Api I C3 1 LD

IST / DEEC / API
Industrial Automation
(Automao de Processos Industriais)
PLC Programming languages Ladder Diagram

http://users.isr.ist.utl.pt/~jag/courses/api1213/api1213.html
Slides 2010/2011 Prof. Paulo Jorge Oliveira Rev. 2011-2013 Prof. Jos Gaspar
IST / DEEC / API
Syllabus:
Chap. 2 Introduction to PLCs [2 weeks] ... Chap. 3 PLC Programming languages [2 weeks] Standard languages (IEC-61131-3): Ladder Diagram; Instruction List, and Structured Text. Software development resources. ... Chap. 4 - GRAFCET (Sequential Function Chart) [1 week]
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Chap. 3 - PLC Programming languages
PLC Programming languages (IEC 1131-3 changed to IEC 61131-3) Ladder Diagram Structured Text
If %I1.0 THEN %Q2.1 := TRUE ELSE %Q2.2 := FALSE END_IF
Instruction List
LD AND ANDN OR ST %M12 %I1.0 %I1.1 %M10 %Q2.0
Sequential Function Chart (GRAFCET) 1

(1) m
2
(2) b
Direita
3
(3) p
Carrega
4
(2) a
Esquerda
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Ladder diagram
A program is a series of instructions that directs the PLC to execute actions.
Relay ladder logic, the standard programming language, is based on electromagnetic relay control.
Input Instructions Output Instructions
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Ladder diagram
Types of operands:
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Ladder diagram
Types of operands:
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Ladder diagram Basic Instructions

Load
Normally open contact: contact is active (result is 1) when the control bit is 1. Normally closed contact: contact is active (result is 1) when the control bit is 0.
P
Contact in the rising edge: contact is active during a scan cycle where the control bit has a rising edge. Contact in the falling edge: contact is active during a scan cycle where the control bit has a falling edge.
%I1.0
%Q2.0
I1.0
P
Q2.0
t t
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Load operands
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Store
The result of the logic function activates the coil. The inverse result of the logic function activates the coil. The result of the logic function energizes the relay (sets the latch). The result of the logic function de-energizes the relay (resets the latch)..
%Q2.0 I1.0
%I1.0
S
Q2.0
t t Page 9
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Store operands
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Ladder diagram Allen Bradley notation

Relays with latch and unlatch
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Ladder diagram
Relay-type instructions Example:
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AND
AND of the operand with the result of the previous logical operation. AND of the operand with the inverted result of the previous logical operation.
P
AND of the rising edge with the result of the previous logical operation. AND of the falling edge with the result of the previous logical operation.
%I1.0 %I1.0 %Q2.0
I1.0
S
Q2.0
t t Page 13
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OR
OR of the operand with the result of the previous logical operation. OR of the operand with the inverted result of the previous logical operation. OR of the rising edge with the result of the previous logical operation. OR of the falling edge with the result of the previous logical operation.
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XOR
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Ladder diagram
Ladder assembling
Input Instructions
N
Output Instructions
S
The outputs that have a TRUE logical function, evaluated from the left to right and from the top to the bottom, are energized (Schneider, Micro PLCs).
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Ladder diagram
Example:
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Ladder diagram
Example:
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Ladder diagram
Example:
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Ladder diagram
General case of Inputs and Outputs in parallel, with derivations
Note: it is important to study the constraints and potentialities of the development tools.
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Ladder diagram
Imbricated (nested) contacts and alternative solution
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Ladder diagram
Contacts in the vertical and alternative solution
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Ladder diagram
Contacts in the vertical and alternative solution Another example:
Solves the problem of disallowed right to left scanning (FDBC in fig5.30). Page 23
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Ladder diagram
Temporized Relays or Timers
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Ladder diagram
Temporized Relays or Timers (pneumatic)
The instantaneous contacts change state as soon as the timer coil is powered. The delayed contacts change state at the end of the time delay.
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Ladder diagram

Off-delay, provides time delay when the relay coil is de-energized.
On-delay, provides time delay when the relay coil is energized.
Tables: Relay symbols used for timed contacts.
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Ladder diagram
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Ladder diagram
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Ladder diagram Temporized Relays or Timers (PLC)
Characteristics:
Identifier: %TMi Input: Mode: 0..63 in the TSX37 IN TON TOF TP TB to activate On delay Off delay Monostable 1mn (def.), 1s, 100ms, 10ms
%TMi IN
MODE: TON TB: 1mn TM.P: 9999 MODIF: Y
Time basis:
Programmed value: Actual value:
%TMi.P
0...9999 (def.) period=TB*TMi.P %TMi.V 0...TMi.P (can be read or tested) can be modified from the console
Modifiable:
Y/N
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Ladder diagram TON mode Temporized Relays or Timers (PLC)

%TMi IN
MODE: TON TB: 1mn TM.P: 9999 MODIF: Y
App. example: start ringing the alarm if N sec after door open there is no disarm of the alarm. Page 30
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Ladder diagram TOF mode Temporized Relays or Timers (PLC)

%TMi IN
MODE: TOF TB: 1mn TM.P: 9999 MODIF: Y
App. example: turn off stairways lights after N sec the lights button has been released. Page 31
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Ladder diagram Temporized Relays or Timers (PLC)
TP mode
Works as a monostable or as a pulse generator (with pre-programmed period)
%TMi IN
MODE: TP TB: 100msec TM.P: 5 MODIF: Y
App. example: positive input edge give a controlled (fixed) duration pulse to start a motor. Page 32
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Ladder diagram Timers in the Allen-Bradley PLC-5

Two alternative representations
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Ladder diagram Timers implementation in the Allen-Bradley PLC-5:
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Ladder diagram Timers operation in the Allen-Bradley PLC-5
EN TT
DN EN = Enable Bit TT = Timer-Timing Bit DN = Done Bit Page 35
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Ladder diagram
Example of timer on-delay
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Ladder diagram
Example of a timer on-delay that sets an output after a count-down
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Ladder diagram
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Ladder diagram
Coil is energized if the switch remains closed for 12 seconds
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Ladder diagram
If PB2 is activated, powers on the oil pumping motor. When the pressure augments, PS1 detects the increase and activates the main motor. 15 seconds later the main drive motor starts.
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Ladder diagram
Example of timer programmed as off-delay
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Ladder diagram
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Ladder diagram
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Ladder diagram
Example of timers programmed as off-delay and on-delay
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Ladder diagram Timers

Animated demonstration:
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Ladder diagram Retentive Timers

Switch-off region Switch-on region
Motor accumulated motion (rotation) defines the on/off timing.
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Ladder diagram
Example of retentive timers
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Ladder diagram Retentive Timers

Animated demonstration: (search on the Schneider PLC or discuss implementation)
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Ladder diagram
Example:
SW ON to start operation Before motor starts, lubrificate 10 s with oil. SW OFF to stop. (lubrificate 15 s more). After 3 hours of pump operation, stop motor and signal with pilot light. Reset available after servicing.
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Ladder diagram Cascaded Timers
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Ladder diagram Cascaded Timers (bistable system)
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Ladder diagram Timers for very long time intervals
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Ladder diagram
Example of a semaphore
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Example of a semaphore in both directions
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Example of a semaphore in both directions
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Ladder diagram Counters
Some applications...
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Ladder diagram Implementation of Counters in the PLC-5 of Allen-Bradley:
Internal structure representation
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Ladder diagram Implementation of Counters in the PLC-5 of Allen-Bradley:

Two alternative representations:
Coil-formatted counter and reset instructions
Block-formatted counter instruction

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Ladder diagram Up-counters
Usage of an incremental up-counter and the corresponding temporal diagram: PB1 increments counting PB2 resets the counting
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Ladder diagram Example:

Counting parts
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Ladder diagram Example
1. Start conveyor motor 2. Passing cases increment counter 3. After 50 cases, stop motor
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Ladder diagram Up/down-counters
Usage of an incremental up-down-counter and the corresponding temporal diagram: PB1 increments counting PB2 decrements the counting PB3 resets the counter
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Ladder diagram Up/down-counters

Example: Finite parking garage
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Ladder diagram Cascaded Counters

Example:
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Example:
Count
24 hours clock
Reset
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Example: Memory time of event Internal relay OFF stops clock
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Ladder diagram Incremental Encoder

counter measures rotation angle or rotation speed (if divided by time)
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Ladder diagram Incremental Encoder

Example: counter as a length sensor
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Ladder diagram
Example with counters and timers (cont.): Specs:
Starts M1 conveyor upon pushing button . After 15 plates stops M1 and starts conveyor M2 . M2 operates for 5 seconds and then stops. Restart sequence.
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Ladder diagram
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Ladder diagram
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Ladder diagram
Example with counters and timers (cont.): To use a timer to command a counter, to implement large periods of time.
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Ladder diagram Counters

Example:
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Ladder diagram Counters in PL7

Characteristics:
Identifier: %Ci 0..31 in the TSX37 %Ci.P %Ci.V Y/N 0...9999 (def.) 0...Ci.P (only to be read) can be modified from the console Reset Ci.V=0 Preset Ci.V=Ci.P Count Up Count Down Overrun %Ci.E=1 %Ci.V=0->9999 Done %Ci.D=1 %Ci.V=Ci.P Full %Ci.F=1 %Ci.V=9999->0
%Ci R S
CP: 9999 MODIF: Y
Value progr.: Value Actual:
E D
Modifiable:
Inputs:
CU CD
F
Outputs:
R S CU CD E D F
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Ladder diagram Counters in Unity Pro
CU "0" to "1" => CV is incremented by 1 CV PV => Q:=1 R=1 => CV:=0
CU "0" to "1" => CV is incremented by 1 CD "0" to "1" => CV is decremented by 1 CV PV => QU:=1 CV 0 => QD:=1 R=1 => CV:=0 LD=1 => CV:=PV R has precedence over LD
NOTE: counters are saturated such that no overflow occurs
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Ladder diagram
Numerical Processing
Algebraic and Logic Functions
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Ladder diagram
Numerical Processing Arithmetic Functions
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Ladder diagram
Numerical Processing Example: Arithmetic functions
Use of a system variable: %S18 flag de overflow

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Ladder diagram
Numerical Processing Logic Functions
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Ladder diagram
Numerical Processing Example: Logic functions
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Ladder diagram
Numerical Processing Priorities on the execution of the operations
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Ladder diagram
Structures for Control of Flux Subroutines Call and Return
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Ladder diagram
Structures for Control of Flux JUMP instructions: Conditional and unconditional
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Ladder diagram
Structures for Control of Flux Example: Use of jump instructions Attention to: INFINITE LOOPS ... It is not a good style of programming!... Does not improove the legibility of the proposed solution.
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Ladder diagram
Structures for Control of Flux Halt
Stops all processes! Events masking
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Ladder diagram
There are other advanced instructions (see manual) Monostable Registers of 256 words (LIFO ou FIFO) DRUMs Comparators Shift-registers ... Functions to manipulate floats Functions to convert bases and types
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Ladder diagram
Numerical Tables
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Ladder diagram
System information: system bits
See manual for the remaining 100 bits generated...
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Ladder diagram
System information: system words
See manual for the remaining 140 words generated...
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Ladder diagram
Software Organization
A program can be built from: Tasks, that are executed cyclically or periodically. Tasks MAST / FAST / AUX are built from: Sections Subroutines Event processing, that is carried out before all other tasks. Event processing is built from: Sections for processing time controlled events Sections for processing hardware controlled events
Unity - Project Browser Page 90
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Ladder diagram
Sas (LD)
MAST Master Task Program Composed by sections Execution Cyclic or Periodic

Oven1 (GRAFCET) PRL (LD) Chart POST (IL) SR0 Drying (LD) Cleaning (IL)
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Ladder diagram
FAST Fast Task Program Priority greater than MAST
Executed Periodically (1-255ms) Verified by a Watchdog, impacts on %S11 %S31 Enables or disables a FAST %S33 gives the execution time for FAST
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Ladder diagram
Event Processes Processes that can react to external changes (16 in the Micro 3722 EV0 a EV15) Priority greater than MAST and FAST!
Event Generators
Inputs 0 to 3 in module 1, given transitions Counters Upon telegrams reception %S38 Enables or disables event processes (also with MASKEVT() or UNMASKEVT())
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Ladder diagram
Development tools
Each PLC has limitations in terms of connections Example:
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Ladder diagram
Development tools
It is important to learn the potentialities and ... the limitations of the developing tools, i.e. STUDYING the manuals is a MUST.
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Ladder diagram
Development tools
Last but not least, learn how to develop and debug programs (and how to do some fine tuning).
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Ladder diagram
Development tools
Last but not least, learn how to develop and debug programs (and how to do some fine tuning).
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PLC Programming languages Ladder Diagram

IST / DEEC / API

IST / DEEC / API

Chap. 3 - PLC Programming languages

Sequential Function Chart (GRAFCET) 1

IST / DEEC / API

A program is a series of instructions that directs the PLC to execute actions.

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

Ladder diagram Basic Instructions

IST / DEEC / API

Chap. 3 - PLC Programming languages

Ladder diagram Basic Instructions

IST / DEEC / API

Chap. 3 - PLC Programming languages

Ladder diagram Basic Instructions

IST / DEEC / API

Chap. 3 - PLC Programming languages

Ladder diagram Basic Instructions

IST / DEEC / API

Chap. 3 - PLC Programming languages

Ladder diagram Allen Bradley notation

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

Ladder diagram Basic Instructions

%I1.0 %I1.0 %Q2.0

IST / DEEC / API

Chap. 3 - PLC Programming languages

Ladder diagram Basic Instructions

IST / DEEC / API

Chap. 3 - PLC Programming languages

Ladder diagram Basic Instructions

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

IST / DEEC / API

Chap. 3 - PLC Programming languages

Temporized Relays or Timers

IST / DEEC / API

Chap. 3 - PLC Programming languages

Temporized Relays or Timers (pneumatic)

IST / DEEC / API

Chap. 3 - PLC Programming languages