not even the most powerful model of CPM1A family satisfies your needs, then extra modules with 20 I/O lines are added. This form of connection reaches 100 input/outputs, which is a significant number in industrial proportions.

A.1. Differences and similarities

Taking the other model of PLC controller from CPM1A class basically doesn’t change a thing! Everything said for one model also applies to the other. Only thing that changes is the number of screw terminal and the number of bits in IR area connected to that screw terminal. If model with 10 I/O lines (model described in the book) has 6 inputs on addresses IR0000 - IR0005, then the 20 I/O lines model will have 12 inputs on addresses IR0000 - IR0011. Expanding itself should not be a problem. After taking off the cover on the right side, there is a connector which is then connected to the expansion module via flat cable. Still, it requires skill when assigning inputs and outputs because expansion increases the cost of the project. All the models and expansions of CPM1A class carry additional marks defining them more precisely.

Description      

Input points Output points

Power Supply Model

Number

10 I/O points      

6 points 4 point Relay Output

100 to240 VAC, 50/60 Hz

CPM1A-10CDR-A 

24 VDC CPM1A-10CDR-D

Transistor NPN

24 VDC CPM1A-l0CDT-D

Transistor PNP

24 VDC CPM1A-10CDT1-D

20 I/O points 

12 points 8 points100 to 240 VAC, 50/60 Hz

CPMlA-20CDR-A

24 VDC CPM1A-20CDR-D

Transistor NPN

24 VDC CPM1A-20CDT-D

Transistor PNP

24 VDC CPMlA-20CDT1-D

30 I/O points 18 points               

12 points100 to 240 VAC, 50/60 Hz

CPM1A-30CDR-A

24 VDC CPM1A-30CDR-D

Transistor NPN

24 VDC CPM1A-30CDT-D

Transistor PNP

24 VDC CPM1A-30CDT1-D

40 I/O points 

24 points               

16 points100 to 240 VAC, 50/60 Hz

CPM1A-40CDR-A

24 VDC CPM1A-40CDR-D

Transistor NPN

24 VDC CPM1A-40CDT-D

Transistor PNP

24 VDC CPM1A-40CDT1-D

Notice that PLC controllers with 10 and 20 I/O lines do not have an expansion port. Generally speaking, if there is the slightest possibility for expansion in the project, PLC controller with 30 or 40 I/O lines should be used. 

A.2. Marking the PLC controller

Marking the controller and the expansion module undergoes three criteria. The first is voltage, the second is the type of input/output and the third is number of I/O lines. The picture below is self-explanatory.

A.3. Specific case

If two 20 I/O lines expansion modules and one analog module are added to 30 I/O lines model, assigned inputs/outputs will have the addresses from the following table.

Unit Assigned input bits Assigned output bits

1 Central processing unit (CPM2A-30CDX-X)

IR 00000-IR 00011 and IR 00100-IR 00105

IR 01000-IR 01007 and IR 01100-IR 01103

2 Unit for I/O expansion (CPM1A-20EDxxx)

IR 00200-IR 02011 IR 01200-IR 01207

3 Analog I/O unit (CPM1A-MAD01)

IR 00300-IR 03015 and IR 00400-IR 00415

IR 01300-IR 01315

4 Unit for I/O expansion (CPM1A-EDxxx)

IR 00500-IR 00511 IR 01400-IR 01415

 

APPENDIX B  Detailed memory map of PLC controller

 INTRODUCTION

 B.1 General explanation of memory areas

 B.2 IR memory area

 B.3 SR memory area

 B.4 AR memory area

 B.5 PC memory area

 

Introduction

Purpose of this appendix is to explain certain memory areas in detail. As the following tables cover whole memory, there are options left unused in this book. They should be skipped during the first reading, and used later according to needs.

B.1 General explanation of memory areas

Memory of PLC controller consists of several areas, some of these having predefined functions.

Data area Word(s) Bit(s) Function

IR area

input area IR 000 - IR 009 (10 words)

IR 00000 - IR 00915 (160 bits)

These bits may be assigned to an external I/O connection. Some of these have direct output on screw terminal (for example, IR000.00 - IR000.05 and IR010.00 - IR010.03 with CPM1A model)

output areaIR 010 - IR 019 (10

words)IR 01000 - IR 01915 (160

bits)

working area

IR 200 - IR 231 (32 words)

IR 20000 - IR 23115 (512 bits)

Working bits that can be used freely in the program. They are commonly used as swap bits

SR area SR 232 - SR 255 (24 words)

SR23200 - SR25515 (384 bits)

Special functions, such as flags and control bits

TR area --- TR 0 - TR 7 (8 bits)Temporary storage of ON/OFF states when jump takes place

HR area HR 00 - HR 19 (20 words)HR0000 - HR1915 (320

bits)

Data storage; these keep their states when power is off

AR area AR 00 - AR 15 (16 words) AR0000 - AR1515 (256 bits)

Special functions, such as flags and control bits

LR area LR 00 - LR 15 (16 words) LR0000 - LR1515 (256 bits)

1:1 connection with another PC

Timer/counter area TC 000 - TC 127 (timer/counter numbers)Same numbers are used for both timers and counters

DM area

Read/writeDM 0000 - DM 0999 and

DM 1022 - DM 1023 (1002 words)

---

Data of DM area may be accessed only in word form. Words keep their contents after the power is off

Error writing

DM 1000 - DM 1021 (22 words)

--- Part of the memory for storing the time and code of error that occurred. When not used for this purpose, they can be used as regular DM words for reading and writing. They cannot be changed from within the program

Read only DM 6144 - DM 6599 (456 words)

---

PC setupDM 6600 - DM 6655 (56

words) --- Storing various parameters for controlling the PC

Note: 1. IR and LR bits, when not used to their purpose, may be used as working bits. 2. Contents of HR area, LR area, counter and DM area for reading/writing is stored within backup condenser. On 25C, condenser keeps the memory contents for up to 20 days.3. When accessing the current value of PV, TC numbers used for data have the form of word. When accessing the Completing flags, they are used as data bits. 4. Data from DM6144 to DM6655 must not be changed from within the program, but can be changed by peripheral device.

B.2. SR memory area

IR area doesn’t have predefined memory locations, but is meant for general use in the program. Of all the locations this memory area consists of, only those directly connected to PLC controller input/output lines are of interest for this appendix.

IR area can be divided into 3 parts:

1. Input area is located from word IR000 to IR009, totaling 160 bits. Most important of these are in the word IR000 because they are directly connected to screw terminal of PLC controller. Input IR000.01 is directly connected to screw terminal marked with 01 on the casing of the PLC controller.

2. Output area is located from word IR010 to IR019, totaling 160 bits. Most important of these are in the word IR010 because they are directly connected to screw terminal of PLC controller. Output IR000.00 is directly connected to screw terminal marked with 00 on the casing of the PLC controller.

3. Working area is located from word IR200 to IR231 totaling 512 bits for general use.

As IR memory area does not have predefined memory locations, more detailed explanations are not necessary.

 

B.3. IR memory area

Unlike IR area, SR area does have predefined memory locations. These bits are usually tied to the PLC controller work or contain current and set values of different functions. Purpose of specific memory locations of SR area is explained in the following table:

Words Bits Function

SR 232 - SR 235 00 - 15Input area for macro functions. Contains input operands for MCRO(99) (may be used for working bits, when MCRO(99) is not used)

SR 236 - SR 239 00 - 15 Output area for macro functions. Contains output operands

for MCRO(99) (may be used for working bits, when MCRO(99) is not used)

SR 240 00 - 15

Contains set value SV, when input interrupt 0 is used in counter mode (4 hexadecimal digits) (may be used for working bits, when input interrupt 0 is not used in counter mode)

SR 241 00 - 15

Contains set value SV, when input interrupt 1 is used in counter mode (4 hexadecimal digits) (may be used for working bits, when input interrupt 1 is not used in counter mode)

SR 242 00 - 15

Contains set value SV, when input interrupt 2 is used in counter mode (4 hexadecimal digits) (may be used for working bits, when input interrupt 2 is not used in counter mode)

SR 243 00 - 15

Contains set value SV, when input interrupt 3 is used in counter mode (4 hexadecimal digits) (may be used for working bits, when input interrupt 3 is not used in counter mode)

SR 244 00 - 15 Contains current value (PV-1), when input interrupt 0 is used in counter mode (4 hexadecimal digits)

SR 245 00 - 15 Contains current value (PV-1), when input interrupt 1 is used in counter mode (4 hexadecimal digits)

SR 246 00 - 15 Contains current value (PV-1), when input interrupt 2 is used in counter mode (4 hexadecimal digits)

SR 247 00 - 15 Contains current value (PV-1), when input interrupt 3 is used in counter mode (4 hexadecimal digits)

SR 248, SR 249 00 - 15 Contains current value PV of the high-speed counter (may be used for working bits, when high-speed counter is not used)

SR 250 00 - 15Analog setting of value 0. Keeps 4 digit BCD value (0000 - 0200) set via analog potentiometer on the PLC controller casing.

SR 251 00 - 15Analog setting of value 1. Keeps 4 digit BCD value (0000 - 0200) set via analog potentiometer on the PLC controller casing.

SR 252 00 Reset of the high-speed counter

  01 - 07 Not used

  08

Peripheral port. Switches on for the reset of the peripheral port (this doesn't apply to a case when peripheral device is connected). Bit automatically changes state to OFF after the reset

  09 Not used

  10PLC Setup Reset Bit. When on, it initializes PC setup (DM6600-DM6655). It automatically goes to OFF after the reset. This applies only if the PC is in PROGRAM mode

  11

Forced Status Hold Bit. OFF: bits used in the operation of forced set/reset are cleared when changing from PROGRAM to MONITOR mode. ON: bits used in the operation of forced set/reset keep their states when changing from PROGRAM to MONITOR mode.

  12 I/O Hold bit. OFF: IR and LR bits are reset when starting or ending an operation. ON: IR and LR bits keep their states when starting or ending an operation.

  13 Not used

  14 Error Log Reset Bit. Bit state OFF clears the record of error taking place. Bit automatically goes off after the operation

  15 Not used

SR 253 00 - 07 FAL error code. Location contains error code (2 digit number). FAL number is stored at this location upon executing FAL(06) or FAL(07) instructions. Location contents

are reset upon executing FAL 00 instruction or by clearing an error from peripheral device

  08 Not used

  09Cycle Time Overrun Flag. Bit goes to ON when program length doesn't allow cycle of input/output scanning to be executed in a specified time period

  10 - 12 Not used

  13 Flag always on

  14 Flag always off

  15 First Cycle Flag. Goes ON during the first cycle at the beginning of the operation

SR 254 00 1 min clock impulse (30s on, 30s off)

  01 0.02s clock impulse (0.01s on, 0.01s off)

  02 Negative (N) flag

  03 - 05 Not used

  06 Differential Monitor Flag

  07 STEP(8) execution flag

  08 - 15 Not used

SR 255 00 0.1s clock impulse (0.05s on, 0.05s off)

  01 0.2s clock impulse (0.1s on, 0.1s off)

  02 1.0s clock impulse (0.5s on, 0.5s off)

  03 Instruction Execution Error (ER) Flag. Changes state to ON if error occurs during instruction execution

  04 Carry (CY) flag

  05 "Greater than" (GR) flag

  06 "Equals" (EQ) flag

  07 "Less than" (LE) flag

  08 - 15 Not used

 

B.4. AR memory area

Purpose of this memory area is to provide information on PLC controller state, malfunctions and some system data. Memory locations of this area keep their states after the power has been shut down.

Word(s) Bit(s) FunctionAR00 and AR01 00 - 15 Not used

AR02 00 Status flag of the first I/O unit for expanding I/O lines (I/O units status flag)

  01 Status flag of the second I/O unit for expanding I/O lines (I/O units status flag)

  02 Status flag of the third I/O unit for expanding I/O lines (I/O units status flag)

  03 - 07 Not used

  12 - 15 Number of connected I/O units

AR03 - AR07 00 - 15 Not used

AR08 00 - 07 Not used

  08 - 11 Peripheral device error code

  12 Flag of peripheral device error

  13 Peripheral Device Transmission Enabled Flag

  14 - 15 Not used

AR09 00 - 15 Not used

AR10 00 - 15 Power-off counter. Contains 4-digit BCD value

AR11 00 - 07 High-speed Counter Range Comparison Flags

  08 - 14 Not used

  15 Pulse Output Status. ON: stopped; OFF: Impulse at output

AR12 00 - 15 Not used

AR13 00 Power-up PC Setup Error Flag. Goes ON when error occurs in area DM 6600 - DM 6614

  01 Start-up PC Setup Error Flag. Goes ON when error occurs in area DM 6615 - DM 6644

  02 RUN PC Setup Error Flag. Goes ON when error occurs in area DM 6645 - DM 6655

  03 - 04 Not used

  05 Long Cycle Time Flag. Goes ON if real cycle length exceeds length set in DM 6619

  06 - 07 Not used

  08 Memory Area Specification Error Flag. Goes ON when non-existing address is specified in the program

  09 Flash Memory Error Flag

  10 Read-only DM Error Flag. Goes ON when checksum error occurs in DM 6144 - DM 6599 range

  11 PC Setup Error Flag. Goes ON when checksum error occurs in PC Setup area

  12Program Error Flag. Goes ON when checksum error occurs in program memory (UM) or inappropriate instruction is executed

  13 Expansion Instruction Error Flag

  14 - 15 Not used

AR14 00 - 15 Maximum Cycle Time. 4 BCD digits. Cleared at the beginning of the operation

AR15 00 - 15 Current Cycle Time. 4 BCD digits. Not cleared when the operation ends

 Note: 1. IR and LR bits when not used for their function may be used as working bits. 2. Contents of HR area, LR area, counter, and DM area for reading/writing are kept by battery of central processing unit. In case that the battery is removed or malfunction occurs, this data will be lost.

3. When accessing the current value of PV, TC numbers used for data have form of word. When accessing Completing flags, they are used as data bits.4. Data stored from DM6144 to DM6655 cannot be changed from within the program, but can be changed by peripheral device.5. Program and data from DM 6144 to DM 6655 are stored in the flash memory. 

B.5. PC memory area

PLC setup area can be roughly divided into 4 categories:

1. Settings related to basic operations of PLC controller and I/O processes2. Settings related to cycle duration3. Settings related to interrupts4. Settings related to communication.

Word(s) Bit(s) FunctionSettings are active only upon resetting the PLC and sending data from PC to PLC

DM 6600 00 - 07 Startup Mode. Active only if bits 08 - 15 are set to 02. 00: PROGRAM; 01: MONITOR; 02: RUN

  08 - 15Startup mode designation. 00: programming console switch; 01: proceeds in the mode last used before turning off the power; 02: settings in 00 - 07

DM 6601 00 - 07 Not used (set to 0)

  08 - 11 IOM Hold Bit (SR 25212). 0: Reset; 1: Keeps the state

  12 - 15 Forced Status Hold Bit (SR 25211). 0: Reset; 1: Keeps the state

DM 6602 00 - 03 Writing to program memory protection. 00: OFF; 01: ON (except for DM 6602)

  04 - 07 Programming console display language. 00: English; 01: Japanese

  08 - 11 Not used

DM 6603 00 - 15 Not used

DM 6604 00 - 0700: in case of battery malfunction, error will not be generated; 01: in case of battery malfunction, error will be generated

  08 - 15 Not used

DM 6605 - DM 6614 00 - 15 Not used

Cycle Time Settings (DM 6615 - DM 6619) take effect after the transfer to PC area, next time you start working

DM 6615 - DM 6616 00 - 15 Not used

DM 6617 00 - 07Servicing time for peripheral port. Active when bits 08 - 15 are set to 01. It is expressed in percentage of cycle time duration (00 to 99 (BCD))

  08 - 15 Peripheral port servicing setting enable. 00: 5% of cycle duration; 01: time defined in first half of the word

DM 6618 00 - 07 Cycle monitor time. Settings are identical to those of the second half of the previous word

  08 - 15Cycle monitor enable (Setting in 00 to 07 x unit; 99 5 max). 00:120ms (settings in bits 00-07 are disabled) ; 01: setting unit 10ms; 02: setting unit 100ms; 03: setting unit 1s

DM 6619 00 - 15 Cycle time. 0000: variable (no minimum); 0001: up to 9999 (BCD). Minimal time is expressed in ms

Interrupt Processing (DM 6620 - DM 6639) take effect after the transfer to PC area, next time you start working

DM 6620 00 - 03 Input constant for IR  00000 - IR 00002. 0: 0.8ms; 1: 1ms; 2: 2ms; 3: 4ms; 4: 8ms; 5: 16ms; 6: 32ms; 7: 64ms; 8: 128ms 

  04 - 07 Input constant for IR  00003 and IR 00004. Settings are same as with bits 00-03

  08 - 11 Input constant for IR  00005 and IR 00006. Settings are same as with bits 00-03

  12 - 15 Input constant for IR  00007 and IR 00011. Settings are same as with bits 00-03

DM 6621 00 - 07 Input constant for IR  001. 0: 0.8ms; 1: 1ms; 2: 2ms; 3: 4ms; 4: 8ms; 5: 16ms; 6: 32ms; 7: 64ms; 8: 128ms

  08 - 15 Input constant for IR  002. Settings are same as with IR 001

DM 6622 00 - 07 Input constant for IR  003. Settings are same as with IR 001

  08 - 15 Input constant for IR  004. Settings are same as with IR 001

DM 6623 00 - 07 Input constant for IR  005. Settings are same as with IR 001

  08 - 15 Input constant for IR  006. Settings are same as with IR 001

DM 6624 00 - 07 Input constant for IR  007. Settings are same as with IR 001

DM 6625 00 - 07 Input constant for IR  008. Settings are same as with IR 001

  08 - 15 Input constant for IR  009. Settings are same as with IR 001

DM 6626 - DM 6627 00 - 15 Not used

DM 6628 00 - 03 Interrupt enabled on IR 00000. (0: regular input; 1: interrupt input; 2: fast-reaction input)

  04 - 07 Interrupt enabled on IR 00001. (0: regular input; 1: interrupt input; 2: fast-reaction input)

  08 - 11 Interrupt enabled on IR 00002. (0: regular input; 1: interrupt input; 2: fast-reaction input)

  12 - 15 Interrupt enabled on IR 00003. (0: regular input; 1: interrupt input; 2: fast-reaction input)

High-speed counter settings (DM 6640-DM 6644) take effect after the transfer to PC area, next time you start working

DM 6640 - DM 6641 00 - 15 Not used

DM 6642 00 - 03 High-speed counter mode. 0: counting up/down; 4: incremental mode

  04 - 07 High-speed counter reset mode. 0: Z phase and software reset; 1: software reset only 

  08 - 15 High-speed counter enable. 0: high-speed counter not used; 1: high-speed counter used with settings 00-07

DM 6643 - DM 6644 00 - 15 Not used

 Peripheral port settings take effect after the transfer to PC area

DM 6645 - DM 6649 00 - 15 Not used

DM 6650 00 - 07Port settings. 00: standard (1 start bit, even parity, 2 stop bits, 9600bps); 01: Settings in DM 6651 (settings other than this cause error and turn on AR 1302)

  08 - 11 Area for 1:1 connection with a PC via peripheral port. 0: LR00-LR15

  12 - 15Modes of communication. 0: Host link; 2: one-to-one PC link (slave); 3: one-to-one PC link (master); 4: NT link (settings other than this cause error and turn on AR 1302)

DM 6651 00 - 07 Baud rate. 00: 1200 bps; 01: 2400 bps; 02: 4800 bps; 03: 9600 bps; 04: 19200 bps

  08 - 15 Frame format (Start bits/Data bits/Stop bits/Parity).      00:1/7/1/even; 01:1/7/1/odd; 02:1/7/1/none; 03:1/7/2/even; 04:1/7/2/odd; 05:1/7/2/none; 06:1/7/1/even; 07:1/7/1/odd;

08:1/7/1/none; 09:1/7/2/even; 10:1/7/2/odd; 11:1/7/2/none          (settings other than this cause error and turn on AR 1302)   

DM 6652 00 - 15 Host Link Transmission Delay (0000 - 9999ms)                      (settings other than this cause error and turn on AR 1302)

DM 6653 00 - 07 Host Link (00 - 31 BCD)                                                        (settings other than this cause error and turn on AR 1302)

  08 - 15 Not used

DM 6654 00 - 15 Not used

Error log settings (DM 6655) take effect after the transfer to PLC controller

DM 6655 00 - 03 Style. 0: move after 7 records; 1: keep only first 7 (no moving);   2-F: no records

  04 - 07 Not used

  08 - 11 Cycle Time monitor Enable. 0: detect long cycles as non-fatal errors; 1: do not detect long cycles

  12 - 15 Not used

 

APPENDIX C  PLC diagnostics

 INTRODUCTION

 C.1 Diagnostic functions of PLC

 C.2 Non-fatal errors

 C.3 Fatal errors

 C.4 User defined errors

 C.5 Failure alarm - FAL(06)

 C.6 Severe Failure alarm - FALS(07)

 C.7 MESSAGE - MSG(46)

 C.8 Syntax errors

 C.9 Algorithm for finding errors in the program

 

Introduction

The whole work of PLC controller can be represented with a diagram shown on the following page. After turning on the power, PLC is first initialized (clearing IR, SR i AR

areas, presetting system timers and checking I/O lines), and if no errors were detected, monitoring process, program execution, calling the I/O lines and serving the peripheral devices starts to occur in cycles.

C.1 Diagnostic functions of PLC

PLC controller features additional functions that make locating errors easier. Errors can be divided into two categories according to severity :

1. Fatal errors are severe and they prevent PLC controller from operating until their cause is located and solved.

2. Non-fatal errors are those that do not prevent PLC controller from operating. After detecting one or more non-fatal errors, program execution will continue.

Nevertheless, it is necessary to correct these errors as soon as possible.

C.2 Non-fatal errors

When one of these errors takes place, indicators POWER and RUN will be on, and the indicator ERR/ALM will blink. Upon locating non-fatal error, manual for the given PLC controller should be consulted and the flags checked in order to understand the cause of a problem and correct the error.

C.3 Fatal erros

When any of the fatal errors take place, PLC controller stops operating and all outputs are shut down. PLC controller cannot be put back to work until the controller is turned off and then turned back on, or until it is switched to PROGRAM mode via peripheral device and the fatal error corrected. With these errors, indicators ERR/ALM are on, while the RUN indicator remains off. It is necessary to check the error flag in the manual of the given PLC in order to locate the cause of the problem and to correct the error.

C.4 User defined errors

There are three instructions for user to define his own errors or messages. FAL(06) causes non-fatal error, FAL(07) causes fatal error, while MSG(46) sends a message to program console or to the host computer connected to the PLC controller.

 

C.5 Failure alarm - FAL(06)

Instruction FAL(06) generates the code of non-fatal error that took place to provide the information on the possible cause of the problem for the programmer. Upon execution of the instruction FAL(06) following events take place:

1. Indicator ERR/ALM will blink, while PLC continues to work.2. Two-digits BCD number of instruction FAL (01 do 99) is written from SR253000 to SR25307.

Same number must not be assigned to both FAL and FALS instructions. To delete the code of an error, error should be corrected and FAL 00 instruction executed.

C.6 Severe failure alarm - FALS(07)

Instruction FALS(07) generates the code of fatal error that took place. In this case the following happens:

1. Program stops and all outputs are shut down.2. Indicator ERR/ALM is turned on.3. Two-digit BCD number (01 do 99) of instruction FALS is written from SR 253000 to SR25307.4. If memory card with RTC is used, part of the memory where the presence of error

is recorded will also contain numbers of FALS instruction and exact time when error took place.

Numbers of FALS instruction can be assigned to certain states. Same number must not be assigned to both FAL and FALS instructions. To delete FALS error, PLC controller must be in PROGRAM mode, cause of error solved and then error code deleted.

C.7 Message - MSG (46)

MSG(46) is used for printing messages on program console display. Message cannot exceed 16 characters, and it appears when specified condition is fulfilled.

C.8 Syntax errors

During the program check with operation Program Check, syntax errors are detected. There are three levels of program check at user’s disposal. By selecting the level, types of errors to be checked for are selected. The following table shows types of errors, corresponding messages that appear on display and explains all of syntax errors. Zero level check searches for errors of A, B and C type. First level check searches for errors of A and B type, while the second searches only for errors of type A.

Type Message Meaning and the appropriate action

A

????? Program is damaged by creating non-existing function in the code. Re-enter your program.

CIRCUIT ERR Number of logical blocks doesn't match the instructions of logical blocks. Check the program.

OPERAND ERR Entered constant is not in allowed range. Change the constant so that it fits in the proper range.

NO END INSTR Program is missing the instruction END(01). Add END(01) to the last address of the program.

LOCN ERR Instruction is in the wrong place of the program. Check what the instruction demands and correct the mistake.

JME UNDEFD Instruction JME(04) is missing the instruction JMP(05). Correct the number of jump and add the correct JME(04) instruction.

DUPLSame number of jump or subroutine is used twice in the program. Correct the program so that each number is used only once. 

SBN UNDEFDInstruction SBS(091) is programmed for non-existing subroutine. Correct the number of subroutine or create the missing one.

STEP ERRSTEP(08) with the number of section and STEP(08) without the number of section are used illegally. Check the demands of instruction STEP(08) and correct the mistake. 

BIL-ILC-ERR

IL(02) and ILC(03) are not used in pair. Check if every instruction IL(02) has its corresponding ILC(03). This message will also appear in case that multiple IL(02) instructions were used with single ILC(03) instruction. Check if that's exactly what you wanted...

JMP=JME ERR JMP(04) and JME(05) are not used in pair. Before proceeding, check if the program is written exactly the way you wanted.

SEN-RET ERR If the address of instruction SBN(92) is displayed, there are two different subroutines with the same number. Change one of the numbers or delete one of the subroutines in question. If the address of instruction RET(93) is displayed,

RET(93) wasn't used appropriately. Check the demands of this instruction and correct the mistake.

C

COIL DUPL

Same bit is controlled by more than one instruction (for example, OUT, OUT NOT, DIFU(13), KEEP(11), SFT(10)...). Although certain instructions allow this, you should check the demands of specific instructions, make sure that the program is correct or rearrange the program so that each bit is controlled by single instruction.

JMP UNDEFDJME(05) is used without JMP(04) with the same number of jump. Add the instruction JMP(04) with the same number or delete JME(05) that is not used.

SBS UNDEFDThere is a subroutine that is not called by SBS(91). Add subroutine call to an appropriate place in the program or delete the subroutine.

C.9 Algorithm for finding errors in the program

 

APPENDIX E  Ladder diagram instructions (1/3)

 

Introduction

"Ladder" is the most frequent method of programming PLC controllers at present. We could divide instructions on the input ones for stating the conditions and the output ones that are executed when the conditions are fulfilled. By combining the two, logical blocks are created according to the logic of the system being automated. The purpose of this appendix is to introduce these instructions and to give details on flags and limitations of

each of these.

INDIRECT ADDRESSING

Placing the character “*” ahead of operand from DM memory area allows us to use the indirect addressing. Simply put, value in the word *DM will be the address of the word that is the true operand. The picture below shows the MOV instruction with one operand given indirectly. The contents of location DM0003 equal “1433” which is actually a pointer marking the address DM1433 with contents “0005”. The result of this instruction will be moving the value “0005” from word DM1433 to word LR00.

In order to use the indirect addressing, contents of the word that is the indirect operand have to be in BCD format. Besides that, value of the contents of indirect operand must not be greater than the number of addresses in DM area.

INSTRUCTION FORMAT

Operand is the address of a word or a bit in PLC controller memory (most of the instructions has one or more operands). The common term for a word is just “operand” and in the case of bit we call it “operand bit”. Also, operand can be a direct numerical value marked by character “#” placed ahead of the value (i.e.. #12, #345 etc).

The state of operand bit can be ON or OFF. ON means that its logic state equals “1”, while OFF stands for “0”. Besides these, terms “set” and “reset” are also used.

Symbols SV and PV commonly appear in instruction syntax. These abbreviations stand for “Set Value” and

“Present Value” and are most frequently encountered with instructions concerning counters and timers.

DIFFERENTIAL INSTRUCTION FORM

Differential form is supported by almost all of the instructions. What differs this form from the classical one is the character “@” placed ahead of the name of the instruction. This form ensures that the instruction with condition fulfilled will not be executed in every cycle, but only when its condition changes state from OFF to ON. Differential from is commonly used because it has a lot of applications in real-life problems.

DIFFERENCE BETWEEN BINARY AND BCD REPRESENTATIONS OF WORD CONTENTS

Generally, there are two dominant ways for comprehending values of memory locations. The first is binary and is related to the contents of the word which is treated as a union of 16 bits. Value is calculated as a sum of each bit (0 or 1) multiplied by 2 on power n, where n represents the position of bit in the word. Bit of the least value has position zero, while bit of greatest value has position 15.

BCD is an abbreviation for “Binary Coded Decimal number”. It is nothing more than representing each decimal figure with 4 bits, similar to binary coding hence the name comes from. The picture below shows the difference between binary and BCD representations of the number. Same contents can be interpreted as either 612 or 264. For that reason, proper attention should be given to the format of the value within the word that will be sent to the instruction as an operand.

 

LADDER DIAGRAM INSTRUCTIONS

Instructions may be divided into several basic groups according to their purpose :

- Input instructions- Output instructions- Control instructions - Timer/counter instructions- Data comparison instructions- Data movement instructions- Increment/decrement instructions- BCD/binary calculation instructions- Data conversion instructions- Logic instructions- Special calculation instructions- Subroutine instructions- Interrupt control instructions- I/O units instructions- Display instructions- High-speed counter control instructions- Damage diagnosis instructions- Special system instructions

Each of these instruction groups is introduced with a brief description in the following tables and with more detailed examples and descriptions afterwards.

 

 

Sequence Input Instructions

Instruction Mnemonic Code

Function

LOAD LD 0 Connects an NO condition to the left bus bar.

LOAD NOT LD NOT 0 Connects an NC condition to the left bus bar.

AND AND 0Connects an NO condition in series with the previous condition

AND NOT AND NOT 0Connects an NC condition in series with the previous condition

OR OR 0Connects an NO condition in parallel with the previous condition.

OR NOT OR NOT 0Connects an NC condition in parallel with the previous condition.

AND LOAD AND LD 0 Connects two instruction blocks in series.

OR LOAD OR LD 0 Connects two instruction blocks in parallel.

 

Sequence Output Instructions

Instruction Mnemonic Code

Function

OUTPUT OUT 0 Outputs the result of logic to a bit.

OUT NOT OUT NOT 0Reverses and outputs the result of logic to a bit.

SET SET 0 Force sets (ON) a bit.RESET RESET 0 Force resets (OFF) a bit.KEEP KEEP 11 Maintains the status of the designated bit.DIFFERENTIATE UP

DIFU 13Turns ON a bit for one cycle when the execution condition goes from OFF to ON.

DIFFERENTIATE DOWN

DIFD 14Turns ON a bit for one cycle when the execution condition goes from ON to OFF.

 

Sequence Control Instructions

Instruction Mnemonic Code FunctionNO OPERATION

NOP 00---

END END 01 Required at the end of the program.

INTERLOCK IL 02It the execution condition for IL(02) is OFF, all outputs are turned OFF and all timer PVs reset between IL(02) and the next ILC(03).

INTERLOCK CLEAR

ILC 03 ILC(03) indicates the end of an interlock (beginning at IL(02)).

JUMP JMP 04 If the execution condition for JMP(04) is ON, all instructions between JMP(04) and JME(05) are treated as NOP(OO).

JUMP END JME 05JME(05) indicates the end of a jump (beginning at JMP(04)).

 

Timer/Counter Instructions

Instruction Mnemonic Code

Function

TIMER TIM 0 An ON-delay (decrementing) timer.

COUNTER CNT 0 A decrementing counter.

REVERSIBLE COUNTER

CNTR 12 Increases or decreases PV by one.

HIGH-SPEED TIMER

TIMH 15 A high-speed, ON-delay (decrementing) timer.

 

Data Comparison Instructions

Instruction Mnemonic Code

Function

COMPARE CMP 20 Compares two four-digit hexadecimal values.

DOUBLE COMPARE

CMPL 60 Compares two eight-digit hexadecimal values.

BLOCK COMPARE

(@)BCMP 68Judges whether the value of a word is within 16 ranges (defined by lower and upper limits).

TABLE COMPARE

(@)TCMP 85Compares the value of a word to 16 consecutive words.

 

Data Movement Instructions

Instruction Mnemonic Code

Function

MOVE (@)MOV 21Copies a constant or the content of a word to a word.

MOVE NOT (@)MVN 22Copies the complement of a constant or the content of a word to a word.

BLOCK TRANSFER

(@)XFER 70Copies the content of a block of up to 1,000 consecutive words to a block of consecutive words.

BLOCK SET (@)BSET 71Copies the content of a word to a block of consecutive words.

DATA EXCHAGE

(@)XCHG 73 Exchanges the content of two words.

SINGLE WORD DISTRIBUTE

(@)DIST 80Copies the content of a word to a word (whose address is determined by adding an offset to a word address).

DATA COLLECT

(@)COLL 81Copies the content of a word (whose address is determined by adding an offset to a word address) to a word.

MOVE BIT (@)MOVB 82Copies the specified bit from one word to the specified bit of a word.

MOVE DIGIT (@)MOVD 83Copies the specified digits (4-bit units) from a word to the specified digits of a word.

 

Shift Instructions

Instruction Mnemonic Code Function

SHIFT REGISTER 

SFT 0/10Copies the specified bit (0 or 1) into the rightmost bit of a shift register and shifts the other bits one bit to the left.

WORD SHIFT (@)WSFT 16Creates a multiple-word shift register that shifts data to the left in one-word units.

ASYNCHRONOUS SHIFT REGISTER (@)ASFT 17

Creates a shift register that exchanges the contents of adjacent words when one is zero and the other is not.

ARITHMETIC SHIFT LEFT

(@)ASL 25Shifts a 0 into bit 00 of the specified word and shifts the other bits one bit to the left.

ARITHMETIC SHIFT RIGHT

(@)ASR 26Shifts a 0 into bit 15 of the specified word and shifts the other bits one bit to the right.

ROTATE LEFT (@)ROL 27Moves the content of CY into bit 00 of the specified word, shifts the other bits one bit to the left, and moves bit 15 to CY.

ROTATE RIGHT (@)ROR 28Moves the content of CY into bit 15 of the specified word, shifts the other bits one bit to the left, and moves bit 00 to CY.

ONE DIGIT SHIFT LEFT

(@)SLD 74Shifts a 0 into the rightmost digit (4-bit unit) of the shift register and shifts the other digits one digit to the left.

ONE DIGIT SHIFT RIGHT

(@)SRD 75Shifts a 0 into the rightmost digit (4-bit unit) of the shift register and shifts the other digits one digit to the right.

REVERSIBLE SHIFT REGISTER (@)SFTR 84

Creates a single or multiple-word shift register that can shift data to the left or right.

 

Increment/Decrement Instructions

Instruction Mnemonic Code

Function

INCREMENT (@)INC 38Increments the BCD content of the specified word by 1.

DECREMENT (@)DEC 39Decrements the BCD content of the specified word by 1.

 

 

BCD/Binary Calculation Instructions

Instruction Mnemonic Code Function

BCD ADD (@)ADD 30 Adds the content of a word (or a constant).BCD SUBTRACT

(@)SUB 31Subtracts the contents of a word (or constant) and CY from the content of a word (or constant).

BDC MULTIPLY

(@)MUL 32Multiplies the content of two words (or contents).

BCD DIVIDE (@)DIV  33Divides the contents of a word (or constant) by the content of a word (or constant).

BINARY ADD     

(@)ADB 50Adds the contents of two words (or constants) and CY.

BINARY (@)SBB 51 Subtracts the content of a word (or constant) an

SUBTRACT CY from the content of the word (or constant).BINARY MULTIPLY

(©)MLB 52Multiplies the contents of two words (or constants).

BINARY DIVIDE

(@)DVB 53Divides the content of a word (or constant) by the content of a word and obtains the result and remainder.

DOUBLE BCD ADD

(@)ADDL 54Add the 8-digit BCD contents of two pairs of words (or constants) and CY.

DOUBLE BCD SUBTRACT

(@)SUBL 55

Subtracts the 8-digit BCD contents of a pair of words (or constants) and CY from the 80digit BCD contents of a pair of words (or constants)

DOUBLE BCD MULITPLY

(@)MULL 56Multiplies the 8-digit BCD contents of two pairs of words (or constants).

DOUBLE BCD DIVIDE

(@)DIVL 57Divides the 8-digit BCD contents of a pair of words (or constants) by the 8–digits BCD contents of a pair of words (or constants)

               

Data Conversion Instructions

Instruction Mnemonic Code FunctionBCD TO BINARY

(@)BIN 23 Converts 4-digit BCD data to 4-digit binary data.

BINARY TO BCD

(@)BCD 24 Converts 4-digit binary data to 4 digit BCD data.

4 to 16 DECODER

(@)MLPX 76Takes the hexadecimal value of the specified digit(s) in a word and turn ON the corresponding bit in a word(s).

16 to 4 DECODER

(@)DPMX 77

Identifies the highest  ON bit in the specified word(s) and moves the hexadecimal value(s) corresponding to its location to the specified digit(s) in a word.

ASCII CODE CONVERT

(@)ASC 86Converts the designated digit(s) of a word into the equivalent 8-bit ASCII code.

 

Logic Instructions

Instruction Mnemonic Code Function

COMPLEMENT (@)COM 29Turns OFF all ON bits and turns ON all OFF bits in the specified word

LOGICAL AND (@)ANDW 34Logically ANDs the corresponding bits of two word (or constants)

LOGICAL OR (@)ORW 35Logically ORs the corresponding bits of two word (or constants)

EXCLUSIVE OR

(@)XORW    36Exclusively ORs the corresponding bits of two words (or constants)

EXCLUSIVE NOR

(@)XNRW   37Exclusively NORs the corresponding bits of two words (or constants).

 

Special Calculation Instructions

Instruction Mnemonic Code FunctionBIT COUNTER

(@)BCNT 67Counts the total number of bits that are ON in the specified block

 

Subroutine Instructions

Instruction Mnemonic Code FunctionSUBROUTINE ENTER

(@)SBS 91 Executes a subroutine in the main program.

SUBROUTINE ENTRY

SBN 92 Marks the beginning of a subroutine program.

SUBROUTINE RETURN

RET 93 Marks the end of a subroutine program.

MACRO MACRO 99

Calls and executes the specified subroutine, substituting the specified input and output words for the input and output words in the subroutine.

 

Interrupt Control Instructions

Instruction Mnemonic Code FunctionINTERVAL TIMER

(@)STIM 69Controls interval timers used to perform scheduled interrupts.

INTERRUPT CONTROL

(@)INT 89Performs interrupts control, such as masking and unmasking the interrupt bits for I/O interrupts.

 

Step Instructions

Instruction Mnemonic

Code Function

STEP DEFINE

STEP 08

Defines the start of a new step and resets the previous step when used with a control bit. Defines the end of step execution when used without a control bit.

STEP START SNXT 09Starts the execution of the step when used with a control bit.

 

Peripheral Device Control Instructions

Instruction Mnemonic Code FunctionBCD TO BINARY

(@)BIN 23 Converts 4-digit BCD data to 4-digit binary data.

BINARY TO BCD

(@)BCD 24 Converts 4-digit binary data to 4-digit BCD data.

4 to 16 DECODER

(@)MLPX 76Takes the hexadecimal value of the specified digit(s) in a word and turn ON the corresponding bit in a word(s).

16 to 4 DECODER

(@)DPMX 77

Identifies the highest  ON bit in the specified word(s) and moves the hexadecimal value(s) corresponding to its location to the specified digit(s) in a word.

ASCII CODE CONVERT

(@)ASC 86Converts the designated digit(s) of a word into the equivalent 8-bit ASCII code.

 

I/O Units Instructions

Instruction Mnemonic

Code Function

7-SEGMENT DECODER

(@)SDEC 78Converts the designated digit(s)of a word into an 8-bit, 7-segment display code.

I/O REFRESH

(@)IORF 97 Refreshes the specified I/O word.

 

Display Instructions

Instruction Mnemonic

Code Function

MEASSAGE (@)MSG 46 Reads up to 8 words of ASCII code (16 characters) from memory and displays the message on the Programming Console or other Peripheral Device.

 

High Speed Counter Control Instructions

Instruction Mnemonic

Code Function

MODE CONTROL

(@)INI 61Starts and stops counter operation, compares and changes counter PVs, and stops pulse output.

PV READ (@)PRV 62 Reads counter PVs and status data.

COMPARE TABLE LOAD

(@)CTBL 63Compares counter PVs and generates a direct table or starts operation.

 

Damage Diagnosis Instructions

Instruction Mnemonic

Code Function

FAILURE ALARM

(@)FAL 06Generates a non-fatal error when executed. The Error/Alarm indicator flashes and the CPU continues operating.

SEVERE FAILURE ALARM

FAL 07Generates a fatal error when executed. The Error/Alarm indicator lights and the CPU stops operating.

 

Special System Instructions

Instruction Mnemonic

Code Function

SET CARRY (@)STC 40 Sets Carry Flag 25504 to 1.CLEAR CARRY

(@)CLC 41 Sets Carry Flag 25504 to 0.

 

 

E.1  LOAD - Normally open output

Description

First condition, that any logical block in the ladder diagram starts with, corresponds to LOAD or LOAD NOT instructions. Both of these instructions require one line in mnemonic code. On the right of these instructions any executive instruction may be used.

Ladder symbol

Limitations There are no limitations, except that it is used as the first instruction from left to right.

Flag It has no effect on any particular flag.

Example

Pressing the button on the input “00” in the word IR000 activates the relay “00” on the output of PLC controller. Conditional instruction doesn’t have be from input memory area; it can be any bit from other memory areas, i.e. SR area as in the following example.

When one of the instructions activates the bit “00” in the word SR200, bit “00” is activated in the output word IR010. In a word, every ON state of the bit at input causes the ON state at output.

 

E.2  LOAD NOT - Normally closed input

Description First condition, that any logical block in the ladder diagram starts with, corresponds to LOAD or LOAD NOT instructions. Both of these instructions require one line in mnemonic code. On the right of these instructions any executive instruction may be used.

Ladder symbol

Limitations There are no limitations, except that it is used as the first instruction from left to right.

Flag It has no effect on any particular flag.

Example

Pressing the button on the input “00” in the word IR000 activates the relay “00” on the output of PLC controller. Conditional instruction doesn’t have be from input memory area; it can be any bit from other memory areas, i.e. SR area as in the following example.

When one of the instructions activates the bit “00” in the word SR200, bit “00” is activated in the output word IR010. In a word, every ON state of the bit at input causes the OFF state at output.

 

E.3  AND - Logical "AND" with normally open contacts

Description When two are linked serially in one instruction line, first of them corresponds to instructions LOAD or LOAD NOT, while the other represents instructions AND or AND NOT.

Ladder symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

After the LOAD instruction on ‘00’ input, AND instruction is linked to input ‘01’.

Instruction on the right will be executed only when both of the conditions from the line are fulfilled, i.e. when both inputs ‘00’ and ‘01’ are in the ON state.

 

E.4  AND NOT - Logical "AND" with normally closed contacts

Description When two or more conditions are linked serially in one instruction line, first of them corresponds to instruction LOAD or LOAD NOT, while the other represents instruction AND or AND NOT.

Ladder symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

After the LOAD instruction on ‘00’ input, AND NOT instruction is linked to input ‘01’. Instruction on the right will be executed only when both of the conditions from the line are fulfilled, i.e. when input ‘00’ is in ON state and input ‘01’ is in OFF state.

 

E.5  OR - Logical "OR" with normally open contacts

Description When two or more conditions coexist on separate, paralel lines that connect at a given point, the first condition corresponds to LOAD or LOAD NOT instructions, while others correspond to OR or OR NOT instructions.

Ladder symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

Inputs ‘00’ and ‘01’ are in OR relation with the output ‘00’. One of the inputs with ON state is sufficient to activate the output ‘00’.

 

E.6  OR NOT - Logical "OR" with normally closed contacts

Description When two or more conditions coexist on separate, paralel lines that connect at a given point, the first condition corresponds to LOAD or LOAD NOT instructions, while others correspond to OR or OR NOT instructions.

Ladder symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

Inputs ‘000.00’ and ‘000.01’ are in OR NOT relation with the output ‘010.00’. Bit ‘010.00’ will retain ON state until bit “01” changes to ON state (thus breaking the connection, because it is normally closed). One of the inputs with ON state is sufficient to activate the output ‘00’.

 

E.7  OUTPUT - Normally open output

Description The easiest way for getting results that fulfill input conditions is their direct connection to the instructions OUTPUT and OUTPUT NOT. These instructions are used for controlling the status bit, which is defined as the instruction carrier. When OUTPUT instruction is used, bit assigned to it will be ON if the execution condition is ON, and it will be OFF if the execution condition is OFF.

Ladder symbol

Limitations Attention should be paid not to “overlap” the instructions concerning the bit being controlled.

Flag It has no effect on any particular flag.

Example

Bit IR010.00 will remain ON as long as bit IR000.00 is ON. When bit IR000.00 changes to OFF, bit IR010.00 also changes to OFF.

This instruction cannot be used for assigning ON or OFF states to more than one bit. In case that there is a need for assigning values to all of the bits in word, it can be done only one bit at a time.

 

E.8  OUTPUT NOT - Normally closed output

Description The easiest way for getting results that fulfill input conditions is their direct connection to the instructions OUTPUT and OUTPUT NOT. These instructions are used for controlling the status bit, which is defined as the instruction carrier. When OUTPUT instruction is used, bit assigned to it will be ON if the execution condition is OFF, and it will be OFF if the execution condition is ON.

Ladder symbol

Limitations Attention should be paid not to “overlap” the instructions concerning the bit being controlled.

Flag It has no effect on any particular flag.

Example

Bit IR010.00 will remain ON as long as bit IR000.00 is OFF, while prelaskom changing bit IR000.00 to ON changes bit IR010.00 to OFF.

This instruction cannot be used for assigning ON or OFF states to more than one bit. In case that there is a need for assigning values to all of the bits in word, it can be done only one bit at a time.

 

E.9 SET - Changes bit state to ON

Description Instruction changes the state of the specified bit to ON when the execution condition is ON. In case that the condition is OFF, bit state remains unchanged (unlike the instruction OUT which changes bit state to OFF even when the condition is OFF).

Ladder symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

If condition state on bit IR000.00 changes to ON, state of bit IR200.00 also changes to ON. When condition state of bit IR000.00 changes from ON to OFF, bit IR200.00 remains ON.

 

E.10 RESET - Changes bit state to OFF

Description Instruction changes the state of the specified bit to OFF when the execution condition is ON. In case that the condition is OFF, bit state remains unchanged.

Ladder symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

If condition state on bit IR000.00 changes to ON, state of bit IR200.00 changes to OFF. When condition state of bit IR000.00 changes from ON to OFF, bit IR200.00 remains OFF.

 

E.11 KEEP - Changes bit state according to 2 inputs

Description Instruction is used for maintaining the status of corresponding bit according to 2 inputs. The first input changes bit state to ON whenever the condition of the first line is fulfilled, while the second changes bit state to OFF whenever the condition of the second line is fulfilled. Bit state remains unchanged as long as inputs remain unchanged.

Ladder symbol

Flag It has no effect on any particular flag.

Example

When the state of bit IR000.00 changes to ON bit IR200.00 also changes to ON. If bit

IR000.01 changes to ON, bit IR200.00 changes to OFF and remains OFF until state of bit IR000.00 is ON again.

 

E.12 DIFFERENTIATE UP - Changes bit state to ON for duration  of one cycle

Description Instruction changes bit state to ON during one cycle when the preceding condition is fulfilled.

Ladder symbol

Flag It has no effect on any particular flag.

Example

Instruction changes state of bit IR200.00 to ON for duration of one cycle. If bit IR000.00 is ON, bit IR200.00 changes to ON for duration of one scan cycle.

 

E.13 DIFFERENTIATE DOWN - Changes bit state to OFF for duration  of one cycle

Description Instruction changes bit state to OFF during one cycle when the preceding condition is fulfilled.

Ladder symbol

Flag It has no effect on any particular flag.

Example

If bit IR000.00 is ON, state of bit IR200.00 changes to OFF for duration of one scan cycle.

 

E.14 NO OPERATION - No operation

Description Generally, usage of this instruction in programs is not recommended. When PLC gets to this instruction nothing happens and the following instruction is executed.

Ladder symbol

Flag It has no effect on any particular flag.

 

E.15 INTERLOCK - Interlock

Description Instruction IL is always used in pair with the instruction ILC. Their purpose is to reset all the outputs, flags, control bits, timers and counters that are within instructions between IL and ILC. Timers and counters stop working and retain values they had at the moment of executing IL instruction. It is possible to have multiple IL instructions and to reset one or more parts of the program, accordingly. Instruction is executed when condition state changes from ON to OFF!

Ladder symbol

Flag It has no effect on any particular flag.

 

E.16 INTERLOCK CLEAR - End of the program part encompassed by interlock

Description Instruction ILC is always used in pair with instruction IL. When the condition of instruction IL is fulfilled all the outputs, flags, control bits, timers and counters that are

within instructions between IL and ILC are reset. Timers and counters stop working and retain values they had at the moment of executing IL instruction.

Ladder symbol

Flag It has no effect on any particular flag.

 

E.17 END - End of program

Description This is mandatory instruction at the end of every program. Any instruction following this one will not be executed. It can be used for debugging purposes in program, so as to designate the point where the monitoring of program execution stops. If the program uses subroutines, it is necesssary to have instruction END following the last subroutine.

Ladder symbol

Limitations There are no limitations.

Flag Changes states of flags ER, CY, GR, EQ and LE to OFF.

 

E.18 JUMP - Jump to another location in the program

Description Certain part of the program may be skipped depending on the state of defined condition for jump execution. Jumps can be created using JUMP (JMP(04)) or JUMP END (JME(05)) instructions. If condition state is ON, program executes normally, as if the instruction was never used. If status of execution condition is OFF, program execution continues from the JUMP END instruction corresponding to JUMP instruction. Which JUMP END corresponds to which JUMP instruction is defined with a number that follows the instruction. Value 0 can be used unlimited number of times in the course of program for this purpose, while each of other 99 available numbers may be used only once.

Ladder symbol

Limitations Total number of JUMP and JUMP END pairs cannot exceed 99. Each value from 1-99 range can be used only once.

Flag It has no effect on any particular flag.

 

E.19 JUMP END - Location where the program execution continues after JUMP

Description Instruction JME is used in pair with JMP instruction as integral part of it. If there is no JME assigned to JMP instruction, program will report an error.

Ladder symbol

Limitations Total number of JUMP and JUMP END pairs cannot exceed 99. Each value from 1-99 range can be used only once.

Flag It has no effect on any particular flag.

Example

When the state of bit IR000.00 changes to OFF, jump instruction skips all the instruction lines between itself and the corresponding JME instruction.

Another way for using jump instruction is assigning value “0” to JMP instruction. Unlimited number of jumps can be programmed in this way and the destination for each of these is a unique location defined with instruction JUMP END with index 0. Instruction JUMP END with parameter 0 may be used multiple times in the program. In that case, program execution after the jump defined with JUMP (index 0) continues from the first following JUMP END instruction with this index. Time of execution with this form of jump function is somewhat longer, as the program must first locate the closest appropriate JUMP END instruction. The following example demonstrates programming greater number of jump functions ending at the same destination:

Changing the state of bits IR000.00 or IR000.03 to OFF executes the jump to the line containing instruction JME.

 

E.20 TIMER - Timer with 0.1s resolution

Description

Timers are complex instructions with the purpose of separating two programming actions. Changing the state of condition to ON starts the timing with 0.1s increments starting from zero.

Value of parameter SV (abbreviation for Set Value) is multiplied by 0.1 s, the result being total time in seconds. Value given in the middle part of the block is called TC number. Each TC number can be used for defining one couner or timer. It can take values from 000 - 127 range. Lower part of the block is reserved for displaying the starting value of timer. Word with this role

can belong to sectors IR, AR, DM, HR, LR or can be given as a constant, with values from 000.0 - 999.9 range. The most common and the simplest way to apply a timer is to have a constant here, whether given directly or programmed on some memory location (if parameter SV is given as a constant, it is necessary to put character “#” ahead of value).

Ladder symbol

Limitations The number of timer cannot be used for counter or another timer.

Flag Affects the appropriate flag in TC area.

Example

Changing the state of bit IR000.00 to ON starts the timing (in this case, time is 100*0.1s=10 seconds). After the passing of given period of time, the appropriate bit IM002 changes state to ON, thus fulfilling the condition for executing the instructions on the right (in this case bit IR010.01 changes state to ON).

Condition bit must be constantly ON for a given time period for bit TIM002 to be set. If condition state changes to OFF during the given time period, timer resets and goes back to the beginning of period.

 

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