bee2931 basic plc 2011

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BEE2931 BEE2931 -- Basic PLC Basic PLC Based Model : OMRON CQM1HBased Model : OMRON CQM1H-- CPU51CPU51

Instructor : syahrulnaim bin mohamad nawiE-Mail : [email protected]:09-4242129 h.p: 019-9825807Room no:E10-C25

Universiti Malaysia Pahang ©2011 snaim

Course OutcomesCourse Outcomes

By the end of semester, students should be able to:ab e to:

CO1 Describe the basic principle of PLC and it’s function.

CO2 Implement PLC Hardware configuration.CO3 Identify PLC system wiring and

component.CO4 E d i PLC P i CO4 Execute and practice PLC Programming

for specific tasks.CO5 Practice right attitude and safety procedure.


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Mark distribution Mark distribution

Quizzes 5%Lab Report 10%Lab Report 10%Assessment 1 25%Assessment 2 30%Test 30%Total 100%Total 100%

References References

1 Jon Stenerson “Industrial Automation and Process Control”,Upper Saddle River, NJ: Prentice Hall,2003

2 John R Hackworth & Frederick D Hackworth,Jr “Programmable Logic Controller:Programming Method and Application”,Upper Saddle River,NJ:Prentice Hall,2004

3 OMRON “Sysmac CQM1H Series Operation Manual”,Revised August 2005

4 F k D P t ll “P bl L i C t ll ” 3 d Editi M4 Frank D. Petruzella, “Programmable Logic Controllers”, 3rd Edition, Mc-Graw Hill, 2005.

5 Omron, “Programming Manual”, Revised December 2003, Omron Corporation, 2003.

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1.0 INTRODUCTION1.0 INTRODUCTION


1.1 What is Control System1.1 What is Control System

In general, a control system is a collection of electronics devices and equipments to of electronics devices and equipments to ensure the stability ,accuracy and smooth transition of a process or a manufacturing activity.


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1.1 What is Control System1.1 What is Control System

A control system consists of three sections: input processing and outputsections: input, processing and output.

Sensor

Input

Processor

Processing/ “Brain”

Actuator

Output

Binary (on/off)• Push Button Switch

Hard – wired System• Relay

Binary• Motor


• Limit Switch• ProximityContinuous• Transducer• Transmitter

• Electronic Logic• Pneumatic LogicSoftware – Programmable System• Computer• Micro-processor• PLC System

• Relay• CylinderContinuous• Control Valve


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1.2 What is a Programmable 1.2 What is a Programmable ControllerController

In an automated system, the PLC is commonly regarded as the heart of the commonly regarded as the heart of the control system.The PLC may used to control a simple and repetitive task.Or a few of them may be interconnected together with other controller or host together with other controller or host computer through a sort of communication network, in order to integrate the control in a complex process.


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1.2 What is a Programmable 1.2 What is a Programmable ControllerControllerPLC (Programmable Logic Controller)

A PLC works by looking at its inputs and depending on their state, and the user entered program, turns on/off outputs.

A PLC can be thought of as: Industrial Computers with

i ll d i d p

specially designed architecture in both their central units (the PLC itself) and their interfacing circuitry to field devices (input / output connections to the real world).


1.3 PLC Development1.3 PLC DevelopmentEarly control systems consisted of huge control boards consisting of hundreds to thousands of electromechanical relaysthousands of electromechanical relays.

The schematic was commonly called “Ladder Schematic”

The Ladder displayed all switches, sensors, motors, valves, relays etc in the system.

Problems: Long commissioning time, Mechanical Reliance, Any system logic design change required the power to the control board to be isolated stopping production.


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1.3 PLC Development1.3 PLC DevelopmentGeneral Motors was among the first to recognize a need to replace the systems “wired control board”

Goal – Eliminate the high cost associated with inflexible, relay controlled systems.

New Controller Specifications:◦ Solid State System◦ Computer Flexibility

O ( ) ◦ Operate in Industrial Environment (vibrations, heat, dust etc.) ◦ Capability of being reprogrammed◦ Easily programmed and maintained by electricians and

technicians.


1.3 PLC Development1.3 PLC DevelopmentIn 1969 Gould Modicon developed the first PLC.

St th P d ith L dd L i f ti Strength – Programmed with Ladder Logic, function block, statement list

Initially called Programmable Controllers PC’s Now - PLC’s, Programmable Logic Controllers

PLC’s have evolved from simple on/off control to being PLC s have evolved from simple on/off control to being able to communicate with other control systems, provide production reports, schedule production, diagnose machine and process faults.


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1.3 PLC Development1.3 PLC Development


Wire Logic Vs PLCWire Logic Vs PLCITEM WIRED LOGIC PLC

Controlled Device (Hardware)

Specific Purpose General Purpose ( )Control Scale Small and Medium Medium and large

Change or addition to specification

Difficult Easy

Delivery period Several Days Almost immediate

Maintenance (by makers and users)

Difficult Easy and users)Reliability Depends on design and

manufacture Very High

Economic Efficiency Advantage on small scale operation

Advantage on small medium and large scale operation

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Advantageous of using PLC Advantageous of using PLC Shorter project implementation timeEasier modification without cost penaltyp yProject cost can be accurately calculatedShorter training time requiredDesign easily changed using softwareA wide range control applicationEasy maintenanceHigh reliabilityStandardization of Controller Hardware

What PLC Can Do?What PLC Can Do?CONTROL TYPE FUNCTIONS

Sequences Control •Conventional Relay Control Logic Replacer /P.C.B Card Controller Replacerp•Timers/Counters•Auto/Semi-auto/Manual Control of machine and Processes

Sophisticated Control / Regulatory Control

•Arithmetic Operation•Information handling•Analog Control (Temperature, Pressure)•P I D (Proportional-Integral-Derivation)P.I.D (Proportional Integral Derivation)•Servo Motor and Stepper Motor

Supervisory Control •Process Monitoring and Alarm•Fault Diagnostic and Monitoring•Interfacing with Computer -Printer/ASCII •Factory Automation•Local Area Network / Wide Area Network

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PLCs’ manufacturerPLCs’ manufacturerOMRONAllen BradleySchneider (Modicon, Telemecanique, Square D)GE FanucSiemensAutomation Direct (Koyo)ToshibaMitsubishiHitachiKeyenceFestoEberleTexas Instruments

HoneywellYokogawaEmerson

PLC operationPLC operation1. CHECK INPUT STATUS◦ First the PLC takes a look at each input to determine

if it is on or off. In other words, is the sensor if it is on or off. In other words, is the sensor connected to the first input on? How about the second input? How about the third... It records this data into its memory to be us

2. EXECUTE PROGRAM◦ Next the PLC executes your program one instruction

at a time. Maybe your program said that if the first input was on then it should turn on the first output input was on then it should turn on the first output. Since it already knows which inputs are on/off from the previous step it will be able to decide whether the first output should be turned on based on the state of the first input. It will store the execution results for use later during the next step.

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PLC operationPLC operation3. UPDATE OUTPUT STATUS◦ Finally the PLC updates the status of the outputs. It updates

the outputs based on which inputs were on during the first the outputs based on which inputs were on during the first step and the results of executing your program during the second step. Based on the example in step 2 it would now turn on the first output because the first input was on and your program said to turn on the first output when this condition is true.

Check i/p Status Execute Program Update o/p Status

2.0 PLC HARDWARE 2.0 PLC HARDWARE DESIGNDESIGN

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PLC ConfigurationPLC Configuration

Rack Mini

Shoe Box

Micro

PLC ConfigurationPLC ConfigurationThe configuration of PLC refers to the packaging of the components.

Typical configurations are listed below from largest to smallest.◦ Rack Type : A rack can often be as large as 18” by 30” by 10”

◦ Mini: These are similar in function to PLC racks, but about the half size. Dedicated Backplanes can be used to support the cards OR DIN rail mountable with incorporated I/O bus in module.

◦ Shoebox: A compact, all-in-one unit that has limited expansion biliti L t d t k th id l f ll capabilities. Lower cost and compactness make these ideal for small

applications. DIN rail mountable.

◦ Micro: These units can be as small as a deck of cards. They tend to have fixed quantities of I/O and limited abilities, but costs will be lowest. DIN rail mountable.

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Sizing of PLCSizing of PLC

Micro PLC: I/O up to 32 points

Small PLC: I/O up to 128 points

Medium PLC: I/O up to 1024 points

Large PLC: I/O up to 4096 points

Very Large: I/O up to 8192 points

Basic PLC SchemaBasic PLC Schema

CPUCPUPower SupplyMemoryInput BlocksOutput BlocksCommunicationsExpansion Connections

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CPU ModuleCPU Module

The Central Processing Unit (CPU) Module is the brain of the

SelfCheck

ExecuteC d

ScanInputs

UpdateO t t

PLC.Primary role to read inputs, execute the control program, update outputs.The CPU consists of the arithmetic logic unit (ALU), timing/control circuitry,

CodeOutputsaccumulator, scratch pad memory, program counter, address stack and instruction register.A PLC works by continually scanning a program

PLC ProgramSCAN

MemoryMemoryThe memory includes pre-programmed ROM memory containing the PLC’s operating system, driver programs and application programs and the RAM memory.

PLC manufacturer offer various types of retentive memory to save user-programs and data while power is removed, so that the PLC can resume execution of the user-written control program as soon as power is restoredrestored.

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Memory cont’dMemory cont’dMany PLCs also offer removable memory modules, which are plugged into the CPU module.

Memory can be classified into two basic categories: volatile and non-volatile.

- Volatile memory is that which loses state (the stored information) when power is removed.

- Nonvolatile memory, on the other hand, maintains the information in memory even if the power is interrupted.

Memory cont’dMemory cont’dSome types of memory used in a PLC include:

ROM (Read-Only Memory)ROM (Read-Only Memory)

RAM (Random Access Memory)

PROM (Programmable Read-Only Memory)

EPROM (Erasable Programmable Read-Only Memory)

EEPROM (Electronically Erasable Programmable Read-Only Memory)Only Memory)

FLASH Memory

Compact Flash – Can store complete program information, read & write text files

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I/O ModulesI/O Modules

Input and output (I/O) modules connect the PLC to sensors and connect the PLC to sensors and actuators.

Provide isolation for the low-voltage, low-current signals that the PLC uses internally from the higher-power electrical circuits required by

d most sensors and actuators.

Wide range of I/O modules available including: digital (logical) I/O modules and analog(continuous) I/O modules.

Inputs ModulesInputs ModulesInputs come from sensors that translate physical or chemical phenomena into electrical signals.

The simplest form of inputs are digital/discrete in

AC/DC.

In smaller PLCs the inputs are normally built in and are

specified when purchasing the PLC.

F l PLC h i h d d l For larger PLCs the inputs are purchased as modules, or cards, with 8,16, 32, 64, 96 inputs of the same type on each card.

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Inputs ModulesInputs Modules

The list below shows typical ranges for input voltagesranges for input voltages.

◦ 5 Vdc

◦ 12 Vdc

◦ 24 Vdc

◦ 48 Vdc

◦ 12 Vac

◦ 24 Vac

◦ 120 Vac

◦ 240 Vac

Outputs ModulesOutputs ModulesOutput modules rarely supply any power, but instead act as switches.

External power supplies are connected to the output card and the card will switch the power on or off for each output.

A common choice when purchasing output cards is relays, transistors or triacs.

Relay are the most flexible output devices. They are capable of switching both AC and DC outputs. But, they are slower, cost more, and they will wear out after millions of cycles.

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RelaysRelaysThe most important consideration when selecting grelays, or relay outputs on a PLC, is the rated current and voltage.

For transistor outputs or higher density output cards relay terminal blocks are available. terminal blocks are available. ◦ Advantage of individual standard

replaceable relays

Output ModulesOutput Modules

Typical output voltages are listed belowlisted below.

◦ 5 Vdc

◦ 12 Vdc

◦ 24 Vdc

◦48 Vdc

◦24 Vac

◦120 Vac

◦240 Vac

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Analogue Inputs/OutputsAnalogue Inputs/OutputsAnalogue input cards convert continuous signals via a A/D converter into discrete values for the PLC

Analogue output cards convert digital values in then PLC to continuous signals via a D/A converter.

Resolution can be important in choosing an applicable card

Example, for a temperature input of 0 to 100 degrees C◦ For 8 bit resolution the value in the PLC is 0 to 255

◦ For 12 bit resolution the value in the PLC is 0 to 4095◦ For 12 bit resolution the value in the PLC is 0 to 4095

◦ For 12.5 bit resolution the value in the PLC is 0 to 6000

◦ For 13 bit resolution the value in the PLC is 0 to 8192

◦ For 16 bit resolution the value in the PLC is 0 to 32768

Analogue CardsAnalogue CardsTypical Analogue Input signals are:

Analogue Output signals control:◦ Analogue Valves

◦ Flow sensors

◦ Humidity sensors

◦ Load Cells

◦ Potentiometers

◦ Pressure sensors

◦ Temperature sensors

◦ Analogue Valves◦ Analog Actuators◦ Chart Resorders◦ Variable Speed Drives◦ Analogue Meters

Typical Analogue Signal Levels

◦ Vibration ◦ 1-5 Vdc◦ 4-20mA◦ 0-10 Vdc◦ -10 – 10Vdc

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Special ModulesSpecial ModulesRF ID VoiceG Fl C l l i

Fast Response (Interrupt)PIDL C llGas Flow Calculation

Weigh CellHydraulic ServoASCIIFuzzy LogicTemperature SensorTemperature Control

Loop ControllerBASIC CardsRS232 Comm’s Modbus ASCII/RTUEthernet Comm’sHigh Speed CountersPosition Control Cardsp

Heat/Cool ControlField Bus Cards◦ DeviceNet, Profibus etc◦ Lonworks, BACNet

Per to Per Comm’s◦ Controller Link◦ DH+◦ Modbus Plus

NetworksNetworksASIDevicenet

Ethernet I/PSmart Distributed Devicenet

Interbus-SProfibusInterbusFieldbus

Smart Distributed System (SDS)SeriplexCANopenLonworksBACNet

• Gateways enable communications between different network topologies

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OMRON PLC OMRON PLC CQM1HCQM1H--CPU51CPU51


CQM1H CPU51CQM1H CPU51

Power Supply CPU unit Input Output

PA206

pp yUnit

CPU unit pModule

Output module

CQM1H-CPU51 0 CH OC 221

RS-232 PORT

INNERBOARDSLOT 1

INNERBOARDSLOT 2

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ConfigurationConfiguration



I/O point capacity : 512 points.CPU BlockCPU Block◦ Dedicated I/Os module up to 11 units

connectable.


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CPU and Expansion I/O Block◦ CPU: Up to 5 units (exclude I/O Control unit)◦ CPU: Up to 5 units (exclude I/O Control unit)◦ Expansion: Up to 11 units (exclude I/O Interface

Unit)


Power ConsumptionPower Consumption

Important to select suitable power supply modulemodule.Requirement to power up each module that attached.


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Power ConsumptionPower Consumption


Output unit current consumptionOutput unit current consumption


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PLC WIRING SYSTEMPLC WIRING SYSTEM


Incoming Power SupplyIncoming Power Supply


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I/Os wiring circuit I/Os wiring circuit -- inputinput

Input Card:

1 2 3 4 5 6 7 8 9 10

H H

G

F

E

D

G

F

E

D

COM 0000 0001 0002 0003 0004 0005 0006

X2: 11 X2: 12 X2: 13 X2: 14 X2: 15 X2: 16 X2: 17 X2: 18

K6.5

Universiti Malaysia Pahang ©2011 snaim1 2 3 4 5 6 7 8 9 10

C

B

A

C

B

A

NAME DATE

VERIFY BY

CHECK BY

DRAW BY

SheetDrawing Number

File Name Rev.

FKEE Skills Center,Faculty of Electrical & Electronics Engineering,KUKTEM,Locked Bag 12,25000 Kuantan, PahangPhone No: 09-5492318Fax No: 09-5492377Rev Decription Date

Title

Input Card <Drawing No>

ELECTRICAL_DRAWING_MCC2. vsd

2

SNAIM

<Name>

<Name>

05/12/2006

<date>

<date>

<Rev.>

SENSOR 1START Remote DCS1 /6.6

STOP SELECTORSWITCH

N24

P24

I/Os wiring circuit I/Os wiring circuit -- outputoutput


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Inductive device connectionInductive device connection


Point assignmentPoint assignmentRack: 01FChannel: .Card: Digital Input - OCH

Point No.

Address Description Name Tag Lebel/mark

00 0000 Start PB1 0000

01 0001 Stop PB2

©snaim 2008

02 0002 Auto/manual SS1

03 0003 Sensor 1 S1

04 0004

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Address AssignmentAddress Assignment

Inputp0000

Input slot/channel no Input point no.

©snaim 2008


Outputp10000

Input slot/channel no Input point no.

©snaim 2008

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For CQM1H, the address are address are dedicated by the system (can’t setting by user)E.g.◦ Build in 0CH card is Build in 0CH card is

start from 00.00◦ Next second input

card will start at 01.00


CXCX--POGRAMMINGPOGRAMMING


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Introduction Introduction –– PLC programmingPLC programmingStatement List

If PB1 AND PB2 then

set output1reset output2

Block Diagram

Ladder Diagram


Basic Element of LDBasic Element of LD


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Anatomy of a LDAnatomy of a LD

Typically flows from left to right. • Divided into sections called rungs, • Each i/os instruction is assigned an address Each i/os instruction is assigned an address

indicating the location in the PLC memory where the state of that instruction is stored.

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CXCX--ProgrammerProgrammer

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Main windowsMain windows

LaderLader LogicLogic


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LaderLader LogicLogic


AND ApplicationAND Application

IN A IN B OUTIN A IN B OUT

0 0

0 1

1 0


1 0

1 1

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AND Application AND Application -- exerciseexercise

MAN MODEMAN MODE&

PUSH START PB

GREEN LIGHT ON


GREEN LIGHT OFF

REMOTE MODE OR

RELEASE START PB

OR ApplicationOR Application

IN A IN B OUTIN A IN B OUT

0 0

0 1

1 0


1 0

1 1

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OR ApplicationOR Application

IN A IN B OUT

0 0

0 1

©snaim 2008

0 1

1 0

1 1

Latching / holding circuitLatching / holding circuit

To hold the output for desire rung.TechniqueTechnique◦ Or ladder◦ KEEP instruction◦ SET & RSET Instruction


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Latching by using or functionLatching by using or function


KEEP InstructionKEEP Instruction

Purpose:◦ Defines a bit (B) as a latch, controlled by the

set (S) and reset (R) inputs.( ) ( ) pOperand Data Areas:◦ B: Bit IO, AR, HR, LR.

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Flow chart

start

Push Start button

I/O Assignments Input Devices

000.00 Start PB

000.01 Stop PB

100.01 Green Light

Green Light On

Push Stop Button

Green

Ladder Diagram

Light OFF

End

SET & RSET InstructionSET & RSET Instruction

•Turns ON B for an ON execution condition; does not affect B for an OFF execution condition.•Operand Data Areas:B: Bit IO, AR, HR, LR.

Turns OFF B for an ON execution condition; does not affect B for an OFF execution condition.Operand Data Areas:B: Bit IO, AR, HR, LR

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More Exercise….More Exercise….

Timer (TIM)Timer (TIM)

A timer is activated when its execution di i ON d i ( S) condition goes ON and is reset (to S)

when the execution condition goes OFF. Once activated, TIM measures in units of 0.1 second from the S.


N TC Number 000 - 511

S Set value (word, BCD)

IO, AR, DM, HR, #

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Timer (TIM)Timer (TIM)

If the execution condition remains ON long enough for TIM to time down to

ONON

long enough for TIM to time down to zero, the Completion Flag for the TC number used will turn ON and will remain ON until TIM is reset (execution condition goes OFF).


BASIC TIMER: EXERCISE 1BASIC TIMER: EXERCISE 1

Start

Push Start button

Timer 5 Sec?

Yes

No

Yellow Light ON

End

Yes

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BASIC TIMER: BASIC TIMER: EXERCISE 2EXERCISE 2

Start A

Select Manual Mode

Timer 5 Sec?

Yes

No

Timer 5 Sec?

Green Light ON

Select Auto

Yellow Light ON

End

Yes

A

Auto Mode

Yellow & Green Light

OFF

FLICKER: EXERCISE 3FLICKER: EXERCISE 3

Start A

Push Start button

Timer 1 Sec?

Yes

No

Timer 1 Sec?

Green Light OFF

Push StopGreen Light ON

End

Yes

A

Push Stop

System RESET

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FLICKER: EXERCISE 4FLICKER: EXERCISE 4

Start

Push Start button

A

Timer 1 Sec?

No

Timer 3 Sec?

Green Light

Yes

No

1 Sec?

Green Light OFF

Continuous Blinking

Yes

Light ON

End

A

Push Stop

System RESET

TIMER APPLICATIONTIMER APPLICATIONLab sheet 2 : Exercise 5

Input A i

Input DevicesAssignment0000 Start PB0001 Stop PB0002 Auto/Man SelectorOutput Assignment

Output Devices

10001 Green Light


g10002 Red Light10003 Yellow Light

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Counter (CNT)Counter (CNT)

CNT is used to count down from SV when the execution condition on the count pulse -CP, goes execution condition on the count pulse CP, goes from OFF to ON.The present value (PV) will be decremented by one whenever CNT is executed with an ON execution condition for CP and the execution condition was OFF for the last execution


N CNT Number

000 - 511

SV Set value (word, BCD)

IO, AR, DM, HR, #

Counter (CNT)Counter (CNT)

The Completion Flag for a counter is turned ON when the PV reaches zero and will

ONON

ON when the PV reaches zero and will remain ON until the counter is reset.CNT is reset with a reset input, R.When R goes from OFF to ON, the PV is reset to SV.


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Timer and CounterTimer and Counter

Please note that TIM number and Please note that TIM number and CNT number should be unique (NOT SAME) in a same program.

E.g.

!E.g.◦ CNT000 then use TIM000 in same

program.


BASIC COUNTER: BASIC COUNTER: EXERCISE 6EXERCISE 6

Start

Push Start Button

Counter 5 X ?

Green Light ON

Yes

No

End

Push Stop Button

Green Light OFF

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TIME DELAYED 60 SEC: TIME DELAYED 60 SEC: EXERCISE 7EXERCISE 7

Start A

Push Start button

Timer 6 Sec?

Yes

No

Yellow Light ON

Push Stop

System

End

Yes

A

Counter 10 X?

yRESETNo

Yes

Extra exercise…Extra exercise…

MAN MODE NG PART ON &MAN MODE

OK PART BLINKING

AUTO MODE

RUN PART BLINKING &

NG PART ON &RUN PART OFF

STOP PB

IF STOP PB5 x

NO


BLINKING &OK PART OFF

START PB ALL PART OFF OR RESET SYSTEM

5 x

YES

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•DIFU & DIFD•INC & DEC•Shift Register•Move & Compare

INTERMEDIATE INTERMEDIATE PROGRAMPROGRAM

p•Interlocking

DIFU instructionDIFU instruction

Differential UP (rise edge)DIFU (13) turns ON the designated bit (B) for one scan on reception of the leading (rising) edge of the input signal


Operand Data Areas

B Bit IO, AR, HR, LR

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DIFD instructionDIFD instruction

Differential Down (fall edge)DIFD(14) turns ON the designated bit (B) for one scan on reception of the trailing (falling) edge of the input signal.


Operand Data Areas

B Bit IO, AR, HR, LR

DIFU DIFU vsvs DIFDDIFD


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MOVE instructionMOVE instruction

Copies the contents of S to D

Operand Data Areas


S Source Word IO, AR, DM, HR, LR, #

D Destination word

IO, AR, DM, HR, LR

Compares (CMP) instructionCompares (CMP) instruction

Compares Cp1 and Cp2 and;Outputs the result to the GR, EQ and LE flags in the SR area

Operand Data Areas


Cp1 1st compare word

IO, AR, DM, HR, TC, LR, #

Cp2 2nd compare word

IO, AR, DM, HR, TC, LR, #

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Increment (INC) instructionIncrement (INC) instruction

Increments Wd, without affecting Carry (CY)Carry (CY).For INC(38) and DEC(39) the source and result words are the same. That is, the contents of the source word is overwritten with the instruction result.


Operand Data Areas

Wd Increment Words

IO,AR,DM,HR,LR

Decrement (DEC) instructionDecrement (DEC) instruction

DEC(39) decrements Wd, without ff i CY affecting CY.

DEC(39) works the same way as INC(38) except that it decrements the value instead of incrementing it.


Operand Data Areas

Wd Decrement Words

IO,AR,DM,HR,LR

bee2931 basic plc 2011

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