Engg3490-Plc L4 L4: Plcs Ref. (3) Programming Timers P I C T Programming Counters

ENGG3490-PLC L4
PLCs Ref. [3]; 1. Programming Timers 2. P Programming C i Counters t
ENGG3490: Mechatronics W07. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill
Timers
There are very few industrial control systems that do not need at least one or two timed functions. They are used to activate or de-activate a device after a preset interval of time. time
Time delay relays and solid-state timers are used to provide a time delay. They may have displays, pots or other means of operator interface for time settings and electromechanical or solid state outputs.
Time Delay Relay
Solid State Solid-State Timer
On-Delay Timing Relay

Operating coil NO Instantaneous contacts NC Nontimed contacts are controlled directly by the timer coil, as in a th ti il i general-purpose control relay.
ENGG3490: Mechatronics W07.
When the coil is energized, the timed contacts are prevented from opening or closing NO until the time delay period has elapsed. Time control However, when the coil is contacts de-energized, the timed NC contacts return Time adjustment instantaneously to their Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 3 normal state.
Timed Contact Symbols

On-Delay Symbols
Normally open, timed closed contact (NOTC) Contact is open when relay coil is de-energized
Normally closed, timed open contact (NCTO) Contact is closed when relay coil is de-energized
When relay is energized, When relay is energized, there is a time delay in there is a time delay in closing Mechatronics W07. Adapted From Programmable Logic Controllers ByopeningMcGraw-Hill ENGG3490: F. D. Petruzella, 4
Timed Contact Symbols

Off Delay Symbols
Normally open, timed open contacts (NOTO). Contact is normally open when relay coil is de-energized. No Normally closed, timed y c osed, ed closed contacts (NCTC). Contact is normally closed when relay coil is de-energized.
When relay coil is When relay coil is energized, contact closes i d t t l energized, contact opens i d t t instantly. instantly. When relay coil is deWhen relay coil is deenergized, there is a time energized, there is a time delay before the contact delay before the contact ENGG3490: Mechatronics W07. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 5 opens. closes.
On-Delay Relay Timer Circuit (NOTC Contact)

L1 S1 L2
Sequence of operation S1 open, TD de-energized, TD1 open L1 is off open, off.
L1
10 s 10 s
S1 closes, TD energizes, timing period starts, TD1 still open, L1 is still off. After 10 s, TD1 closes, L1 is switched on.
ON
Input OFF
S1 is opened, TD deenergizes, TD1 opens Output instantly, L1 is switched off.6 Timing Diagram ENGG3490: Mechatronics W07. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill
On-Delay Relay Timer Circuit (NCTO Contact)

L1 S1 L2
Sequence of operation S1 open, TD de-energized, TD1 closed, L1 is on. closed on S1 closes, TD energizes, timing period starts, TD1 is still closed, L1 is still on. After 10 s, TD1 opens, L1 is switched off.
L1 10 s
10 s Input Output
S1 is opened, TD de-energizes, TD1 closes instantly, L1 is switched on. Timing Diagram Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill ENGG3490: Mechatronics W07. 7
Off
On
Off-Delay Relay Timer Circuit (NOTO Contact)

L1 S1 L2
Sequence of operation S1 open, TD de-energized, TD1 open L1 is off open, off.
L1
10 s 10 s Input On Output Off Timing Diagram
S1 closes, TD energizes, TD1 closes instantly, L1 is switched on. S1 is opened, TD de-energizes, timing period starts TD1 is starts, still closed, L1 is still on. After 10 s, TD1 opens, L1 is switched off.
8
Off-Delay Relay Timer Circuit (NCTC Contact)

L1 S1 L2
Sequence of operation S1 open, TD de-energized, TD1 closed, L1 is on. closed on

L1
10 s 10 s
S1 closes, TD energizes, TD1 opens instantly, L1 is switched off. S1 is opened, TD de energizes, timing de-energizes, period starts, TD1 is still open, L1 is still off. After 10 s, TD1 closes, L1 is switched on.
9
Input Output On Off Timing Diagram
Programmed Timer Instructions

PLC timers are output instructions that provide the same functions as timing relays and solid state timers.
Some advantages of PLC timers: their settings can be altered easily the number of PLC timers used can be increased or decreased by programming changes without wiring changes timer accuracy and repeatability are extremely high
ENGG3490: Mechatronics W07. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 10
RSLogic Timer Commands

TON
Timer/Counter
Command
Name Timer On-Delay
Description Counts time base intervals when the instruction is true
TON
11

TOF
Timer/Counter
Command
Name Timer Off-Delay
Description Counts time base intervals when the instruction is false
TOF
12

RTO RES
Timer/Counter
Command
Name Retentive Timer ON
Description
Counts time base intervals when the instruction is true and retains the accumulated value when the l h th instruction goes "false" or when power cycle occurs
RTO
RES
When this instruction is "true" it resets the count Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 13 of the RTO counter
Reset
Quantities Associated with the Timer Instruction

Preset Time Represents the time duration of the timing circuit. For example, if a time delay of 10 s is required, the timer will have a preset of 10 s. Accumulated Time Represents the amount of time that has elapsed from the moment the timing coil became energized. Time Base Timers can typically be programmed with several different time bases: 1 s, 0.1 s, and 0.01 s are typical time bases. For example, if you enter 0.1 for the time base and 50 for the preset time the timer would have a 5 s delay (50 x 0.1 s = 5 s).
Coil-Formatted Timer Instruction

Contact determines rung continuity The timer assigned an address The type of timer XXX is specified
TON
Preset value PR:YYY Time base 0.1 s Accumulated value AC:000 When th ti Wh the timer rung h l i continuity, the timer's has logic ti it th ti ' accumulated value increases. When accumulated value equals the preset value, the output is energized and and the timed output contact associated with the output is closed. The timed contact can be used as many times as you wish throughout the ENGG3490: Mechatronics W07. Adapted From Programmable Logic 15 program as a NO or NC contact. Controllers By F. D. Petruzella, McGraw-Hill
Generic Block-Formatted Timer Instruction

Timers are most often represented by boxes in a ladder logic.
Control line controls the actual timing operation of the timer. Whenever this line is true the timer will time. Wh hi li i h i ill i Retentive timer block
Preset time Time base Accumulated time
Reset line resets the the timer's accumulated value to zero.

Generic Block-Formatted Timer Instruction

Timers are most often represented by boxes in a ladder logic.
Retentive timer block

Preset time Time base Accumulated time
Output line
The timer continuously compares its accumulated time with its preset time. Its output is logic 0 as long as the accumulated time is less than the preset time. When the two become equal the output ENGG3490: Mechatronics W07. 17 changes to logic 1. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill
On-Delay Timer Instruction

The on-delay timer operates so that, when the rung containing the timer is true, the timer time-out period commences.
Timer Sequence Rung condition Timed period False True The timed output becomes true sometimes after the timer rung becomes true; hence the timer is said to have an on delay.
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Input
Timer
On delay time duration True False
Timed output bit
ON OFF Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill ENGG3490: Mechatronics W07.
Allen-Bradley On-Delay Timer Instruction

Allen-Bradley PLC-5 and SLC-500 controller timer elements each take three data table words: the control word, preset word, and accumulated word. ,p , The control word uses three control bits: Enable (EN) bit, Timer-Timing (TT) bit, and Done-Bit (DN). TIMER TABLE /EN T4:0 0 /TT 0 /DN 0
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The Enable (EN) bit is true (has a status of 1) whenever the timer instruction is true. When the timer instruction is false, the enable bit is false (has a status of 0)
Enable bit false
TON TIMER ON DELAY Timer T4:0
EN
T4:0 EN
Enable bit true

20
10

The Timer-Timing (TT) bit is true whenever the accumulated value of the timer is changing, which means the timer is timing.
TON TIMER ON DELAY Timer T4:0 Preset 50 Accumulated 10 T4:0 TT
EN
Timer-Timing bit true
21

The Done-Bit (DN) changes state whenever the accumulated value reaches the preset value. Its state depends on the type of timer being used.
TON TIMER ON DELAY Timer T4:0 Preset 50 Accumulated 10 50 T4:0 DN
EN DN
Done-bit changes state
22
11

The preset value (PRE) word is the set point of the timer, that is, the value up to which the timer will time. The accumulated value (ACC) word is the value that increments as the timer is timing. The accumulated value will stop incrementing when its value reaches the preset value. TIMER TABLE /EN T4:0 0 /TT 0 /DN 0 .PRE 0 .ACC 0
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The information to be entered includes:
TON TIMER ON DELAY Timer Time base Preset Accumulated
T4:0 1.0 15 0
EN DN
Timer number which must come from the timer file. Time base which is expressed in seconds. Preset value which is the length of the time delay. Accumulated value which is normally entered as 0.
12
On-Delay Timer Program

Ladder Logic Program L1
Input A Input A TON TIMER ON DELAY Timer Time base Preset Accumulated Output B G
L2
T4:0 1.0 10 0 10
EN DN
Output C
T4:0 EN T4:0 TT T4:0 DN
Output B Output D Y
Output C
Output D
25

Timing Diagram On Input condition A Timer-enable bit Timer-timing bit Off On O Off On Off On Timer-done bit Off 4s 10 s
Timer accumulated 0 value

13

Timers are 3-word elements
Word EN TT DN Internal use Preset value PRE Accumulated value ACC Word 0 is the control word Word 1 stores the preset value Word 2 stores the accumulated value
0 1 2
On-Delay Timer With Instantaneous Output

Relay Ladder Schematic Diagram
L1 Stop Start 1TD L2
1TD-1 (instantaneous contact)
M 1TD-2 (5 s) (timed contact)
28
14
On-Delay Timer With Instantaneous Output

Programmed Circuit
Ladder logic program Inputs L1 Stop Motor Start Internal relay Timer PR: 5 TB: 1 s Motor M M Stop Start Internal relay Output L2
Output line
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Start-Up Warning Signal Circuit

L1 Start-up PB1 Reset PB2 CR1 L2
CR1-1 1TD CR1-2 Horn CR1-3 1TD-1 (10 Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill ENGG3490: Mechatronics W07.s)
30
15
Start-Up Warning Signal Circuit

Programmed Circuit
Inputs p Ladder logic program Output PB1 PB2 TON TIMER ON DELAY Timer T4:0 Time base 1.0 Preset 10 Accumulated 0 10 Horn
Start-up
PB1
EN DN Horn
Reset
PB2
T4:0 EN T4:0 T4 0 DN T4:0 T4 0
EN
31
Timed Closed Solenoid Valve Program

Input L1 Switch S itch SW_1 SW_1 SW 1 TON Timer On Delay Timer timer_1 Preset 12000 Accumulated 12000 0 EN DN Ladder logic program Output L2
Valve
timer_1.dn
Valve
32
16
Automatic Sequential Control System

L1
Stop PB1
Start PB2
L2 Lube oil pump motor M1 OL
M1-1 PS1
Main drive motor M2
OL
(lube oil pressure switch)
1TD OL M3
1TD-1 (15 s)
Feed motor
33
Automatic Sequential Control System

Programmed Circuit
Ladder logic program Inputs PB1 M1 PB2 PS1 PS1 M2 M2 OL M3 TON TIMER ON DELAY Timer T4:0 Time base 1.0 Preset 15 15 Accumulated 0 T4:0 DN M3 PB1 PB2 M1 Outputs OL M1 OL
EN DN
34
17
Off-Delay Programmed Timer

The off-delay timer (TOF) operation will keep the output energized for a period after the rung containing the timer has gone false.
Input L1 S1 I:1.0/0 TIMER Time base Preset Accumulated T4:3/DN T4:3 1.0 15 0 15 I:1.0/0 TOF TIMER OFF DELAY EN DN O:2.0/1 PL Ladder logic program Output L2
O:2.0/1
35
Off-Delay Programmed Timer

Timing Diagram
True Input condition S1 False
Timed period Off delay timed duration
True (logic 1) Timed output O:2.0/1 Preset value = accumulated value

36
False (logic 0)
18
Off-Delay Timer Used To Switch Motors Off

Input L1 Ladder logic program Output L2
5000
10000
15000
37
Pneumatic Off-Delay Timer

L1 L2
38
19
Programmed Pneumatic Off-Delay Timer

Equivalent Programmed Circuit
Input L1 Ladder logic program Outputs L2
39
Fluid Pumping Process
Operation Before starting, PS1 must be closed. When the pump start button is pressed, the pump starts. The button can then be released and the pump continues to operate. When the stop button is pushed, the pump stops. PS2 and PS3 must be closed for 5 s after the pump starts. If either PS2 or PS3 opens, the pump will shut off and will not not be able toMechatronics W07. Adaptedfor Programmable Logic14 s. By F. D. Petruzella, McGraw-Hill start again From another Controllers ENGG3490: 40
20
Fluid Pumping Process Program

Ladder logic program
Inputs L1
Output L2
5 0
41
Retentive Timer
A retentive timer accumulates time whenever the device receives power, and maintains the current time should power be removed from the device. Once the device accumulates time equal to its preset value, the contacts of value the device change state. The retentive timer must be intentionally reset with a separate signal for the accumulated time to be reset.
Electromechnical Retentive Timer
Once power is applied, the motor starts turning the cam. The positioning of the lobes determines Cam operated contact the time it takes to activate the contacts. If power is removed from the motor, the shaft stops but does Motor-driven Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 42 cam not reset.
21
Retentive On-Delay Timer Program

The PLC-programmed RETENTIVE ON-DELAY timer (RTO) operates in the same way as the nonretentive ondelay timer (TON), with one major exception. There is a retentive timer reset (RTR) instruction. instruction
Unlike the TON, the RTO will hold its accumulated value when the timer rung goes false and will continue timing where it left off when the timer rung goes true again. This timer must be accompanied by a timer reset Same address (RES) instruction to reset the accumulated value of the Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 43 timer to zero.
Retentive On-Delay Timer Program
0 9 3
44
22
Retentive On-Delay Timing Chart

Enable bit is reset when input pushbutton PB1 is opened
Accum value retained when rung goes false
Accum = Preset
When reset PB2 is closed, the T4:2/DN bit is reset to 0. Accumulated value is reset and held at zero until the reset pushbutton is Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 45 opened.
Retentive On-delay Alarm Program

Ladder logic program L1 L2
60000 0
The purpose of the RTO timer is to detect whenever a piping system has sustained a cumulative overpressure condition of 60 s. At that point, a horn is sounded automatically. You can silence the alarm by switching the key switch to the By F. D. Petruzella, McGraw-Hill ENGG3490: Mechatronics W07. Adapted From Programmable Logic Controllers rest position. 46
23
Bearing Lubrication Program

Sequence Of Operation
To start the machine, the operator turns SW on.
Before the motor shaft starts to turn, the bearings are supplied with oil by the pump for 10 s. The bearings also receive oil when the machine is running. When the operator turns SW off to stop the machine, the oil pump continues to supply oil for 15 s. A retentive timer is used to track the total running time of the i i i d k h l i i f h pump. When the total running time is 3 h, the motor is shut down and a pilot light is turned on to indicate that the filter and oil need to be changed. A reset button is provided to reset the process after the filter and ENGG3490: Mechatronics W07. Adapted From 47 oil have been changed. Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill
Bearing Lubrication Program
10 0
15
10800
24
Cascading Timers
The programming of two or more timers together is called cascading. Timers may be interconnected, or cascaded to satisfy any required control logic.
Relay Schematic Diagram Three motors started automatically in sequence with a 20-s time delay between each motor startup.
Equivalent Time-Delayed Motor-Starting Program
20000
20000
50
25
Annunciator Flasher Circuit

Two timers can be interconnected to form an oscillator circuit. The oscillator logic is basically a timing circuit programmed to generate periodic output pulses of any duration. They can be used as part of an annunciator system to indicate an alarm condition.
The oscillator circuit output is programmed in series with the alarm condition. If the alarm condition is true, the appropriate output indicating light will flash.
Annunciator Flasher Circuit
52
26
Cascading of Timers for Longer Time Delays
30000
12000
53
Control of Traffic Lights in One Direction

A typical application for PLC timers is the control of traffic lights.
Control of Traffic in One Direction Sequence of Operation
Red 30 s
Green 25 s
Amber 5s
54
27
Control of Traffic Lights in One Direction
30
25
55
ENGG3490-WEEK9-11 L4
PLCs Ref. [3]; 1. Programming Timers 2. P Programming C i Counters t
56
28
Counters
Common applications of counters include keeping track of the number of items moving past a given point, and determining the number of times a given action occurs. g g
A preset counter can control an external circuit when its counted t t l matches th t d total t h the user-entered preset limits.
57
Mechanical Counters
Programmed counters can serve the same functions as mechanical counters.
Every time the actuating lever is moved over the counter adds one number, number while the actuating lever returns automatically to its original position. Resetting to zero is done with a pushbutton located on the side of the unit. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 58
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Electronic Counters
Electronic counters can count up, count down, or be combined to count up and down. They are dependent on external sources, such as parts traveling past a sensor or actuating a limit switch for counting.
Counter Applications
59
Coil-Formatted Counter Instruction

The coil is assigned an address as well as being identified as a counter
Increments counter by 1 for every false-to-true transition
Like the timer, preset and accumulated values are included
When the accumulated count equals the preset count, the output is energized and the counter output is closed. The counter contact can be used as many times as you wish throughout the program as an NO or By F. D. Petruzella, McGraw-Hill NC contact. ENGG3490: Mechatronics W07. Adapted From Programmable Logic Controllers
60
30
Coil-Formatted Counter And Reset Instruction
Same address
Resets counter when true
61
Block-Formatted Counter Instruction

Count line Type of counter Preset value Reset line Accumulated value Output line
PLC counters operate or count on the leading edge of the input signal. The counter will either increment or decrement whenever the count input transfers from an "off" state to an "on" state. The counter will not operate on the trailing edge, or on-to-off transition of the input condition.
31
Counter Counting Sequence

PLC counters are normally retentive. Whatever count was contained in the counter at the time of a processor shutdown will be restored to the counter on power-up. The counter may be reset, however, if the reset condition is activated at the time of power restoration.
PLC counters can be designed to count up to a preset value or to count down to a preset value.

The up-counter is incremented by 1 each time the rung containing the counter is energized.
The counter will increment until the accumulated value is equal to or greater than the preset value, at which time an output will be produced.
64
32

The down-counter decrements by 1 each time the rung containing the counter is energized.
A counter reset is always provided to cause the counter accumulated value to be reset to a predetermined value.
Simple Up-counter Program
66
33
Up-counter Program Timing Diagram
67
C5 Counter Data File

Each counter address is made of a 3-word element
Bit 0-9: Internal Use Bit 10: UA - Update accumulation value. value Bit 11: UN - Underflow bit. Bit 12: OV - Overflow bit. Bit 13: DN - Done Bit 14: CD - Count down is enabled. Bit 15: CU - Count up is enabled.
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Specifies the l S ifi th value, which th counter must reach b f hi h the t t h before th controller the t ll sets the done bit. When the accumulated value becomes equal to or greater than the preset value, the done status bit is set. You can use this bit to control an output device.
69

This is the number of times of false to true transitions that have occurred since the counter was last reset.
70
35
PLC-5 And SLC 500 Count-Up Counter Instruction
71
ControlLogix Count-Up Counter Instruction
The counter address in the PLC-5 and SLC 500 is a data table address, whereas in the ControlLogix it is a predefined structure of the data type. In the PLC-5 and SLC 500, the max value for the preset and accumulated values is 32,767 and the min value is 32,768; for the ControlLogix controller the max value is 2,147,438,647 and the min value is 2,147,438,648.
36
RSLogic Counter Commands
Command
Name
Description Increments the accumulated value at each false-to-true transition and retains the accumulated value when power cycle occurs
73
CTU
Count-Up
RSLogic Counter Commands
Command
Name
Description
CTD
Decrements the accumulated Count-Down value at each false-to-true transition and retains the accumulated value when power cycle occurs
74
37
Parts Counting Program

Counter C5:2 counts the total number of parts coming off an assembly line for final packaging
Each package must contain 10 parts When 10 parts are detected, counter C5:1 sets bit B3/1 to initiate the box closing sequence Counter C5:3 counts the total number of packages filled per day A pushbutton is used to restart the total part and package count from zero daily
Parts Counting Program
10 09
9 10
76
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One-Shot, Or Transitional, Contact Program

The transitional or one shot contact program can be used to automatically clear or reset a counter. The program is designed to generate an output pulse that, when triggered, goes on for the duration of one program scan and then g p g goes off.
77
One-Shot, Or Transitional, Contact Program

The transitional or one shot contact program can be used to automatically clear or reset a counter. The program is designed to generate an output pulse that, when triggered, goes on for p g goes off. the duration of one program scan and then g
The one-shot can be triggered from a momentary signal, or one that comes on and stays on for some time. From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill ENGG3490: Mechatronics W07. Adapted
78
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Types Of Transitional Contacts

Off-To-On Transitional Contact
On Off
Symbol
Off
On One scan
Is programmed to provide a one-shot pulse when the referenced trigger signal makes a positive (off-to-on) transition
On-To-Off Transitional Contact

On Off
Symbol
Off
On
One scan
Is programmed to provide a one-shot pulse when the referenced trigger signal makes a negative (on-to-off) transition
79
Conveyor Motor Circuit That Uses A Programmed One-Shot Reset Circuit

Proximity switch
Sequential Task: The start button i pressed is to start the conveyor motor Cases move pass the proximity switch and increment the counter's accumulated value
Case
Conveyor motor Start/Stop t ti St t/St station
Count reset button
After a count of 50, the conveyor motor stops automatically and the counter's accumulated value is reset to zero The conveyor motor can be stopped or started manually at anytime without loss of the accumulatedPetruzella, McGraw-Hill ENGG3490: Mechatronics W07. Adapted From Programmable Logic Controllers By F. D. count 80
40
Conveyor Motor Circuit That Uses A Programmed One-Shot Reset Circuit
50
81
One-Shot Rising (OSR) Instruction
Triggers a one-time event. The OSR instruction is a retentive input instruction that triggers an event to occur only one time. Use the OSR instruction when an event must start based on change of state of the rung from false to true true. When the input instruction goes from false to true, the OSR instruction conditions the rung so that the output goes true for one scan. The output goes false and remains false for successive scans until the input makes another false to true transition. ENGG3490: Mechatronics W07. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill
82
41
Alarm Monitor Program
The alarm is triggered by the closing of liquid level switch LS1 The light will flash whenever the alarm condition is triggered and has not been acknowledged, even if the alarm condition clears in the meantime The alarm is acknowledged by closing selector switch SS1 The light will operate in the steady mode when the alarm trigger condition exists but has Logic Controllers By F. D. Petruzella, McGraw-Hill been acknowledged ENGG3490: Mechatronics W07. Adapted From Programmable
83
Alarm Monitor Program
84
42
Down-Counter
The down-counter output instruction will count down or decrement by 1 each time the counted event occurs. Each time the down-count event occurs, the accumulated value is decremented. Normally the downcounter is used in conjunction with the up counter to form an up/down counter.
Generic up/down counter program 85 Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill
Up/Down Counter Timing diagram
Preset Value = 3
86
43
Parking Garage Counter Program
As a car enters, it triggers the up-counter output instruction and increments the accumulated count by 1. As a car leaves, it triggers the down-counter output y instruction and decrements the accumulated count by 1. Since both the up- and down-counters have the same address, the accumulated value will be the same in both. Whenever the accumulated value equals the preset value, the counter output is energized to light Controllers By F.Lot Full sign. up the D. Petruzella, McGraw-Hill ENGG3490: Mechatronics W07. Adapted From Programmable Logic 87
Parking Garage Counter Program
50 38 150
50 150 38
88
44
PLC-5 And SLC-500 Count-Down Counter Instruction
If the accumulation value is below the minimum range then the underflow (UN) bit By F. D. Petruzella, McGraw-Hill Adapted From Programmable Logic Controllers will be true. 89
Up/Down-Counter Program
1 10
1 10 When the CTU instruction When the CTD instruction When the accumulated value is true, C5:2/CU will be true is true, C5 2/CD will because t true Input CC5:2/CD equal to the going or will t isi greateroutputtrue ill b true than causing output A to be true causing B to be both value, C5:2/DN will be presetcounter instructions to reset true, causing output C to be true
90
45
In-Process Monitoring System
Before start-up, the system is completely empty of parts, and the counter is reset manually to zero.
In-Process Monitoring System
5 8
8 5
92
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Counter Speed
The maximum speed of transitions you can count is determined by your program's scan time. Any counter input signal must be fixed for one scan time to be counted reliably.
If the input changes faster than one scan period, the count value will become unreliable because counts will be missed. When this is the case you need to use a high-speed counter.
Cascading Counters
Depending on the application, it may be li ti b necessary to count events that exceed the maximum number allowable per counter instruction. One way of accomplishing this is by interconnection, or cascading, two counters.
94
47
Counting Beyond The Maximum Count
15000
95
Counting Beyond The Maximum Count
The status bits of both counters are t programmed in series to produce an output
The output of the first counter is programmed into the input of the second counter These two counters allow twice as many counts to be measured
96
48
Cascading Counters For Extremely Large Counts
500 0
Whenever counter C5:1 reaches 500, its done bit resets counter C5:1 and increments counter C5:2 by 1
The output light turns on after 500 x 500, or 250,000 transitions of the count Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill input 97
24 Hour Clock Program

The timer times for a 60 s period, after which its done bit is set. This, in turn cases C5:0 to increment 1 count. On the next processor scan, the timer is reset and begins timing again. Whenever C5:0 reaches its preset value of 60, its done bit is set. This, in turn causes it to reset itself and C5:1 to increment 1 count. Whenever C5:1 reaches its preset value of 24, its done bit is set to reset itself.
98
49
Program For Monitoring The Time Of An Event
99
Incremental Encoder
An incremental encoder creates a series of square waves as its shaft is rotated.
The encoder disk interrupts the light as the encoder shaft is rotated to produce the square wave output waveform.
100
50
Incremental Encoder
The number of square waves obtained from the output of the encoder can be made to correspond to the mechanical movement required.
To divide a shaft revolution into 100 parts, an encoder could be selected to supply 100 square wave cycles per revolution. By using a counter to those cycles, we could tell how far the shaft has rotated.
Cutting Objects To A Specific Size
The object is advanced for a specific distance and measured by encoder pulses to determine the correct length for cutting.
51
Counter Used For Length Measurement

Count input pulses generated by the magnetic sensor, which detects passing teeth on a conveyor drive sprocket. If 10 teeth per foot of conveyor motion pass the sensor, the accumulated count of the counter would indicate feet in tenths tenths.
The photoelectric sensor monitors a reference point on the conveyor. When activated, it prevents the unit from counting, thus permitting the counter to accumulate counts only when bar ENGG3490: Mechatronics 103 stock is moving.W07. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill
Counter Used For Length Measurement
10
Photo sensor activated, therefore, accumulated count remains at 10
104
52
Combining Counter And Timer Functions

When the start button is pressed, conveyor M1 begins running. After 15 plates have been stacked, p , conveyor M1 stops and conveyor M2 begins running. After conveyor M2 has been operated for 5 s, it stops and the sequence is repeated automatically. y The done bit of the timer resets the timer and counter, and provides a momentary pulse to Automatic Stacking Process automatically restart conveyor M1. ENGG3490: Mechatronics W07. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill 105
Automatic Stacking Program
106
53
Motor Lock-Out Program

Designed to prevent a machine operator from starting a motor that has tripped off more than 5 times in an hour.
The normally open (OL) relay contact momentarily closes each time an overload current is i sensed. d Every time the motor stops due to an overload condition, the motor start circuit is locked out for 5 min.
If the motor trips off more than 5 times in an hour, the motor start circuit is permanently locked out and cannot be started until the Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill reset button is actuated.
107
Motor Lock-Out Program P
108
54
Product Flow Rate Program

Parts
This program is designed to indicate how many parts per minute pass a given p process p point.
Sensor
When the start switch is closed, both the counter and timer are enabled. The counter is pulsed for each part passing the sensor. The counting begins and the timer starts timing through its 1-min time interval. At the end of 1 min, the timer done bit causes the counter rung to go false. Sensor pulses continue but do not affect the PLC counter. The number of parts for the past minutes are represented by the accumulated Controllers ByofD.the counter. ENGG3490: Mechatronics W07. Adapted From Programmable Logic value F. Petruzella, McGraw-Hill 109
Product Flow Rate Program
60
28
110
55
Timer Driving A Counter For Long Time-Delay Period
0 10,000
Each timer T4:0 input closes for 10,000 s, its done bit resets itself and increments C5:0 by 1. C5 0 b 1
The output light turns on 10,000 x 100, or 1,000,000 seconds after the timer input contact closes. Adapted From Programmable Logic Controllers By F. D. Petruzella, McGraw-Hill
111
Assignments

Chapter 7 and 8 (PLC) book: Problems See PLC-Problem-Set2 pdf file on the course PLC Problem Set2 web page.
112
56
113
57

Engg3490-Plc L4 L4: Plcs Ref. (3) Programming Timers P I C T Programming Counters

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Engg3490-Plc L4 L4: Plcs Ref. (3) Programming Timers P I C T Programming Counters

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ENGG3490-PLC L4

PLCs Ref. [3]; 1. Programming Timers 2. P Programming C i Counters t

Time Delay Relay

Solid State Solid-State Timer

On-Delay Timing Relay

ENGG3490: Mechatronics W07.

Timed Contact Symbols

Timed Contact Symbols

On-Delay Relay Timer Circuit (NOTC Contact)

Sequence of operation S1 open, TD de-energized, TD1 open L1 is off open, off.

On-Delay Relay Timer Circuit (NCTO Contact)

Off-Delay Relay Timer Circuit (NOTO Contact)

Sequence of operation S1 open, TD de-energized, TD1 open L1 is off open, off.

10 s 10 s Input On Output Off Timing Diagram

Off-Delay Relay Timer Circuit (NCTC Contact)

Sequence of operation S1 open, TD de-energized, TD1 closed, L1 is on. closed on

Input Output On Off Timing Diagram

Programmed Timer Instructions

RSLogic Timer Commands

Name Timer On-Delay

Description Counts time base intervals when the instruction is true

RSLogic Timer Commands

Name Timer Off-Delay

Description Counts time base intervals when the instruction is false

RSLogic Timer Commands

Name Retentive Timer ON

Quantities Associated with the Timer Instruction

Coil-Formatted Timer Instruction

Generic Block-Formatted Timer Instruction

Reset line resets the the timer's accumulated value to zero.

Generic Block-Formatted Timer Instruction

Retentive timer block

On-Delay Timer Instruction

On delay time duration True False

Timed output bit

Allen-Bradley On-Delay Timer Instruction

Allen-Bradley On-Delay Timer Instruction

Enable bit true

Allen-Bradley On-Delay Timer Instruction

Timer-Timing bit true

Allen-Bradley On-Delay Timer Instruction

Done-bit changes state

Allen-Bradley On-Delay Timer Instruction

Allen-Bradley On-Delay Timer Instruction

On-Delay Timer Program

T4:0 EN T4:0 TT T4:0 DN

On-Delay Timer Program

Timer accumulated 0 value

On-Delay Timer Program

On-Delay Timer With Instantaneous Output

1TD-1 (instantaneous contact)

M 1TD-2 (5 s) (timed contact)

On-Delay Timer With Instantaneous Output

Start-Up Warning Signal Circuit

Start-Up Warning Signal Circuit

T4:0 EN T4:0 T4 0 DN T4:0 T4 0

Timed Closed Solenoid Valve Program

Automatic Sequential Control System

Relay Ladder Schematic Diagram

L2 Lube oil pump motor M1 OL

Main drive motor M2

(lube oil pressure switch)