IST / DEEC / APIIndustrial Automation(Automação de Processos Industriais)PLC Programming languagesLadder Diagramhttp://users.isr.ist.utl.pt/ jag/courses/api1213/api1213.htmlSlides 2010/2011 Prof. Paulo Jorge OliveiraRev. 2011-2013 Prof. José Gaspar
IST / DEEC / APISyllabus: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]Page 2
Chap. 3 - PLC Programming languagesIST / DEEC / APIPLC Programming languages(IEC 1131-3 changed to IEC 61131-3)Ladder DiagramStructured TextIf %I1.0 THEN%Q2.1 : TRUEELSE%Q2.2 : FALSEEND IFSequential Function Chart(GRAFCET)1Instruction tab(2)3Carregap(3)4(2)EsquerdaaPage 3
IST / DEEC / APILadder diagramA program is a series of instructionsthat directs the PLC to executeactions.Relay ladder logic, the standardprogramming language, is based onelectromagnetic relay control.InputInstructionsNOutputInstructionsSPage 4
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesTypes of operands:Page 5
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesTypes of operands:Page 6
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramBasic InstructionsLoadNormally 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.PContact in the rising edge: contact is active during a scan cyclewhere the control bit has a rising edge.NContact in the falling edge: contact is active during a scan cyclewhere the control bit has a falling edge.%I1.0%Q2.0I1.0tPQ2.0tPage 7
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramBasic InstructionsLoad operandsPage 8
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramBasic InstructionsStoreThe result of the logic function activates the coil.The inverse result of the logic function activates the coil.SThe result of the logic function energizes the relay(sets the latch).RThe result of the logic function de-energizes the relay(resets the latch).%I1.0%Q2.0NSI1.0tQ2.0tPage 9
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramBasic InstructionsStore operandsPage 10
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramAllen Bradley notationRelays with latch and unlatchPage 11
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramRelay-type instructionsExample:Page 12
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramBasic InstructionsANDAND of the operand with the result of the previouslogical operation.AND of the operand with the inverted result of the previouslogical operation.PAND of the rising edge with the result of the previouslogical operation.NAND of the falling edge with the result of the previouslogical operation.%I1.0 %I1.0 %Q2.0NPI1.0tSQ2.0tPage 13
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramBasic InstructionsOROR of the operand with the result of the previouslogical operation.OR of the operand with the inverted result of the previouslogical operation.POR of the rising edge with the result of the previouslogical operation.NOR of the falling edge with the result of the previouslogical operation.Page 14
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramBasic InstructionsXORPage 15
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramLadder assemblingInputInstructionsNOutputInstructionsSThe outputs that have a TRUE logical function, evaluatedfrom the left to right and from the top to the bottom, areenergized (Schneider, Micro PLCs).Page 16
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample:Page 17
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample:Page 18
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample:Page 19
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramGeneral case of Inputs and Outputs in parallel, with derivationsNote: it is important to study the constraints and potentialities of thedevelopment tools.Page 20
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramImbricated (nested) contacts and alternative solutionPage 21
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramContacts in the vertical and alternative solutionPage 22
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramContacts in the vertical and alternative solutionAnother example:Solves the problem of disallowed right toleft scanning (FDBC in fig5.30).Page 23
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesTemporized Relays or TimersPage 24
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesTemporized 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.Page 25
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramTemporized Relays or TimersOn-delay, provides time delaywhen the relay coil is energized.Off-delay, provides time delay when therelay coil is de-energized.Tables: Relay symbols used for timed contacts.Page 26
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesTemporized Relays or TimersPage 27
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesTemporized Relays or TimersPage 28
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramCharacteristics:Temporized RelaysIdentifier: %TMi0.63 in the TSX37Input:INto activateMode:TONTOFTPOn delayOff delayMonostableTime basis:TB1mn (def.), 1s,100ms, 10msProgrammed value:%TMi.Por Timers (PLC)%TMiINMODE: TONTB: 1mnTM.P: 9999MODIF: YQActual value:Modifiable:0.9999 (def.)period TB*TMi.P%TMi.V 0.TMi.P(can be read or tested)Y/Ncan be modified fromthe consolePage 29
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramTON modeTemporized Relaysor Timers (PLC)%TMiINQMODE: TONTB: 1mnTM.P: 9999MODIF: YApp. example: start ringing the alarm if N sec after door open there is no disarm of the alarm.Page 30
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramTOF modeTemporized Relaysor Timers (PLC)%TMiINQMODE: TOFTB: 1mnTM.P: 9999MODIF: YApp. example: turn off stairways lights after N sec the lights’ button has been released.Page 31
IST / DEEC / APILadder diagramTemporized RelaysChap. 3 - PLC Programming languagesTP modeWorks as a monostable or as a pulse generator(with pre-programmed period)or Timers (PLC)%TMiINQMODE: TPTB: 100msecTM.P: 5MODIF: YApp. example: positive input edge give a controlled (fixed) duration pulse to start a motor.Page 32
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramTimers in the Allen-Bradley PLC-5Two alternative representationsPage 33
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramTimers implementation in the Allen-Bradley PLC-5:Page 34
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramTimers operation in the Allen-Bradley PLC-5ENTTDNEN Enable BitTT Timer-Timing BitDN Done BitPage 35
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of timer on-delayPage 36
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of a timer on-delay that sets an output after a count-downPage 37
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of timer on-delayPage 38
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of timer on-delayCoil is energized if the switch remains closed for 12 secondsPage 39
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of timer on-delay If PB2 is activated, powers on the oil pumping motor. When the pressure augments, PS1 detects the increase andactivates the main motor. 15 seconds later the maindrive motor starts.Page 40
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of timer programmed as off-delayPage 41
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of timer programmed as off-delayPage 42
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of timer programmed as off-delayPage 43
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of timers programmed as off-delay and on-delayPage 44
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramTimersAnimated demonstration:Page 45
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramRetentive TimersSwitch-off regionSwitch-on regionMotor accumulatedmotion (rotation)defines the on/offtiming.Page 46
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of retentive timersPage 47
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramRetentive TimersAnimated demonstration:(search on the Schneider PLC or discuss implementation)Page 48
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample: 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 pumpoperation, stop motor andsignal with pilot light. Reset available afterservicing.Page 49
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramCascaded TimersPage 50
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramCascaded Timers (bistable system)Page 51
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramTimers for very long time intervalsPage 52
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample of a semaphorePage 53
IST / DEEC / APIChap. 3 - PLC Programming languagesExample of a semaphore in both directionsPage 54
IST / DEEC / APIChap. 3 - PLC Programming languagesExampleof asemaphorein bothdirectionsPage 55
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramCountersSome applications.Page 56
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramImplementation of Countersin the PLC-5 of Allen-Bradley:Internal structure representationPage 57
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramImplementation of Countersin the PLC-5 of Allen-Bradley:Two alternative representations:Coil-formatted counter and resetinstructionsBlock-formatted counterinstructionPage 58
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramUp-countersUsage of anincremental up-counterand the correspondingtemporal diagram:PB1 increments countingPB2 resets the countingPage 59
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample:Counting partsPage 60
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample1. Start conveyor motor2. Passing cases increment counter3. After 50 cases, stop motorPage 61
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramUp/down-countersUsage of an incrementalup-down-counterand the correspondingtemporal diagram:PB1 increments countingPB2 decrements the countingPB3 resets the counterPage 62
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramUp/down-countersExample:Finite parking garagePage 63
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramCascaded CountersExample:Page 64
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramCascaded CountersExample:Count24 hours clockResetPage 65
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramCascaded CountersExample:Memory time of eventInternal relay OFF stops clockPage 66
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramIncremental Encodercounter measures rotation angle orrotation speed (if divided by time)Page 67
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramIncremental EncoderExample:counter as a ”length sensor”Page 68
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample with counters and timers (cont.):Specs: Starts M1 conveyorupon pushing button . After 15 plates stops M1and starts conveyor M2 . M2 operates for 5 seconds andthen stops. Restart sequence.Page 69
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample with counters and timers (cont.):Specs: Starts M1 conveyorupon pushing button . After 15 plates stops M1and starts conveyor M2 . M2 operates for 5 seconds andthen stops. Restart sequence.Page 70
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample with counters and timers (cont.):Specs: Starts M1 conveyorupon pushing button . After 15 plates stops M1and starts conveyor M2 . M2 operates for 5 seconds andthen stops. Restart sequence.Page 71
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramExample with counters and timers (cont.):To use a timer to command a counter, to implement large periods of time.Page 72
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramCountersExample:Page 73
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramCounters in PL7%CiRSECP: 9999MODIF: YCUCDCharacteristics:Identifier: %Ci0.31 in the TSX37Value progr.:Value Actual:%Ci.P%Ci.V0.9999 (def.)0.Ci.P (only to be read)Modifiable:Y/Ncan be modified fromthe consoleInputs:RSCUCDReset Ci.V 0Preset Ci.V Ci.PCount UpCount DownOutputs:EDFOverrun %Ci.E 1 %Ci.V 0- 9999Done %Ci.D 1 %Ci.V Ci.PFull %Ci.F 1 %Ci.V 9999- 0DFPage 74
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramCounters in Unity ProCU "0" to "1" CV is incremented by 1CV PV Q: 1CU "0" to "1" CV is incremented by 1CD "0" to "1" CV is decremented by 1CV PV QU: 1CV 0 QD: 1R 1 CV: 0R 1 CV: 0 LD 1 CV: PVR has precedence over LDNOTE: counters are saturated such that no overflow occursPage 75
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramNumerical ProcessingAlgebraic and Logic FunctionsPage 76
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramNumerical ProcessingArithmetic FunctionsPage 77
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramNumerical ProcessingExample:Arithmetic functionsUse of a system variable:%S18 – flag de overflowPage 78
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramNumerical ProcessingLogic FunctionsPage 79
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramNumerical ProcessingExample:Logic functionsPage 80
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramNumerical ProcessingPriorities on the execution of the operationsPage 81
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramStructures for Control of FluxSubroutinesCall and ReturnPage 82
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramStructures for Control of FluxJUMP instructions:Conditional and unconditionalPage 83
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramStructures for Control of FluxExample:Use of jump instructionsAttention to: INFINITE LOOPS . It is not a good style ofprogramming!. Does not improove the legibilityof the proposed solution.Page 84
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramStructures for Control of FluxHaltStops all processes!Events maskingPage 85
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramThere 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 typesPage 86
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramNumerical TablesPage 87
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramSystem information: system bitsSee manualfor the remaining100 bits generated.Page 88
IST / DEEC / APIChap. 3 - PLC Programming languagesLadder diagramSystem information: system wordsSee manualfor the remaining140 words generated.Page 89
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesSoftware OrganizationA program can be built from:Tasks, that are executed cyclically or periodically.Tasks MAST / FAST / AUX are built from:SectionsSubroutinesEvent processing, that is carried out before all other tasks.Event processing is built from:Sections for processing time controlled eventsSections for processing hardware controlled eventsUnity - Project BrowserPage 90
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramSoftware OrganizationSas (LD)MAST – Master Task ProgramComposed by sectionsExecution Cyclic or PeriodicOven1 (GRAFCET)PRL (LD)ChartPOST (IL)SR0Drying (LD)Cleaning (IL)Page 91
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramSoftware OrganizationFAST – Fast Task ProgramPriority 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 FASTPage 92
Chap. 3 - PLC Programming languagesIST / DEEC / APILadder diagramSoftware OrganizationEvent 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())Page 93
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesDevelopment toolsEach PLC has limitations in terms of connectionsExample:Page 94
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesDevelopment toolsIt is important to learn the potentialities and .the limitations of the developing tools,i.e. STUDYING the manuals is a MUST.Page 95
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesDevelopment toolsLast but not least, learn how to develop and debug programs(and how to do some fine tuning).Page 96
IST / DEEC / APILadder diagramChap. 3 - PLC Programming languagesDevelopment toolsLast but not least, learn how to develop and debug programs(and how to do some fine tuning).Page 97
Chap. 3 - PLC Programming languages Temporized Relays or Timers (PLC) IST / DEEC / API. IST / DEEC / API Page 30 IN Q %TMi MODE: TON TB: 1mn TM.P: 9999 MODIF: Y Ladder diagram Chap. 3 - PLC Programming languages Temporized Relays or Timers (PLC) TON mode App. example: start ringing the alarm if N sec after door open there is no disarm of the alarm.
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