Programmable logic controller questions
MODULE TITLE: PROGRAMMABLE LOGIC CONTROLLERS
TOPIC TITLE: THE STRUCTURE OF THE PLC
LESSON 2: SYSTEM FEATURES I
PLC - 5 - 2
© Teesside University 2011
Published by Teesside University Open Learning (Engineering)
School of Science & Engineering
Teesside University
Tees Valley, UK
TS1 3BA
+44 (0)1642 342740
All rights reserved. No part of this publication may be reproduced, stored in a
retrieval system, or transmitted, in any form or by any means, electronic, mechanical,
photocopying, recording or otherwise without the prior permission
of the Copyright owner.
This book is sold subject to the condition that it shall not, by way of trade or
otherwise, be lent, re-sold, hired out or otherwise circulated without the publisher's
prior consent in any form of binding or cover other than that in which it is
published and without a similar condition including this
condition being imposed on the subsequent purchaser.
________________________________________________________________________________________
INTRODUCTION ________________________________________________________________________________________
In a previous lesson we were introduced to ladder diagrams, their symbols and
meaning and some methods of rung simplification. In this lesson we shall look
at how program listings relate to ladder diagrams.
We shall be introduced to examples of PLC programmer unit hardware that is
used to enter instructions into the PLC and build up a program.
A common ladder diagram is used to illustrate three variations in presentation
together with a brief assessment of the keyboards and displays used to handle
each variant.
Common blocks of hardware, anticipated to be a requirement of every system,
are also mentioned or expanded upon if previously mentioned in earlier
lessons.
________________________________________________________________________________________
YOUR AIMS ________________________________________________________________________________________
Upon completion of this lesson you should be able to:
• relate ladder diagrams to program listings for different machines
• explain common methods of entering program listings into PLCs
• draw comparisons between the facilities and operations of
commercial PLC keyboards
• explain the differences between common PLC display methods.
1
Teesside University Open Learning (Engineering)
© Teesside University 2011
________________________________________________________________________________________
PROGRAMMING IMPLICATIONS ________________________________________________________________________________________
When a ladder diagram drawn on paper is to be implemented by a PLC it must
first be entered into the machine so that it may be RUN. The diagram is stored
as a sequence of data within a special section of the memory of the
microcomputer which controls the operation of the PLC. This data is used to
produce a microprocessor program. In digital computers all programs are
sequential in operation. This means that the microprocessor which executes
the machine instructions does so one at a time as if it were working through a
list of jobs.
Due to the microprocessor being held to this sequential method of operation
the programmer must arrange the 'list of jobs' in the correct order so that the
PLC will behave in the expected manner. To do this the programmer converts
the ladder diagram into a program listing and enters this listing into the PLC
using some form of programmer unit.
Manufacturers each make their own programmer unit, which means that
variations in programming procedures are bound to exist from machine to
machine.
The ladder diagram of FIGURE 1 will now be used to provide examples of
program listings.
NOTE: At this point you will notice that we have stopped drawing in the
right vertical upright of the ladder diagrams. Since nothing is allowed to
follow an output element on a rung we simply assume that it is there and don't
bother drawing it in. This is a generally accepted convention and will be
followed in all future ladder diagrams.
2
Teesside University Open Learning (Engineering)
© Teesside University 2011
FIG. 1
Example 1
The first example breaks down the ladder diagram into steps.
Each step is programmed by having:
(a) the step identified by a step number
(b) the operation specified by an op-code (a mnemonic)
(c) the element concerned specified as an operand.
This is very similar to assembly language programming of a microprocessor
based system.
The listing is derived in a step-by-step manner in the same way as the
conventional method of reading ladder diagrams mentioned in previous
lessons. Each operation with the element concerned is specified as each rung
of the ladder is traced out.
Rung 1
Rung 2
Rung 3
000 001 MR000
002 MR000 MR001
MR001 OUT 000
MR000
End
3
Teesside University Open Learning (Engineering)
© Teesside University 2011
The ladder diagram of FIGURE 1 becomes the following listing:
Step Mnemonic Operand
op-code
000 LD 000 The first operation and element specified
001 OR MR000 The second operation and element specified
002 AND NOT 001 The third operation and element specified
003 OUT MR000 The fourth operation and element specified
The first four steps (000 to 003) define RUNG 1.
The remainder of the rungs are listed in a similar way.
004 LD 002
005 AND MR000 Steps 004 to 006 define RUNG 2
006 OUT MR001
007 LD MR001 Steps 007 to 008 define RUNG 3
008 OUT 000
009 END Defines the end of the listing
When this type of listing is entered into the PLC it is entered one step at a
time. Each step is set up on a display panel and then written into the PLC's
memory before the next step is set up. After the last step in the program an
END instruction must be added to indicate that the listing is complete. The
END instruction is considered to be very important in most systems. If it is
omitted the PLC will probably not run the program, an error message would
almost certainly be displayed.
4
Teesside University Open Learning (Engineering)
© Teesside University 2011
The programming sequence for this listing would be:
000 → LD → 000 → WRITE (the step to memory) 001 → OR → MR → 000 → WRITE 002 → AND NOT → 001 → WRITE 003 → OUT → MR → 000 → WRITE 004 → LD → 002 → WRITE 005 → AND → MR → 000 → WRITE 006 → OUT → MR → 001 → WRITE 007 → LD → MR → 001 → WRITE 008 → OUT → 000 → WRITE 009 → END → WRITE
The arrows indicate the flow of the sequence of the programming procedure.
The WRITE operation is not a part of the listing but it is a vital part of the
procedure. Each time the WRITE key is pressed the step data is entered into
memory and the next step number is presented ready for the next step. A
favourite mistake by newcomers to this method is forgetting to write the END
instruction into memory. Eagerly switching to RUN displays the error
message 'NO END INSTRUCTION'.
5
Teesside University Open Learning (Engineering)
© Teesside University 2011
Consider now the ladder diagram of FIGURE 2. Provide a listing of the type just
considered which would be suitable for the programming of this diagram. Write the
listing below.
FIG. 2
Step Op-code Operand
000
001
002
003
004
005
006
007
008
009
________________________________________________________________________________________
Check your listing against that given on page 26.
Rung 1
Rung 2
000 001 MR000
004
MR000 OUT 000
MR001
End
003
002
6
Teesside University Open Learning (Engineering)
© Teesside University 2011
Example 2
The second example follows a similar format to the previous listing. This time
the step is called a step address and the op-code is specified as a number
representing the operation required. The element identification (operand) has
been changed to fall in line with that used in the ladder diagram of FIGURE 3.
The circuits and operation of FIGURES 1 and 3 are the same.
FIG. 3
The listing for FIGURE 3 becomes:
Step Address Op-code Operand
0000 01 000 (Next Address)
0001 05 288 " "
0002 04 001 " "
0003 10 288 " "
0004 01 002 " "
0005 03 288 " "
Rung 1
Rung 2
Rung 3
000 001 288
002 288 289
289 OUT 032
288
End
7
Teesside University Open Learning (Engineering)
© Teesside University 2011
0006 10 289 " "
0007 01 289 " "
0008 10 032 " "
0009 20 0000 " "
Here again each step is programmed before the 'next address' key is pressed.
The operation of this key writes the step into the computer memory and
increments the step address ready for the next step.
Compare this listing with the diagram of FIGURE 3. Add the op-codes to the
diagram and then answer the following questions.
What operation does each of the following numerical codes perform?
(a) 05
(b) 03
(c) 04
(d) 10
(e) 20
(f) 01.
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
________________________________________________________________________________________
Answers on pages 26 and 27.
8
Teesside University Open Learning (Engineering)
© Teesside University 2011
FIG. 4
Refer now to the diagram of FIGURE 4.
Provide a listing below, using the method of example 2, which would be suitable for the
programming of the diagram of FIGURE 4. FIGURE 4 represents the same circuit as
FIGURE 2.
Step Address Op-code Operand
0000
0001
0002
0003
0004
0005
0006
0007
0008
0009
Solution given on page 27 and 28.
Rung 1
Rung 2
000 001 288
004
OUT 032
288
End
003
002
288
9
Teesside University Open Learning (Engineering)
© Teesside University 2011
The methods employed in Examples 1 and 2 are often used with a hand-held
programmer unit which can only display information about one step at any one
time. The information is lost from the display when the WRITE or NEXT
ADDRESS key is pressed.
Example 3
The third example illustrates the programming of the diagram of FIGURE 1 by
a function key method. This method is slightly different from the other two
previous examples and would be used with a programmer unit equipped with a
display screen. The ladder diagram is progressively drawn on the display as
the function keys are pressed. In this way the build up of the ladder diagram is
in full view all of the time making mistakes less likely.
The diagram of FIGURE 1 has had the element identification changed so that
it conforms with the programming method. Note the return of the use of X, Y
and R.
FIGURE 5 shows the redefined diagram of FIGURE 1.
FIG. 5
Rung 1
Rung 2
Rung 3
X000 X001 R000
X002 R000 R001
R001 Y000
R000
End
10
Teesside University Open Learning (Engineering)
© Teesside University 2011
Function key listing for the diagram of Figure 5.
FIG. 6
Three variations of programming procedures have now been examined. These
are by no means the only procedures employed but they do help to establish
the fact that the sequence of entering information into the PLC must be a
faithful reproduction of the contents of the ladder diagram.
END
PRG
W R T
PRG
W R T
PRG
W R T
PRG
W R T
PRG
W R T
PRG
W R T
PRG
W R T
PRG
W R T
PRG
W R T
PRG
W R T
X000
X001
R000
R000
X002
R000
R001
R001
Y000
FUNCTION KEY OPERAND WRITE (TO THE DISPLAY)
SFT
11
Teesside University Open Learning (Engineering)
© Teesside University 2011
PROGRAMMING KEYBOARD
Any computer, no matter how powerful it is, would be useless if it did not
allow communication between itself and the outside world. It must be able to
take in data and give out the results of its computations as well as having a
means of receiving instructions which it will interpret as a program to be
executed.
Personal computers have their keyboards laid out in a similar way to
typewriters i.e. a QWERTY keyboard. Larger PLCs and those programmed by
high level language are provided with similar keyboards.
The keyboard provided at a bank's cash dispenser needs to be more robust and
weatherproof and does not require very many keys. Most are arranged in a
matrix having either a 3 × 4 or a 4 × 5 layout. The keys are marked with the numbers from 0 to 9 and simple answers/commands such as YES, NO,
ENTER, CANCEL etc.
What would you expect to be needed for the keyboard of a PLC?
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
________________________________________________________________________________________
12
Teesside University Open Learning (Engineering)
© Teesside University 2011
Certainly some numbers; 0 to 7 for an octal system or 0 to 9 for a decimal
system. Additionally we would probably expect some program command
keys, although these will vary with the manufacturer and the programming
method used. Command keys may be given in the form of function keys
showing directly the functions which are to be carried out (i.e. an 'AND' key,
an 'OR' key, etc.).
The diagram of FIGURE 7 shows the layout of the keyboard of a popular PLC.
The key arrangement is a five by six matrix laid out in a strategic manner.
Each key is clearly labelled. The top two rows are function keys relating
directly to the elements used in the ladder diagram. Some of these functions
are still to be examined in future lessons. The ten numeric keys are grouped to
the left and more specialised operation keys to the right. The WRITE (to
memory) key is at the bottom, extreme right; far (so to speak) away from the
other keys so that a conscious effort is required to press it at the end of entering
the step data.
This type of keyboard is suitable for programming the listings considered
earlier in this lesson as method 1.
13
Teesside University Open Learning (Engineering)
© Teesside University 2011
FIG. 7
In many cases some of the keys which are provided will serve more than one
purpose. For example, at one time a key may represent a number and at
another time the same key may represent a function. This may be achieved by
the use of a SHIFT key to obtain the upper case specification of the key or it
may be achieved by the machine's own interpretation of the order in which the
keys have been pressed. Whichever method is used it can result in almost
halving the number of keys required because nearly each one could do two
jobs.
FIGURE 8 shows another version of a keyboard. This is also an actual
keyboard which is in common use.
ORAND LD NOT END
OUT/1 MR/2 KR/3 TIM/4 CNT/5
DELETE SEARCH7 8 9
4 5 6
1 2 3
0 CLEAR
INSERT MONITOR
CLEAR DISPLAY
CLEAR VERIFY READ WRITE
(+)
(–)
Ladder function
keys
Numeric keys
Special operation
keys
14
Teesside University Open Learning (Engineering)
© Teesside University 2011
FIG. 8
Examine the keyboards of FIGURE 7 and FIGURE 8.
What differences are apparent?
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
________________________________________________________________________________________
Possibly the most notable difference is what appears to be a lack of keys in
FIGURE 8. Only sixteen keys are provided which means that this keyboard is
smaller.
7 8 9
4 5 6
1 2 3
0 L E C
–
+
A
15
Teesside University Open Learning (Engineering)
© Teesside University 2011
Why only sixteen keys? Does this mean that fewer or no functions are available?
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
________________________________________________________________________________________
We have the numbers in the same range of 0 to 9 but none of the keys is
marked as a function. This is because the functions are also specified as
numbers. A different number code is used to represent each function. Listings
of the type previously mentioned as method 2 are programmed using this
keyboard.
It should be noted that the keyboard of FIGURE 7 provides twelve ladder
diagram functions but the keyboard of FIGURE 8 provides in excess of thirty!
The simplicity of the appearance of the keyboard can, therefore, be deceptive
and should not, in any way, be taken as an indication of the function ability of
the PLC.
Keyboards may be part of the PLC as a permanent facility. However, the
temptation for unauthorised personnel to tamper with them is sometimes too
great and this could well result in a malfunction of the PLC or corruption of
the program. To reduce this possibility modern PLCs have their keyboards
provided as part of a detachable programmer unit. Authorised personnel can
carry the programmer unit from PLC to PLC. This also reduces the number of
programmer units required and produces a consequential saving.
16
Teesside University Open Learning (Engineering)
© Teesside University 2011
The most modern programmer units are, in fact, microcomputers in their own
right as they possess a microprocessor and circuitry in addition to that housed
in the PLC. The microprocessor in the programmer unit handles the reading of
the keyboard, the provision of a programming display, the temporary storage
of a user's program (such as those of the listings previously mentioned) and
possibly the driving of the circuitry to transfer the program from the
programmer unit to the PLC via a cable link.
Programmer units which can themselves store user programs are very useful if
the same program is to be used in many identical PLCs. The programmer unit
can be plugged-in, the program downloaded and it can then be unplugged
before progressing to the next PLC. The keying-in is therefore done only
once.
FIGURE 9 shows a third version of a keyboard. The keys are laid out in a five
by seven matrix. Again each key is clearly and indelibly marked, different
colours being employed to indicate groupings. In use, the keys are pressed by
working through the groups of keys from left to right. The blue keys to the left
signify the ladder diagram operation and type of element concerned. The grey
keys in the middle (0 to 9) identify the number of the element and the yellow
keys to the right are the specialised operations. Note that a number of the keys
have two purposes. The code shown above the line drawn across the key is
brought into action by first pressing the red SFT shift key.
17
Teesside University Open Learning (Engineering)
© Teesside University 2011
FIG. 9
The first two keyboards examined use separate keyswitches but this example
uses a touch membrane keypad which some users may find awkward to use.
There is very little sensation experienced in pressing the surface of the keypad
which makes it difficult to tell if the keypress has been recognised. To
alleviate this problem the system emits an audible beep each time a key is
pressed.
The keyboard of FIGURE 9 is used to program the listing of Example 3.
C
T
END SFT
SCR
CLR
S
R
F
L
PRG
WRT
FI N
Blue keys
Grey keys
Red key
Yellow keys
TOP
X
Y
7
4
1
0
8
5
2
9
6
3 BLK
MON
TRC
SCH
DIS
RST
DIS
SET
PRG
INS
FWD REV
JMP
MC
DEL
CMD
18
Teesside University Open Learning (Engineering)
© Teesside University 2011
DISPLAY DEVICE
What form should the display device take?
If a personal computer is being used as the programming console, the viewing
monitor would seem to be the obvious choice of display device. However, the
major problem with this is its lack of portability, especially when it is to be
carried around a factory as part of a technician's tool kit. A small, portable
device is called for which will be reasonably robust and cheap and yet capable
of supplying enough information when it is needed.
What information is needed and when should it be displayed?
The main use of the display device is at the time of entering the program
listing into the machine. When this process is complete and the program is
running at normal speed there is simply not sufficient time to display what is
happening at every point in time. The display, like the programming keyboard,
could be disconnected, leaving the PLC working in the RUN mode.
However, when checking program execution, especially when a fault exists, it
is advantageous to be able to see what is happening inside the PLC. This does
not mean removing the covers and watching the integrated circuits, because no
indication of correct operation can be obtained in this way. It would, however,
be useful to have an indication of whether, for example, internal memory
relays were switched on or off. Remember from previous lessons that these
relays are not physical relays but simply memory cells within the
microcomputer. The display could be used to indicate the state of such
elements by calling upon a MONITORING function whilst the program is
being run.
19
Teesside University Open Learning (Engineering)
© Teesside University 2011
Monitoring is extremely useful even if only one element can be monitored at
any one time. Progressively monitoring selected elements can quickly
indicate what is, and what is not, working to expectation.
The first example of a display is shown in FIGURE 10. This display is a
permanent fixture of its PLC. The diagram shows the use of single and seven
segment LEDs instead of a cathode-ray tube. During the programming
procedure a single line of the program listing would be present on the display.
When that line is written into memory the display clears in readiness to accept
the next line. This display, together with the first keyboard examined, is used
to program the listing of Example 1 (page 3).
FIG. 10
The display is shown with step 002 of Example 1 lit up,
i.e. 002 AND NOT 001.
The second example of a display device is shown in FIGURE 11. This display
has been designed to be extremely portable. As with the previous display,
LEDs are used to show the data for one step address at a time. This display is
used, together with the keyboard of FIGURE 8, to program the listing of
Example 2.
END
CNT
NOT
TIM
LD
OUT
AND
OR
DATASUBADDRESS
20
Teesside University Open Learning (Engineering)
© Teesside University 2011
FIG. 11
As data is entered the single LEDs illuminate to indicate the data field
presently being used. When that field (i.e. step, code or operand) is filled, the
programmer unit moves the indicator so that the user knows that the unit is
interpreting the entered data. Upon completion of the operand field the step
address data is written to memory and the display increments the step address
in readiness for the next step.
The diagram shows step 0002 04 0001 from example 2.
The third example of a display device, shown as FIGURE 12, is slightly more
modern than the first two (FIGURE 10 and FIGURE 11). In this case the
display is of a liquid crystal type. As the steps are entered they appear at the
top left of the screen in the form of the elements of the ladder diagram. When
the element data is complete it is written to the screen at a position indicated
by a cursor. Progressively the ladder diagram builds up on the screen, eight
lines of the diagram representing a full screen. The diagram can spill over onto
a second and subsequent screens. Ladder diagram programming errors are
reduced because of the amount of data displayed. The display, together with
the keyboard of FIGURE 9, is used to provide the programming of the
STEP CODE OPERAND
21
Teesside University Open Learning (Engineering)
© Teesside University 2011
function key listing of Example 3. It is, in fact, the display from the
programmer unit which you will be using for the practical programming
exercises.
FIG. 12
The final programmer unit we shall consider is shown in FIGURE 13. It is
provided with a very simple keyboard and a liquid crystal display. The simple
keyboard does not indicate the powerful capabilities of the system. Option
menus are called up from the keyboard and in each case the keys service the
requirements of that particular menu. Each time the menu is changed the same
keys are used for a different purpose. Again the number of keys in no way
indicates the true capabilities of such a programmer unit.
Y 000
( (
(
) )
)
22
Teesside University Open Learning (Engineering)
© Teesside University 2011
FIG. 13
In a modern commercial PLC, a simple keyboard is likely to indicate more
complex software. If the keyboard has a large number of keys the software
driving it is likely to be relatively simple, although this would not concern
most users. Keyboards with fewer keys are smaller and easier to make but
fewer keys can tend to make the keying-in process slower. As an example,
suppose each key of a simple keyboard had four uses. It would be unlikely that
an indication of each use could be marked on the actual key (or its surround)
because there would not be sufficient space. It would be probable, therefore,
that the user would be expected to cross reference with information provided
on the display or in the accompanying manual before the correct key could be
chosen.
NOP
9
AND NOT
3
LCD display
COMMSFR LD
0
CTR
TIM
END
LD NOT
1
OR
4
AND BLK
7 OR BLK
8
OR NOT
5
AND
2
OUT
6
OPTIONS
INSERT
ENTER
DELETEEDIT
BREAK
23
Teesside University Open Learning (Engineering)
© Teesside University 2011
Alternatively the programmer may need to provide an indication of the
keystrokes required at the time of making up the listing.
DIAGNOSTIC ROUTINES
When power is first applied the CPU an initial program is used to set the
system in readiness for the execution of the user's program. This initial control
program is sometimes called the monitor routine or the executive program.
One important task of this program is to check the serviceability of various
parts of the system before handing over control to the user or the user program.
The term used to represent these checks is 'software diagnostics', i.e. a program
used to diagnose faults in the system. Typical tasks carried out by the
diagnostics program are: checking that the system RAM is working, testing the
condition of the backup battery, supercharged capacitors etc.
Some systems may require an interaction between the PLC and the user –
checking the operation of each key on the keyboard for example. The user,
following prompts, presses each key in a set sequence while the program
checks that the operation of the keyboard is as expected. If any part of the
system fails the test then an indication of some kind is given. An error LED
may light or flash or the display may show a warning.
This is a very valuable asset for the system. Imagine someone trying to use a
computer which is broken and not realising that it is broken. Quite often the
user will think that it's not working because of some error that he/she has
made.
24
Teesside University Open Learning (Engineering)
© Teesside University 2011
Upon conclusion of the diagnostic tests the system runs other sections of
programs which may, for example, do one of the following.
• Request the user to input a password before gaining access to the
machine operation. This prevents unauthorised alterations to
programs held in the computer memory.
• Interrogate a slide or key switch to establish the MODE of operation
required – RUN MODE, PROGRAM MODE, HALT MODE, etc.
Depending upon the mode selected, a further program will be run in
order to satisfy the requirements of that mode.
Now attempt the Self-Assessment Questions given on page 30.
25
Teesside University Open Learning (Engineering)
© Teesside University 2011
________________________________________________________________________________________
ANSWERS TO QUESTIONS ________________________________________________________________________________________
LISTING FOR LADDER DIAGRAM OF FIGURE 2 (FROM PAGE 6)
Step Op-code Operand
000 LD 000
001 OR MR 001
002 AND 001
003 OR 002
004 AND NOT 003
005 OUT MR 000
006 LD MR 000
007 OR 004
008 OUT 000
009 END
FROM PAGE 8
With the op-codes added FIGURE 3 becomes FIGURE 14 below.
FIG. 14
Rung 1
Rung 2
Rung 3
000 001 288
002 288 289
289 OUT 032
288
End
01
04
03
05
10
10
10
01
01
20
26
Teesside University Open Learning (Engineering)
© Teesside University 2011
(a) 05 is the code for OR with a normally open set of contacts.
(b) 03 is the code for AND with a normally open set of contacts.
(c) 04 is the code for AND NOT i.e. a series connected set of normally closed
contacts.
(d) 10 is the code for OUTPUT.
(e) 20 could be taken as meaning the END instruction and this is a perfectly
acceptable answer. In actual fact in this particular case the code 20 causes
the control to jump back to a specified step address – in this case address
0000 which is the beginning of the program listing.
(f) 01 is the code for START A NEW RUNG with a normally open set of
contacts.
FROM PAGE 9
With the op-codes added the diagram becomes:
FIG. 15
Rung 1
Rung 2
000 001 288
288 OUT 032
288
End
01
03
05
10
10
01
20
004 05
002 05
003 04
27
Teesside University Open Learning (Engineering)
© Teesside University 2011
The listing for the ladder diagram of FIGURE 4 is:
Step Address Op-code Operand
0000 01 000
0001 05 288
0002 03 001
0003 05 002
0004 04 003
0005 10 288
0006 01 288
0007 05 004
0008 10 032
0009 20 0000
28
Teesside University Open Learning (Engineering)
© Teesside University 2011
________________________________________________________________________________________
NOTES ________________________________________________________________________________________
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
29
Teesside University Open Learning (Engineering)
© Teesside University 2011
________________________________________________________________________________________
SELF-ASSESSMENT QUESTIONS ________________________________________________________________________________________
1. Explain how a ladder diagram is converted into a program listing in
readiness to be entered into a PLC.
2. Explain the purpose of software diagnostics as used in PLCs.
3. How can one key on a programming keyboard be used for more than one
purpose?
4. What are the advantages of a detachable programming unit?
5. Why should manufacturers find it necessary to provide a beep sound to
accompany certain types of keyboard?
30
Teesside University Open Learning (Engineering)
© Teesside University 2011
________________________________________________________________________________________
NOTES ________________________________________________________________________________________
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
31
Teesside University Open Learning (Engineering)
© Teesside University 2011
________________________________________________________________________________________
ANSWERS TO SELF-ASSESSMENT QUESTIONS ________________________________________________________________________________________
1. A ladder diagram is a well known method of representing an electrical
control system. However, not all programmable controllers will accept
programming in a diagrammatic form. Most PLCs are programmed by
first converting the ladder diagram into a program listing and then keying
this listing into the programmer unit. The device controlling the PLC is a
microprocessor and, as with all microprocessor based systems, the
programming must be very precise and exact in detail if the required
operation is to be obtained. Listings derived from ladder diagrams are
drawn up as a faithful reproduction by working through the diagram using
the conventional reading method. That is to say, starting from the top left
of the diagram and working along the rung towards the output device.
After each output or rung terminating device has been handled the next
rung is considered. Each rung element must be precisely defined as the
function being performed together with sufficient information to clearly
distinguish it from all other possible elements. Upon completion of the
list the END instruction is used so that the size of the program can be
identified by the PLC.
2. Software diagnostics is the term used to describe the technique of using a
computer program (firmware) which is resident within the PLC to
conduct a series of tests on the microelectronics and circuitry of the
controller. This is done at the time of power up and before the system
hands over control to the user. System irregularities, if any are found, are
reported using ERROR messages. The user therefore knows that if no
errors have been reported the system should be healthy and it should
operate to expectations.
32
Teesside University Open Learning (Engineering)
© Teesside University 2011
3. Manufacturers may produce keyboards with keys which fulfil more than
one function for the purpose of reducing the size and therefore the cost of
the keyboard. Different methods of achieving this are employed.
(a) Keys which have two functions may be displayed either:
(i) with a line drawn across the middle and having the functions
marked above and below this line.
or (ii) with the functions marked on the switch surround, again above
and below.
Obtaining the lower function would be achieved by pressing the key
on its own. The upper function is accessed by first pressing a shift
key to register the above the line requirement, followed by the
function key.
(b) Alternatively, the software which is driving the keyboard could
interpret the pressed key with respect to the present programming
field being considered. For example, a particular key would
represent a function when the PLC is expecting an operation
(because it happens to be in that field at that time) but when the
operation field is complete and the programmer moves into the
operand field then that same key would now represent an operand.
(c) An extension of (b) is achieved by software interpretation of the
pressed key dependent upon a particular menu being displayed by the
PLC. If the display changes, the key press has a meaning relevant to
the new display. This method is very powerful because the keyboard
limitations are defined by software and not the keyboard hardware.
33
Teesside University Open Learning (Engineering)
© Teesside University 2011
4. A detachable programming unit has the following advantages:
(a) If, for example, a factory installs ten identical PLCs then each PLC
would not need its own programmer unit. Perhaps two units would
be considered adequate which would reduce the initial outlay costs.
(b) If the unit is detached then the possibility of unauthorised tampering
is removed, authorised personnel having the only access to the units.
5. With certain types of keyboard, such as those employing a touch
membrane keypad, users experience very little sensation when pressing
the surface of the keypad. This makes it difficult to know if the keypress
has been recognised. To alleviate this problem the system emits an
audible beep each time a key is pressed.
34
Teesside University Open Learning (Engineering)
© Teesside University 2011
________________________________________________________________________________________
SUMMARY ________________________________________________________________________________________
This lesson was the second in the topic 'Structure of the PLC'. The lesson
started at the point where a completed ladder diagram has been prepared in
readiness for entry into the PLC. The same ladder diagram was coded to make
it suitable for three different, but commercially common, variations in program
listings. Each listing was examined to gain an insight into the method of entry
into the PLC.
The lesson also dealt with the requirements of keyboards and displays. An
analysis of a number of such devices, taken from the equipment of leading
manufacturers, enabled points of special interest to be made.
The third lesson in this topic deals with possible methods of handling a
program listing once it has been entered into the PLC.
35
Teesside University Open Learning (Engineering)
© Teesside University 2011
<< /ASCII85EncodePages false /AllowTransparency false /AutoPositionEPSFiles true /AutoRotatePages /None /Binding /Left /CalGrayProfile (Dot Gain 20%) /CalRGBProfile (sRGB IEC61966-2.1) /CalCMYKProfile (U.S. Web Coated \050SWOP\051 v2) /sRGBProfile (sRGB IEC61966-2.1) /CannotEmbedFontPolicy /Error /CompatibilityLevel 1.4 /CompressObjects /Tags /CompressPages true /ConvertImagesToIndexed true /PassThroughJPEGImages true /CreateJDFFile false /CreateJobTicket false /DefaultRenderingIntent /Default /DetectBlends true /ColorConversionStrategy /LeaveColorUnchanged /DoThumbnails false /EmbedAllFonts true /EmbedJobOptions true /DSCReportingLevel 0 /SyntheticBoldness 1.00 /EmitDSCWarnings false /EndPage -1 /ImageMemory 1048576 /LockDistillerParams false /MaxSubsetPct 100 /Optimize true /OPM 1 /ParseDSCComments true /ParseDSCCommentsForDocInfo true /PreserveCopyPage true /PreserveEPSInfo true /PreserveHalftoneInfo false /PreserveOPIComments false /PreserveOverprintSettings true /StartPage 1 /SubsetFonts true /TransferFunctionInfo /Apply /UCRandBGInfo /Preserve /UsePrologue false /ColorSettingsFile () /AlwaysEmbed [ true ] /NeverEmbed [ true ] /AntiAliasColorImages false /DownsampleColorImages true /ColorImageDownsampleType /Bicubic /ColorImageResolution 300 /ColorImageDepth -1 /ColorImageDownsampleThreshold 1.50000 /EncodeColorImages true /ColorImageFilter /DCTEncode /AutoFilterColorImages true /ColorImageAutoFilterStrategy /JPEG /ColorACSImageDict << /QFactor 0.15 /HSamples [1 1 1 1] /VSamples [1 1 1 1] >> /ColorImageDict << /QFactor 0.15 /HSamples [1 1 1 1] /VSamples [1 1 1 1] >> /JPEG2000ColorACSImageDict << /TileWidth 256 /TileHeight 256 /Quality 30 >> /JPEG2000ColorImageDict << /TileWidth 256 /TileHeight 256 /Quality 30 >> /AntiAliasGrayImages false /DownsampleGrayImages true /GrayImageDownsampleType /Bicubic /GrayImageResolution 300 /GrayImageDepth -1 /GrayImageDownsampleThreshold 1.50000 /EncodeGrayImages true /GrayImageFilter /DCTEncode /AutoFilterGrayImages true /GrayImageAutoFilterStrategy /JPEG /GrayACSImageDict << /QFactor 0.15 /HSamples [1 1 1 1] /VSamples [1 1 1 1] >> /GrayImageDict << /QFactor 0.15 /HSamples [1 1 1 1] /VSamples [1 1 1 1] >> /JPEG2000GrayACSImageDict << /TileWidth 256 /TileHeight 256 /Quality 30 >> /JPEG2000GrayImageDict << /TileWidth 256 /TileHeight 256 /Quality 30 >> /AntiAliasMonoImages false /DownsampleMonoImages true /MonoImageDownsampleType /Bicubic /MonoImageResolution 1200 /MonoImageDepth -1 /MonoImageDownsampleThreshold 1.50000 /EncodeMonoImages true /MonoImageFilter /CCITTFaxEncode /MonoImageDict << /K -1 >> /AllowPSXObjects false /PDFX1aCheck false /PDFX3Check false /PDFXCompliantPDFOnly false /PDFXNoTrimBoxError true /PDFXTrimBoxToMediaBoxOffset [ 0.00000 0.00000 0.00000 0.00000 ] /PDFXSetBleedBoxToMediaBox true /PDFXBleedBoxToTrimBoxOffset [ 0.00000 0.00000 0.00000 0.00000 ] /PDFXOutputIntentProfile () /PDFXOutputCondition () /PDFXRegistryName (http://www.color.org) /PDFXTrapped /Unknown /Description << /ENU (Use these settings to create PDF documents with higher image resolution for high quality pre-press printing. The PDF documents can be opened with Acrobat and Reader 5.0 and later. These settings require font embedding.) /JPN <FEFF3053306e8a2d5b9a306f30019ad889e350cf5ea6753b50cf3092542b308030d730ea30d730ec30b9537052377528306e00200050004400460020658766f830924f5c62103059308b3068304d306b4f7f75283057307e305930023053306e8a2d5b9a30674f5c62103057305f00200050004400460020658766f8306f0020004100630072006f0062006100740020304a30883073002000520065006100640065007200200035002e003000204ee5964d30678868793a3067304d307e305930023053306e8a2d5b9a306b306f30d530a930f330c8306e57cb30818fbc307f304c5fc59808306730593002> /FRA <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> /DEU <FEFF00560065007200770065006e00640065006e0020005300690065002000640069006500730065002000450069006e007300740065006c006c0075006e00670065006e0020007a0075006d002000450072007300740065006c006c0065006e00200076006f006e0020005000440046002d0044006f006b0075006d0065006e00740065006e0020006d00690074002000650069006e006500720020006800f60068006500720065006e002000420069006c0064006100750066006c00f600730075006e0067002c00200075006d002000650069006e00650020007100750061006c00690074006100740069007600200068006f006300680077006500720074006900670065002000410075007300670061006200650020006600fc0072002000640069006500200044007200750063006b0076006f0072007300740075006600650020007a0075002000650072007a00690065006c0065006e002e00200044006900650020005000440046002d0044006f006b0075006d0065006e007400650020006b00f6006e006e0065006e0020006d006900740020004100630072006f0062006100740020006f0064006500720020006d00690074002000640065006d002000520065006100640065007200200035002e003000200075006e00640020006800f600680065007200200067006500f600660066006e00650074002000770065007200640065006e002e00200042006500690020006400690065007300650072002000450069006e007300740065006c006c0075006e00670020006900730074002000650069006e00650020005300630068007200690066007400650069006e00620065007400740075006e00670020006500720066006f0072006400650072006c006900630068002e> /PTB <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> /DAN <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> /NLD <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> /ESP <FEFF0055007300650020006500730074006100730020006f007000630069006f006e006500730020007000610072006100200063007200650061007200200064006f00630075006d0065006e0074006f0073002000500044004600200063006f006e0020006d00610079006f00720020007200650073006f006c00750063006900f3006e00200064006500200069006d006100670065006e00200071007500650020007000650072006d006900740061006e0020006f006200740065006e0065007200200063006f007000690061007300200064006500200070007200650069006d0070007200650073006900f3006e0020006400650020006d00610079006f0072002000630061006c0069006400610064002e0020004c006f007300200064006f00630075006d0065006e0074006f00730020005000440046002000730065002000700075006500640065006e00200061006200720069007200200063006f006e0020004100630072006f00620061007400200079002000520065006100640065007200200035002e003000200079002000760065007200730069006f006e0065007300200070006f00730074006500720069006f007200650073002e0020004500730074006100200063006f006e0066006900670075007200610063006900f3006e0020007200650071007500690065007200650020006c006100200069006e0063007200750073007400610063006900f3006e0020006400650020006600750065006e007400650073002e> /SUO <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> /ITA <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> /NOR <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> /SVE <FEFF0041006e007600e4006e00640020006400650020006800e4007200200069006e0073007400e4006c006c006e0069006e006700610072006e00610020006e00e40072002000640075002000760069006c006c00200073006b0061007000610020005000440046002d0064006f006b0075006d0065006e00740020006d006500640020006800f6006700720065002000620069006c0064007500700070006c00f60073006e0069006e00670020006600f60072002000700072006500700072006500730073007500740073006b0072006900660074006500720020006100760020006800f600670020006b00760061006c0069007400650074002e0020005000440046002d0064006f006b0075006d0065006e00740065006e0020006b0061006e002000f600700070006e006100730020006d006500640020004100630072006f0062006100740020006f00630068002000520065006100640065007200200035002e003000200065006c006c00650072002000730065006e006100720065002e00200044006500730073006100200069006e0073007400e4006c006c006e0069006e0067006100720020006b007200e400760065007200200069006e006b006c00750064006500720069006e00670020006100760020007400650063006b0065006e0073006e006900740074002e> >> >> setdistillerparams << /HWResolution [2400 2400] /PageSize [612.000 792.000] >> setpagedevice