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CHAPTER 1

Process 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
wouldnt 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 wasnt 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
relays
3. 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 parts
6. 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


Introduction
2.1 First programmed controllers
2.2 PLC controller parts
2.3 Central Processing unit -CPU
2.4 Memory
2.5 How to program a PLC controller
2.6 Power supply
2.7 Input to a PLC controller
2.8 Input adjustable interface
2.9 Output from a PLC controller
2.10 Output adjustable interface
2.11 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 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 a 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


Introduction
3.1 Sinking-sourcing concept
3.2 Input lines
3.3 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


Introduction
4.1 Why OMRON?
4.2 CPM1A PLC controller
4.3 PLC controller input lines
4.4 PLC controller output lines
4.5 How PLC controller works
4.6 CPM1A PLC controller memory map
4.7 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 "delayon" 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


Introduction
5.1 Ladder diagram
5.2 Normally open and normally closed contacts
5.3 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

Introduction
6.1 Connecting a PLC controller with a PC computer
6.2 SYSWIN program installation
6.3 Writing your first program
6.4 Saving a project
6.5 Program transfer to PLC controller
6.6 Testing program function
6.7 Interpretation of "Tools" icons
6.8 PLC controller working modes
6.9 Run mode
6.10 Monitor mode
6.11 Program-Stop mode
6.12 Program execution and monitoring
6.13 Impact on the program during monitoring
6.14 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 ON
Force Reset - used for permanent forced set up of bit status to OFF
Cancel - cancels out the forced status
Set (1) - used for a brief change of bit status from OFF to ON status
Reset (0) - used for a brief change of bit status from ON to OFF status
Cancel 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
Introduction
7.1 Self-maintenance
7.2 Making large time intervals
7.3 Delays of ON and OFF status
7.4 Counter over 9999
7.5 Alternate ON-OFF output
7.6 Automation of parking garage
7.7 Operating a charge and discharge process
7.8 Automation of product packaging
7.9 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 selfmaintenance 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
lines

Expanding the number of input/output

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 its 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 doesnt 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

10 I/O
points

Input points
6 points

Output
points
4 point
Relay
Output

Power
Model Number
Supply
100 to240 CPM1AVAC, 50/60 10CDR-A
Hz
24 VDC

Transistor 24 VDC
NPN
Transistor 24 VDC
PNP

CPM1A10CDR-D
CPM1Al0CDT-D
CPM1A10CDT1-D

20 I/O points 12 points

8 points

100 to 240
CPMlAVAC, 50/60 Hz 20CDR-A

24 VDC

30 I/O points 18
points

40 I/O points 24
points

Transistor
NPN
Transistor
PNP
12 points

Transistor
NPN
Transistor
PNP
16 points

Transistor
NPN
Transistor
PNP

CPM1A20CDR-D
24 VDC
CPM1A20CDT-D
24 VDC
CPMlA20CDT1-D
100 to 240
CPM1AVAC, 50/60 Hz 30CDR-A
24 VDC
CPM1A30CDR-D
24 VDC
CPM1A30CDT-D
24 VDC
CPM1A30CDT1-D
100 to 240
CPM1AVAC, 50/60 Hz 40CDR-A
24 VDC
CPM1A40CDR-D
24 VDC
CPM1A40CDT-D
24 VDC
CPM1A40CDT1-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.

1
2
3
4

Unit
Assigned input bits
Assigned output bits
Central processing unit IR 00000-IR 00011 and IR 01000-IR 01007 and IR
(CPM2A-30CDX-X)
IR 00100-IR 00105
01100-IR 01103
Unit for I/O expansion
IR 00200-IR 02011
IR 01200-IR 01207
(CPM1A-20EDxxx)
Analog I/O unit (CPM1A- IR 00300-IR 03015 and
IR 01300-IR 01315
MAD01)
IR 00400-IR 00415
Unit for I/O expansion
IR 00500-IR 00511
IR 01400-IR 01415
(CPM1A-EDxxx)

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

input area

IR 000 - IR 009 (10


words)

IR 00000 - IR 00915
(160 bits)

output area

IR 010 - IR 019 (10


words)

IR 01000 - IR 01915
(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)

IR 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)

Data storage; these keep


HR0000 - HR1915 (320
their states when power
bits)
is off

AR area

AR 00 - AR 15 (16
words)

AR0000 - AR1515 (256 Special functions, such as


bits)
flags and control bits

LR area

LR 00 - LR 15 (16 words)

working
area

Timer/counter area

LR0000 - LR1515 (256 1:1 connection with


bits)
another PC

TC 000 - TC 127 (timer/counter numbers)

Same numbers are used


for both timers and
counters

DM 0000 - DM 0999 and


Read/write
DM 1022 - DM 1023
(1002 words)

---

Error
writing

DM 1000 - DM 1021 (22


words)

---

Read only

DM 6144 - DM 6599
(456 words)

---

PC setup

DM 6600 - DM 6655 (56


words)

---

DM area

Data of DM area may be


accessed only in word
form. Words keep their
contents after the power
is off
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
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 doesnt 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 - 15

Input 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 - 15

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

SR 251

00 - 15

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

SR 252

00
01 - 07

Reset of the high-speed counter


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

10

PLC 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.

SR 253

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

00 - 07

08

Not used

09

Cycle 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

SR 254

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

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
SR 255

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

Not used

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

B.4. AR memory area

Not used

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)

Function

AR00 and AR01

00 - 15

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)

Not used

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

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
05
06 - 07

Not used

Not used
Long Cycle Time Flag. Goes ON if real cycle length exceeds
length set in DM 6619
Not used

08

Memory Area Specification Error Flag. Goes ON when nonexisting 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

12

Program 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.
2.
3.
4.

Settings
Settings
Settings
Settings

related
related
related
related

Word(s)

to
to
to
to

basic operations of PLC controller and I/O processes


cycle duration
interrupts
communication.
Bit(s)

Function

Settings are active only upon resetting the PLC and sending data from PC to PLC
00 - 07

Startup Mode. Active only if bits 08 - 15 are set to 02. 00:


PROGRAM; 01: MONITOR; 02: RUN

08 - 15

Startup mode designation. 00: programming console switch;


01: proceeds in the mode last used before turning off the
power; 02: settings in 00 - 07

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

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 - 07

00: in case of battery malfunction, error will not be


generated; 01: in case of battery malfunction, error will be
generated

08 - 15

Not used

00 - 15

Not used

DM 6600

DM 6601

DM 6602

DM 6605 - DM 6614

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 - 07

Servicing 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

00 - 07

Cycle monitor time. Settings are identical to those of the


second half of the previous word

08 - 15

Cycle 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

00 - 15

Cycle time. 0000: variable (no minimum); 0001: up to 9999


(BCD). Minimal time is expressed in ms

DM 6618

DM 6619

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

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

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

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)

DM 6620

DM 6621

DM 6622

DM 6623

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

00 - 15

Not used

DM 6643 - DM 6644

Peripheral port settings take effect after the transfer to PC area

DM 6645 - DM 6649

00 - 15

Not used

DM 6650

00 - 07

Port 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 - 15

Modes 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)

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

00 - 15

Not used

DM 6651

DM 6654

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 users 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
?????
CIRCUIT ERR

Meaning and the appropriate action


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

DUPL

Same number of jump or subroutine is used twice in the


program. Correct the program so that each number is used
only once.

SBN UNDEFD

Instruction SBS(091) is programmed for non-existing


subroutine. Correct the number of subroutine or create the
missing one.

STEP ERR

STEP(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.

IL-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.

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 UNDEFD

JME(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 UNDEFD

There 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
Connects an NO condition to the left bus bar.
LOAD
LD
0
Connects an NC condition to the left bus bar.
LOAD NOT
LD NOT
0
AND

AND

AND NOT

AND NOT

OR

OR

OR NOT

OR NOT

AND LOAD

AND LD

Connects an NO condition in series


previous condition
Connects an NC condition in series
previous condition
Connects an NO condition in parallel
previous condition.
Connects an NC condition in parallel
previous condition.
Connects two instruction blocks in series.

with the

OR LOAD

OR LD

Connects two instruction blocks in parallel.

with the
with the
with the

Sequence Output Instructions


Instruction
OUTPUT
OUT NOT
SET
RESET
KEEP
DIFFERENTIATE
UP
DIFFERENTIATE
DOWN

Mnemonic Code
Function
OUT
0 Outputs the result of logic to a bit.
OUT NOT
0 Reverses and outputs the result of logic to a bit.
SET
0 Force sets (ON) a bit.
RESET
0 Force resets (OFF) a bit.
KEEP
11 Maintains the status of the designated bit.
Turns ON a bit for one cycle when the execution
DIFU
13
condition goes from OFF to ON.
Turns ON a bit for one cycle when the execution
DIFD
14
condition goes from ON to OFF.

Sequence Control Instructions

Instruction Mnemonic
NO
NOP
OPERATION
END

END

Code
00
01

INTERLOCK

IL

02

INTERLOCK
CLEAR

ILC

03

JUMP

JMP

04

JUMP END

JME

05

Function
--Required at the end of the program.
It 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).
ILC(03) indicates the end of an interlock
(beginning at IL(02)).
If the execution condition for JMP(04) is ON, all
instructions between JMP(04) and JME(05) are
treated as NOP(OO).
JME(05) indicates the end of a jump (beginning
at JMP(04)).

Timer/Counter Instructions
Instruction

Mnemonic

Code

Function

TIMER

TIM

An ON-delay (decrementing) timer.

COUNTER

CNT

A decrementing counter.

REVERSIBLE
CNTR
COUNTER
HIGH-SPEED
TIMH
TIMER

12 Increases or decreases PV by one.


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

Data Comparison Instructions


Instruction
COMPARE
DOUBLE
COMPARE
BLOCK
COMPARE
TABLE
COMPARE

Mnemonic

Code

Function

CMP

20 Compares two four-digit hexadecimal values.

CMPL

60 Compares two eight-digit hexadecimal values.

(@)BCMP

68

(@)TCMP

Data Movement Instructions

Judges whether the value of a word is within 16


ranges (defined by lower and upper limits).
Compares the value of a word to 16 consecutive
85
words.

Instruction

Mnemonic

Code

Function
Copies a constant or the content of a word to a
word.
Copies the complement of a constant or the
content of a word to a word.
Copies the content of a block of up to 1,000
consecutive words to a block of consecutive words.
Copies the content of a word to a block of
consecutive words.

MOVE

(@)MOV

21

MOVE NOT

(@)MVN

22

BLOCK
TRANSFER

(@)XFER

70

BLOCK SET

(@)BSET

71

(@)XCHG

73 Exchanges the content of two words.

DATA
EXCHAGE
SINGLE
WORD
DISTRIBUTE

(@)DIST

80

DATA
COLLECT

(@)COLL

81

MOVE BIT

(@)MOVB

82

MOVE DIGIT (@)MOVD

83

Shift Instructions

Copies the content of a word to a word (whose


address is determined by adding an offset to a
word address).
Copies the content of a word (whose address is
determined by adding an offset to a word address)
to a word.
Copies the specified bit from one word to the
specified bit of a word.
Copies the specified digits (4-bit units) from a
word to the specified digits of a word.

Instruction

Mnemonic

SHIFT
REGISTER

SFT

WORD SHIFT

(@)WSFT

Code

Function
Copies the specified bit (0 or 1) into the
0/10 rightmost bit of a shift register and shifts the
other bits one bit to the left.
16

Creates 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

25

Shifts a 0 into bit 00 of the specified word and


shifts the other bits one bit to the left.

ARITHMETIC
SHIFT RIGHT

(@)ASR

26

Shifts a 0 into bit 15 of the specified word and


shifts the other bits one bit to the right.

ROTATE LEFT

(@)ROL

27

ROTATE RIGHT (@)ROR

28

ONE DIGIT
SHIFT LEFT

(@)SLD

74

ONE DIGIT
SHIFT RIGHT

(@)SRD

75

REVERSIBLE
SHIFT REGISTER

(@)SFTR

84

Moves 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.
Moves 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.
Shifts a 0 into the rightmost digit (4-bit unit) of
the shift register and shifts the other digits one
digit to the left.
Shifts a 0 into the rightmost digit (4-bit unit) of
the shift register and shifts the other digits one
digit to the right.
Creates a single or multiple-word shift register
that can shift data to the left or right.

Increment/Decrement Instructions
Instruction

Mnemonic

INCREMENT

(@)INC

DECREMENT

(@)DEC

Code

Function
Increments the BCD content of the specified word
38
by 1.
Decrements the BCD content of the specified word
39
by 1.

BCD/Binary Calculation Instructions


Instruction Mnemonic
BCD ADD
(@)ADD
BCD
(@)SUB
SUBTRACT
BDC
(@)MUL
MULTIPLY
BCD DIVIDE (@)DIV
BINARY
ADD
BINARY
SUBTRACT
BINARY
MULTIPLY
BINARY
DIVIDE

30
31
32
33

(@)ADB

50

(@)SBB

51

()MLB

52

(@)DVB

53

DOUBLE BCD
(@)ADDL
ADD
DOUBLE
BCD
SUBTRACT
DOUBLE
BCD
MULITPLY

Code

54

Function
Adds the content of a word (or a constant).
Subtracts the contents of a word (or constant)
and CY from the content of a word (or constant).
Multiplies the content of two words (or contents).
Divides the contents of a word (or constant) by
the content of a word (or constant).
Adds the contents of two words (or constants) and
CY.
Subtracts the content of a word (or constant) an
CY from the content of the word (or constant).
Multiplies the contents of two words (or
constants).
Divides the content of a word (or constant) by the
content of a word and obtains the result and
remainder.
Add the 8-digit BCD contents of two pairs of
words (or constants) and CY.

(@)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)

(@)MULL

56

Multiplies the 8-digit BCD contents of two pairs


of words (or constants).

57

Divides the 8-digit BCD contents of a pair of


words (or constants) by the 8digits BCD
contents of a pair of words (or constants)

DOUBLE
(@)DIVL
BCD DIVIDE

Data Conversion Instructions

Instruction Mnemonic
BCD TO
(@)BIN
BINARY
BINARY TO
(@)BCD
BCD

Code

Function

23

Converts 4-digit BCD data to 4-digit binary data.

24

Converts 4-digit binary data to 4 digit BCD data.

4 to 16
DECODER

(@)MLPX

76

16 to 4
DECODER

(@)DPMX

77

ASCII CODE
CONVERT

(@)ASC

86

Takes the hexadecimal value of the specified


digit(s) in a word and turn ON the corresponding
bit in a word(s).
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.
Converts the designated digit(s) of a word into the
equivalent 8-bit ASCII code.

Logic Instructions
Instruction

Mnemonic

Code

COMPLEMENT (@)COM

29

LOGICAL AND (@)ANDW

34

LOGICAL OR

(@)ORW

35

(@)XORW

36

(@)XNRW

37

EXCLUSIVE
OR
EXCLUSIVE
NOR

Function
Turns OFF all ON bits and turns ON all OFF bits in
the specified word
Logically ANDs the corresponding bits of two
word (or constants)
Logically ORs the corresponding bits of two word
(or constants)
Exclusively ORs the corresponding bits of two
words (or constants)
Exclusively NORs the corresponding bits of two
words (or constants).

Special Calculation Instructions


Instruction Mnemonic
BIT
(@)BCNT
COUNTER
Subroutine Instructions

Code

67

Function
Counts the total number of bits that are ON in the
specified block

Instruction Mnemonic
SUBROUTINE
(@)SBS
ENTER
SUBROUTINE
SBN
ENTRY
SUBROUTINE
RET
RETURN
MACRO

MACRO

Code

Function

91

Executes a subroutine in the main program.

92

Marks the beginning of a subroutine program.

93

Marks the end of a subroutine program.

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
INTERVAL
(@)STIM
TIMER
INTERRUPT
(@)INT
CONTROL

Code

69
89

Function
Controls interval timers used to perform scheduled
interrupts.
Performs interrupts control, such as masking and
unmasking the interrupt bits for I/O interrupts.

Step Instructions
Instruction Mnemonic Code
STEP
DEFINE

STEP

08

STEP START SNXT

09

Function
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.
Starts the execution of the step when used with
a control bit.

Peripheral Device Control Instructions

Instruction Mnemonic
BCD TO
(@)BIN
BINARY
BINARY TO
(@)BCD
BCD

Code

Function

23

Converts 4-digit BCD data to 4-digit binary data.

24

Converts 4-digit binary data to 4-digit BCD data.

4 to 16
DECODER

(@)MLPX

76

16 to 4
DECODER

(@)DPMX

77

ASCII CODE
CONVERT

(@)ASC

86

Takes the hexadecimal value of the specified


digit(s) in a word and turn ON the corresponding
bit in a word(s).
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.
Converts the designated digit(s) of a word into the
equivalent 8-bit ASCII code.

I/O Units Instructions


Instruction Mnemonic Code
Function
7-SEGMENT
Converts the designated digit(s)of a word into an 8(@)SDEC
78
DECODER
bit, 7-segment display code.
I/O
(@)IORF
97 Refreshes the specified I/O word.
REFRESH
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
Starts and stops counter operation, compares and
(@)INI
61
CONTROL
changes counter PVs, and stops pulse output.
PV READ

(@)PRV

COMPARE
(@)CTBL
TABLE LOAD

62

Reads counter PVs and status data.

63

Compares counter PVs and generates a direct table


or starts operation.

Damage Diagnosis Instructions

Instruction Mnemonic Code


FAILURE
ALARM

(@)FAL

06

SEVERE
FAILURE
ALARM

FAL

07

Function
Generates a non-fatal error when executed. The
Error/Alarm indicator flashes and the CPU continues
operating.
Generates a fatal error when executed. The
Error/Alarm indicator lights and the CPU stops
operating.

Special System Instructions


Instruction Mnemonic
SET CARRY (@)STC
CLEAR
(@)CLC
CARRY

Code

40

Function
Sets Carry Flag 25504 to 1.

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 doesnt 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 doesnt 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.

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