Chapter 4 - Advanced Programming Techniques

Table 4-5 - Truth

Table for R-S Flip
Flop Using a T Flip
Flop
The J, K and Q columns account for all possible states of the three inputs and the
T column indicates whether the flip flop must toggle. If T is a 1, the one shot function must
be allowed to occur upon the turning on of IN3. The Karnough Map representing this truth
table with the input states filled in is shown in Table 4-6.
JK
Q

00

01

0
1

11

10

Table 4-6 - Karnaugh Map for

Table 4-5

From the map, the simplified equation for the trigger enable will be T = KQ + J Q .

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Chapter 4 - Advanced Programming Techniques

If we implement this expression using ladder contact logic, the ladder portion would
be as shown in Figure 4-9. The input definitions already set are used in this figure.

Figure 4-9 - Contact Logic Required to

Implement T = KQ + J Q
If you refer back to Figure 4-8, you will see this contact configuration in the first rung
of the ladder controlling the triggering of the one shot from IN3. The result is that the ladder
diagram of Figure 4-8 will function as a J-K flip flop.
4-10. Counters
A counter is a special function included in the PLC program language that allows
the PLC to increment or decrement a number each time the control logic for the rung
switches from false to true. This special function generally has two control logic lines, one
which causes the counter to count each time the control becomes true and one which
causes the counter to reset when the control line is true. A typical counter is shown in
Figure 4-10.

Figure 4-10 - Counter

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Chapter 4 - Advanced Programming Techniques

Notice that this special function has two control lines one containing a normally open
contact IN1 and one containing normally open contact IN2. The counter itself has a coil
associated with it that is numbered CTR1. Notice too, that inside the function block are two
labels, ACTUAL and PRESET. These ACTUAL and PRESET items contain numbers. The
PRESET value is the maximum count allowed for the counter. This number may be held
as a constant value in permanent memory or as a variable in a Holding Register. A
holding register is a memory location in RAM which may be altered as required. The
programmer would use a holding register for the PRESET value of the counter if the
maximum count value needed to change depending upon program operation such as in a
program that needed to count items to be placed in a box. If different size boxes were used
depending upon the product and quantity to be shipped, the counter maximum may need
to change. The ACTUAL value is maintained in a RAM location because it is the present
value of the counter. As the counter counts, this value must change and it is this value
compared to the PRESET value that the PLC uses to determine if the counter is at its
maximum value. As the ACTUAL value increases with each count it is compared to the
PRESET value. When the ACTUAL value is equal to the PRESET value, the counter will
stop counting and the coil associated with the counter (in this case CTR1) will be
energized.
In our example in Figure 4-10, contacts IN1 and IN2 control the counter. The top
line, containing IN1, is referred to as the COUNT LINE. The lower control line, containing
IN2 is referred to as the RESET LINE. Note that with some PLC manufacturers the two
input lines are reversed that shown in Figure 4-10, with the RESET line on top and the
COUNT line below. In operation, if IN2 is closed the counter will be held in the reset
condition, that is, the ACTUAL value will be set to zero no matter whether IN1 is open or
closed. As long as the reset line is true, the ACTUAL value will be held at zero regardless
of what happens to the count line. If the RESET LINE is opened, the counter will be
allowed to increment the ACTUAL value each time the count control line switches from
false to true (off to on). In our example that will be each time IN1 switches from open to
closed. The counter will continue to increment the ACTUAL value each time IN1 switches
from open to closed until the ACTUAL value is equal to the PRESET value. At that time
the counter will stop incrementing the ACTUAL value and coil CTR1 will be energized. If
at any time during the counting process the RESET control line containing IN2 is made to
switch to true, the ACTUAL value will be reset to zero and the next count signal from IN1
will cause the ACTUAL value to increment to 1.
Different PLC manufacturers handle counters in different ways. Some counters
operate as described above. Another approach taken in some cases is to reset the
ACTUAL value to the PRESET value (rather than reset it to zero), and decrement the
ACTUAL value toward zero. In this case the coil associated with the counter is energized
when the ACTUAL value is equal to zero rather than when it is equal to the PRESET value.

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Chapter 4 - Advanced Programming Techniques

Some manufacturers have counters that are constructed using two separate rungs.
These have an advantage in that the reset rung can be located anywhere in the program
and does not need to be located immediately following the count rung. Figure 4-11 shows
a counter of this type. In this sample program, note that N/O IN1 in rung 1 causes the
counter to increment (or decrement, if it is a down counter) and N/O IN2 in rung 2 causes
the counter C1 to reset to zero (or reset to the preset value if it is a down counter). Rung
3 has been added to show how a counter of this type can be used. Contact C1 in rung 3
is a contact of counter C1. It is energized when counter C1 reaches its preset value (if it
is a down counter, it will energize when C1 reaches a count of zero). The result is that
output OUT1 will be energized when input IN1 switches on a number of times equal to the
preset value of counter C1.
*
IN1
C1
1)))1 /)))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))(CTR)1
*
*
*
*

IN2
C1
2)))1 /)))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))[RSctr]1

*
*
*
*

C1
OUT1
3)))1 /)))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))(OUT)1
*

Figure 4-11 - Two-Rung Counter and Output Rung

In some cases it is convenient to have a counter that can count in either of the two
directions, called a bidirectional counter. For example, in a situation where a PLC needs
to maintain a running tally of the total number of parts in a que where parts are both
entering and exiting the que, a bidirectional counter can be incremented when a part enters
and decremented when a part exits the que. Figure 4-12 shows a bidirectional counter, C2,
which has three inputs and consists of three rungs. Rung one controls the counting of C2
in the up direction, rung two controls C2 in the down direction, and rung three resets C2.

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Chapter 4 - Advanced Programming Techniques

*
IN1
C2
1)))1 /)))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))[Upctr]1
*
*
*
*
IN2
C2
2)))1 /)))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))[DNctr]1
*
*
*
*
IN3
C2
3)))1 /)))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))[RSctr]1
*

Figure 4-12 - UP/Down Counter

4-11. Sequencers
Some machine control applications require that a particular sequence of events
occur, and with each step of the controller, a different operation be performed. The
programming element to do this type of control is called a sequencer. For example, the
timer in a washing machine is a mechanical sequencer in that it has the machine perform
different operations (fill, wash, drain, spin) in a predetermined sequence. Although a
washing machine timer is a timed sequencer, sequencers in a PLC are not necessarily
timed. An example of a non-timed sequencer is a garage door opener. It performs the
sequence ...up, stop, down, stop, up stop,... with each step in the sequence being activated
by a switch input or remote control input.
PLC sequencers are fundamentally counters with some extra features and some
minor differences. Counters will generally count to either their preset value (in the case of
up counters) or zero (for down counters) and stop when they reach their terminal count.
However, sequencers are circular counters; that is, they will roll over (much like an
automobile odometer) and continue counting. If the sequencer is of the type that counts
up from zero to the preset, on the next count pulse after reaching the preset, it will reset to
zero and begin counting up again. If the sequencer is of the type that counts down, on the
next count pulse after it reaches zero, it will load the preset value and continue counting
down. Like counters, sequencers have reset inputs that reset them either to zero (for the
types that count up) or to the preset value (for the types that count down). As with
counters, some PLC manufacturers provide sequencers with a third input (usually called
UP/DN) that controls the count direction. These are called bidirectional sequencers or
reversible sequencers. Alternately, other bidirectional sequencers have separate count
up and count down inputs.
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