Basics of PLC Programming
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1 Basics of PLC Programming Industrial Control Systems Fall 2006 Lecture PLC Programming Basics MME 486 Fall of 62
2 PLC Architecture Lecture PLC Programming Basics MME 486 Fall of 62
3 PLC System Lecture PLC Programming Basics MME 486 Fall of 62
4 Processor Memory Organization The memory of a PLC is organized by types. The memory space can be divided into two broad categories: program and data memory. Advanced ladder logic functions allow controllers to perform calculations, make decisions and do other complex tasks. Timers and counters are examples of ladder logic functions. They are more complex than basic inputs contacts and output coils and rely heavily upon data stored in the memory of the PLC. Lecture PLC Programming Basics MME 486 Fall of 62
5 Memory Map A memory map can be used to show how memory is organized in a PLC. Data table Input/output locations Internal relay and timer/counter locations User program Housekeeping memory The user program causes the controller to operate in a particular manner Used to carry out functions needed to make the processor operate (no access by user) Lecture PLC Programming Basics MME 486 Fall of 62
6 Program Files The user program will account for most of the memory of a PLC system. Program files contain the logic controlling machine operation. Program file organization for SLC-500 controller. This logic consists of instructions that are programmed in a ladder logic format. Lecture PLC Programming Basics MME 486 Fall of 62
7 Data file organization for SLC-500 controller. Data Files The data file portion of memory stores input and output status, processor status, the status of various bits and numerical data. Lecture PLC Programming Basics MME 486 Fall of 62
8 Data Files Data files are organized by the type of data they contain Lecture PLC Programming Basics MME 486 Fall of 62
9 Input Table File Operation Switch Open Input module Binary 0 stored 0 Lecture PLC Programming Basics MME 486 Fall of 62
10 Input Table File Operation Input module Switch Closed Processor continually reads current input status and updates input image table file Binary 1 stored 1 Lecture PLC Programming Basics MME 486 Fall of 62
11 Output Table File Operation Output module Processor continually activates or deactivates output status according to output image table file status Output OFF 0 Status 0 Lecture PLC Programming Basics MME 486 Fall of 62
12 Output Table File Operation Output module Processor continually activates or deactivates output status according to output image table file status 1 Output ON Status 1 Lecture PLC Programming Basics MME 486 Fall of 62
13 Program Scan During each operating cycle, the processor reads all inputs, takes these values, and energizes or de-energizes the outputs according to the user program. This process is known as a scan. I/O scan records status data of input devices. Energizes output devices that have their associated status bits set to ON (1) Program scan instructions are executed sequentially Because the inputs can change at any time, the PLC must carry on this process continuously. Lecture PLC Programming Basics MME 486 Fall of 62
14 Scan Process The scan time indicates how fast the controller can react to changes in inputs. Scan times vary with computer model and program content, and length. If a controller has to react to an input signal that changes states twice during the scan time, it is is possible that the PLC will never be able to detect this change. Scan time may be a concern in high speed operations Lecture PLC Programming Basics MME 486 Fall of 62
15 Scan Process Read inputs The scan is a a continuous and sequential process Adjusts outputs Run program Lecture PLC Programming Basics MME 486 Fall of 62
16 Data Flow Overview Input modules Input data Input image table file Output image table file Output data Output modules Examine data Return results Program Check/compare/examine specific conditions Take some action Lecture PLC Programming Basics MME 486 Fall of 62
17 Input device Input Module Scan Process Input file Output file Output Module Output device I:3/6 I:3/6 O:4/7 O:4/7 When the input is closed, the input module senses a voltage and an ON condition (1) is entered into the input table bit I:3/6 I:3/6 Program O:4/7 During the program scan the processor sets instructions I:3/6 and O:4/7 to ON (1) The processor turns light output O:4/7 ON during the next I/O scan Lecture PLC Programming Basics MME 486 Fall of 62
18 Scan Patterns Horizontal Scanning Order The processor examines input and output instructions from the first command, top left in the program, horizontally, rung by rung. End of ladder In addition to the program itself, the scan time is also dependent on the clock frequency of the processor! Lecture PLC Programming Basics MME 486 Fall of 62
19 Vertical Scanning Order The processor examines input and output instructions from the first command, vertically, column by column and page by page. Pages are executed in sequence. Scan Patterns End of ladder Misunderstanding the way the PLC scans can cause programming bugs! Lecture PLC Programming Basics MME 486 Fall of 62
20 PLC Programming Languages The term PLC programming language refers to the method by which the user communicates information to the PLC. The three most common language structures are: ladder diagram language, Boolean language, and functional chart. Ladder diagram language Boolean language Functional chart Lecture PLC Programming Basics MME 486 Fall of 62
21 Comparing Programming Language PB1 CR1 CR2 LS1 PB1 CR1 CR2 LS1 SOL SOL Relay Schematic Equivalent ladder diagram language Equivalent Boolean language Lecture PLC Programming Basics MME 486 Fall of 62
22 Relay-Type Instructions The ladder diagram language is basically a symbolic set of instructions used to create the controller program. These ladder instructions symbols are arranged to obtain the desired control logic. Lecture PLC Programming Basics MME 486 Fall of 62
23 Examine If Closed (XIC) Instruction Symbol Analogous to the normally open relay contact. For this instruction we ask the processor to EXAMINE IF (the contact is) CLOSED (XIC) Typically represents any input. Can be a switch or pushbutton, a contact from a connected output, or a contact from an internal output. Has a bit-level address which is examined for an ON condition. The status bit will be either 1 (ON) or 0 (OFF). Lecture PLC Programming Basics MME 486 Fall of 62
24 Examine If Closed (XIC) Instruction I:012 I: Lecture PLC Programming Basics MME 486 Fall of 62
25 Examine If Closed (XIC) Instruction I:012 I: If the status bit is 0 (OFF), then the instruction is FALSE. Lecture PLC Programming Basics MME 486 Fall of 62
26 Examine If Closed (XIC) Instruction I:012 I: If the status bit is 1 (ON), then the instruction is TRUE. Lecture PLC Programming Basics MME 486 Fall of 62
27 Examine If Open (XIO) Instruction Symbol Analogous to the normally closed relay contact. For this instruction we ask the processor to EXAMINE IF (the contact is) OPEN (XIO). Typically represents any input. Can be a switch or pushbutton, a contact from a connected output, or a contact from an internal output. Has a bit-level address which is examined for an OFF condition. The status bit will be either 1 (ON) or 0 (OFF). Lecture PLC Programming Basics MME 486 Fall of 62
28 Examine If Open (XIO) Instruction I:012 I: If the status bit is 0 (OFF), then the instruction is TRUE. Lecture PLC Programming Basics MME 486 Fall of 62
29 Examine If Open (XIO) Instruction I:012 I: If the status bit is 1 (ON), then the instruction is FALSE. Lecture PLC Programming Basics MME 486 Fall of 62
30 Output Energize (OTE) Instruction Symbol Analogous to the relay coil. The processor makes this instruction true (analogous to energizing a coil) when there is path of true XIC and XIO instructions in the rung. Typically represents any output that is controlled by some combination of input logic. Can be a connected device or an internal output (internal relay). If any left-to-right path of input conditions is TRUE, the output is energized (turned ON). Lecture PLC Programming Basics MME 486 Fall of 62
31 Output Energize (OTE) Instruction O:013 I:012 I:012 I:012 O: OUTPUT ENERGIZE instruction - TRUE Lecture PLC Programming Basics MME 486 Fall of 62
32 Output Energize (OTE) Instruction O:013 I:012 I:012 I:012 O: OUTPUT ENERGIZE instruction - FALSE Lecture PLC Programming Basics MME 486 Fall of 62
33 Status Bit Examples A Input module Bit status Button not actuated A False A True Output OFF Output ON Lecture PLC Programming Basics MME 486 Fall of 62
34 Status Bit Examples A Input module Bit status Button actuated A True A False Output ON Output OFF Lecture PLC Programming Basics MME 486 Fall of 62
35 Ladder Rung A B C Output instruction Input conditions D A ladder rung consists of a set of input conditions, represented by contact instructions, and an output instruction at the end of the rung, represented by the coil symbol. Lecture PLC Programming Basics MME 486 Fall of 62
36 Ladder Rung A B C Output instruction Input conditions D For an output to be activated or energized, at least one left-to-right path of contacts most be closed. A complete path is referred to as having logic continuity. When logic exists the rung condition is said to be TRUE. Lecture PLC Programming Basics MME 486 Fall of 62
37 Rung Continuity Bit in memory 1 1 Bit in memory LS_1 SOL_5 The Examine If Closed instruction is TRUE making the rung TRUE Lecture PLC Programming Basics MME 486 Fall of 62
38 Rung Continuity Bit in memory 0 0 Bit in memory LS_1 SOL_5 The Examine If Closed instruction is FALSE making the rung False Lecture PLC Programming Basics MME 486 Fall of 62
39 Allen-Bradley SLC-500 Controller Addressing Output image table file 0 Address output terminal O0:4/6 Address input terminal I1:3/12 Closed input User-programmed rung Input image table file 1 I:3/12 Bit address I1:3 12 O:0:4/6 Bit address O:0:4 6 Energized output Lecture PLC Programming Basics MME 486 Fall of 62
40 Bit Structure of A 16-Bit Word OFF ON Word (16 bits) I/O Connection Diagram L1 PB1 LS1 I:4/5 I:4/6 L2 L1 O:2/3 O:3/6 L2 SOL 1 PL 1 R Lecture PLC Programming Basics MME 486 Fall of 62
41 Parallel Input Branch Instructions A B C Branch instructions are used to create parallel paths of input condition instructions. If at least one of these parallel branches forms a true logic path, the logic is enabled. Lecture PLC Programming Basics MME 486 Fall of 62
42 Parallel Output Branching A B C D E On most PLC models, branches can be established at both the input and output portion of the rung. With output branching, you can program parallel outputs on a rung to allow a true logic path to control multiple outputs. Lecture PLC Programming Basics MME 486 Fall of 62
43 Nested Input and Output Branches Input and output branches can be nested to avoid redundant instructions and to speed up the processor scan time. A nested branch starts or ends within another branch. Lecture PLC Programming Basics MME 486 Fall of 62
44 A B C D E A B C D E Nested Contact Program C Y Nested contact Y Contact instruction C repeated On some PLC models, the programming of a nested branch circuit cannot be done directly. Reprogrammed to obtain the required logic. Lecture PLC Programming Basics MME 486 Fall of 62
45 PLC Matrix Limitation Diagram Max series contacts Max parallel lines No. outputs per rung and location of the output in the rung There may be limitations to the number of series contacts instructions, number of parallel lines, and the number of outputs and their location on the rung. Lecture PLC Programming Basics MME 486 Fall of 62
46 Programming of Vertical Contacts A C D Y Original program B A E D Y = (AD) + (BCD) + (BE) + (ACE) Y B B C D E Reprogrammed to obtain the required logic A C E Lecture PLC Programming Basics MME 486 Fall of 62
47 Programming for Different Scan Patterns A B D C E Y Original program F Y = (ABC) + (ADE) + (FE) + (FDBC) A B C Y A F D E E Reprogrammed to obtain the required logic F D B C Lecture PLC Programming Basics MME 486 Fall of 62
48 Internal Control Relay The internal output operates just as any other output that is controlled by programmed logic; however, the output is used strictly for internal purposes. The internal output does not directly control an output device. The advantage of using internal outputs is that there are many situations where an output instruction is required in a program, but no physical connection to a field device is needed. Their use in this type of instance can minimize output card requirements. Lecture PLC Programming Basics MME 486 Fall of 62
49 Rung 1 Extending the Number of Series Contacts Using an Internal Control Relay Internal relay coil Rung 2 Internal relay contact Discrete output (requires one physical connection on the output module) Lecture PLC Programming Basics MME 486 Fall of 62
50 Programming The XIC Instruction PB1 PB2 PL Hardwired Circuit PB1 PB2 PL User program providing the same results Note that both pushbuttons are represented by the XIC symbol. This is because the normal state of an input (NO or NC) does not matter! What does matter is that if contacts need to close to energize the output, then the XIC instruction is used. Since both PB1 and PB2 must close to energize the PL, the XIC instruction is used for both. Lecture PLC Programming Basics MME 486 Fall of 62
51 PB1 Programming The XIO Instruction CR PB1 PL CR1 Hardwired Circuit PL User program providing the same results When the pushbutton is open in the hardwired circuit, relay coil CR is deenergized and contacts CR1 close to switch the PL on. When the pushbutton is closed, relay coil CR is energized and contacts CR1 open to switch the PL off. The pushbutton is represented in the user program by an XIO instruction. This is because the rung must be true when the external pushbutton is open, and false when the pushbutton is closed. Lecture PLC Programming Basics MME 486 Fall of 62
52 Operation of The XIC and XIO Instructions Summary of status conditions If the data table bit is: The status of the instruction is: XIC Examine If Closed XIO Examine If Open OTE Output Energize Logic 0 False True False Logic 1 True False True Lecture PLC Programming Basics MME 486 Fall of 62
53 Operation of The XIC and XIO Instructions State of the output as determined by the changing state of the inputs in the rung Time XIC Inputs Output Bit status XIO OTE t 1 (initial) False False True XIC XIO OTE t 2 t 3 t4 True True Goes true True False Goes false False False Remains false Input instructions XIC XIO Output instruction OTE Lecture PLC Programming Basics MME 486 Fall of 62
54 Entering the Ladder Diagram A personal computer is most often used to enter the ladder diagram. The computer is adapted to the particular PLC model using the relevant programmable controller software. Lecture PLC Programming Basics MME 486 Fall of 62
55 RSLogix Main Screen Different screens, toolbars and windows dialog boxes are used to navigate through the Windows environment Lecture PLC Programming Basics MME 486 Fall of 62
56 Bit Instructions Tool Bar To place an instruction on a rung, click its icon on the toolbar and simply drag the instruction straight off the toolbar onto the rung of the ladder. Lecture PLC Programming Basics MME 486 Fall of 62
57 Select Processor Type Screen The programming software needs to know what processor is being used in conjunction with the program L40E You simply scroll down the list until you find the processor you are using and select it. Lecture PLC Programming Basics MME 486 Fall of 62
58 I/O Configuration Screen The I/O screen lets you click or drag-and-drop a module from an all inclusive list to assign it to a slot in your configuration. Lecture PLC Programming Basics MME 486 Fall of 62
59 Data File Screen Data file screens contain data that is used in conjunction with ladder program instructions. These include: Input Output Timer Counter Integer Bit Lecture PLC Programming Basics MME 486 Fall of 62
60 Monitoring a Ladder Logic Program Operation of the logic is apparent from the highlighting of rungs of the various instructions on screen, which identifies the logic state in real time and has logic continuity. Highlighted rungs indicate the instruction is true Lecture PLC Programming Basics MME 486 Fall of 62
61 Modes of Operation A processor has basically two modes of operation: the program mode or some variation of the run mode. Program Mode may be used to enter a new program edit or update an existing program upload files download files document programs change software configurations When the PLC is switched into the program mode, all outputs from the PLC are forced off regardless of their rung logic status, and the ladder I/O scan sequence is halted. Lecture PLC Programming Basics MME 486 Fall of 62
62 Variations of the Run Mode Run Mode is used to execute the user program. Input devices are monitored and output devices are energized accordingly. Test Mode is used to operate, or monitor, the user program without energizing any outputs. Remote Mode allows the PLC to be remotely changed between program and run mode by a personnel computer connected to the PLC processor. Lecture PLC Programming Basics MME 486 Fall of 62
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