Automation PDF

IST / DEEC / API
Industrial Automation
(Automação de Processos Industriais)
PLC Programming languages

Ladder Diagram
http://users.isr.ist.utl.pt/~jag/courses/api1213/api1213.html
Slides 2010/2011 Prof. Paulo Jorge Oliveira

Rev. 2011-2013 Prof. José Gaspar
IST / DEEC / API
Syllabus:
Chap. 2 – Introduction to PLCs [2 weeks]
...
Chap. 3 – PLC Programming languages [2 weeks]

Standard languages (IEC-61131-3):
Ladder Diagram; Instruction List, and Structured Text.
Software development resources.
...
Chap. 4 - GRAFCET (Sequential Function Chart) [1 week]
Page 2
IST / DEEC / API Chap. 3 - PLC Programming languages
PLC Programming languages

(IEC 1131-3 changed to IEC 61131-3)
Ladder Diagram Structured Text
If %I1.0 THEN
%Q2.1 := TRUE
ELSE
%Q2.2 := FALSE
END_IF
Instruction List Sequential Function Chart

1
(GRAFCET)
(1) m
LD %M12 2 Direita
AND %I1.0 (2) b
ANDN %I1.1 3 Carrega
OR %M10 (3) p
ST %Q2.0 4 Esquerda
(2) a
Page 3
IST / DEEC / API
Ladder diagram
A program is a series of instructions

that directs the PLC to execute
actions.
Relay ladder logic, the standard

programming language, is based on
electromagnetic relay control.
Input Output
Instructions Instructions
N S
Page 4
Ladder diagram Types of operands:
Page 5
Ladder diagram Types of operands:
Page 6
Ladder diagram
Basic Instructions
Load Normally open contact: contact is active (result is 1)
when the control bit is 1.
Normally closed contact: contact is active (result is 1)
when the control bit is 0.
Contact in the rising edge: contact is active during a scan cycle

P
where the control bit has a rising edge.
Contact in the falling edge: contact is active during a scan cycle

N
where the control bit has a falling edge.
%I1.0 %Q2.0 I1.0
P t
Q2.0
t
Page 7
Ladder diagram
Basic Instructions
Load operands
Page 8
Ladder diagram
Basic Instructions
Store The result of the logic function activates the coil.
The inverse result of the logic function activates the coil.
S
The result of the logic function energizes the relay
(sets the latch).
R
The result of the logic function de-energizes the relay
(resets the latch)..
%I1.0 %Q2.0 I1.0
N S t
Q2.0
t
Page 9
Ladder diagram
Basic Instructions
Store operands
Page 10
Ladder diagram
Allen Bradley notation
Relays with latch and unlatch
Page 11
Ladder diagram
Relay-type instructions
Example:
Page 12
Ladder diagram
Basic Instructions
AND AND of the operand with the result of the previous
logical operation.
AND of the operand with the inverted result of the previous

logical operation.
P
AND of the rising edge with the result of the previous
logical operation.
N
AND of the falling edge with the result of the previous
logical operation.
%I1.0 %I1.0 %Q2.0 I1.0

N P S t
Q2.0
t
Page 13
Ladder diagram
Basic Instructions
OR
OR of the operand with the result of the previous
logical operation.
OR of the operand with the inverted result of the previous

logical operation.
OR of the rising edge with the result of the previous

P logical operation.
OR of the falling edge with the result of the previous

N logical operation.
Page 14
Ladder diagram
Basic Instructions
XOR
Page 15
Ladder diagram
Ladder assembling
Input Output
Instructions Instructions
N S
The outputs that have a TRUE logical function, evaluated

from the left to right and from the top to the bottom, are
energized (Schneider, Micro PLCs).
Page 16
Ladder diagram
Example:
Page 17
Ladder diagram
Example:
Page 18
Ladder diagram
Example:
Page 19
Ladder diagram
General case of Inputs and Outputs in parallel, with derivations
Note: it is important to study the constraints and potentialities of the

development tools.
Page 20
Ladder diagram
Imbricated (nested) contacts and alternative solution
Page 21
Ladder diagram
Contacts in the vertical and alternative solution
Page 22
Ladder diagram
Contacts in the vertical and alternative solution
Another example:
Solves the problem of disallowed right to

left scanning (FDBC in fig5.30).
Page 23
Ladder diagram Temporized Relays or Timers
Page 24
Ladder diagram Temporized Relays or Timers (pneumatic)
The instantaneous contacts change state as soon as the timer coil is powered.
The delayed contacts change state at the end of the time delay.
Page 25
On-delay, provides time delay Off-delay, provides time delay when the
when the relay coil is energized. relay coil is de-energized.
Tables: Relay symbols used for timed contacts.

Page 26
Page 27
Page 28
Ladder diagram Characteristics:
Temporized Relays Identifier: %TMi 0..63 in the TSX37
Input: IN to activate
or Timers (PLC)
Mode: TON On delay
TOF Off delay
TP Monostable
%TMi
IN Q Time basis: TB 1mn (def.), 1s,
100ms, 10ms
MODE: TON
TB: 1mn
Programmed value: %TMi.P 0...9999 (def.)
period=TB*TMi.P
TM.P: 9999 Actual value: %TMi.V 0...TMi.P
MODIF: Y (can be read or tested)
Modifiable: Y/N can be modified from

the console
Page 29
Ladder diagram
TON mode
Temporized Relays
or Timers (PLC)
%TMi
IN Q
MODE: TON
TB: 1mn
TM.P: 9999
MODIF: Y
App. example: start ringing the alarm if N sec after door open there is no disarm of the alarm.
Page 30
Ladder diagram
TOF mode
Temporized Relays
or Timers (PLC)
%TMi
IN Q
MODE: TOF
TB: 1mn
TM.P: 9999
MODIF: Y
App. example: turn off stairways lights after N sec the lights’ button has been released.
Page 31
Ladder diagram TP mode

Works as a monostable or as a pulse generator
Temporized Relays (with pre-programmed period)
or Timers (PLC)
%TMi
IN Q
MODE: TP
TB: 100msec
TM.P: 5
MODIF: Y
App. example: positive input edge give a controlled (fixed) duration pulse to start a motor.
Page 32
Ladder diagram
Timers in the Allen-Bradley PLC-5
Two alternative representations
Page 33
Ladder diagram
Timers implementation in the Allen-Bradley PLC-5:
Page 34
Ladder diagram
Timers operation in the Allen-Bradley PLC-5
EN
TT
DN
EN = Enable Bit
TT = Timer-Timing Bit
DN = Done Bit
Page 35
Ladder diagram
Example of timer on-delay
Page 36
Ladder diagram
Example of a timer on-delay that sets an output after a count-down
Page 37
Ladder diagram
Page 38
Ladder diagram
Coil is energized if the switch remains closed for 12 seconds
Page 39
Ladder diagram
• If PB2 is activated, powers on the oil pumping motor.
• When the pressure augments, PS1 detects the increase and

activates the main motor.
• 15 seconds later the main

drive motor starts.
Page 40
Ladder diagram
Example of timer programmed as off-delay
Page 41
Ladder diagram
Page 42
Ladder diagram
Page 43
Ladder diagram
Example of timers programmed as off-delay and on-delay
Page 44
Ladder diagram
Timers
Animated demonstration:
Page 45
Ladder diagram
Retentive Timers
Switch-off region
Switch-on region
Motor accumulated
motion (rotation)
defines the on/off
timing.
Page 46
Ladder diagram
Example of retentive timers
Page 47
Ladder diagram
Retentive Timers
Animated demonstration:
(search on the Schneider PLC or discuss implementation)
Page 48
Ladder diagram
Example:
• SW ON to start operation
• Before motor starts,

lubrificate 10 s with oil.
• SW OFF to stop.
(lubrificate 15 s more).
• After 3 hours of pump

operation, stop motor and
signal with pilot light.
• Reset available after

servicing.
Page 49
Ladder diagram
Cascaded Timers
Page 50
Ladder diagram
Cascaded Timers (bistable system)
Page 51
Ladder diagram
Timers for very long time intervals
Page 52
Ladder diagram
Example of a semaphore
Page 53
Example of a semaphore in both directions
Page 54
Example
of a
semaphore
in both
directions
Page 55
Ladder diagram
Counters
Some applications...
Page 56
Ladder diagram
Implementation of Counters
in the PLC-5 of Allen-Bradley:
Internal structure representation
Page 57
Ladder diagram
Implementation of Counters
in the PLC-5 of Allen-Bradley:
Two alternative representations:
Coil-formatted counter and reset Block-formatted counter

instructions instruction
Page 58
Ladder diagram
Up-counters
Usage of an
incremental up-counter
and the corresponding
temporal diagram:
PB1 increments counting

PB2 resets the counting
Page 59
Ladder diagram
Example:
Counting parts
Page 60
Ladder diagram
Example
1. Start conveyor motor

2. Passing cases increment counter
3. After 50 cases, stop motor
Page 61
Ladder diagram
Up/down-counters
Usage of an incremental
up-down-counter
and the corresponding
temporal diagram:
PB1 increments counting

PB2 decrements the counting
PB3 resets the counter
Page 62
Ladder diagram
Up/down-counters
Example:
Finite parking garage
Page 63
Ladder diagram
Cascaded Counters
Example:
Page 64
Ladder diagram
Cascaded Counters
Example:
Count
24 hours clock
Reset
Page 65
Ladder diagram
Cascaded Counters
Example:
Memory time of event

Internal relay OFF stops clock
Page 66
Ladder diagram
Incremental Encoder
counter measures rotation angle or

rotation speed (if divided by time)
Page 67
Ladder diagram
Incremental Encoder
Example:
counter as a ”length sensor”
Page 68
Ladder diagram
Example with counters and timers (cont.):
Specs:
• Starts M1 conveyor
upon pushing button .
• After 15 plates stops M1

and starts conveyor M2 .
• M2 operates for 5 seconds and

then stops.
• Restart sequence.
Page 69
Ladder diagram
Specs:


then stops.
Page 70
Ladder diagram
Specs:


then stops.
Page 71
Ladder diagram
To use a timer to command a counter, to implement large periods of time.
Page 72
Ladder diagram
Counters
Example:
Page 73
Ladder diagram
Counters in PL7 Characteristics:
Identifier: %Ci 0..31 in the TSX37
Value progr.: %Ci.P 0...9999 (def.)

%Ci Value Actual: %Ci.V 0...Ci.P (only to be read)
R E
Modifiable: Y/N can be modified from
S the console
CP: 9999
MODIF: Y D
Inputs: R Reset Ci.V=0
CU S Preset Ci.V=Ci.P
CD F CU Count Up
CD Count Down
Outputs: E Overrun %Ci.E=1 %Ci.V=0->9999

D Done %Ci.D=1 %Ci.V=Ci.P
F Full %Ci.F=1 %Ci.V=9999->0
Page 74
Ladder diagram
Counters in Unity Pro
CU "0" to "1" => CV is incremented by 1

CU "0" to "1" => CV is incremented by 1 CD "0" to "1" => CV is decremented by 1
CV ≥ PV => Q:=1 CV ≥ PV => QU:=1

CV ≤ 0 => QD:=1
R=1 => CV:=0
R=1 => CV:=0 LD=1 => CV:=PV
R has precedence over LD
NOTE: counters are saturated such that no overflow occurs

Page 75
Ladder diagram
Numerical Processing
Algebraic and Logic Functions
Page 76
Ladder diagram
Arithmetic Functions
Page 77
Ladder diagram
Example:
Arithmetic functions
Use of a system variable:
%S18 – flag de overflow

Page 78
Ladder diagram
Logic Functions
Page 79
Ladder diagram
Example:
Logic functions
Page 80
Ladder diagram
Priorities on the execution of the operations
Page 81
Ladder diagram
Structures for Control of Flux
Subroutines
Call and Return
Page 82
Ladder diagram
JUMP instructions:
Conditional and unconditional
Page 83
Ladder diagram
Example:
Use of jump instructions
Attention to:
• INFINITE LOOPS ...
• It is not a good style of

programming!...
• Does not improove the legibility

of the proposed solution.
Page 84
Ladder diagram
Halt
Stops all processes!
Events masking
Page 85
Ladder diagram
There are other advanced instructions (see manual)

• Monostable
• Registers of 256 words (LIFO ou FIFO)
• DRUMs
• Comparators
• Shift-registers
...
• Functions to manipulate floats
• Functions to convert bases and types

Page 86
Ladder diagram
Numerical Tables
Page 87
Ladder diagram
System information: system bits
See manual
for the remaining
100 bits generated...
Page 88
Ladder diagram
System information: system words
See manual
for the remaining
140 words generated...
Page 89
Ladder diagram Software Organization
A program can be built from:

Tasks, that are executed cyclically or periodically.
Tasks MAST / FAST / AUX are built from:

Sections
Subroutines
Event processing, that is carried out before all other tasks.
Event processing is built from:

Sections for processing time controlled events
Sections for processing hardware controlled events
Unity - Project Browser
Page 90
Sas (LD)
MAST – Master Task Program
Oven1 (GRAFCET)
Composed by sections
Execution Cyclic or Periodic PRL (LD)
Chart
POST (IL)
SR0
Drying (LD)
Cleaning (IL)
Page 91
FAST – Fast Task Program

Priority greater than MAST
• Executed Periodically (1-255ms)

• Verified by a Watchdog, impacts on %S11
• %S31 Enables or disables a FAST
• %S33 gives the execution time for FAST
Page 92
Event Processes – Processes that can react to external changes

(16 in the Micro 3722 EV0 a EV15)
Priority greater than MAST and FAST!
Event Generators
• Inputs 0 to 3 in module 1, given transitions
• Counters
• Upon telegrams reception
• %S38 Enables or disables event processes
(also with MASKEVT() or UNMASKEVT())
Page 93
Ladder diagram Development tools
Each PLC has limitations in terms of connections
Example:
Page 94

It is important to learn the potentialities and ...
the limitations of the developing tools,
i.e. STUDYING the manuals is a MUST.
Page 95
Last but not least, learn how to develop and debug programs
(and how to do some fine tuning).
Page 96
Last but not least, learn how to develop and debug programs
(and how to do some fine tuning).
Page 97

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IST / DEEC / API

PLC Programming languages

Slides 2010/2011 Prof. Paulo Jorge Oliveira

Chap. 3 – PLC Programming languages [2 weeks]

PLC Programming languages

Instruction List Sequential Function Chart

A program is a series of instructions

Relay ladder logic, the standard

Ladder diagram Types of operands:

Ladder diagram Types of operands:

Contact in the rising edge: contact is active during a scan cycle

Contact in the falling edge: contact is active during a scan cycle

%I1.0 %Q2.0 I1.0

The inverse result of the logic function activates the coil.

%I1.0 %Q2.0 I1.0

AND of the operand with the inverted result of the previous

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

OR of the operand with the inverted result of the previous

OR of the rising edge with the result of the previous

OR of the falling edge with the result of the previous

The outputs that have a TRUE logical function, evaluated

General case of Inputs and Outputs in parallel, with derivations

Note: it is important to study the constraints and potentialities of the

Imbricated (nested) contacts and alternative solution

Contacts in the vertical and alternative solution

Contacts in the vertical and alternative solution

Solves the problem of disallowed right to

Ladder diagram Temporized Relays or Timers

Ladder diagram Temporized Relays or Timers (pneumatic)

Ladder diagram Temporized Relays or Timers

Tables: Relay symbols used for timed contacts.

Ladder diagram Temporized Relays or Timers

Ladder diagram Temporized Relays or Timers

Ladder diagram Characteristics:

Temporized Relays Identifier: %TMi 0..63 in the TSX37

Modifiable: Y/N can be modified from

Ladder diagram TP mode

Timers in the Allen-Bradley PLC-5

Two alternative representations

Timers implementation in the Allen-Bradley PLC-5:

Timers operation in the Allen-Bradley PLC-5

Example of timer on-delay

Example of a timer on-delay that sets an output after a count-down

Example of timer on-delay

Example of timer on-delay

Coil is energized if the switch remains closed for 12 seconds

Example of timer on-delay

• If PB2 is activated, powers on the oil pumping motor.

• When the pressure augments, PS1 detects the increase and

• 15 seconds later the main

Example of timer programmed as off-delay

Example of timer programmed as off-delay

Example of timer programmed as off-delay

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

Example of retentive timers

• Before motor starts,

• After 3 hours of pump

• Reset available after

Cascaded Timers (bistable system)

Timers for very long time intervals

Example of a semaphore in both directions

Internal structure representation

Coil-formatted counter and reset Block-formatted counter