FUNDAMENTALS OF PLC

PROGRAMMING

CPM1A
 Course Outline
i – Overview of PLC
ii – Basic Command
a. LD/LD not
b. And/And not
c. Or/Or not
d. And Load
e. Or Load
f. Timer/Counter
 WHAT A PROGRAMMABLE
CONTROLLER CAN DO ?

Sequence a. Conventional Relay Logic Replacer

Control
b. Timers / Counters

c. PCB Card Controller Replacer

d. Auto/ Semi-auto/Manual control

of machine and processes
 WHAT A PROGRAMMABLE
CONTROLLER CAN DO ?

Sophisticated a. Arithmetic Operation

Control b. Information Handling
c. Analog Control
d. PID
e. Servo motor control
f. Stepper motor control
 WHAT A PROGRAMMABLE
CONTROLLER CAN DO ?

Supervisory a. Process Monitoring and Alarm

Control b. Fault Diagnostic and monitoring
c. Interfacing w/ Computer
d. Printer / ASCII Interfacing
e. Factory Automation Networking
f. Local Area Network
g. Wide area Network, etc.
 ADVANTAGES OF USING P L C
IN AUTOMATION

Shorter project implementation time

Shortest training required

Easy modification of program

Easy maintenance

Higher reliability
 PROGRAMMABLE LOGIC
CONTROLLER

is an electronic devices with a programmable

memory used for logic, sequencing, timing
counting and arithmetic to control machine
and its processes.
 PROGRAMMABLE LOGIC
CONTROLLER

Power Supply

Signal Unit (CPU) Signal to

From Input Output Solenoid,
Switches, Motors,
Sensors Interface Interface Etc.
Etc. Memory

Block Diagram of PLC

Central Processing Unit

is a microprocessor that coordinates the

activities of the PLC system. It executes
the program, processes I/O signals &
communicates with external devices.
Central Processing Unit

CPM2A-_ _ CDR

CPM1A-20EDR
Inputs

Limit Switch Timer Photoelectric

Switch

Rotary Encoder Proximity Switch

Outputs
 Memory

It is the area that hold the operating

system and user memory
 Memory

The operating system is actually a

system software that coordinates the
PLC.
 Memory

Ladder program, timer and counter are

stored in the user memory.
 Types of Memory

1. ROM
2. RAM
3. EPROM
4. EEPROM
Read Only Memory (ROM)

is a non-volatile memory that

can be program only once
 Random Access Memory (RAM)

volatile RAM would be normally lost if

the power source is removed, but it is
solved by backing up the RAM with a
battery.
 Electrically Erasable Programmable
Read Only Memory (EEPROM)

Its content can be erased and reprogram

electrically, however to a limited number
of times.
Omron PLC Software
 Types of Software

1. SSS – Sysmac Support Software

2. Syswin
3. CX-Programmer
4. CX-One
 SSS – Sysmac Support Software

Processor 80386, 80486,Pentium

Main Memory 535kbytes minimum
Hard Disk 9Mbytes min. disk space
Expansion Memory 1.2 Mbytes
Keyboard Home,ESC,Control,Pg up
Pg down,Backspace,End,
F1-F10,Insert, Delete, Tab
Syswin

 50 Mhz
 OS : Windows 3.1 or higher
 Resolution : SVGA X 600 or larger
 RAM : 8 Mbytes or more
 Hard Disk : 40 MB or more
CX-Programmer

 32 Bit application
 OS : Windows 95, NT3.51, NT 4.0
 Resolution : SVGA X 600 or larger
 RAM : 16 Mbytes or more
 Hard Disk : 40 MB or more
PC TYPES SELECTING POINTS
 CPM2A

Max. number of I/O  120 I/O

Program Capacity  4,096 words

TERMINOLOGY

1 Channel = 16 Bits
1 Word = 16 Bits
Internal Relay (IR)

Do not have any specific function, they

Can be freely used within the program

Except those assigned to input, output,

And special I/O cards.
Temporary Relay (TR)

These bits are used to temporary

Store ON and OFF status.
Holding Relay (HR)

These bits retain their ON and OFF

Status during power interruption.
Data Memory (DM)

Can be read in as WORD, retain status

During power interruption
Special Relay (SR)

These bits serve specific function

Such as flag and control bits.
Common Special Relay (SR)

253.13 Always ON flag

253.15 First cycle flag
255.00 0.1 sec clock pulse
255.01 0.2 sec clock pulse
255.02 1 sec clock pulse
Programming Console Operation
Function Key Mode Operation
Run Monitor Program

Input the CLR MONTR CLR

Password

Clear the CLR SET NOT RESET

Memory MONTR CLR
 Inserting instruction

Instruction INS
 Deleting Instruction

Instruction Currently
Display DEL
Overview of Instruction
Load / Load Not (LD/LD NOT)
Electrical Control Circuit Diagram

L1 Sw 1 L2
Lamp 1

Sw 2 Lamp 2
 Load / Load Not (LD/LD NOT)
Control Ladder Diagram

Address Command Data Enter

L1 L2
000.01
10.01
00000 LD 1 write
00001 OUT 1001 write
000.02 10.05 00002 LD NOT 2 write
00003 OUT 1005 write
00004 FUN 01 write
End
And / And Not
Electrical Control Circuit Diagram

Sw 1 Sw 2 Lamp 2

Sw 3 Sw 4 Lamp 4
 And / And Not
Control Ladder Diagram

Address Command Data Enter

000.01 000.02 10.02 00000 LD 1 write
00001 AND 2 write
00002 OUT 1002 write
00003 LD 3 write
00004 AND NOT 4 write
00005 OUT 1004 write
000.03 000.04 10.04 00006 FUN 01 write

End
 OR / OR NOT
Electrical Control Circuit Diagram

Sw 1 Lamp 3

Sw 2
Lamp 5
Sw 3
Sw 4
 OR / OR NOT
Control Ladder Diagram

Address Command Data Enter

00000 LD 1 write
000.01 10.03 00001 OR 2 write
00002 OUT 1003 write
00003 LD 3 write
000.02 00004 OR NOT 4 write
00005 OUT 1005 write
000.03 10.05 00006 FUN 01 write

000.04

End
 AND LD
Control Ladder Diagram

000.03 000.05 000.07

10.06
000.02 000.04

End
 AND LD
Control Ladder Diagram

000.03 000.05 000.07 Address Command Data Enter

00000 LD 3 write
10.06 00001 OR 2 write
000.02 000.04
00002 LD 5 write
00003 OR 4 write
00004 AND LD write
End 00005 AND 7 write
00006 OUT 1006 write
00007 FUN 01 write
 OR LD
Control Ladder Diagram

000.02 000.03 000.11

10.05
000.04 000.05

End
 OR LD
Control Ladder Diagram

000.02 000.03 000.11 Address Command Data Enter

00000 LD 2 write
10.05 00001 AND 3 write
000.04 000.05
00002 LD 4 write
00003 AND NOT 5 write
00004 OR LD write
End 00005 AND NOT 11 write
00006 OUT 1005 write
00007 FUN 01 write
 Practice 1
Convert the ladder diagram below
to the equivalent mnemonic code:
01 02
10.07
03 04

05 06

07 08

End
 Practice 1
Convert the ladder diagram below
to the equivalent mnemonic code:
01 02
10.07
03 04

05 06

07 08

End
 Practice 2
Convert the ladder diagram below
to the equivalent mnemonic code:
TR 0 TR 1
03 04 05
10.00

06
10.02

07 08
10.04

End
 Workbits / Internal Relay

A certain bits to trigger other instruction

Indirectly to manipulate the program.

Often used with OUTPUT, OUTPUT NOT,

DIFFERENTIAL UP (DIFU), DIFFERENTIAL
DOWN (DIFD), and KEEP instruction.
 Work bits / Internal Relay

A relay for the used of the program only,

it is used when you don’t have to turn ON,
or turn OFF external I/O devices.

The relays of CH to which units are not

mounted are also available for work bits.
 Work bits / Internal Relay

The work bits is useful, example, when the

same combination of I/O signal is repeatedly
in the ladder diagram.
 Work bits / Internal Relay
The ff. diagram gives an illustration in which a work bit
Can be used to simplify the program:

01 03 04 01 03
10.00 200.00
02 02

01 03 05 200.00 04
10.01 10.00
02 200.00 05
10.01
01 03 06
200.00 06
10.02
10.02
02
Differential UP – DIFU (13)

Turns an output ON for one scan only

Turns an output ON when it detects an

OFF to ON transition in its input signal.
Differential UP – DIFU (13)

input
DIFU(13)
_____ Bits of
IR, SR, AR, HR,LR
 Differential UP – DIFU (13)
Self Holding Circuit

Address Command Data Enter

01
DIFU(13)
200.00 00000 LD 1 write
00001 FUN 13
200.00 200.01 DIFU 20000 write
00002 LD 20000 write
00003 OR 1003 write
10.03 10.03 00004 AND NOT 200.01 write
00005 OUT 1003 write
00006 LD 2 write
02
DIFU(13) 00007 FUN 13
200.01 DIFU 200.01 write
00008 FUN 01 write
End
 Differential Down – DIFD (14)

input
DIFD(14)
_____ Bits of
IR, SR, AR, HR,LR
 Differential down – DIFD (14)
KEEP (11) Latching relay

Address Command Data Enter

02
DIFD(14)
200.01 00000 LD 2 write
00001 FUN 14
200.01 DIFD 20001 write
set 00002 LD 20001 write
KEEP(11) 00003 LD 04 write
04
reset 10.04 00004 FUN 11
KEEP 1004 write
00005 FUN 01 write
End
 TIMER

Address :

Input TIM 000

TIM _ _ _ TIM 001
#_ _ _ _

TIM 127

Max of 999.9 sec.

 TIMER
Address Command Data Enter
000.01 00000 LD 1 write
TIM 000 00001 TIM 0 write
#0050
#0050 write
TIM 000 Tim 001 00002 LD TIM 0 write
00003 OR 1000 write
010.00 write
010.00 00004 AND NOT TIM 1
00005 OUT 1000 write
010.00
00006 LD 1000 write
TIM 001 00007 TIM 1 write
#0050
#0050 write
End
00008 write
FUN 01
 COUNTER

Address :

Set CNT 000

CNT _ _ _ CNT 001
Reset
#_ _ _ _

CNT 127

Max of 9999 counts

COUNTER
Address Command Data Enter

000.01 S
00000 LD 1 write
00001 LD 2 write
CNT 127
000.02 R # 0005 00002 CNT 127 write
#0005 write
CNT 127 00003 LD CNT 127 write
00004 OUT 1006 write
00005 OUT 1007 write
010.06
00006 FUN 01 write

End 010.07
 EXERCISE

1. After 1 sec. a push button(000.01) is pushed,

let CH 10 bits 00, 01, and 02 lit consecutively
with one second interval.
2. Then, will turn OFF all output 1 second after
the last LED is ON
3. The sequence will repeat only for 10 times
then, the circuit will be totally OFF after the
last LED is ON.
4.The circuit will start again when PB1 is press.
 INTERLOCK (02) /
INTERLOCK CLEAR (03)

IL and ILC instruction unify the several contact

points and enable the program to be simple.
IL is always used in conjunction with ILC to
create interlocks.
INTERLOCK (02) /
INTERLOCK CLEAR (03)

10.00 01
01 02 IL (02)
02 10.00
01 03 10.01

03 10.01
10.02
01 04
10.02
04
End

ILC (03)
End
APPLICATION OF BASIC COMMAND
When a start button is pushed, the motor (M) will move from
Left to right. When LS2 is ON, the motor stops, delay for 5 s
And then moves back to home. When LS1 is ON, the motor
Cuts off signifying the sequence is completed.

LS1 LS2
Start

HOME
PRACTICE – ESCALATOR CONTROL
This escalator is s stationary until someone approaches.
when someone passes by the sensor, the motor starts to
operate, and stop one minute after the last person passed by.