IST / DEEC / ACSDC

MEEC 2007-2008

Industrial Automation
(Automao (A t d de P Processos I Industriais) d t i i)

PLCs Programming Languages Ladder Diagram

http://www.isr.ist.utl.pt/~pjcro/courses/api0708/api0708.html
Prof. Paulo Jorge Oliveira pjcro @ isr.ist.utl.pt Tel: 21 8418053 ou 2053 (internal)

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Syllabus:
Chap. 2 Introduction to PLCs [2 weeks] ... Chap. 3 PLCs Programming Languages [2 weeks] Standard languages (IEC-1131-3): Ladder Diagram; Instruction List, and Structured Text. Software development resources. ... Chap. 4 - GRAFCET (Sequential Function Chart) [1 week]

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Chap. 3 - PLCs Programming languages

PLCs Programming Languages (IEC 11311131-3) 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

Right

3
(3) p

Load

4
(2) a

Left

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Linguagens de programao de PLCs (IEC 11311131-3) 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

Input Instructions

Output Instructions

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Ladder diagram Types of operands:

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Ladder diagram Basic Instructions

Load
Open contact: contact is active (result is 1) while the control bit is 1. Close contact: contacto is active (result is 1) while 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. edge Contact in the falling edge: contact is active during a scan cycle %Q2.0 the control I1.0 where bit has a falling edge.
t
Q2.0

N %I1.0 P

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Ladder diagram Basic Instructions

Load operands

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Chap. 3 - PLCs Programming languages

Ladder diagram Basic Instructions

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). latch) The result of I1.0 the logic function de-energizes the relay %Q2.0 (resets the latch)..
S
Q2.0

R %I1.0 N

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Ladder diagram Basic Instructions

Store operands

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Ladder diagram Allen Bradley notation

Relays with latch and unlatch

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Ladder diagram

Relay-type y yp instructions Example:

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Ladder diagram Basic Instructions

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

AND of the operand with the result of the previous I1.0 logical operation.
t

AND of the operand with the inverted result of the previous Q2.0 logical operation. t
P

AND of the rising edge with the result of the previous logical operation operation. AND of the falling edge with the result of the previous logical operation.

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Ladder diagram Basic Instructions

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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Ladder diagram Basic Instructions

XOR

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Ladder diagram
Ladder assembling
Input Instructions O t t Output Instructions

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
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 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:

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Ladder diagram Temporized Relays or Timers

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Ladder diagram Temporized Relays or Timers

%TMi IN
MODE: TON TB: 1mn TM.P: 9999 MODIF: Y

Characteristics:
Identifier: Input: Mode: %TMi IN TON TOFF TP TB 0..63 in the TSX37 to activate On delay Off delay Monostable 1mn (def.), 1s, 100ms, 10ms

Time basis: Q

Programmed value: %TMi.P 0...9999 (def.) period=TB*TMi.P Actual value: %TMi.V 0...TMi.P (can be real or tested) Modifiable: Y/N can be modified from the console
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Ladder diagram Temporized Relays or Timers

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Ladder diagram
Example:

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Ladder diagram
Example:

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Ladder diagram Temporized Relays or Timers

%TMi IN
MODE: TP TB: 100msec TM.P: 5 MODIF: Y
TMi.P IN

Mode:

TP

Works as a monstable or as a pulse generator (with pre-programmed period)

Q
Q
500ms 500ms

TMi.V

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Ladder diagram Timers implementation in the Allen-Bradley y PLC-5:

Two alternative representations....

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Ladder diagram Timers operation in the Allen-Bradley PLC-5

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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

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Ladder diagram
Example of timer on-delay

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Ladder diagram
Example of timer on-delay
Coil is energized if the switch remains closed for 12 seconds

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Ladder diagram
Example of timer on-delay
If PB2 is activated, powers on the oil pumping motor. When the pressure augments, PS1 detects the increase and activates the main motor. 15 segunds 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
Example of timer programmed as off-delay

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Ladder diagram
Example of timer programmed as off-delay

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Ladder diagram
Example of timers programmed as off-delay and on-delay

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Ladder diagram Timers

Example:

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Ladder diagram Retentive Timers

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Ladder diagram
Example of retentive timers

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Ladder diagram Timers

Example: (search on the Schneider PLC or discuss implementation)

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Ladder diagram
Exemplo:
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 Characteristics: Counters

Identifier: Value progr.: Value Actual: %Ci R S
CP: 9999 MODIF: Y

%Ci %Ci.P %Ci.V Y/N

0..31 in the TSX37 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
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E D F

Modifiable:

Inputs:

CU CD

R S CU CD E D F

Outputs:

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Ladder diagram Implementation of Counters in the PLC-5 of Allen-Bradley y:

Internal Structure

Representation

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Ladder diagram Implementation of Counters y: in the PLC-5 of Allen-Bradley

Alternative representations

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Ladder diagram Up-counters

Implementation of an incremental Up-counter and Corresponding temporal diagram

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Ladder diagram Example: p

Counting parts

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Ladder diagram Example

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Ladder diagram Up/down-counters

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Ladder diagram Up/down-counters

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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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Ladder diagram Cascaded Counters

Example: 24 hours clock

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Ladder diagram Cascaded Counters

Example: Memory time of event

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Ladder diagram Incremental Encoder

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Ladder diagram Incremental Encoder

Example: counter as a lenght sensor

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Ladder diagram
Example with counters and timers (conts.): 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
Example with counters and timers (conts.): 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
Example with counters and timers (conts.): 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
Example with counters and timers (conts.): 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
Numerical Processing

Algebraic and Logic Functions

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Ladder diagram
Numerical Processing Arithmetic Functions

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Ladder diagram
Numerical Processing E Example: l 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 E Example: l Logic functions

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Ladder diagram
Numerical Processing P i iti on the Priorities th execution ti of f the th operations ti

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Ladder diagram
Structures for Control of Flux S b ti Subroutines Call and Return

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Ladder diagram
Structures for Control of Flux JUMP i instructions: t ti Conditional and unconditional

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Ladder diagram
Structures for Control of Flux E Example: l 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 H lt Halt

Stops all processes! Events masking

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Ladder diagram
There are other advanced instrauctions (see manuel) Monostable Registers of 256 words (LIFO ou FIFO) DRUMs Comparators Shift-registers ... Functions to manipulate floats
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Ladder diagram
Numerical Tables

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Ladder diagram
Each PLC has limitations in terms of connections E Example: l

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Ladder diagram
It is important to learn the potentialities and ... the limitations of the developing tools, i e TO STUDY the manuals is a MUST i.e. MUST.

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Ladder diagram
Learn how to develop and debug programs (and how to do the fine tunning).

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Ladder diagram
System information: system bits

See manual for the remaining 100 bits generated...

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Ladder diagram
Informao de Sistema: words de sistema

See manual for the remaining 140 words generated...

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Ladder diagram
Software Organization
Sas (LD)

MAST Master Task Program Composed by sections

Oven1 (GRAFCET) PRL (LD) Chart POST (IL)

Execution Cyclically or Periodically

Cleaning (IL) Drying (LD)

SR0

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Ladder diagram
Software Organization FAST Fast Task Program Priority greater than MAST Executed Periodically (1-255ms) Verified by aWatchdog, impacts on %S11 %S31 Enables E bl or disables di bl a FAST %S33 gives the execution time for FAST

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Ladder diagram
Software Organization 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 1, given transictions Counters Upon telegrams reception %S38 Enables or disables event processes (also with MASKEVT() or UNMASKEVT())
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