CHAPTER 1 Process control system

Introduction
1.1 Conventional control panel
1.2 Control panel with a PLC controller
1.3 Systematic approach to designing a process control system

Introduction

Generally speaking, process control system is made up of a group of electronic devices

and equipment that provide stability, accuracy and eliminate harmful transition statuses
in production processes. Operating system can have different form and implementation,
from energy supply units to machines. As a result of fast progress in technology, many
complex operational tasks have been solved by connecting programmable logic
controllers and possibly a central computer. Beside connections with instruments like
operating panels, motors, sensors, switches, valves and such, possibilities for
communication among instruments are so great that they allow high level of exploitation
and process coordination, as well as greater flexibility in realizing an process control
system. Each component of an process control system plays an important role,
regardless of its size. For example, without a sensor, PLC wouldn’t know what exactly
goes on in the process. In automated system, PLC controller is usually the central part of
an process control system. With execution of a program stored in program memory, PLC
continuously monitors status of the system through signals from input devices. Based on
the logic implemented in the program, PLC determines which actions need to be
executed with output instruments. To run more complex processes it is possible to
connect more PLC controllers to a central computer. A real system could look like the one
pictured below:

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1.1 Conventional control panel

At the outset of industrial revolution, especially during sixties and seventies, relays were
used to operate automated machines, and these were interconnected using wires inside
the control panel. In some cases a control panel covered an entire wall. To discover an
error in the system much time was needed especially with more complex process control
systems. On top of everything, a lifetime of relay contacts was limited, so some relays
had to be replaced. If replacement was required, machine had to be stopped and
production too. Also, it could happen that there was not enough room for necessary
changes. control panel was used only for one particular process, and it wasn’t easy to
adapt to the requirements of a new system. As far as maintenance, electricians had to
be very skillful in finding errors. In short, conventional control panels proved to be very
inflexible. Typical example of conventional control panel is given in the following picture.

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In this photo you can notice a large number of electrical wires, time relays, timers and
other elements of automation typical for that period. Pictured control panel is not one of
the more “complicated” ones, so you can imagine what complex ones looked like.

Most frequently mentioned disadvantages of a classic control panel are:

- Too much work required in connecting wires

- Difficulty with changes or replacements
- Difficulty in finding errors; requiring skillful work force
- When a problem occurs, hold-up time is indefinite, usually long.

1.2 Control panel with a PLC controller

With invention of programmable controllers, much has changed in how an process

control system is designed. Many advantages appeared. Typical example of control panel
with a PLC controller is given in the following picture.

Advantages of control panel that is based on a PLC controller can be presented in few
basic points:

1. Compared to a conventional process control system, number of wires needed for

connections is reduced by 80%
2. Consumption is greatly reduced because a PLC consumes less than a bunch of relays
3. Diagnostic functions of a PLC controller allow for fast and easy error detection.

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4. Change in operating sequence or application of a PLC controller to a different
operating process can easily be accomplished by replacing a program through a console
or using a PC software (not requiring changes in wiring, unless addition of some input or
output device is required).
5. Needs fewer spare parts
6. It is much cheaper compared to a conventional system, especially in cases where a
large number of I/O instruments are needed and when operational functions are
complex.
7. Reliability of a PLC is greater than that of an electro-mechanical relay or a timer.

1.3 Systematic approach in designing an process control system

First, you need to select an instrument or a system that you wish to control. Automated
system can be a machine or a process and can also be called an process control system.
Function of an process control system is constantly watched by input devices (sensors)
that give signals to a PLC controller. In response to this, PLC controller sends a signal to
external output devices (operative instruments) that actually control how system
functions in an assigned manner (for simplification it is recommended that you draw a
block diagram of operations’ flow).

Secondly, you need to specify all input and output instruments that will be connected to
a PLC controller. Input devices are various switches, sensors and such. Output devices
can be solenoids, electromagnetic valves, motors, relays, magnetic starters as well as
instruments for sound and light signalization.
Following an identification of all input and output instruments, corresponding
designations are assigned to input and output lines of a PLC controller. Allotment of these
designations is in fact an allocation of inputs and outputs on a PLC controller which
correspond to inputs and outputs of a system being designed.

Third, make a ladder diagram for a program by following the sequence of operations that
was determined in the first step.
Finally, program is entered into the PLC controller memory. When finished with
programming, checkup is done for any existing errors in a program code (using functions
for diagnostics) and, if possible, an entire operation is simulated. Before this system is
started, you need to check once again whether all input and output instruments are
connected to correct inputs or outputs. By bringing supply in, system starts working.

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CHAPTER 2 Introduction to PLC controllers
Introduction
2.1 First programmed controllers
2.2 PLC controller parts
2.3 Central Processing unit -CPU
2.4 Memory
2.5 How to program a PLC controller
2.6 Power supply
2.7 Input to a PLC controller
2.8 Input adjustable interface
2.9 Output from a PLC controller
2.10 Output adjustable interface
2.11 Extension lines

Introduction

Industry has begun to recognize the need for quality improvement and increase in
productivity in the sixties and seventies. Flexibility also became a major concern (ability
to change a process quickly became very important in order to satisfy consumer needs).

Try to imagine automated industrial production line in the sixties and seventies. There
was always a huge electrical board for system controls, and not infrequently it covered
an entire wall! Within this board there was a great number of interconnected
electromechanical relays to make the whole system work. By word "connected" it was
understood that electrician had to connect all relays manually using wires! An engineer
would design logic for a system, and electricians would receive a schematic outline of
logic that they had to implement with relays. These relay schemas often contained
hundreds of relays. The plan that electrician was given was called "ladder schematic".
Ladder displayed all switches, sensors, motors, valves, relays, etc. found in the system.
Electrician's job was to connect them all together. One of the problems with this type of
control was that it was based on mechanical relays. Mechanical instruments were usually
the weakest connection in the system due to their moveable parts that could wear out. If
one relay stopped working, electrician would have to examine an entire system (system
would be out until a cause of the problem was found and corrected).

The other problem with this type of control was in the system's break period when a
system had to be turned off, so connections could be made on the electrical board. If a
firm decided to change the order of operations (make even a small change), it would
turn out to be a major expense and a loss of production time until a system was
functional again.

It's not hard to imagine an engineer who makes a few small errors during his project. It
is also conceivable that electrician has made a few mistakes in connecting the system.
Finally, you can also imagine having a few bad components. The only way to see if
everything is all right is to run the system. As systems are usually not perfect with a first
try, finding errors was an arduous process. You should also keep in mind that a product
could not be made during these corrections and changes in connections. System had to
be literally disabled before changes were to be performed. That meant that the entire
production staff in that line of production was out of work until the system was fixed up
again. Only when electrician was done finding errors and repairing,, the system was
ready for production. Expenditures for this kind of work were too great even for well-to-
do companies.

2.1 First programmable controllers

"General Motors" is among the first who recognized a need to replace the system's
"wired" control board. Increased competition forced auto-makers to improve production
quality and productivity. Flexibility and fast and easy change of automated lines of

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production became crucial! General Motors' idea was to use for system logic one of the
microcomputers (these microcomputers were as far as their strength beneath today's
eight-bit microcontrollers) instead of wired relays. Computer could take place of huge,
expensive, inflexible wired control boards. If changes were needed in system logic or in
order of operations, program in a microcomputer could be changed instead of rewiring of
relays. Imagine only what elimination of the entire period needed for changes in wiring
meant then. Today, such thinking is but common, then it was revolutionary!

Everything was well thought out, but then a new problem came up of how to make
electricians accept and use a new device. Systems are often quite complex and require
complex programming. It was out of question to ask electricians to learn and use
computer language in addition to other job duties. General Motors Hidromatic Division of
this big company recognized a need and wrote out project criteria for first programmable
logic controller ( there were companies which sold instruments that performed industrial
control, but those were simple sequential controllers û not PLC controllers as we know
them today). Specifications required that a new device be based on electronic instead of
mechanical parts, to have flexibility of a computer, to function in industrial environment
(vibrations, heat, dust, etc.) and have a capability of being reprogrammed and used for
other tasks. The last criteria was also the most important, and a new device had to be
programmed easily and maintained by electricians and technicians. When the
specification was done, General Motors looked for interested companies, and encouraged
them to develop a device that would meet the specifications for this project.

"Gould Modicon" developed a first device which met these specifications. The key to
success with a new device was that for its programming you didn't have to learn a new
programming language. It was programmed so that same language ûa ladder diagram,
already known to technicians was used. Electricians and technicians could very easily
understand these new devices because the logic looked similar to old logic that they
were used to working with. Thus they didn't have to learn a new programming language
which (obviously) proved to be a good move. PLC controllers were initially called PC
controllers (programmable controllers). This caused a small confusion when Personal
Computers appeared. To avoid confusion, a designation PC was left to computers, and
programmable controllers became programmable logic controllers. First PLC controllers
were simple devices. They connected inputs such as switches, digital sensors, etc., and
based on internal logic they turned output devices on or off. When they first came up,
they were not quite suitable for complicated controls such as temperature, position,
pressure, etc. However, throughout years, makers of PLC controllers added numerous
features and improvements. Today's PLC controller can handle highly complex tasks such
as position control, various regulations and other complex applications. The speed of
work and easiness of programming were also improved. Also, modules for special
purposes were developed, like communication modules for connecting several PLC
controllers to the net. Today it is difficult to imagine a task that could not be handled by
a PLC.

2.2 PLC controller components

PLC is actually an industrial microcontroller system (in more recent times we meet
processors instead of microcontrollers) where you have hardware and software
specifically adapted to industrial environment. Block schema with typical components
which PLC consists of is found in the following picture. Special attention needs to be
given to input and output, because in these blocks you find protection needed in isolating
a CPU blocks from damaging influences that industrial environment can bring to a CPU
via input lines. Program unit is usually a computer used for writing a program (often in
ladder diagram).

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2.3 Central Processing Unit - CPU

Central Processing Unit (CPU) is the brain of a PLC controller. CPU itself is usually one of
the microcontrollers. Aforetime these were 8-bit microcontrollers such as 8051, and now
these are 16- and 32-bit microcontrollers. Unspoken rule is that you'll find mostly Hitachi
and Fujicu microcontrollers in PLC controllers by Japanese makers, Siemens in European
controllers, and Motorola microcontrollers in American ones. CPU also takes care of
communication, interconnectedness among other parts of PLC controller, program
execution, memory operation, overseeing input and setting up of an output. PLC
controllers have complex routines for memory checkup in order to ensure that PLC
memory was not damaged (memory checkup is done for safety reasons). Generally
speaking, CPU unit makes a great number of check-ups of the PLC controller itself so
eventual errors would be discovered early. You can simply look at any PLC controller and
see that there are several indicators in the form of light diodes for error signalization.

2.4 Memory

System memory (today mostly implemented in FLASH technology) is used by a PLC for
an process control system. Aside from this operating system it also contains a user
program translated from a ladder diagram to a binary form. FLASH memory contents can
be changed only in case where user program is being changed. PLC controllers were
used earlier instead of FLASH memory and have had EPROM memory instead of FLASH
memory which had to be erased with UV lamp and programmed on programmers. With
the use of FLASH technology this process was greatly shortened. Reprogramming a
program memory is done through a serial cable in a program for application
development.

User memory is divided into blocks having special functions. Some parts of a memory
are used for storing input and output status. The real status of an input is stored either
as "1" or as "0" in a specific memory bit. Each input or output has one corresponding bit

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in memory. Other parts of memory are used to store variable contents for variables used
in user program. For example, timer value, or counter value would be stored in this part
of the memory.

2.5 Programming a PLC controller

PLC controller can be reprogrammed through a computer (usual way), but also through
manual programmers (consoles). This practically means that each PLC controller can
programmed through a computer if you have the software needed for programming.
Today's transmission computers are ideal for reprogramming a PLC controller in factory
itself. This is of great importance to industry. Once the system is corrected, it is also
important to read the right program into a PLC again. It is also good to check from time
to time whether program in a PLC has not changed. This helps to avoid hazardous
situations in factory rooms (some automakers have established communication networks
which regularly check programs in PLC controllers to ensure execution only of good
programs).

Almost every program for programming a PLC controller possesses various useful options
such as: forced switching on and off of the system inputs/ouputs (I/O lines), program
follow up in real time as well as documenting a diagram. This documenting is necessary
to understand and define failures and malfunctions. Programmer can add remarks,
names of input or output devices, and comments that can be useful when finding errors,
or with system maintenance. Adding comments and remarks enables any technician
(and not just a person who developed the system) to understand a ladder diagram right
away. Comments and remarks can even quote precisely part numbers if replacements
would be needed. This would speed up a repair of any problems that come up due to bad
parts. The old way was such that a person who developed a system had protection on
the program, so nobody aside from this person could understand how it was done.
Correctly documented ladder diagram allows any technician to understand thoroughly
how system functions.

2.6. Power supply

Electrical supply is used in bringing electrical energy to central processing unit. Most PLC
controllers work either at 24 VDC or 220 VAC. On some PLC controllers you'll find
electrical supply as a separate module. Those are usually bigger PLC controllers, while
small and medium series already contain the supply module. User has to determine how
much current to take from I/O module to ensure that electrical supply provides
appropriate amount of current. Different types of modules use different amounts of
electrical current.

This electrical supply is usually not used to start external inputs or outputs. User has to
provide separate supplies in starting PLC controller inputs or outputs because then you
can ensure so called "pure" supply for the PLC controller. With pure supply we mean
supply where industrial environment can not affect it damagingly. Some of the smaller
PLC controllers supply their inputs with voltage from a small supply source already
incorporated into a PLC.

2.7 PLC controller inputs

Intelligence of an automated system depends largely on the ability of a PLC controller to

read signals from different types of sensors and input devices. Keys, keyboards and by
functional switches are a basis for man versus machine relationship. On the other hand,
in order to detect a working piece, view a mechanism in motion, check pressure or fluid
level you need specific automatic devices such as proximity sensors, marginal switches,
photoelectric sensors, level sensors, etc. Thus, input signals can be logical (on/off) or
analogue. Smaller PLC controllers usually have only digital input lines while larger also
accept analogue inputs through special units attached to PLC controller. One of the most
frequent analogue signals are a current signal of 4 to 20 mA and milivolt voltage signal

8
generated by various sensors. Sensors are usually used as inputs for PLCs. You can
obtain sensors for different purposes. They can sense presence of some parts, measure
temperature, pressure, or some other physical dimension, etc. (ex. inductive sensors can
register metal objects).

Other devices also can serve as inputs to PLC controller. Intelligent devices such as
robots, video systems, etc. often are capable of sending signals to PLC controller input
modules (robot, for instance, can send a signal to PLC controller input as information
when it has finished moving an object from one place to the other.)

2.8 Input adjustment interface

Adjustment interface also called an interface is placed between input lines and a CPU
unit. The purpose of adjustment interface to protect a CPU from disproportionate signals
from an outside world. Input adjustment module turns a level of real logic to a level that
suits CPU unit (ex. input from a sensor which works on 24 VDC must be converted to a
signal of 5 VDC in order for a CPU to be able to process it). This is typically done through
opto-isolation, and this function you can view in the following picture.
Opto-isolation means that there is no electrical connection between external world and
CPU unit. They are "optically" separated, or in other words, signal is transmitted through
light. The way this works is simple. External device brings a signal which turns LED on,
whose light in turn incites photo transistor which in turn starts conducting, and a CPU
sees this as logic zero (supply between collector and transmitter falls under 1V). When
input signal stops LED diode turns off, transistor stops conducting, collector voltage
increases, and CPU receives logic 1 as information.

2.9 PLC controller output

Automated system is incomplete if it is not connected with some output devices. Some
of the most frequently used devices are motors, solenoids, relays, indicators, sound
signalization and similar. By starting a motor, or a relay, PLC can manage or control a
simple system such as system for sorting products all the way up to complex systems
such as service system for positioning head of CNC machine. Output can be of analogue
or digital type. Digital output signal works as a switch; it connects and disconnects line.
Analogue output is used to generate the analogue signal (ex. motor whose speed is
controlled by a voltage that corresponds to a desired speed).

2.10 Output adjustment interface

Output interface is similar to input interface. CPU brings a signal to LED diode and turns
it on. Light incites a photo transistor which begins to conduct electricity, and thus the
voltage between collector and emmiter falls to 0.7V , and a device attached to this
output sees this as a logic zero. Inversely it means that a signal at the output exists and
is interpreted as logic one. Photo transistor is not directly connected to a PLC controller

9
output. Between photo transistor and an output usually there is a relay or a stronger
transistor capable of interrupting stronger signals.

2.11 Extension lines

Every PLC controller has a limited number of input/output lines. If needed this number
can be increased through certain additional modules by system extension through
extension lines. Each module can contain extension both of input and output lines. Also,
extension modules can have inputs and outputs of a different nature from those on the
PLC controller (ex. in case relay outputs are on a controller, transistor outputs can be on
an extension module).

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CHAPTER 3 Connecting sensors and execution devices
Introduction
3.1 Sinking-sourcing concept
3.2 Input lines
3.3 Output lines

Introduction

Connecting external devices to a PLC controller regardless whether they are input or
output is a special subject matter for industry. If it stands alone, PLC controller itself is
nothing. In order to function it needs sensors to obtain information from environment,
and it also needs execution devices so it could turn the programmed change into a
reality. Similar concept is seen in how human being functions. Having a brain is simply
not enough. Humans achieve full activity only with processing of information from a
sensor (eyes, ears, touch, smell) and by taking action through hands, legs or some tools.
Unlike human being who receives his sensors automatically, when dealing with
controllers, sensors have to be subsequently connected to a PLC. How to connect input
and output parts is the topic of this chapter.

3.1 Sinking-Sourcing Concept

PLC has input and output lines through which it is connected to a system it directs. Input
can be keys, switches, sensors while outputs are led to different devices from simple
signalization lights to complex communication modules.

This is a very important part of the story about PLC controllers because it directly
influences what can be connected and how it can be connected to controller inputs or
outputs. Two terms most frequently mentioned when discussing connections to inputs or
outputs are "sinking" and "sourcing". These two concepts are very important in
connecting a PLC correctly with external environment. The most brief definition of these
two concepts would be:

SINKING = Common GND line (-)

SOURCING = Common VCC line (+)

First thing that catches one's eye are "+" and "-" supply, DC supply. Inputs and outputs
which are either sinking or sourcing can conduct electricity only in one direction, so they
are only supplied with direct current.

According to what we've said thus far, each input or output has its own return line, so 5
inputs would need 10 screw terminals on PLC controller housing. Instead, we use a
system of connecting several inputs to one return line as in the following picture. These
common lines are usually marked "COMM" on the PLC controller housing.

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3.2 Input lines

Explanation of PLC controller input and output lines has up to now been given only
theoretically. In order to apply this knowledge, we need to make it a little more specific.
Example can be connection of external device such as proximity sensor. Sensor outputs
can be different depending on a sensor itself and also on a particular application.
Following pictures display some examples of sensor outputs and their connection with a
PLC controller. Sensor output actually marks the size of a signal given by a sensor at its
output when this sensor is active. In one case this is +V (supply voltage, usually 12 or
24V) and in other case a GND (0V). Another thing worth mentioning is that sinking-
sourcing and sourcing - sinking pairing is always used, and not sourcing-sourcing or
sinking-sinking pairing.

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If we were to make type of connection more specific, we'd get combinations as in
following pictures (for more specific connection schemas we need to know the exact
sensor model and a PLC controller model).

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14
3.3 Output lines

PLC controller output lines usually can be:

-transistors in PNP connection

-transistors in NPN connection
-relays

The following two pictures display a realistic way how a PLC manages external devices. It
ought to be noted that a main difference between these two pictures is a position of
"output load device". By "output load device" we mean some relay, signalization light or
similar.

How something is connected with a PLC output depends on the element being
connected. In short, it depends on whether this element of output load device is
activated by a positive supply pole or a negative supply pole.

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CHAPTER 4 Architecture of specific PLC controller
Introduction
4.1 Why OMRON?
4.2 CPM1A PLC controller
4.3 PLC controller input lines
4.4 PLC controller output lines
4.5 How PLC controller works
4.6 CPM1A PLC controller memory map
4.7 Timers and counters

Introduction

This book could deal with a general overview of some supposed PLC controller. Author
has had an opportunity to look over plenty of books published up till now, and this
approach is not the most suitable to the purposes of this book in his opinion. Idea of this
book is to work through one specific PLC controller where someone can get a real feeling
on this subject and its weight. Our desire was to write a book based on whose reading
you can earn some money. After all, money is the end goal of every business!

4.1 Why OMRON?

Why not? It is a huge company which has high quality and by our standards inexpensive
controllers. Today we can say almost with surety that PLC controllers by manufacturers
round the world are excellent devices, and altogether similar. Nevertheless, for specific
application we need to know specific information about a PLC controller being used.
Therefore, the choice fell on OMRON company and its PLC of micro class CPM1A.
Adjective "micro" itself implies the smallest models from the viewpoint of a number of
attached lines or possible options. Still, this PLC controller is ideal for the purposes of
this book, and that is to introduce a PLC controller philosophy to its readers.

4.2 CPM1A PLC controller

Each PLC is basically a microcontroller system (CPU of PLC controller is based on one of
the microcontrollers, and in more recent times on one of the PC processors) with
peripherals that can be digital inputs, digital outputs or relays as in our case. However,
this is not an "ordinary" microcontroller system. Large teams have worked on it, and a
checkup of its function has been performed in real world under all possible
circumstances. Software itself is entirely different from assemblers used thus far, such as
BASIC or C. This specialized software is called "ladder" (name came about by an
association of program's configuration which resembles a ladder, and from the way
program is written out).

Specific look of CPM1A PLC controller can be seen in the following picture. On the upper
surface, there are 4 LED indicators and a connection port with an RS232 module which is
interface to a PC computer. Aside from this, screw terminals and light indicators of
activity of each input or output are visible on upper and lower sides. Screw terminals
serve to manually connect to a real system. Hookups L1 and L2 serve as supply which is
220V~ in this case. PLC controllers that work on power grid voltage usually have a
source of direct supply of 24 VDC for supplying sensors and such (with a CPM1A source
of direct supply is found on the bottom left hand side and is represented with two screw
terminals. Controller can be mounted to industrial "track" along with other automated
elements, but also by a screw to the machine wall or control panel.

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17
 Controller is 8cm high and divided
vertically into two areas: a lower one
with a converter of 220V~ at 24VDC
and other voltages needed for
running a CPU unit; and, upper area
with a CPU and memory, relays and
digital inputs.

When you lift the small plastic cover

you'll see a connector to which an
RS232 module is hooked up for serial
interface with a computer. This
module is used when programming a
PLC controller to change programs or
execution follow-up. When installing
a PLC it isn't necessary to install this
module, but it is recommended
because of possible changes in
software during operation.

To better inform programmers on PLC controller status, maker has provided for four light
indicators in the form of LED's. Beside these indicators, there are status indicators for
each individual input and output. These LED's are found by the screw terminals and with
their status are showing input or output state. If input/output is active, diode is lit and
vice versa.

4.3 PLC controller output lines

Aside from transistor outputs in PNP and NPN connections, PLC can also have relays as
outputs. Existence of relays as outputs makes it easier to connect with external devices.
Model CPM1A contains exactly these relays as outputs. There a 4 relays whose functional
contacts are taken out on a PLC controller housing in the form of screw terminals. In
reality this looks as in picture below.

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With activation of phototransistor, relay comes under voltage and activates a contact
between points A and B. Contacts A and B can in our case be either in connection or
interrupted. What state these contacts are in is determined by a CPU through
appropriate bits in memory location IR010. One example of relay status is shown in a
picture below. A true state of devices attached to these relays is displayed.

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4.4 PLC controller input lines

Different sensors, keys, switches and other elements that can change status of a joined
bit at PLC input can be hooked up to the PLC controller inputs. In order to realize a
change, we need a voltage source to incite an input. The simplest possible input would
be a common key. As CPM1A PLC has a source of direct voltage of 24V, the same source
can be used to incite input (problem with this source is its maximum current which it can
give continually and which in our case amounts to 0.2A). Since inputs to a PLC are not
big consumers (unlike some sensor where a stronger external supply must be used) it is
possible to take advantage of the existing source of direct supply to incite all six keys.

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4.5 How PLC controller works

Basis of a PLC function is continual scanning of a program. Under scanning we mean

running through all conditions within a guaranteed period. Scanning process has three
basic steps:

Step 1.
Testing input status. First, a PLC checks each of the inputs with intention to see which
one of them has status ON or OFF. In other words, it checks whether a sensor, or a
switch etc. connected with an input is activated or not. Information that processor thus
obtains through this step is stored in memory in order to be used in the following step.

Step 2.
Program execution. Here a PLC executes a program, instruction by instruction. Based on
a program and based on the status of that input as obtained in the preceding step, an
appropriate action is taken. This reaction can be defined as activation of a certain output,
or results can be put off and stored in memory to be retrieved later in the following step.

Step 3.
Checkup and correction of output status. Finally, a PLC checks up output status and
adjusts it as needed. Change is performed based on the input status that had been read

21
during the first step, and based on the results of program execution in step two.
Following the execution of step 3 PLC returns to the beginning of this cycle and
continually repeats these steps. Scanning time is defined by the time needed to perform
these three steps, and sometimes it is an important program feature.

4.6 CPM1A PLC controller memory map

By memory map we mean memory structure for a PLC controller. Simply said, certain
parts of memory have specific roles. If you look at the picture below, you can see that
memory for CPM1A is structured into 16-bit words. A cluster of several such words
makes up a region. All the regions make up the memory for a PLC controller.

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Unlike microcontroller systems where only some memory locations have had their
purpose clearly defined (ex. register that contains counter value), a memory of PLC
controller is completely defined, and more importantly almost entire memory is
addressable in bits. Addressability in bits means that it is enough to write the address of
the memory location and a number of bits after it in order to manipulate with it. In
short, that would mean that something like this could be written: "201.7=1" which would
clearly indicate a word 201 and its bit 7 which is set to one.

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IR region

Memory locations intended for PLC input and output. Some bits are directly connected to
PLC controller inputs and outputs (screw terminal). In our case, we have 6 input lines at
address IR000. One bit corresponds to each line, so the first line has the address
IR000.0, and the sixth IR000.5. When you obtain a signal at the input, this immediately
affects the status of a corresponding bit. There are also words with work bits in this
region, and these work bits are used in a program as flags or certain conditional bits.

SR region

Special memory region for control bits and flags. It is intended first and foremost for
counters and interrupts. For example, SR250 is memory location which contains an
adjustable value, adjusted by potentiometer no.0 (in other words, value of this location
can be adjusted manually by turning a potentiometer no.0.

TR region

When you move to a subprogram during program execution, all relevant data is stored in
this region up to the return from a subprogram.

HR region

It is of great importance to keep certain information even when supply stops. This part
of the memory is battery supported, so even when supply has stopped it will keep all
data found therein before supply stopped.

AR region

This is one more region with control bits and flags. This region contains information on
PLC status, errors, system time, and the like. Like HR region, this one is also battery
supported.

LR region

In case of connection with another PLC, this region is used for exchange of data.

Timer and counter region

This region contains timer and counter values. There are 128 values. Since we will
consider examples with timers and counters, we will discus this region more later on.

DM region

Contains data related to setting up communication with a PC computer, and data on

errors.

Each region can be broken down to single words and meanings of its bits. In order to
keep the clarity of the book, this part is dealt with in Attachments and we will deal with
those regions here whose bits are mostly used for writing.

24
Note:
1. IR and LR bits that are not used for their allocated functions can be used as work bits.
2. The contents of the HR area, LR area, Counter area, and read/write DM area are backed up by a capacitor. At 25
oC, the capacitor will back up memory for 20 days.
3. When accessing a PV, TC numbers are used as word data; when accessing Completing Flags, they are used as bit
data.
4. Data in DM6144 to DM6655 cannot be overwritten from the program, but they can be changed from a Peripheral
Device

4.7 Timers and counters

Timers and counters are indispensable in PLC programming. Industry has to number its
products, determine a needed action in time, etc. Timing functions is very important,
and cycle periods are critical in many processes.

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There are two types of timers delay-off and delay-on. First is late with turn off and the
other runs late in turning on in relation to a signal that activated timers. Example of a
delay-off timer would be staircase lighting. Following its activation, it simply turns off
after few minutes.

Each timer has a time basis, or more precisely has several timer basis. Typical values
are: 1 second, 0.1 second, and 0,01 second. If programmer has entered .1 as time basis
and 50 as a number for delay increase, timer will have a delay of 5 seconds (50 x 0.1
second = 5 seconds).

Timers also have to have value SV set in advance. Value set in advance or ahead of time
is a number of increments that timer has to calculate before it changes the output
status. Values set in advance can be constants or variables. If a variable is used, timer
will use a real time value of the variable to determine a delay. This enables delays to
vary depending on the conditions during function. Example is a system that has
produced two different products, each requiring different timing during process itself.
Product A requires a period of 10 seconds, so number 10 would be assigned to the
variable. When product B appears, a variable can change value to what is required by
product B.

Typically, timers have two inputs. First is timer enable, or conditional input (when this
input is activated, timer will start counting). Second input is a reset input. This input has
to be in OFF status in order for a timer to be active, or the whole function would be
repeated over again. Some PLC models require this input to be low for a timer to be
active, other makers require high status (all of them function in the same way basically).
However, if reset line changes status, timer erases accumulated value.

With a PLC controller by Omron there are two types of timers: TIM and TIMH. TIM timer
measures in increments of 0.1 seconds. It can measure from 0 to 999.9 seconds with
precision of 0.1 seconds more or less.

Quick timer (TIMH) measures in increments of 0.01 seconds. Both timers are "delay-on"
timers of a lessening-style. They require assignment of a timer number and a set value
(SV). When SV runs out, timer output turns on. Numbers of a timing counter refer to
specific address in memory and must not be duplicated (same number can not be used
for a timer and a counter).

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CHAPTER 5 Ladder diagram
Introduction
5.1 Ladder diagram
5.2 Normally open and normally closed contacts
5.3 Brief example

Introduction

Programmable controllers are generally programmed in ladder diagram (or "relay

diagram") which is nothing but a symbolic representation of electric circuits. Symbols
were selected that actually looked similar to schematic symbols of electric devices, and
this has made it much easier for electricians to switch to programming PLC controllers.
Electrician who has never seen a PLC can understand a ladder diagram.

5.1 Ladder diagram

There are several languages designed for user communication with a PLC, among which
ladder diagram is the most popular. Ladder diagram consists of one vertical line found on
the left hand side, and lines which branch off to the right. Line on the left is called a "bus
bar", and lines that branch off to the right are instruction lines. Conditions which lead to
instructions positioned at the right edge of a diagram are stored along instruction lines.
Logical combination of these conditions determines when and in what way instruction on
the right will execute. Basic elements of a relay diagram can be seen in the following
picture.

Most instructions require at least one operand, and often more than one. Operand can be
some memory location, one memory location bit, or some numeric value -number. In the
example above, operand is bit 0 of memory location IR000. In a case when we wish to
proclaim a constant as an operand, designation # is used beneath the numeric writing
(for a compiler to know it is a constant and not an address.)

Based on the picture above, one should note that a ladder diagram consists of two basic
parts: left section also called conditional, and a right section which has instructions.
When a condition is fulfilled, instruction is executed, and that's all!

27
Picture above represents a example of a ladder diagram where relay is activated in PLC
controller when signal appears at input line 00. Vertical line pairs are called conditions.
Each condition in a ladder diagram has a value ON or OFF, depending on a bit status
assigned to it. In this case, this bit is also physically present as an input line (screw
terminal) to a PLC controller. If a key is attached to a corresponding screw terminal, you
can change bit status from a logic one status to a logic zero status, and vice versa.
Status of logic one is usually designated as "ON", and status of logic zero as "OFF".

Right section of a ladder diagram is an instruction which is executed if left condition is

fulfilled. There are several types of instructions that could easily be divided into simple
and complex. Example of a simple instruction is activation of some bit in memory
location. In the example above, this bit has physical connotation because it is connected
with a relay inside a PLC controller. When a CPU activates one of the leading four bits in
a word IR010, relay contacts move and connect lines attached to it. In this case, these
are the lines connected to a screw terminal marked as 00 and to one of COM screw
terminals.

5.2 Normally open and normally closed contacts

Since we frequently meet with concepts "normally open" and "normally closed" in
industrial environment, it's important to know them. Both terms apply to words such as
contacts, input, output, etc. (all combinations have the same meaning whether we are
talking about input, output, contact or something else).

Principle is quite simple, normally open switch won't conduct electricity until it is pressed
down, and normally closed switch will conduct electricity until it is pressed. Good
examples for both situations are the doorbell and a house alarm.

If a normally closed switch is selected, bell will work continually until someone pushes
the switch. By pushing a switch, contacts are opened and the flow of electricity towards
the bell is interrupted. Of course, system so designed would not in any case suit the
owner of the house. A better choice would certainly be a normally open switch. This way
bell wouldn't work until someone pushed the switch button and thus informed of his or
her presence at the entrance.

Home alarm system is an example of an application of a normally closed switch. Let's

suppose that alarm system is intended for surveillance of the front door to the house.
One of the ways to "wire" the house would be to install a normally open switch from
each door to the alarm itself (precisely as with a bell switch). Then, if the door was
opened, this would close the switch, and an alarm would be activated. This system could
work, but there would be some problems with this, too. Let's suppose that switch is not
working, that a wire is somehow disconnected, or a switch is broken, etc. (there are
many ways in which this system could become dysfunctional). The real trouble is that a
homeowner would not know that a system was out of order. A burglar could open the
door, a switch would not work, and the alarm would not be activated. Obviously, this isn't

28
a good way to set up this system. System should be set up in such a way so the alarm is
activated by a burglar, but also by its own dysfunction, or if any of the components
stopped working. (A homeowner would certainly want to know if a system was
dysfunctional). Having these things in mind, it is far better to use a switch with normally
closed contacts which will detect an unauthorized entrance (opened door interrupts the
flow of electricity, and this signal is used to activate a sound signal), or a failure on the
system such as a disconnected wire. These considerations are even more important in
industrial environment where a failure could cause injury at work. One such example
where outputs with normally closed contacts are used is a safety wall with trimming
machines. If the wall doors open, switch affects the output with normally closed contacts
and interrupts a supply circuit. This stops the machine and prevents an injury.

Concepts normally open and normally closed can apply to sensors as well. Sensors are
used to sense the presence of physical objects, measure some dimension or some
amount. For instance, one type of sensors can be used to detect presence of a box on an
industry transfer belt. Other types can be used to measure physical dimensions such as
heat, etc. Still, most sensors are of a switch type. Their output is in status ON or OFF
depending on what the sensor "feels". Let's take for instance a sensor made to feel
metal when a metal object passes by the sensor. For this purpose, a sensor with a
normally open or a normally closed contact at the output could be used. If it were
necessary to inform a PLC each time an object passed by the sensor, a sensor with a
normally open output should be selected. Sensor output would set off only if a metal
object were placed right before the sensor. A sensor would turn off after the object has
passed. PLC could then calculate how many times a normally open contact was set off at
the sensor output, and would thus know how many metal objects passed by the sensor.

Concepts normally open and normally closed contact ought to be clarified and explained
in detail in the example of a PLC controller input and output. The easiest way to explain
them is in the example of a relay.

Normally open contacts would represent relay contacts that would perform a connection

29
upon receipt of a signal. Unlike open contacts, with normally closed contacts signal will
interrupt a contact, or turn a relay off. Previous picture shows what this looks like in
practice. First two relays are defined as normally open , and the other two as normally
closed. All relays react to a signal! First relay (00) has a signal and closes its contacts.
Second relay (01) does not have a signal and remains opened. Third relay (02) has a
signal and opens its contacts considering it is defined as a closed contact. Fourth relay
(03) does not have a signal and remains closed because it is so defined.

Concepts "normally open" and "normally closed" can also refer to inputs of a PLC
controller. Let's use a key as an example of an input to a PLC controller. Input where a
key is connected can be defined as an input with open or closed contacts. If it is defined
as an input with normally open contact, pushing a key will set off an instruction found
after the condition. In this case it will be an activation of a relay 00.

If input is defined as an input with normally closed contact, pushing the key will interrupt
instruction found after the condition. In this case, this will cause deactivation of relay 00
(relay is active until the key is pressed). You can see in picture below how keys are
connected, and view the relay diagrams in both cases.

Normally open/closed conditions differ in a ladder diagram by a diagonal line across a

symbol. What determines an execution condition for instruction is a bit status marked
beneath each condition on instruction line. Normally open condition is ON if its operand
bit has ON status, or its status is OFF if that is the status of its operand bit. Normally
closed condition is ON when its operand bit is OFF, or it has OFF status when the status
of its operand bit is ON.

When programming with a ladder diagram, logical combination of ON and OFF conditions
set before the instruction determines the eventual condition under which the instruction
will be, or will not be executed. This condition, which can have only ON or OFF values is
called instruction execution condition. Operand assigned to any instruction in a relay
diagram can be any bit from IR, SR, HR, AR, LR or TC sector. This means that conditions
in a relay diagram can be determined by a status of I/O bits, or of flags, operational bits,
timers/counters, etc.

5.3 Brief example

Example below represents a basic program. Example consists of one input device and
one output device linked to the PLC controller output. Key is an input device, and a bell
is an output supplied through a relay 00 contact at the PLC controller output. Input
000.00 represents a condition in executing an instruction over 010.00 bit. Pushing the

30
key sets off a 000.00 bit and satisfies a condition for activation of a 010.00 bit which in
turn activates the bell. For correct program function another line of program is needed
with END instruction, and this ends the program.

The following picture depicts the connection scheme for this example.

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32
CHAPTER 6 SYSWIN program for programming a PLC
controller
Introduction
6.1 Connecting a PLC controller with a PC computer
6.2 SYSWIN program installation
6.3 Writing your first program
6.4 Saving a project
6.5 Program transfer to PLC controller
6.6 Testing program function
6.7 Interpretation of "Tools" icons
6.8 PLC controller working modes
6.9 Run mode
6.10 Monitor mode
6.11 Program-Stop mode
6.12 Program execution and monitoring
6.13 Impact on the program during monitoring
6.14 Graphic representation of dimension changes in a program

Introduction

SYSWIN is a software designed for OMRON programmable controllers class C and CV. It
is designed for creating and maintaining a program, as well as for testing PLC controller
function, in off-line and controller's operational regime.
Necessary conditions for starting SYSWIN are Microsoft Windows environment on a
standard IBM or 386/486 compatible or Pentium computer, with 8MB RAM at least, and
10MB free disc space.

6.1 Connecting a PLC controller with a PC computer

PLC controller is linked with a PC computer through an RS-232 cable. One end of the
cable is connected to a serial PC port (9-pin or 25-pin connector), while the other end is
connected to an RS-232C connector on RS232 module of a CPM1A controller. In order to
establish a connection with a PC, DIP switch on the connector must be set in "Host"
position.

6.2 SYSWIN program installation

Instruction package for CPM1A is covered by three SYSWIN installation diskettes. It can
be installed in Windows 3.1, 3.11, 95, 98 or NT 4.0. In order to start the installation you
need to select RUN option from a START menu.

33
A window will come up like the one below where you need to write in the file command
"setup.exe". Mentioned file can be found in the installation directory of Syswin program.
Following a brief installation procedure you will get a program group Syswin 3.4.
Double-click on Syswin icon starts a Syswin program which opens as in the following
picture.

6.3 Writing your first program

Writing a program begins with New Project option from a File menu. In a message
window that appears you need to select options as in picture below.

34
Select a PLC controller by clicking on OK, and a program is ready to be used. It is
recommended when you begin working that you write in a header a title of a program,
author's name and inputs/outputs used. This may seem as a waste of time, but really
isn't because this habit of writing comments will pay off in the future.

Program written here is just a basic program made for learning Syswin. Program can
detect when a key has been pressed and can activate a relay at the PLC controller
output. As long as the key is pressed down, a relay is active. Operation of a relay and a
key can be followed via LED diodes on PLC controller housing. Writing a program begins
with a click on the first icon to the left, recognized by two vertical lines. Icon beneath
this one is similar to the first but for a slash. These two icons correspond with concepts
normally open and normally closed contact which all instruction lines start with. You can
select an option with an open contact by clicking on the first icon. When you click on the
black rectangle to the right, a small window will appear where you need to write in the
address of a bit a contact relates to.

It is very important to use addresses in a regular way when programming with SYSWIN.
Addresses can have two parts, first refers to the word address, and the second to bit
address in that word (both numbers must be separated by a period). For example, if
address 200 is used, SYSWIN will interpret this as 2.00, and a zero bit whose word
address is 2 will be called for. If you wish to access word 200 or its zero bit, you must
use a call 20000, or better even 200.00. In this example address 000.00 is assigned for
input address (key). This address represents a zero bit for word 000 from memory
region IR. Simply said, it is an input screw terminal designated as 00 input. By
connecting a key to it, and to one of the COMM terminal screws, a needed connection
between PLC controller and keys is established.

35
 Address dialogue box for a bit that contact refers to

When you have written in 000.00, select OK, and first segment of the program will come
up. Bit address will appear above the symbol with two vertical lines which refers to this
bit, and a black rectangle will move one space to the right.

First element of a program myprog.swp

First instructions up to the bus bar are called conditions because their execution
activates instructions found to the right of the condition instructions. When a condition is
entered, you also need to enter a corresponding instruction that is set off by an
execution of the condition. In this example it is a relay controlled by a 00 bit in a word
010 of memory region IR. Output instructions are represented by a circle, or a circle and
a line if we are dealing with a normally closed contact. By clicking on the icon with a
circle, you select an output option with normally open contacts. Click on a black
rectangle, and a contact window will come up where you need to write in the address for
the output bit 010.00. Output of the IR region is found at address IR010, and first four
bits of this word represent a relay within a PLC controller (if we are talking about a
model CPM1A with relay outputs). Program done so far looks as in picture below.

36
 Second element of myprog.swp program

The basic functional entirety of some program is Network. Program consists of several
networks found one below the other. Operations with these are found in Block option of
the menu. Of all options, two basic ones, Insert network and Delete network are used
the most. Other makers for PLC controllers use different concepts such as Rung instead
of the term Network. Simply said, we are talking about a PLC program sequence which
has one or more executing instructions, and along with END instruction can make up one
correct PLC program. As the first network in a program is already in use, the next one
has to be added. Adding a Network is done with Insert network command from a Block
menu.

When selecting this option, a small window appears where you need to select whether a
new network will appear above or below the existing one.

37
In our case you should choose the second option and click on OK. Following this, a new
network appears as in picture below.

Last network in every program must contain END instruction. Since this is a simple
example, second network is also the last. End instruction is found among the functions.
In order to come to it, you need to click on FUN icon following which a window as in
picture below will come up.

Selecting a function by clicking on FUN icon.

38
END instruction can be obtained either by writing in "END" in newly obtained window or
by clicking on Select which gives all PLC controller instructions sorted by the regions as
in the following picture.

Selecting END instruction from a set of instructions sorted in regions.

By entering the END instruction your writing of a program is finished. Finished program
looks as in the following picture.

Finished myprog.swp program

39
6.4 Saving a project

Since you've finished writing a program, you need to save a project. Select Save Project
option from a File menu, and write in the file name in a message window (myprog.swp in
this case). After you click on OK, project will be saved. You can access SYSWIN file
contents only from SYSWIN; file type is identified by extension:

Project.swp - SYSWIN program

Project.swl- SYSWIN library

Project.swt - SYSWIN pattern

Project.swb - SYSWIN back-up file

Project.prg - PMD program

6.5 Program transfer to PLC controller

First you need to check whether PLC is connected with a PC correctly, and you'll do this
by checking physical connection through a serial cable. Following this you need to select
a Communication option from Project menu in order to set parameters for serial
communication. Of all the parameters, the most important one to be selected is a serial
port of a computer that PLC is connected to. Default settings for CPM1A are: COM1,
9600 Baud, Unit 00, protocol ASCII 7 bit Even Parity 2 stop and they need to be left so.
To check how communication functions, you can click on Test PLC to test link with a PLC
controller.

When a connection has been established, program transfer begins with a click on
download from Online menu. Select expansion function or memory allocation. Before you
program a PLC, it's good to erase program's memory contents. Finally, after a successful
program transfer to a PLC, a message window will come up to inform us of this.

6.6 Testing program function

Program check option from a Project menu allows testing of program function. Message
that appears following a command has several options that can be selected before you
run a test. Once these options have been selected, click on Execute, and a report on
testing and errors will be displayed. You can further check for errors, and there is also a
'Go to Network' command which transfers you to a segment where the error was found.

SYSWIN has classic editorial capabilities, such as Edit/Find or Edit/Replace commands.

Searching through a program for assigned values or symbols is quick and offers a large

40
number of optional filters. We can search through an entire program or its segments,
and this is defined with option call. Also, there are possibilities for defining a search path,
as well as for different actions when looking for a desired element.

Beside this, SYSWIN provides various advantages in situations where we need

permanent archiving of user program. It is especially important to periodically print
projects that are made quick and easy by SYSWIN. Projects can be printed in many
different formats, and printing can include specific sections of a project.

6.7 Meaning of "Tools" icons

SYSWIN has several types of editors among whom a relay diagram also known as relay
editor, or first editor that awaits us upon starting a SYSWIN program is the most
frequently used editor.

First we need to explain tools palette (Drawing Tools) and the meaning of each icon.
Aside through the usual mouse click, you can access the specific elements of this palette
from a keyboard. You'll find a corresponding key of the keyboard by each icon, and you
can accomplish the same action with it as you would using a mouse.

By clicking on the icon, we have selected a desired tool, and with a click on network
section this symbol will be stored in a program. Explanation for each of the icons is given
as follows:

Open contact icon. By clicking on this icon (or using a key '"') we enter an open contact
into Network. We need to position the element we have entered at a specified place
(black space). Following this, a message window where data can be entered (open
contact address-number of words, bit position) is activated automatically.

Closed contact icon. By clicking on this icon (or '/' on keyboard) we enter a closed
contact or inverted condition into network.

Horizontal line. By clicking on this icon (or using '-' on a keyboard), horizontal line is
lengthened out from left to right. SYSWIN, however, retains a right to make drawn lines
optimal in terms of length, or to point out possible errors. This option is used when you
need to add another condition before an instruction contingent upon this condition, or
when something simply can not fit.

41
Vertical line. With a click on this icon, or use of '?', we draw vertical lines from top to
bottom. This option is necessary to realize parallel connections between contacts.

Output instruction. This represents an instruction that is executed if condition instruction

preceding it is executed. With the help of this instruction we advance a result of logical
expression with output variables (bits). We can arrive to this instruction with the help of
keyboard ('O' key).

Inverted output instruction (shortcut-key 'Q'). Similarly to the previous case, with this
executing instruction we advance a result of logical expression to an output bit, and the
only difference is that this bit is turned on if a condition is not executed and vice versa.

PLC functions (shortcut-key 'F'). Click on this icon accomplishes possibility of installment
of complex PLC instructions into a program. Window that appears following a click on the
icon contains all instructions sorted by sections. Some of these instructions are given
separately as icons, and some can be accessed only through this option. One such
instruction is END instruction which is used in each program. Window that comes up is
displayed in the following picture.

When this window pops up, select an instruction and click on OK.

Click on this icon (or using 'T' key) will give you an option to enter a timer into the
program. Using a mouse, click on the bright area of the monitor, and a message window
comes up where you can enter needed information relating to a timer (timer designation
and duration in milliseconds). This way, we get a classic timer or timer with a delay when
turned on. If some other version of a timer is needed, preceding FUN icon should be
used, and option Timers and counters (see picture above) selected.

Counter icon. Click on this icon (or 'C' key), and this will install a classic counter into a
PLC program. Prior to this we enter needed information in message window: designation
of the counter (CNT001 for instance) and counter value. Change of counter status
(decrementing by 1) is done when an input signal (CP) changes from OFF to ON status.

42
With this icon we can invert previously entered contact, output or input. Inversion is
done so that we first click on this icon, and then on a variable whose inversion we wish
to perform.

Erase icon. Click on this icon and a shaded area of network erases the shaded part of the
program.

Mouse plays an important part in the SYSWIN program. Each double-click on any PLC
instruction results in a corresponding editor where necessary changes can be entered.
This principle is accordingly installed into SYSWIN, so double-click on block or network
heading (BLOCK HEADER BAR or NETWORK HEADER BAR) gives the same results.

6.8 PLC controller working modes

There are several ways to find out the present working mode, for example from an
Online Mode menu or its display in a Toolbar. This option is accessible if communication
was successfully established with a PLC controller.

If we choose a mode that differs from a present one, change of mode will be momentary.
In order to avoid an accidental change of PLC controller mode, there is an option that
obliges a computer to ask a question before each mode change, whether that is the
option a user really wants (this option is included as default). PLC controller has three
modes in class C, MONITOR, RUN and PROGRAM/STOP mode.

6.9 RUN MODE

This PLC mode enables program to be executed as basic operation. It is used in final
testing, after a program has been tested in detail, and errors have been eliminated.
SYSWIN can not change memory contents of PLC controller in this mode, neither is the
change of a program being executed possible. Of course, when program is finished and
tested, PLC begins its new life in command closet, being first set to RUN mode.

6.10 Monitor mode

In this mode, program execution is possible, as well as editing and monitoring during
operation. This is the most frequently used mode in program development. When this
mode has been selected, controller has an obligation to supply a PC with information
which relates to program itself, or more precisely to status of variables in the program. If
we additionally confirm Monitoring option from an Online menu, we can follow current
values of variables on the monitor itself, in real time.

All changes in inputs and outputs can be viewed on the monitor, and status of variables
and program locations used in the program are registered and memorized.

6.11 Program-Stop mode

Choosing this mode simply stops a PLC controller if PLC was in RUN or MONITOR mode.
It is used for data and program transfer to PLC controller.

6.12 Program execution and monitoring

Program transferred from a PC to a PLC starts executing at the moment when you move
from a Stop/Program mode to a Monitor or Run mode. When Monitoring function starts
executing, some sections of the monitor will be shaded (see picture above), and this way
you can follow program execution. Monitoring is active during editing of some program
segment, and is stopped at the moment when a changed section of the program is

43
transferred into a PLC controller.

6.13 Impact on the program during monitoring

During monitoring, you can use the right button on the mouse to call up a menu of some
elements of ladder diagram. Menu that appears when we click on location where address
of some bit is positioned, contains the following elements:

Force Set - used for permanent forced set up of bit status to ON

Force Reset - used for permanent forced set up of bit status to OFF
Cancel - cancels out the forced status
Set (1) - used for a brief change of bit status from OFF to ON status
Reset (0) - used for a brief change of bit status from ON to OFF status
Cancel All - cancels out forced status of all bits

With the help of these options, status of bits can be changed, word contents in controller
memory can also be changed, and all or some of the earlier forced settings can be
cancelled out. The concept of forcing entails forced set up of some input/output to ON or
OFF status for program reevaluation. At the moment when PLC leaves monitoring
regime, data on forced bits and words is lost. Simultaneous forcing and evaluation of
contents of a greater number of dimensions, and Data Set Bar is used for this, usually
found at the bottom of the monitor (see previous picture). Editing as well as defining an
area in Data Set Bar is accomplished with a double click following which a corresponding
message window appears, and we write here address for the bit whose status we are
following.

6.14 Graphic representation of dimension changes in a program

SYSWIN allows graphic representation of dimensions with time as abscissa. When a

monitoring mode is in use, monitor display changes through time, showing changes in
values of monitored dimensions. Monitor refreshment is done after a reception of each
sample where sample intervals are 0,1-65.5 seconds. Graphics saved in this way can be
stored for later analysis as a file, or read in an already saved file.

Procedure for starting graphic monitoring is following:

- from Editors menu select Time chart monitoring option

- from a new tools palette select Trace Configure (pictured as a key).
- Fill out message box Configure Time Chart Monitor (see next picture)
- From Online menu choose Tracing.

With Trace/Configure command adjust parameters for monitoring. Necessary parameters

are Trigger or an event where saving will begin, sampling period and bits and/or words
whose values we are monitoring. Mapping of a time diagram for dimensions previously
specified begins after the last command.

Quitting is done with a click on a black square icon, and restarting is performed by
clicking on an a red circle icon. Return to the editor with a ladder diagram by clicking on
Editors menu and Program editor submenu.

44
CHAPTER 7 EXAMPLES
Introduction
7.1 Self-maintenance
7.2 Making large time intervals
7.3 Delays of ON and OFF status
7.4 Counter over 9999
7.5 Alternate ON-OFF output
7.6 Automation of parking garage
7.7 Operating a charge and discharge process
7.8 Automation of product packaging
7.9 Automation of storage door

Introduction

Programming only related examples make up the first group of examples. They are given
as separate small programs that can later be incorporated into larger ones. Second
group consists of examples which can be applied to some real problems.

7.1 Self-maintenance

Program allows input to remain at ON status even when the condition that brought it to
that status stops. Example in picture below illustrates how use of a key connected to the
input IR000.00 changes IR010.01 output status to ON. By letting the key go, output
IR010.01 is not reset. This is because IR010.01 output keeps itself at status ON through
OR circuit (having IR000.00), and it stays in this status until key at input IR000.01 is
pressed. Input IR000.01 is in I connection with the output pin IR010.01 which cancels
out a condition, and resets an IR010.01 bit. Example of self-maintenance is quite
frequent in specific applications. If a user was connected to IR010.01 output, START and
STOP functions could be realized from two keys (without the use of switches).
Specifically, input IR000.00 would be a START key, and IR000.01 would be a STOP key.

7.2 Making large time intervals

If it's necessary to make a bigger time interval of 999.9 seconds (9999x0.1s) two linked
timers, or a timer and a counter can be used as in this example. Counter is set to count

45
to 2000, and timer is set to 5 seconds which gives a time interval of 10.000 seconds or
2.77 hours. By executing a condition at IR000.00 input, timer begins to count. When it
reaches the limit, it sets a flag TIM001 which interrupts the link and simultaneously
resets a timer. Once 5 seconds have run out, flag TIM001 changes its status to ON and
executes a condition at the counter input CNT002. When a counter numbers 2000 such
changes in timer flag status, TIM001 sets its flag CNT002 which in turn executes a
condition for IR010.00 to change status to ON. Time that has elapsed from the change of
IR000.00 input status to ON and a change of IR010.00 input status to ON comes to
10.000 seconds.

Ladder Diagram:

7.3 Delays of ON and OFF status

Example shows how to make output (IR010.00) delay as opposed to ?(in relation to ??
unclear meaning) input (IR000.00). By executing a condition at IR000.00 input, timer
TIM000 begins counting a set value 10 in steps of 0.1 seconds each. After one second
has elapsed, it set its flag TIM000 which is a condition in changing output status
IR010.00 to ON. Thus we accomplish a delay of one second between ON status of
IR000.00 input and ON status IR010.00 input. By changing IR010.00 output status to
ON, half of the condition for activation of the second timer is executed. Second half of
the timer is executed when IR000.00 input changes status to OFF (normally closed
contact). Timer TIM001 sets its flag TIM001 after one second, and interrupts a condition
for keeping an output in ON status.

46
Ladder Diagram:

7.4 Counter over 9999

If you need to count over 9999 (maximum value for a counter), you can use two
connected timers. First counter counts up to certain value, and the other one counts flag
status changes of the first counter. Thus you get the possibility of counting up to a value
which is a result of set values of the first and second counter. In an example at the
bottom, first counter counts up to 1000, and second up to 20 which allows you to count
to 20000. By executing a condition at IR000.00 input (line whose changes are followed is
brought to it), first counter decreases its value by one. This is repeated until counter
arrives at zero when it sets its flag CNT001 and simultaneously resets itself (is made
ready for a new cycle of counting from 1000 to 0). Each setting of CNT001 influences the
other counter which sets its flag after twenty settings of the first counter's flag. By
setting CNT002 flag of the second counter, a condition is executed for an IR010.00
output to be activated and to stay in that status through self-maintenance.

Ladder Diagram:

47
Same effect can be achieved with a modified program below. First change is that there is
a "switch" for the whole program, and this is IR000.00 input (program can accomplish its
function only while this switch is active). Second change is that the line whose status is
followed is brought to IR000.01 input. The rest is the same as in the previous version of
the program. Counter CNT002 counts status changes of the CNT001 counter flag. When
it numbers them, it changes the status of its flag CNT002 which executes the condition
for status change of IR010.00 output. This changes IR010.00 output status after 20000
changes of input IR000.01.

Ladder Diagram:

48
7.5 Alternate ON-OFF output

Example makes a certain number of impulses of desired duration at PLC controller

IR010.00 output. Number of impulses is given in instruction of the counter (here it is a
constant #0010 or ten impulses) impulse duration in two timer instructions. First timer
defines duration of ON status, and second one duration of OFF status of IR010.00 output
bit. In the example these two durations are the same, but through assigning them
different parameters they can differ so that duration of ON status can be different from
duration of OFF status.

Program starts executing a condition at IR000.00 bit. Since a normally closed contact
which refers to counter flag (that isn't set ) is linked with this IR000.00 bit in "I" circuit,
this status of IR200.00 bit will change to ON. Bit IR200.00 keeps its status through self-
maintenance until counter flag is not set and a condition interrupted.

When an IR200.00 bit is set, timers TIM001 and TIM002 start counting a set interval
number at 0.1 s ( in the example, this number is 10 for the first timer, or 20 for the

49
second timer, and this sets the period of one or two seconds). With both timers, a
normally closed contact which refers to TIM002 timer flag is connected with IR200.00
bit. When this flag is set which happens every two seconds, both timers are reset. Timer
TIM002 resets timer TIM001 and itself, and this starts a new cycle.

At the start of a program, IR010.00 output bit changes status to ON and stays in this
status until TIM001 flag changes status to ON (after one second). By changing TIM001
flag status to ON, condition is broken (because it is represented as normally closed
contact) and IR010.00 bit changes status to OFF.

IR010.00 output status changes to ON again when time has run out on TIM002 timer.
This resets TIM001 timer and its flag which in turn executes a condition for status
change of the IR010.00 output. Cycle is thus repeated until a counter numbers 10
changes of TIM001 flag status. With the change of status of CNT000 counter flag, a
condition for an assisting bit IR200.00 is broken, and program stops working.

Ladder Diagram:

50
7.6 Automation of parking garage

We are dealing with a simple system that can control 100 car at the maximum. Each
time a car enters, PLC automatically adds it to a total sum of other cars found in the
garage. Each car that comes out will automatically be taken off. When 100 cars park, a
signal will turn on signalizing that a garage is full and notifying other drivers not to enter
because there is no space available.

Signal from a sensor at the garage entrance sets bit IR200.00. This bit is a condition for
execution of the following two instructions in a program. First instruction resets carry bit
CY (it is always done before some other calculation that would influence it), and the
other instruction adds one to a number of cars in word HR00, and a sum total is again
stored in HR00. HR memory space is selected for storing a total number of cars because
this keeps the status even after supply stops.

Symbol "#" in addition and subtraction instructions defines decimal constant that is
being added or subtracted from a number of cars already in the garage. Condition for
executing comparison instruction CPM is always executed because bit SR253.13 is
always set; this practically means that comparison will be done in each cycle regardless
whether car has entered or left the garage.

Signal lamp for "garage full" is connected to an output IR010.00. Working of the lamp is
controlled by EQ (equal) flag at address SR255.06 and GR (greater than) flag at address
SR255.05. Both bits are in OR connection with an output IR010.00 where the signal
lamp is. This way lamp will emit light when a number of cars is greater than or equal to
100. Number of cars in a real setting can really be greater than 100 because some
untrusting driver may decide to check whether there is any space left, and so a current
number of cars can increase from a 100 to 101. When he leaves the garage, a number of
cars goes down to 100 which is how many parking spots there are in fact.

51
Ladder diagram:

52
7.7 Operating a charge and discharge process

Charge and discharge of a reservoir is a common process in industry as well as a need

for mixing two or more substances. By using automated valves this process can be
completely automated. Let's say that fluid used in the example is water, and that a
reservoir has to be filled up and emptied four times.

When you push T1 on the operating panel, valve V1 opens and a reservoir starts filling
up with water. At the same time, motor M of the mixer starts working. When the
reservoir fills up, water level goes up and reaches the level set by a sensor S1. V1 valve
closes and motor of the mixer stops. Valve V2 opens then, and a reservoir starts
emptying. When water level falls below the level set by a sensor S2, valve V2 closes. By
repeating the same cycle four times, lamp that indicates end of a cycle is activated.
Pressing T1 key will start a new cycle.

Both types of differentiators are used in this example. You can get an idea of what their
role is from picture below. Level S1 and S2 sensors provide information on whether fluid
level goes beyond a specified value. This type of information is not important when you
wish to know whether fluid level goes up or down in a certain sequence. Mainly, event of
approaching the upper level, or a moment when fluid that fills up a reservoir goes
beyond upper level and activates sensor S1 is detected in segment 3 of a ladder
diagram. Brief activation of IR200.02 output has as a consequence a turn off of an
output V1 (valve for water, prevents further flow of water but also motor operation in the
mixer). Moment prior to this (segment 5) valve V2 turns on which marks a beginning of

53
fluid outflow. Other two differentiators (in segments 6 and 7) have a task of registering
events such as closing a valve MV2 and drop in fluid level below allowed minimum.

Ladder diagram:

54
55
7.8 Automation of product packaging

Product packaging is one of the most frequent cases for automation in industry. It can be
encountered with small machines (ex. packaging grain like food products) and large
systems such as machines for packaging medications. Example we are showing here
solves the classic packaging problem with few elements of automation. Small number of
needed inputs and outputs provides for the use of CPM1A PLC controller which
represents simple and economical solution.

56
By pushing START key you activate Flag1 which represents an assisting flag (Segment 1)
that comes up as a condition in further program (resetting depends only on a STOP key).
When started, motor of an conveyor for boxes is activated. The conveyor takes a box up
to the limit switch, and a motor stops then (Segment 4). Condition for starting a
conveyor with apples is actually a limit switch for a box. When a box is detected, a
conveyor with apples starts moving (Segment 2). Presence of the box allows counter to
count 10 apples through a sensor used for apples and to generate counter CNT010 flag
which is a condition for new activation of a conveyor with boxes (Segment 3). When the
conveyor with boxes has been activated, limit switch resets counter which is again ready
to count 10 apples. Operations repeat until STOP key is pressed when condition for
setting Flag1 is lost. Picture below gives a time diagram for a packaging line signal.

57
Ladder diagram:

58
7.9 Automation of storage door

Storage door or any door for that matter can be automated, so that man does not have
to be directly involved in their being opened or closed. By applying one three-phased
motor where you can change direction of its movement, doors can be lifted up and
lowered back down. Ultrasonic sensor is used in recognizing presence of a vehicle by the
doors, and photo-electric sensor is used to register a passing vehicle. When a vehicle
approaches, the doors move up, and when a vehicle passes through the door (a ray of
light is interrupted on photo-electric sensor) they lower down.

59
By setting a bit IR000.00 at the PLC controller input where ultrasonic sensor is
connected, output IR010.00 (a switch is attached to this output) is activated, so that a
motor lifts the doors up. Aside from this condition, the power source for lifting the doors
must not be active (IR010.01) and the doors must not be in upper position already
(IR000.02). Condition for upper limit switch is given as normally closed, so change of its
status from OFF to ON (when doors are lifted) will end a condition for bit IR010.00 where
power source for lifting the doors is (Segment 1).

Photo-electric switch registers a vehicle that passes by, and sets flag IR200.00. DIFD
instruction is used. This instruction is activated when a condition that precedes it
changes status from ON to OFF. When a vehicle passes through a door, it interrupts a ray
and bit IR000.01 status changes from ON to OFF (Segment 2).

60
By changing status of an assisting flag from OFF to ON a condition for lowering a door is
executed (Segment 3). Aside from this condition, it is necessary that a unit power source
for lifting a door is turned off, and that door is not in lower position already. Bit which
operates this power source for lowering, IR010.01 is automatic, so doors are lowered
until they come to the bottom limit switch which is represented in a condition as
normally closed. Its status change from OFF to ON interrupts a condition of the power
source for lowering doors. With oncoming new vehicle, cycle is repeated.

Ladder diagram:

61
APPENDIX A Expanding the number of input/output lines
INTRODUCTION

A.1 Differences and similarities

A.2 Marking the PLC controller

A.3 Specific case

Introduction

This appendix is an answer to the question “What if more input or output lines are
needed ?”. Model detailed in the book carries the mark CPM1A-10CDR-A and is taken as
an optimal for it’s price and features. Alternative models with greater number of lines
include CPM1A-20CDR-A, CPM1A-30CDR-A or CPM1A-40CDR-A. The last two can be
expanded with three additional modules with 20 extra I/O lines each, totaling 100 I/O
lines as a maximum (if this is still insufficient, maybe it is time for you to start using
some of more powerful PLC controllers).

If not even the most powerful model of CPM1A family satisfies your needs, then extra
modules with 20 I/O lines are added. This form of connection reaches 100 input/outputs,
which is a significant number in industrial proportions.

A.1. Differences and similarities

Taking the other model of PLC controller from CPM1A class basically doesn’t change a
thing! Everything said for one model also applies to the other. Only thing that changes is
the number of screw terminal and the number of bits in IR area connected to that screw
terminal. If model with 10 I/O lines (model described in the book) has 6 inputs on
addresses IR0000 - IR0005, then the 20 I/O lines model will have 12 inputs on
addresses IR0000 - IR0011. Expanding itself should not be a problem. After taking off
the cover on the right side, there is a connector which is then connected to the
expansion module via flat cable. Still, it requires skill when assigning inputs and outputs
because expansion increases the cost of the project. All the models and expansions of
CPM1A class carry additional marks defining them more precisely.

Output Power
Description Input points Model Number
points Supply

62
10 I/O 6 points 4 point 100 to240 CPM1A-10CDR-
points Relay VAC, 50/60 A
Output Hz

24 VDC CPM1A-10CDR-
D
Transistor 24 VDC CPM1A-l0CDT-
NPN D
Transistor 24 VDC CPM1A-
PNP 10CDT1-D
20 I/O points 12 points 8 points 100 to 240 VAC, CPMlA-20CDR-
50/60 Hz A
24 VDC CPM1A-20CDR-
D
Transistor 24 VDC CPM1A-20CDT-
NPN D
Transistor 24 VDC CPMlA-
PNP 20CDT1-D
30 I/O points 18 12 points 100 to 240 VAC, CPM1A-30CDR-
points 50/60 Hz A
24 VDC CPM1A-30CDR-
D
Transistor 24 VDC CPM1A-30CDT-
NPN D
Transistor 24 VDC CPM1A-
PNP 30CDT1-D
40 I/O points 24 16 points 100 to 240 VAC, CPM1A-40CDR-
points 50/60 Hz A
24 VDC CPM1A-40CDR-
D
Transistor 24 VDC CPM1A-40CDT-
NPN D
Transistor 24 VDC CPM1A-
PNP 40CDT1-D

Notice that PLC controllers with 10 and 20 I/O lines do not have an expansion port.
Generally speaking, if there is the slightest possibility for expansion in the project, PLC
controller with 30 or 40 I/O lines should be used.

A.2. Marking the PLC controller

Marking the controller and the expansion module undergoes three criteria. The first is
voltage, the second is the type of input/output and the third is number of I/O lines. The
picture below is self-explanatory.

63
A.3. Specific case

If two 20 I/O lines expansion modules and one analog module are added to 30 I/O lines
model, assigned inputs/outputs will have the addresses from the following table.

Unit Assigned input bits Assigned output bits

Central processing unit IR 00000-IR 00011 and IR 01000-IR 01007 and IR
1
(CPM2A-30CDX-X) IR 00100-IR 00105 01100-IR 01103
Unit for I/O expansion
2 IR 00200-IR 02011 IR 01200-IR 01207
(CPM1A-20EDxxx)
Analog I/O unit (CPM1A- IR 00300-IR 03015 and
3 IR 01300-IR 01315
MAD01) IR 00400-IR 00415
Unit for I/O expansion
4 IR 00500-IR 00511 IR 01400-IR 01415
(CPM1A-EDxxx)

64
APPENDIX B Detailed memory map of PLC controller
INTRODUCTION

B.1 General explanation of memory areas

B.2 IR memory area

B.3 SR memory area

B.4 AR memory area

B.5 PC memory area

Introduction

Purpose of this appendix is to explain certain memory areas in detail. As the following
tables cover whole memory, there are options left unused in this book. They should be
skipped during the first reading, and used later according to needs.

B.1 General explanation of memory areas

Memory of PLC controller consists of several areas, some of these having predefined
functions.

Data area Word(s) Bit(s) Function

IR 000 - IR 009 (10 IR 00000 - IR 00915 (160 These bits may be
input area
words) bits) assigned to an external I/O
connection. Some of these
have direct output on
screw terminal (for
IR 010 - IR 019 (10 IR 01000 - IR 01915 (160 example, IR000.00 -
output area
words) bits) IR000.05 and IR010.00 -
IR area
IR010.03 with CPM1A
model)
Working bits that can be
working IR 200 - IR 231 (32 IR 20000 - IR 23115 (512 used freely in the program.
area words) bits) They are commonly used
as swap bits
SR 232 - SR 255 (24 SR23200 - SR25515 (384 Special functions, such as
SR area
words) bits) flags and control bits
Temporary storage of
TR area --- TR 0 - TR 7 (8 bits) ON/OFF states when jump
takes place
Data storage; these keep
HR0000 - HR1915 (320
HR area HR 00 - HR 19 (20 words) their states when power is
bits)
off
AR0000 - AR1515 (256 Special functions, such as
AR area AR 00 - AR 15 (16 words)
bits) flags and control bits
LR0000 - LR1515 (256 1:1 connection with
LR area LR 00 - LR 15 (16 words)
bits) another PC
Same numbers are used
Timer/counter area TC 000 - TC 127 (timer/counter numbers) for both timers and
counters

65
 Data of DM area may be
DM 0000 - DM 0999 and accessed only in word
Read/write DM 1022 - DM 1023 --- form. Words keep their
(1002 words) contents after the power is
off
DM 1000 - DM 1021 (22 Part of the memory for
Error writing ---
words) storing the time and code
of error that occurred.
DM area
When not used for this
purpose, they can be used
DM 6144 - DM 6599 (456 as regular DM words for
Read only ---
words) reading and writing. They
cannot be changed from
within the program
DM 6600 - DM 6655 (56 Storing various parameters
PC setup ---
words) for controlling the PC

Note:
1. IR and LR bits, when not used to their purpose, may be used as working bits.
2. Contents of HR area, LR area, counter and DM area for reading/writing is stored within
backup condenser. On 25C, condenser keeps the memory contents for up to 20 days.
3. When accessing the current value of PV, TC numbers used for data have the form of
word. When accessing the Completing flags, they are used as data bits. 4. Data from
DM6144 to DM6655 must not be changed from within the program, but can be changed
by peripheral device.

B.2. SR memory area

IR area doesn’t have predefined memory locations, but is meant for general use in the
program. Of all the locations this memory area consists of, only those directly connected
to PLC controller input/output lines are of interest for this appendix.

IR area can be divided into 3 parts:

1. Input area is located from word IR000 to IR009, totaling 160 bits. Most important of
these are in the word IR000 because they are directly connected to screw terminal of
PLC controller. Input IR000.01 is directly connected to screw terminal marked with 01 on
the casing of the PLC controller.

2. Output area is located from word IR010 to IR019, totaling 160 bits. Most important of
these are in the word IR010 because they are directly connected to screw terminal of
PLC controller. Output IR000.00 is directly connected to screw terminal marked with 00
on the casing of the PLC controller.

3. Working area is located from word IR200 to IR231 totaling 512 bits for general use.

As IR memory area does not have predefined memory locations, more detailed
explanations are not necessary.

B.3. IR memory area

Unlike IR area, SR area does have predefined memory locations. These bits are usually
tied to the PLC controller work or contain current and set values of different functions.
Purpose of specific memory locations of SR area is explained in the following table:

Words Bits Function

SR 232 - SR 235 00 - 15 Input area for macro functions. Contains input operands for
MCRO(99) (may be used for working bits, when MCRO(99) is not

66
 used)
Output area for macro functions. Contains output operands for
SR 236 - SR 239 00 - 15 MCRO(99) (may be used for working bits, when MCRO(99) is not
used)
Contains set value SV, when input interrupt 0 is used in counter
SR 240 00 - 15 mode (4 hexadecimal digits) (may be used for working bits,
when input interrupt 0 is not used in counter mode)
Contains set value SV, when input interrupt 1 is used in counter
SR 241 00 - 15 mode (4 hexadecimal digits) (may be used for working bits,
when input interrupt 1 is not used in counter mode)
Contains set value SV, when input interrupt 2 is used in counter
SR 242 00 - 15 mode (4 hexadecimal digits) (may be used for working bits,
when input interrupt 2 is not used in counter mode)
Contains set value SV, when input interrupt 3 is used in counter
SR 243 00 - 15 mode (4 hexadecimal digits) (may be used for working bits,
when input interrupt 3 is not used in counter mode)
Contains current value (PV-1), when input interrupt 0 is used in
SR 244 00 - 15
counter mode (4 hexadecimal digits)
Contains current value (PV-1), when input interrupt 1 is used in
SR 245 00 - 15
counter mode (4 hexadecimal digits)
Contains current value (PV-1), when input interrupt 2 is used in
SR 246 00 - 15
counter mode (4 hexadecimal digits)
Contains current value (PV-1), when input interrupt 3 is used in
SR 247 00 - 15
counter mode (4 hexadecimal digits)
Contains current value PV of the high-speed counter (may be
SR 248, SR 249 00 - 15
used for working bits, when high-speed counter is not used)
Analog setting of value 0. Keeps 4 digit BCD value (0000 - 0200)
SR 250 00 - 15
set via analog potentiometer on the PLC controller casing.
Analog setting of value 1. Keeps 4 digit BCD value (0000 - 0200)
SR 251 00 - 15
set via analog potentiometer on the PLC controller casing.
SR 252 00 Reset of the high-speed counter

01 - 07 Not used

Peripheral port. Switches on for the reset of the peripheral port

(this doesn't apply to a case when peripheral device is
08
connected). Bit automatically changes state to OFF after the
reset

09 Not used

PLC Setup Reset Bit. When on, it initializes PC setup (DM6600-

10 DM6655). It automatically goes to OFF after the reset. This
applies only if the PC is in PROGRAM mode
Forced Status Hold Bit. OFF: bits used in the operation of forced
set/reset are cleared when changing from PROGRAM to
11 MONITOR mode. ON: bits used in the operation of forced
set/reset keep their states when changing from PROGRAM to
MONITOR mode.
I/O Hold bit. OFF: IR and LR bits are reset when starting or
12 ending an operation. ON: IR and LR bits keep their states when
starting or ending an operation.

13 Not used

Error Log Reset Bit. Bit state OFF clears the record of error
14
taking place. Bit automatically goes off after the operation

15 Not used

FAL error code. Location contains error code (2 digit number).

FAL number is stored at this location upon executing FAL(06) or
SR 253 00 - 07
FAL(07) instructions. Location contents are reset upon executing
FAL 00 instruction or by clearing an error from peripheral device

08 Not used

Cycle Time Overrun Flag. Bit goes to ON when program length

09 doesn't allow cycle of input/output scanning to be executed in a
specified time period

10 - 12 Not used

13 Flag always on

67
 14 Flag always off

First Cycle Flag. Goes ON during the first cycle at the beginning
15
of the operation
SR 254 00 1 min clock impulse (30s on, 30s off)

01 0.02s clock impulse (0.01s on, 0.01s off)

02 Negative (N) flag

03 - 05 Not used

06 Differential Monitor Flag

07 STEP(8) execution flag

08 - 15 Not used

SR 255 00 0.1s clock impulse (0.05s on, 0.05s off)

01 0.2s clock impulse (0.1s on, 0.1s off)

02 1.0s clock impulse (0.5s on, 0.5s off)

Instruction Execution Error (ER) Flag. Changes state to ON if

03
error occurs during instruction execution

04 Carry (CY) flag

05 "Greater than" (GR) flag

06 "Equals" (EQ) flag

07 "Less than" (LE) flag

08 - 15 Not used

B.4. AR memory area

Purpose of this memory area is to provide information on PLC controller state,

malfunctions and some system data. Memory locations of this area keep their states
after the power has been shut down.

Word(s) Bit(s) Function

AR00 and AR01 00 - 15 Not used
Status flag of the first I/O unit for expanding I/O lines (I/O units
AR02 00
status flag)
Status flag of the second I/O unit for expanding I/O lines (I/O
01
units status flag)
Status flag of the third I/O unit for expanding I/O lines (I/O units
02
status flag)

03 - 07 Not used

12 - 15 Number of connected I/O units

AR03 - AR07 00 - 15 Not used

AR08 00 - 07 Not used

08 - 11 Peripheral device error code

12 Flag of peripheral device error

13 Peripheral Device Transmission Enabled Flag

14 - 15 Not used

AR09 00 - 15 Not used

AR10 00 - 15 Power-off counter. Contains 4-digit BCD value
AR11 00 - 07 High-speed Counter Range Comparison Flags

08 - 14 Not used

68
 15 Pulse Output Status. ON: stopped; OFF: Impulse at output

AR12 00 - 15 Not used

Power-up PC Setup Error Flag. Goes ON when error occurs in
AR13 00
area DM 6600 - DM 6614
Start-up PC Setup Error Flag. Goes ON when error occurs in area
01
DM 6615 - DM 6644
RUN PC Setup Error Flag. Goes ON when error occurs in area DM
02
6645 - DM 6655

03 - 04 Not used

Long Cycle Time Flag. Goes ON if real cycle length exceeds

05
length set in DM 6619

06 - 07 Not used

Memory Area Specification Error Flag. Goes ON when non-

08
existing address is specified in the program

09 Flash Memory Error Flag

Read-only DM Error Flag. Goes ON when checksum error occurs

10
in DM 6144 - DM 6599 range
PC Setup Error Flag. Goes ON when checksum error occurs in PC
11
Setup area
Program Error Flag. Goes ON when checksum error occurs in
12
program memory (UM) or inappropriate instruction is executed

13 Expansion Instruction Error Flag

14 - 15 Not used

Maximum Cycle Time. 4 BCD digits. Cleared at the beginning of

AR14 00 - 15
the operation
Current Cycle Time. 4 BCD digits. Not cleared when the
AR15 00 - 15
operation ends

Note:
1. IR and LR bits when not used for their function may be used as working bits.
2. Contents of HR area, LR area, counter, and DM area for reading/writing are kept by
battery of central processing unit. In case that the battery is removed or malfunction
occurs, this data will be lost.
3. When accessing the current value of PV, TC numbers used for data have form of word.
When accessing Completing flags, they are used as data bits.
4. Data stored from DM6144 to DM6655 cannot be changed from within the program,
but can be changed by peripheral device.
5. Program and data from DM 6144 to DM 6655 are stored in the flash memory.

B.5. PC memory area

PLC setup area can be roughly divided into 4 categories:

1. Settings related to basic operations of PLC controller and I/O processes

2. Settings related to cycle duration
3. Settings related to interrupts
4. Settings related to communication.

Word(s) Bit(s) Function

Settings are active only upon resetting the PLC and sending data from PC to PLC
Startup Mode. Active only if bits 08 - 15 are set to 02. 00:
DM 6600 00 - 07
PROGRAM; 01: MONITOR; 02: RUN
08 - 15 Startup mode designation. 00: programming console switch; 01:

69
 proceeds in the mode last used before turning off the power; 02:
settings in 00 - 07
DM 6601 00 - 07 Not used (set to 0)

08 - 11 IOM Hold Bit (SR 25212). 0: Reset; 1: Keeps the state

12 - 15 Forced Status Hold Bit (SR 25211). 0: Reset; 1: Keeps the state

Writing to program memory protection. 00: OFF; 01: ON (except

DM 6602 00 - 03
for DM 6602)
Programming console display language. 00: English; 01:
04 - 07
Japanese

08 - 11 Not used

DM 6603 00 - 15 Not used

00: in case of battery malfunction, error will not be generated;
DM 6604 00 - 07
01: in case of battery malfunction, error will be generated

08 - 15 Not used

DM 6605 - DM 6614 00 - 15 Not used

Cycle Time Settings (DM 6615 - DM 6619) take effect after the transfer to PC area, next time you start
working
DM 6615 - DM 6616 00 - 15 Not used
Servicing time for peripheral port. Active when bits 08 - 15 are
DM 6617 00 - 07 set to 01. It is expressed in percentage of cycle time duration
(00 to 99 (BCD))
Peripheral port servicing setting enable. 00: 5% of cycle
08 - 15
duration; 01: time defined in first half of the word
Cycle monitor time. Settings are identical to those of the second
DM 6618 00 - 07
half of the previous word
Cycle monitor enable (Setting in 00 to 07 x unit; 99 5 max).
08 - 15 00:120ms (settings in bits 00-07 are disabled) ; 01: setting unit
10ms; 02: setting unit 100ms; 03: setting unit 1s
Cycle time. 0000: variable (no minimum); 0001: up to 9999
DM 6619 00 - 15
(BCD). Minimal time is expressed in ms
Interrupt Processing (DM 6620 - DM 6639) take effect after the transfer to PC area, next time you start
working
Input constant for IR 00000 - IR 00002. 0: 0.8ms; 1: 1ms; 2:
DM 6620 00 - 03
2ms; 3: 4ms; 4: 8ms; 5: 16ms; 6: 32ms; 7: 64ms; 8: 128ms
Input constant for IR 00003 and IR 00004. Settings are same
04 - 07
as with bits 00-03
Input constant for IR 00005 and IR 00006. Settings are same
08 - 11
as with bits 00-03
Input constant for IR 00007 and IR 00011. Settings are same
12 - 15
as with bits 00-03
Input constant for IR 001. 0: 0.8ms; 1: 1ms; 2: 2ms; 3: 4ms;
DM 6621 00 - 07
4: 8ms; 5: 16ms; 6: 32ms; 7: 64ms; 8: 128ms

08 - 15 Input constant for IR 002. Settings are same as with IR 001

DM 6622 00 - 07 Input constant for IR 003. Settings are same as with IR 001

08 - 15 Input constant for IR 004. Settings are same as with IR 001

DM 6623 00 - 07 Input constant for IR 005. Settings are same as with IR 001

08 - 15 Input constant for IR 006. Settings are same as with IR 001

DM 6624 00 - 07 Input constant for IR 007. Settings are same as with IR 001
DM 6625 00 - 07 Input constant for IR 008. Settings are same as with IR 001

08 - 15 Input constant for IR 009. Settings are same as with IR 001

DM 6626 - DM 6627 00 - 15 Not used

Interrupt enabled on IR 00000. (0: regular input; 1: interrupt
DM 6628 00 - 03
input; 2: fast-reaction input)
Interrupt enabled on IR 00001. (0: regular input; 1: interrupt
04 - 07
input; 2: fast-reaction input)
Interrupt enabled on IR 00002. (0: regular input; 1: interrupt
08 - 11
input; 2: fast-reaction input)
12 - 15 Interrupt enabled on IR 00003. (0: regular input; 1: interrupt

70
 input; 2: fast-reaction input)
High-speed counter settings (DM 6640-DM 6644) take effect after the transfer to PC area, next time you
start working
DM 6640 - DM 6641 00 - 15 Not used
High-speed counter mode. 0: counting up/down; 4: incremental
DM 6642 00 - 03
mode
High-speed counter reset mode. 0: Z phase and software reset;
04 - 07
1: software reset only
High-speed counter enable. 0: high-speed counter not used; 1:
08 - 15
high-speed counter used with settings 00-07
DM 6643 - DM 6644 00 - 15 Not used
Peripheral port settings take effect after the transfer to PC area
DM 6645 - DM 6649 00 - 15 Not used
Port settings. 00: standard (1 start bit, even parity, 2 stop bits,
DM 6650 00 - 07 9600bps); 01: Settings in DM 6651 (settings other than this
cause error and turn on AR 1302)
Area for 1:1 connection with a PC via peripheral port. 0: LR00-
08 - 11
LR15
Modes of communication. 0: Host link; 2: one-to-one PC link
12 - 15 (slave); 3: one-to-one PC link (master); 4: NT link (settings
other than this cause error and turn on AR 1302)
Baud rate. 00: 1200 bps; 01: 2400 bps; 02: 4800 bps; 03: 9600
DM 6651 00 - 07
bps; 04: 19200 bps
Frame format (Start bits/Data bits/Stop bits/Parity).
00:1/7/1/even; 01:1/7/1/odd; 02:1/7/1/none; 03:1/7/2/even;
04:1/7/2/odd; 05:1/7/2/none; 06:1/7/1/even; 07:1/7/1/odd;
08 - 15
08:1/7/1/none; 09:1/7/2/even; 10:1/7/2/odd;
11:1/7/2/none (settings other than this cause error and
turn on AR 1302)
Host Link Transmission Delay (0000 - 9999ms)
DM 6652 00 - 15
(settings other than this cause error and turn on AR 1302)
Host Link (00 - 31 BCD)
DM 6653 00 - 07
(settings other than this cause error and turn on AR 1302)

08 - 15 Not used

DM 6654 00 - 15 Not used

Error log settings (DM 6655) take effect after the transfer to PLC controller
Style. 0: move after 7 records; 1: keep only first 7 (no
DM 6655 00 - 03
moving); 2-F: no records

04 - 07 Not used

Cycle Time monitor Enable. 0: detect long cycles as non-fatal

08 - 11
errors; 1: do not detect long cycles

12 - 15 Not used

71
APPENDIX C PLC diagnostics
INTRODUCTION

C.1 Diagnostic functions of PLC

C.2 Non-fatal errors

C.3 Fatal errors

C.4 User defined errors

C.5 Failure alarm - FAL(06)

C.6 Severe Failure alarm - FALS(07)

C.7 MESSAGE - MSG(46)

C.8 Syntax errors

C.9 Algorithm for finding errors in the program

Introduction

The whole work of PLC controller can be represented with a diagram shown on the
following page. After turning on the power, PLC is first initialized (clearing IR, SR i AR
areas, presetting system timers and checking I/O lines), and if no errors were detected,
monitoring process, program execution, calling the I/O lines and serving the peripheral
devices starts to occur in cycles.

72
C.1 Diagnostic functions of PLC

PLC controller features additional functions that make locating errors easier. Errors can
be divided into two categories according to severity :

1. Fatal errors are severe and they prevent PLC controller from operating until their
cause is located and solved.
2. Non-fatal errors are those that do not prevent PLC controller from operating. After
detecting one or more non-fatal errors, program execution will continue. Nevertheless, it
is necessary to correct these errors as soon as possible.

C.2 Non-fatal errors

When one of these errors takes place, indicators POWER and RUN will be on, and the
indicator ERR/ALM will blink. Upon locating non-fatal error, manual for the given PLC

73
controller should be consulted and the flags checked in order to understand the cause of
a problem and correct the error.

C.3 Fatal erros

When any of the fatal errors take place, PLC controller stops operating and all outputs
are shut down. PLC controller cannot be put back to work until the controller is turned off
and then turned back on, or until it is switched to PROGRAM mode via peripheral device
and the fatal error corrected. With these errors, indicators ERR/ALM are on, while the
RUN indicator remains off. It is necessary to check the error flag in the manual of the
given PLC in order to locate the cause of the problem and to correct the error.

C.4 User defined errors

There are three instructions for user to define his own errors or messages. FAL(06)
causes non-fatal error, FAL(07) causes fatal error, while MSG(46) sends a message to
program console or to the host computer connected to the PLC controller.

C.5 Failure alarm - FAL(06)

Instruction FAL(06) generates the code of non-fatal error that took place to provide the
information on the possible cause of the problem for the programmer. Upon execution of
the instruction FAL(06) following events take place:

1. Indicator ERR/ALM will blink, while PLC continues to work.

2. Two-digits BCD number of instruction FAL (01 do 99) is written from SR253000 to
SR25307.

Same number must not be assigned to both FAL and FALS instructions. To delete the
code of an error, error should be corrected and FAL 00 instruction executed.

C.6 Severe failure alarm - FALS(07)

Instruction FALS(07) generates the code of fatal error that took place. In this case the
following happens:

1. Program stops and all outputs are shut down.

2. Indicator ERR/ALM is turned on.
3. Two-digit BCD number (01 do 99) of instruction FALS is written from SR 253000 to
SR25307.
4. If memory card with RTC is used, part of the memory where the presence of error is
recorded will also contain numbers of FALS instruction and exact time when error took
place.

Numbers of FALS instruction can be assigned to certain states. Same number must not
be assigned to both FAL and FALS instructions. To delete FALS error, PLC controller must
be in PROGRAM mode, cause of error solved and then error code deleted.

C.7 Message - MSG (46)

MSG(46) is used for printing messages on program console display. Message cannot
exceed 16 characters, and it appears when specified condition is fulfilled.

74
C.8 Syntax errors

During the program check with operation Program Check, syntax errors are detected.
There are three levels of program check at user’s disposal. By selecting the level, types
of errors to be checked for are selected. The following table shows types of errors,
corresponding messages that appear on display and explains all of syntax errors. Zero
level check searches for errors of A, B and C type. First level check searches for errors of
A and B type, while the second searches only for errors of type A.

Type Message Meaning and the appropriate action

Program is damaged by creating non-existing function in the
????? code. Re-enter your program.
Number of logical blocks doesn't match the instructions of logical
CIRCUIT ERR blocks. Check the program.
Entered constant is not in allowed range. Change the constant so
OPERAND ERR that it fits in the proper range.
Program is missing the instruction END(01). Add END(01) to the
NO END INSTR last address of the program.
Instruction is in the wrong place of the program. Check what the
LOCN ERR instruction demands and correct the mistake.
A Instruction JME(04) is missing the instruction JMP(05). Correct
JME UNDEFD the number of jump and add the correct JME(04) instruction.
Same number of jump or subroutine is used twice in the
DUPL program. Correct the program so that each number is used only
once.
Instruction SBS(091) is programmed for non-existing
SBN UNDEFD subroutine. Correct the number of subroutine or create the
missing one.
STEP(08) with the number of section and STEP(08) without the
STEP ERR number of section are used illegally. Check the demands of
instruction STEP(08) and correct the mistake.
IL(02) and ILC(03) are not used in pair. Check if every
instruction IL(02) has its corresponding ILC(03). This message
IL-ILC-ERR will also appear in case that multiple IL(02) instructions were
used with single ILC(03) instruction. Check if that's exactly what
you wanted...
JMP(04) and JME(05) are not used in pair. Before proceeding,
JMP=JME ERR
B check if the program is written exactly the way you wanted.
If the address of instruction SBN(92) is displayed, there are two
different subroutines with the same number. Change one of the
numbers or delete one of the subroutines in question. If the
SEN-RET ERR address of instruction RET(93) is displayed, RET(93) wasn't used
appropriately. Check the demands of this instruction and correct
the mistake.
Same bit is controlled by more than one instruction (for
example, OUT, OUT NOT, DIFU(13), KEEP(11), SFT(10)...).
Although certain instructions allow this, you should check the
COIL DUPL demands of specific instructions, make sure that the program is
correct or rearrange the program so that each bit is controlled
by single instruction.
C JME(05) is used without JMP(04) with the same number of jump.
JMP UNDEFD Add the instruction JMP(04) with the same number or delete
JME(05) that is not used.
There is a subroutine that is not called by SBS(91). Add
SBS UNDEFD subroutine call to an appropriate place in the program or delete
the subroutine.

75
C.9 Algorithm for finding errors in the program

76
APPENDIX D Numerical systems
INTRODUCTION

D.1 Decimal numerical system

D.2 Binary numerical system

D.3 Hexadecimal numerical system

Introduction

People were always difficult to except the fact that something is different from
themselves or their way of thinking. It is probably one of the reasons why numerical
systems other than decimal are hard to understand. Still, whether we like it or not,
reality is quite different. Decimal system used in everyday life is by far less used than
binary code, which is the working basis for millions of computers across the world.

Each numerical system rests upon its basis. With decimal numerical system, this basis is
10, with binary it is 2, while with hexadecimal it equals 16. Value of each digit depends
on it’s position in the number, represented in certain numerical system. Sum of values of
each digit is the value of the number. Binary and hexadecimal systems are especially
interesting for this course. Besides these two, decimal system will be detailed, too, for
the sake of comparison. Although there is nothing new to tell about decimal system, we
will give it a look for its relations with other numerical systems.

D.1 Decimal numerical system

Decimal numerical system is defined with its basis 10 and decimal positioning from right
to left, and it consists of digits 0,1,2,3,4,5,6,7,8,9. This means that the rightmost digit is
multiplied by 1 in total sum, next digit to it is multiplied by 10, next one by 100, etc.

Example:

Operations of addition, subtraction, division and multiplication in decimal numerical

system are well known, so we will not detail these.

D.2 Binary numerical system

Binary numerical system is quite different from the decimal that we got used to in
common life. Its basis is 2 and each digit can have one of two values, “1” or “0”. Binary
numerical system is used for computers and microcontrollers, because it is much easier

77
for processing than decimal. Usually, binary number consists of 8, 16 or 32 binary digits.
Origins of this division are irrelevant for this course, so we will just take it for granted.

Example:
10011011 - binary number with 8 digits

To understand the logic of binary numbers, let us have an example. Let’s assume that we
have a cabinet with four drawers and that we should tell someone to bring us something
from one of these. Nothing simpler, we could say “in the lower row on the left” and it
would be quite sufficient. However, if it must be done without this kind of orientation,
left, right, up, down and the likes, then we have a problem. There is a plenty of solutions
for the situation, but we should look for the best and the most efficient! Let us mark the
columns with A and rows with B. If A=1, we assume the upper row of drawers, and if
A=0 we assume the lower. Similar with columns, B=1 is the left column and B=0 is the
right column (following picture). Now, it is easier to explain which drawer we think of,
just use one of the four combinations 00, 01, 10 or 11. This “naming” of each drawer is
nothing more than binary nomenclature of numbers, that is, converting decimal numbers
into binary system. In short, labels “first, second, third and fourth” are substituted with
“00, 01, 10 and 11”.

We still need to understand the logic of binary numerical system, i.e. how to get the
decimal value of a number out of the sequence consisting of ones and zeros. This
procedure is called conversion of binary number to decimal value.

As it can be seen, conversion of binary number to decimal value is done by totaling the
sum on the right. Depending on the position in the binary number, digits carry different
“weight” multiplied by themselves, and totaling them all gives us an understandable
decimal number.

Let’s further assume that there are marbles in each of the drawers, 2 in the first, 4 in the
second, 7 in the third and 3 in the fourth. Let the person opening the drawers also use

78
the binary system. Under these conditions, question would be “How many marbles are
there in 01?”, and the answer would be “There are 100 marbles in 01!” Notice that both
question and answer are clear, although we did not use common terminology. Further,
notice that two digits are sufficient for decimal numbers from 0 to 3, and that all values
greater than 3 require additional binary digits. Thus, for 0 ~ 7 range, three digits are
sufficient, four digits cover the range 0 ~ 15, etc. Simply put, the greatest decimal
number that can be represented with n binary digits is 2 raised to power n, decreased by
one.

Example:
24-1 = 16 - 1 = 15

So, 4 binary digits cover decimal values from 0 to 15, including the values “0” and “15”,
which is 16 different values.

Arithmetical operations that exist in decimal numerical system also apply in binary
system. In this chapter, we will cover only addition and subtraction, for simplicity sake.

Basic rules that apply to binary addition are:

Addition works similar to decimal numerical system - we add the digits of the same
weight. If both digits added are zero, the result remains zero, while “0” and “1” total “1”.
Two ones give zero, but one is carried to the left position.

We can do the check by converting these numbers to decimal system and adding them.
Value of the first number is 10, value of the second is 9 and 19 as result, which means
that operation was done correctly. Problem occurs when the result is greater than can be
represented with given number of binary digits. There are various solutions, one of them
being expanding the number of binary digits like in the example below.

Subtraction works on the same principles as addition does. Two zeros give zero in result,
as do two ones, while subtraction of one from zero requires borrowing one from the
higher position in binary number. Example:
Conversion of numbers to decimal system gives as values 10 and 9, with the result of
subtraction of 1, which is correct.

D.3 Hexadecimal numerical system

Hexadecimal numerical system has number 16 for basis. Therefore, there are 16
different digits used in this system. These are “0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E,
F”. Letters A, B, C, D, E and F represent values 10, 11, 12, 13, 14, 15 and are used for
the sake of easier notation. As with binary numerical system, we can apply the same
formula here for determining the greatest decimal number that can be represented with
a given number of hexadecimal digits.

79
Example:
162 - 1 = 256 - 1 = 255

Usually, hexadecimal numbers have prefix “$” or “0x” to emphasize the fact that
hexadecimal system is used. Thus, number A37E should be represented with $A37E or
0xA37E. No calculations are needed for converting the hexadecimal number to binary
system - it is simple substituting of hexadecimal digits with binary ones. Since maximum
value of hexadecimal digit is 15, 4 binary digits are required per one hexadecimal.

Example:
Check, i.e. converting both numbers to decimal system, gives us value 228 which is
correct.

In order to calculate decimal equivalent of hexadecimal number, each digit of number

should be multiplied by 16 raised to power equal to the position in the number and then
added altogether.

Addition works similar to two previous numerical systems.

Example:
It is required to add the appropriate digits of a number, and if their sum equals 16, that
position takes value “0”. Values exceeding 16 should be added to the sum of digits on
higher position. First number converted equals 14891, while other is 43457. Their sum is
58348, that is $E3EC converted to decimal numerical system. Subtraction works
identically to previously mentioned systems.

Example:
Conversion gives us numbers 11590 and 5970, and the result of subtractions is 5620,
that is $15F4 converted to decimal numerical system.

Conclusion

80
Binary numerical system remains the most commonly used, decimal system the most
intelligible, while hexadecimal is somewhere in between. It’s simple conversion to binary
system makes it, besides binary and decimal, the most important numerical system to
us.

APPENDIX E Ladder diagram instructions (1/3)

Introduction

"Ladder" is the most frequent method of programming PLC controllers at present. We

could divide instructions on the input ones for stating the conditions and the output ones
that are executed when the conditions are fulfilled. By combining the two, logical blocks
are created according to the logic of the system being automated. The purpose of this
appendix is to introduce these instructions and to give details on flags and limitations of
each of these.

INDIRECT ADDRESSING

Placing the character “*” ahead of operand from DM memory area allows us to use the
indirect addressing. Simply put, value in the word *DM will be the address of the word
that is the true operand. The picture below shows the MOV instruction with one operand
given indirectly. The contents of location DM0003 equal “1433” which is actually a
pointer marking the address DM1433 with contents “0005”. The result of this instruction
will be moving the value “0005” from word DM1433 to word LR00.

In order to use the indirect addressing, contents of the word that is the indirect operand
have to be in BCD format. Besides that, value of the contents of indirect operand must
not be greater than the number of addresses in DM area.

INSTRUCTION FORMAT

81
Operand is the address of a word or a bit in PLC controller memory (most of the
instructions has one or more operands). The common term for a word is just “operand”
and in the case of bit we call it “operand bit”. Also, operand can be a direct numerical
value marked by character “#” placed ahead of the value (i.e.. #12, #345 etc).

The state of operand bit can be ON or OFF. ON means that its logic state equals “1”,
while OFF stands for “0”. Besides these, terms “set” and “reset” are also used.

Symbols SV and PV commonly appear in instruction syntax. These abbreviations stand

for “Set Value” and “Present Value” and are most frequently encountered with
instructions concerning counters and timers.

DIFFERENTIAL INSTRUCTION FORM

Differential form is supported by almost all of the instructions. What differs this form
from the classical one is the character “@” placed ahead of the name of the instruction.
This form ensures that the instruction with condition fulfilled will not be executed in
every cycle, but only when its condition changes state from OFF to ON. Differential from
is commonly used because it has a lot of applications in real-life problems.

DIFFERENCE BETWEEN BINARY AND BCD REPRESENTATIONS OF WORD

CONTENTS

Generally, there are two dominant ways for comprehending values of memory locations.
The first is binary and is related to the contents of the word which is treated as a union
of 16 bits. Value is calculated as a sum of each bit (0 or 1) multiplied by 2 on power n,
where n represents the position of bit in the word. Bit of the least value has position
zero, while bit of greatest value has position 15.

BCD is an abbreviation for “Binary Coded Decimal number”. It is nothing more than
representing each decimal figure with 4 bits, similar to binary coding hence the name
comes from. The picture below shows the difference between binary and BCD
representations of the number. Same contents can be interpreted as either 612 or 264.
For that reason, proper attention should be given to the format of the value within the
word that will be sent to the instruction as an operand.

82
LADDER DIAGRAM INSTRUCTIONS

Instructions may be divided into several basic groups according to their purpose :

- Input instructions
- Output instructions
- Control instructions
- Timer/counter instructions
- Data comparison instructions
- Data movement instructions
- Increment/decrement instructions
- BCD/binary calculation instructions
- Data conversion instructions
- Logic instructions
- Special calculation instructions
- Subroutine instructions
- Interrupt control instructions
- I/O units instructions
- Display instructions
- High-speed counter control instructions
- Damage diagnosis instructions
- Special system instructions

Each of these instruction groups is introduced with a brief description in the following
tables and with more detailed examples and descriptions afterwards.

83
 Sequence Input Instructions

Instruction Mnemonic Code Function

LOAD LD 0 Connects an NO condition to the left bus bar.
LOAD NOT LD NOT 0 Connects an NC condition to the left bus bar.
Connects an NO condition in series with the
AND AND 0
previous condition
Connects an NC condition in series with the
AND NOT AND NOT 0
previous condition
Connects an NO condition in parallel with the
OR OR 0
previous condition.
Connects an NC condition in parallel with the
OR NOT OR NOT 0
previous condition.
AND LOAD AND LD 0 Connects two instruction blocks in series.
OR LOAD OR LD 0 Connects two instruction blocks in parallel.

Sequence Output Instructions

Instruction Mnemonic Code Function

OUTPUT OUT 0 Outputs the result of logic to a bit.
OUT NOT OUT NOT 0 Reverses and outputs the result of logic to a bit.
SET SET 0 Force sets (ON) a bit.
RESET RESET 0 Force resets (OFF) a bit.
KEEP KEEP 11 Maintains the status of the designated bit.
DIFFERENTIATE Turns ON a bit for one cycle when the execution
DIFU 13
UP condition goes from OFF to ON.
DIFFERENTIATE Turns ON a bit for one cycle when the execution
DIFD 14
DOWN condition goes from ON to OFF.

Sequence Control Instructions

Instruction Mnemonic Code Function

NO ---
NOP 00
OPERATION
END END 01 Required at the end of the program.

It the execution condition for IL(02) is OFF, all

INTERLOCK IL 02 outputs are turned OFF and all timer PVs reset
between IL(02) and the next ILC(03).
INTERLOCK ILC(03) indicates the end of an interlock
ILC 03
CLEAR (beginning at IL(02)).
If the execution condition for JMP(04) is ON, all
JUMP JMP 04 instructions between JMP(04) and JME(05) are
treated as NOP(OO).

84
 JME(05) indicates the end of a jump (beginning
JUMP END JME 05
at JMP(04)).

Timer/Counter Instructions

Instruction Mnemonic Code Function

TIMER TIM 0 An ON-delay (decrementing) timer.
COUNTER CNT 0 A decrementing counter.
REVERSIBLE
CNTR 12 Increases or decreases PV by one.
COUNTER
HIGH-SPEED
TIMH 15 A high-speed, ON-delay (decrementing) timer.
TIMER

Data Comparison Instructions

Instruction Mnemonic Code Function

COMPARE CMP 20 Compares two four-digit hexadecimal values.
DOUBLE
CMPL 60 Compares two eight-digit hexadecimal values.
COMPARE
BLOCK Judges whether the value of a word is within 16
(@)BCMP 68
COMPARE ranges (defined by lower and upper limits).
TABLE Compares the value of a word to 16 consecutive
(@)TCMP 85
COMPARE words.

Data Movement Instructions

Instruction Mnemonic Code Function

Copies a constant or the content of a word to a
MOVE (@)MOV 21
word.
Copies the complement of a constant or the
MOVE NOT (@)MVN 22
content of a word to a word.
BLOCK Copies the content of a block of up to 1,000
(@)XFER 70
TRANSFER consecutive words to a block of consecutive words.
Copies the content of a word to a block of
BLOCK SET (@)BSET 71
consecutive words.
DATA
(@)XCHG 73 Exchanges the content of two words.
EXCHAGE
SINGLE Copies the content of a word to a word (whose
WORD (@)DIST 80 address is determined by adding an offset to a
DISTRIBUTE word address).
Copies the content of a word (whose address is
DATA
(@)COLL 81 determined by adding an offset to a word address)
COLLECT
to a word.

85
 Copies the specified bit from one word to the
MOVE BIT (@)MOVB 82
specified bit of a word.
Copies the specified digits (4-bit units) from a
MOVE DIGIT (@)MOVD 83
word to the specified digits of a word.

Shift Instructions

Instruction Mnemonic Code Function

Copies the specified bit (0 or 1) into the
SHIFT
SFT 0/10 rightmost bit of a shift register and shifts the
REGISTER
other bits one bit to the left.
Creates a multiple-word shift register that shifts
WORD SHIFT (@)WSFT 16
data to the left in one-word units.
Creates a shift register that exchanges the
ASYNCHRONOUS
SHIFT REGISTER
(@)ASFT 17 contents of adjacent words when one is zero and
the other is not.
ARITHMETIC Shifts a 0 into bit 00 of the specified word and
(@)ASL 25
SHIFT LEFT shifts the other bits one bit to the left.

ARITHMETIC Shifts a 0 into bit 15 of the specified word and

(@)ASR 26
SHIFT RIGHT shifts the other bits one bit to the right.
Moves the content of CY into bit 00 of the
ROTATE LEFT (@)ROL 27 specified word, shifts the other bits one bit to the
left, and moves bit 15 to CY.
Moves the content of CY into bit 15 of the
ROTATE RIGHT (@)ROR 28 specified word, shifts the other bits one bit to the
left, and moves bit 00 to CY.
Shifts a 0 into the rightmost digit (4-bit unit) of
ONE DIGIT
(@)SLD 74 the shift register and shifts the other digits one
SHIFT LEFT
digit to the left.
Shifts a 0 into the rightmost digit (4-bit unit) of
ONE DIGIT
(@)SRD 75 the shift register and shifts the other digits one
SHIFT RIGHT
digit to the right.
REVERSIBLE Creates a single or multiple-word shift register
SHIFT REGISTER
(@)SFTR 84
that can shift data to the left or right.

Increment/Decrement Instructions

Instruction Mnemonic Code Function

Increments the BCD content of the specified word
INCREMENT (@)INC 38
by 1.
DECREMENT (@)DEC 39 Decrements the BCD content of the specified word

86
 by 1.

BCD/Binary Calculation Instructions

Instruction Mnemonic Code Function

BCD ADD (@)ADD 30 Adds the content of a word (or a constant).
BCD Subtracts the contents of a word (or constant)
(@)SUB 31
SUBTRACT and CY from the content of a word (or constant).
BDC
(@)MUL 32 Multiplies the content of two words (or contents).
MULTIPLY
Divides the contents of a word (or constant) by
BCD DIVIDE (@)DIV 33
the content of a word (or constant).
BINARY Adds the contents of two words (or constants) and
(@)ADB 50
ADD CY.
BINARY Subtracts the content of a word (or constant) an
(@)SBB 51
SUBTRACT CY from the content of the word (or constant).
BINARY Multiplies the contents of two words (or
(©)MLB 52
MULTIPLY constants).
Divides the content of a word (or constant) by the
BINARY
(@)DVB 53 content of a word and obtains the result and
DIVIDE
remainder.
DOUBLE BCD Add the 8-digit BCD contents of two pairs of words
(@)ADDL 54
ADD (or constants) and CY.
Subtracts the 8-digit BCD contents of a pair
DOUBLE
of words (or constants) and CY from the
BCD (@)SUBL 55
80digit BCD contents of a pair of words (or
SUBTRACT
constants)
DOUBLE
Multiplies the 8-digit BCD contents of two
BCD (@)MULL 56
pairs of words (or constants).
MULITPLY
Divides the 8-digit BCD contents of a pair of
DOUBLE
(@)DIVL 57 words (or constants) by the 8–digits BCD
BCD DIVIDE
contents of a pair of words (or constants)

Data Conversion Instructions

Instruction Mnemonic Code Function

BCD TO
(@)BIN 23 Converts 4-digit BCD data to 4-digit binary data.
BINARY
BINARY TO
(@)BCD 24 Converts 4-digit binary data to 4 digit BCD data.
BCD

87
 Takes the hexadecimal value of the specified
4 to 16
(@)MLPX 76 digit(s) in a word and turn ON the corresponding
DECODER
bit in a word(s).
Identifies the highest ON bit in the specified
16 to 4 word(s) and moves the hexadecimal value(s)
(@)DPMX 77
DECODER corresponding to its location to the specified
digit(s) in a word.
ASCII CODE Converts the designated digit(s) of a word into the
(@)ASC 86
CONVERT equivalent 8-bit ASCII code.

Logic Instructions

Instruction Mnemonic Code Function

Turns OFF all ON bits and turns ON all OFF bits in
COMPLEMENT (@)COM 29
the specified word
Logically ANDs the corresponding bits of two
LOGICAL AND (@)ANDW 34
word (or constants)
Logically ORs the corresponding bits of two word
LOGICAL OR (@)ORW 35
(or constants)
EXCLUSIVE Exclusively ORs the corresponding bits of two
(@)XORW 36
OR words (or constants)
EXCLUSIVE Exclusively NORs the corresponding bits of two
(@)XNRW 37
NOR words (or constants).

Special Calculation Instructions

Instruction Mnemonic Code Function

BIT Counts the total number of bits that are ON in the
(@)BCNT 67
COUNTER specified block

Subroutine Instructions

Instruction Mnemonic Code Function

SUBROUTINE
(@)SBS 91 Executes a subroutine in the main program.
ENTER
SUBROUTINE
SBN 92 Marks the beginning of a subroutine program.
ENTRY
SUBROUTINE
RET 93 Marks the end of a subroutine program.
RETURN
Calls and executes the specified subroutine,
MACRO MACRO 99 substituting the specified input and output words
for the input and output words in the subroutine.

88
 Interrupt Control Instructions

Instruction Mnemonic Code Function

INTERVAL Controls interval timers used to perform scheduled
(@)STIM 69
TIMER interrupts.
INTERRUPT Performs interrupts control, such as masking and
(@)INT 89
CONTROL unmasking the interrupt bits for I/O interrupts.

Step Instructions

Instruction Mnemonic Code Function

Defines the start of a new step and resets
STEP the previous step when used with a
STEP 08
DEFINE control bit. Defines the end of step
execution when used without a control bit.
Starts the execution of the step when
STEP START SNXT 09
used with a control bit.

Peripheral Device Control Instructions

Instruction Mnemonic Code Function

BCD TO
(@)BIN 23 Converts 4-digit BCD data to 4-digit binary data.
BINARY
BINARY TO
(@)BCD 24 Converts 4-digit binary data to 4-digit BCD data.
BCD
Takes the hexadecimal value of the specified
4 to 16
(@)MLPX 76 digit(s) in a word and turn ON the corresponding
DECODER
bit in a word(s).
Identifies the highest ON bit in the specified
16 to 4 word(s) and moves the hexadecimal value(s)
(@)DPMX 77
DECODER corresponding to its location to the specified
digit(s) in a word.
ASCII CODE Converts the designated digit(s) of a word into the
(@)ASC 86
CONVERT equivalent 8-bit ASCII code.

I/O Units Instructions

Instructio Mnemonic Code Function

n
7-SEGMENT Converts the designated digit(s)of a word into an 8-
(@)SDEC 78
DECODER bit, 7-segment display code.

89
I/O
(@)IORF 97 Refreshes the specified I/O word.
REFRESH

Display Instructions

Instructio Mnemonic Code Function

n
MEASSAGE (@)MSG 46 Reads up to 8 words of ASCII code (16 characters)
from memory and displays the message on the
Programming Console or other Peripheral Device.

High Speed Counter Control Instructions

Instructio Mnemonic Code Function

n
MODE Starts and stops counter operation, compares and
(@)INI 61
CONTROL changes counter PVs, and stops pulse output.
PV READ (@)PRV 62 Reads counter PVs and status data.
COMPARE Compares counter PVs and generates a direct table
(@)CTBL 63
TABLE LOAD or starts operation.

Damage Diagnosis Instructions

Instructio Mnemonic Code Function

n
Generates a non-fatal error when executed. The
FAILURE
(@)FAL 06 Error/Alarm indicator flashes and the CPU continues
ALARM
operating.
SEVERE Generates a fatal error when executed. The
FAILURE FAL 07 Error/Alarm indicator lights and the CPU stops
ALARM operating.

Special System Instructions

Instructio Mnemonic Code Function

n
SET CARRY (@)STC 40 Sets Carry Flag 25504 to 1.
CLEAR
(@)CLC 41 Sets Carry Flag 25504 to 0.
CARRY

90
E.1 LOAD - Normally open output

Description First condition, that any logical block in the ladder diagram starts with,
corresponds to LOAD or LOAD NOT instructions. Both of these instructions
require one line in mnemonic code. On the right of these instructions any
executive instruction may be used.

Ladder
symbol

Limitations There are no limitations, except that it is used as the first instruction from
left to right.

Flag It has no effect on any particular flag.

Example

Pressing the button on the input “00” in the word IR000 activates the relay
“00” on the output of PLC controller. Conditional instruction doesn’t have be
from input memory area; it can be any bit from other memory areas, i.e.
SR area as in the following example.

When one of the instructions activates the bit “00” in the word SR200, bit
“00” is activated in the output word IR010. In a word, every ON state of the
bit at input causes the ON state at output.

E.2 LOAD NOT - Normally closed input

Description First condition, that any logical block in the ladder diagram starts with,
corresponds to LOAD or LOAD NOT instructions. Both of these instructions
require one line in mnemonic code. On the right of these instructions any
executive instruction may be used.

Ladder
symbol

Limitations There are no limitations, except that it is used as the first instruction from
left to right.

91
Flag It has no effect on any particular flag.

Example

Pressing the button on the input “00” in the word IR000 activates the relay
“00” on the output of PLC controller. Conditional instruction doesn’t have be
from input memory area; it can be any bit from other memory areas, i.e.
SR area as in the following example.

When one of the instructions activates the bit “00” in the word SR200, bit
“00” is activated in the output word IR010. In a word, every ON state of the
bit at input causes the OFF state at output.

E.3 AND - Logical "AND" with normally open contacts

Description When two are linked serially in one instruction line, first of them
corresponds to instructions LOAD or LOAD NOT, while the other represents
instructions AND or AND NOT.

Ladder
symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

After the LOAD instruction on ‘00’ input, AND instruction is linked to input
‘01’. Instruction on the right will be executed only when both of the
conditions from the line are fulfilled, i.e. when both inputs ‘00’ and ‘01’ are
in the ON state.

E.4 AND NOT - Logical "AND" with normally closed contacts

Description When two or more conditions are linked serially in one instruction line, first
of them corresponds to instruction LOAD or LOAD NOT, while the other
represents instruction AND or AND NOT.

92
Ladder
symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

After the LOAD instruction on ‘00’ input, AND NOT instruction is linked to
input ‘01’. Instruction on the right will be executed only when both of the
conditions from the line are fulfilled, i.e. when input ‘00’ is in ON state and
input ‘01’ is in OFF state.

E.5 OR - Logical "OR" with normally open contacts

Description When two or more conditions coexist on separate, paralel lines that connect
at a given point, the first condition corresponds to LOAD or LOAD NOT
instructions, while others correspond to OR or OR NOT instructions.

Ladder
symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

Inputs ‘00’ and ‘01’ are in OR relation with the output ‘00’. One of the
inputs with ON state is sufficient to activate the output ‘00’.

E.6 OR NOT - Logical "OR" with normally closed contacts

Description When two or more conditions coexist on separate, paralel lines that connect

93
 at a given point, the first condition corresponds to LOAD or LOAD NOT
instructions, while others correspond to OR or OR NOT instructions.

Ladder
symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

Inputs ‘000.00’ and ‘000.01’ are in OR NOT relation with the output
‘010.00’. Bit ‘010.00’ will retain ON state until bit “01” changes to ON state
(thus breaking the connection, because it is normally closed). One of the
inputs with ON state is sufficient to activate the output ‘00’.

E.7 OUTPUT - Normally open output

Description The easiest way for getting results that fulfill input conditions is their direct
connection to the instructions OUTPUT and OUTPUT NOT. These instructions
are used for controlling the status bit, which is defined as the instruction
carrier. When OUTPUT instruction is used, bit assigned to it will be ON if the
execution condition is ON, and it will be OFF if the execution condition is
OFF.

Ladder
symbol

Limitations Attention should be paid not to “overlap” the instructions concerning the bit
being controlled.

Flag It has no effect on any particular flag.

Example

Bit IR010.00 will remain ON as long as bit IR000.00 is ON. When bit
IR000.00 changes to OFF, bit IR010.00 also changes to OFF.

94
 This instruction cannot be used for assigning ON or OFF states to more than
one bit. In case that there is a need for assigning values to all of the bits in
word, it can be done only one bit at a time.

E.8 OUTPUT NOT - Normally closed output

Description The easiest way for getting results that fulfill input conditions is their direct
connection to the instructions OUTPUT and OUTPUT NOT. These instructions
are used for controlling the status bit, which is defined as the instruction
carrier. When OUTPUT instruction is used, bit assigned to it will be ON if the
execution condition is OFF, and it will be OFF if the execution condition is
ON.

Ladder
symbol

Limitations Attention should be paid not to “overlap” the instructions concerning the bit
being controlled.

Flag It has no effect on any particular flag.

Example

Bit IR010.00 will remain ON as long as bit IR000.00 is OFF, while prelaskom
changing bit IR000.00 to ON changes bit IR010.00 to OFF.

This instruction cannot be used for assigning ON or OFF states to more than
one bit. In case that there is a need for assigning values to all of the bits in
word, it can be done only one bit at a time.

E.9 SET - Changes bit state to ON

Description Instruction changes the state of the specified bit to ON when the execution
condition is ON. In case that the condition is OFF, bit state remains
unchanged (unlike the instruction OUT which changes bit state to OFF even
when the condition is OFF).

Ladder
symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

95
Example

If condition state on bit IR000.00 changes to ON, state of bit IR200.00 also
changes to ON. When condition state of bit IR000.00 changes from ON to
OFF, bit IR200.00 remains ON.

E.10 RESET - Changes bit state to OFF

Description Instruction changes the state of the specified bit to OFF when the execution
condition is ON. In case that the condition is OFF, bit state remains
unchanged.

Ladder
symbol

Limitations There are no limitations.

Flag It has no effect on any particular flag.

Example

If condition state on bit IR000.00 changes to ON, state of bit IR200.00

changes to OFF. When condition state of bit IR000.00 changes from ON to
OFF, bit IR200.00 remains OFF.

E.11 KEEP - Changes bit state according to 2 inputs

Description Instruction is used for maintaining the status of corresponding bit according
to 2 inputs. The first input changes bit state to ON whenever the condition
of the first line is fulfilled, while the second changes bit state to OFF
whenever the condition of the second line is fulfilled. Bit state remains
unchanged as long as inputs remain unchanged.

96
Ladder
symbol

Flag It has no effect on any particular flag.

Example

When the state of bit IR000.00 changes to ON bit IR200.00 also changes to
ON. If bit IR000.01 changes to ON, bit IR200.00 changes to OFF and
remains OFF until state of bit IR000.00 is ON again.

E.12 DIFFERENTIATE UP - Changes bit state to ON for duration

of one cycle

Description Instruction changes bit state to ON during one cycle when the preceding
condition is fulfilled.

Ladder
symbol

Flag It has no effect on any particular flag.

Example

Instruction changes state of bit IR200.00 to ON for duration of one cycle. If

bit IR000.00 is ON, bit IR200.00 changes to ON for duration of one scan
cycle.

97
E.13 DIFFERENTIATE DOWN - Changes bit state to OFF for
duration of one cycle

Description Instruction changes bit state to OFF during one cycle when the preceding
condition is fulfilled.

Ladder
symbol

Flag It has no effect on any particular flag.

Example

If bit IR000.00 is ON, state of bit IR200.00 changes to OFF for duration of
one scan cycle.

E.14 NO OPERATION - No operation

Description Generally, usage of this instruction in programs is not recommended. When

PLC gets to this instruction nothing happens and the following instruction is
executed.

Ladder
symbol

Flag It has no effect on any particular flag.

E.15 INTERLOCK - Interlock

Description Instruction IL is always used in pair with the instruction ILC. Their purpose
is to reset all the outputs, flags, control bits, timers and counters that are
within instructions between IL and ILC. Timers and counters stop working
and retain values they had at the moment of executing IL instruction. It is
possible to have multiple IL instructions and to reset one or more parts of
the program, accordingly. Instruction is executed when condition state
changes from ON to OFF!

98
Ladder
symbol

Flag It has no effect on any particular flag.

E.16 INTERLOCK CLEAR - End of the program part

encompassed by interlock

Description Instruction ILC is always used in pair with instruction IL. When the
condition of instruction IL is fulfilled all the outputs, flags, control bits,
timers and counters that are within instructions between IL and ILC are
reset. Timers and counters stop working and retain values they had at the
moment of executing IL instruction.

Ladder
symbol

Flag It has no effect on any particular flag.

E.17 END - End of program

Description This is mandatory instruction at the end of every program. Any instruction
following this one will not be executed. It can be used for debugging
purposes in program, so as to designate the point where the monitoring of
program execution stops. If the program uses subroutines, it is necesssary
to have instruction END following the last subroutine.

Ladder
symbol

Limitations There are no limitations.

Flag Changes states of flags ER, CY, GR, EQ and LE to OFF.

E.18 JUMP - Jump to another location in the program

Description Certain part of the program may be skipped depending on the state of
defined condition for jump execution. Jumps can be created using JUMP
(JMP(04)) or JUMP END (JME(05)) instructions. If condition state is ON,
program executes normally, as if the instruction was never used. If status
of execution condition is OFF, program execution continues from the JUMP
END instruction corresponding to JUMP instruction. Which JUMP END
corresponds to which JUMP instruction is defined with a number that follows
the instruction. Value 0 can be used unlimited number of times in the
course of program for this purpose, while each of other 99 available

99
 numbers may be used only once.

Ladder
symbol

Limitations Total number of JUMP and JUMP END pairs cannot exceed 99. Each value
from 1-99 range can be used only once.

Flag It has no effect on any particular flag.

E.19 JUMP END - Location where the program execution

continues after JUMP

Description Instruction JME is used in pair with JMP instruction as integral part of it. If
there is no JME assigned to JMP instruction, program will report an error.

Ladder
symbol

Limitations Total number of JUMP and JUMP END pairs cannot exceed 99. Each value
from 1-99 range can be used only once.

Flag It has no effect on any particular flag.

100
Example

When the state of bit IR000.00 changes to OFF, jump instruction skips all
the instruction lines between itself and the corresponding JME instruction.

Another way for using jump instruction is assigning value “0” to JMP
instruction. Unlimited number of jumps can be programmed in this way and
the destination for each of these is a unique location defined with
instruction JUMP END with index 0. Instruction JUMP END with parameter 0
may be used multiple times in the program. In that case, program
execution after the jump defined with JUMP (index 0) continues from the
first following JUMP END instruction with this index. Time of execution with
this form of jump function is somewhat longer, as the program must first
locate the closest appropriate JUMP END instruction. The following example
demonstrates programming greater number of jump functions ending at
the same destination:

Changing the state of bits IR000.00 or IR000.03 to OFF executes the jump
to the line containing instruction JME.

101
 E.20 TIMER - Timer with 0.1s resolution

Description Timers are complex instructions with the purpose of separating two programming actions.
Changing the state of condition to ON starts the timing with 0.1s increments starting from zero.

Value of parameter SV (abbreviation for Set Value) is multiplied by 0.1 s, the result being total
time in seconds. Value given in the middle part of the block is called TC number. Each TC
number can be used for defining one couner or timer. It can take values from 000 - 127 range.
Lower part of the block is reserved for displaying the starting value of timer. Word with this role
can belong to sectors IR, AR, DM, HR, LR or can be given as a constant, with values from 000.0
- 999.9 range. The most common and the simplest way to apply a timer is to have a constant
here, whether given directly or programmed on some memory location (if parameter SV is given
as a constant, it is necessary to put character “#” ahead of value).

102
Ladder
symbol

Limitations The number of timer cannot be used for counter or another timer.

Flag Affects the appropriate flag in TC area.

Example

Changing the state of bit IR000.00 to ON starts the timing (in this case, time is 100*0.1s=10
seconds). After the passing of given period of time, the appropriate bit IM002 changes state to
ON, thus fulfilling the condition for executing the instructions on the right (in this case bit
IR010.01 changes state to ON).

Condition bit must be constantly ON for a given time period for bit TIM002 to be set. If
condition state changes to OFF during the given time period, timer resets and goes back to the
beginning of period.

103
APPENDIX E Ladder diagram instructions (2/3)

E.21 HIGH-SPEED TIMER - Timer with 0.01s resolution

Description This instruction is identical to the previous TIM instruction, except for the
resolution of decrementing. In case of TIM instruction this interval equals
0.1s, while with TIMH instruction it equals 0.01s. Changing the condition to
ON starts the countdown with 0.01s decrements from the predefined value
down to zero. If the state of condition changes to OFF timer will be reset.
Value of parameter SV (abbreviation for Set Value) is multiplied by 0.01 s
resulting in total time in seconds. Value given in the middle part of the
block is called TC number. Each TC number can be used for defining one
couner or timer. It can take values from 000 - 127 range. Lower part of the
block is reserved for displaying the starting value of timer. Word with this
role can belong to sectors IR, AR, DM, HR, LR or can be given as a
constant, with values from 00.00 - 99.9.9 range. If parameter SV is given
as a constant, it is necessary to put character “#” ahead of value.

Ladder
symbol

Limitations The number of timer cannot be used for a counter or another timer. Value
of SV must be in 00.00 - 99.99 range. Recommended range for a number
of timer is 000 - 003.

Flag Affects the appropriate flag in TC area.

Example

104
 Changing the state of condition bit IR000.00 to ON starts the countdown (in
this case for 27*0.01s=0.27 seconds). After the passing of given period of
time, the appropriate bit IM003 changes state to ON, thus fulfilling the
condition for executing the instructions on the right (in this case bit
IR010.01 changes state to ON).

Condition bit must be constantly ON for a given time period for bit TIM002
to be set. If condition state changes to OFF during the given time period,
timer resets and goes back to the beginning.

E.22 COUNTER - Counter

Descripti Counter decrements the value given with SV for every ON state of the
on condition on CP line (abbreviation for Count Pulse). Each time the state on CP
line changes from OFF to ON value of SV is decremented by one. Fulfilling the
condition on R (reset) line sets the counter to a starting state with a given SV
value. When the zero is reached, instruction changes the state of appropriate
bit from TC area corresponding to the number of a counter (bit can be
returned to OFF state by fulfilling the condition on reset line). If parameter SV
is given as a constant, it is necessary to place a character “#” ahead of value.

Ladder
symbol

Limitatio
The number of timer cannot be used for a counter or another timer.
ns

Flag Affects the appropriate flag in TC area.

105
Example

When the state of bit IR000.00 changes from OFF to ON, counter value
decreases to 299, next change of bit IR000.00 lowers it to 298 and so on.
When counter value reaches zero, state of bit CNT004 changes to ON, fulfilling
the condition for executing instructions on the right (in this case, it is a
normally closed contact that will open).

E.23 REVERSIBLE COUNTER - Incrementing / decrementing

counter

Descripti This instruction is an extension of the previous one, having the added input
on for increasing counter value by one. Counter CNTR has two counting inputs:
incrementing and decrementing. Decrementing input is identical to one from
CNT instruction. For every ON state of condition on II line (Increment Input)
counter value increases by one. If this value reached SV, counter value
remains unchanged. Every time state on DI line (Decrement Input) changes
from OFF to ON, value of SV decreases by one. If counter value reached zero
it remains unchanged. Fulfilling the condition on R (reset) line sets the counter
to a starting state given with value of SV. With reaching the zero, instruction
changes the state of bit in TC area appropriate to the number of the counter.
This bit can be returned to OFF state by fulfilling the condition on na reset line
or increment II line. If the parameter SV is given as a constant it is necessary
to place the character “#” ahead of value.

106
Ladder
symbol

Limitatio
Number of a counter cannot be used for a timer or another counter.
ns

Flag Affects the appropriate bit in TC area.

Example

When the state of bit IR000.00 changes from OFF to ON, counter value
decreases to 122, next change of bit IR000.00 lowers it to 121 and so on.
When the state of bit IR000.01 changes counter value increases by one. When
counter value reaches zero, state of bit CNT006 changes to ON fulfilling the
condition for executing instructions on the right (in this case, it is normally
closed contact that will open). ON state of bit IR00.02 will return the counter
to a given value, while a bit CNT006 returns it to OFF state.

107
E.24 COMPARE - Compares two memory locations

Description Instruction CMP(20) compares two words upon fulfilling the preceding
condition. Depending on the relation of the two words, output can be:

1. Equal - state of bit EQ in SR memory area changes to ON.

2. Cp1 is lower than Cp2 - state of bit LE in SR memory area changes to
ON.
3. Cp1 is greater than Cp2 - state of bit GR in SR memory area changes
to ON.

Flag Address Cp1<Cp2 Cp1=Cp2 Cp1>Cp2

GR 25505 OFF OFF ON
EQ 25506 OFF ON OFF
LE 25507 ON OFF OFF

Ladder
symbol

Limitations Comparations that include the current values of timer or a counter require
values in BCD format. Checking the flags GR, LE and EQ should take place
immediately after the CMP(20) instruction, because another instruction may
affect their states.

Flag Affects the flags GR, LE and EQ in SR memory area.

108
Example

When the state of bit IR000.00 changes to ON, condition for comparing the
values of memory locations IR200 and IR201 is fulfilled. If value of IR200 is
greater than IR201, state of bit IR010.00 changes to ON. If value of IR200
is lesser than IR201, state of bit IR010.02 changes to ON. In case of equal
values of locations IR200 and IR201, state of bit IR010.01 changes to ON.

E.25 DOUBLE COMPARE - Compares two consecutive words

Description Instruction CMPL(60) compares the two consecutive words with other two
consecutive words. Depending on the relation, output can be:

1. Equal - state of bit EQ in SR memory area changes to ON.

2. Cp1+1, Cp1 is lower than Cp2+1, Cp2 - state of bit LE in SR memory
area changes to ON.
3. Cp1+1, Cp1 is greater than Cp2+1, Cp2 - state of bit GR in SR
memory area changes to ON.

109
 Cp1+1,Cp1
Flag Address <Cp2+1,Cp2
Cp1+1,Cp1=Cp2+1,Cp2 Cp1+1,Cp1>Cp2+1,Cp2

GR 25505 OFF OFF ON

EQ 25506 OFF ON OFF
LE 25507 ON OFF OFF

Ladder
symbol

Limitations Checking the flags GR, LE and EQ should take place immediately after the
CMP(20) instruction, because another instruction may affect their states.

Flag Affects the flags GR, LE and EQ in SR memory area.

Example

When the state of bit IR000.00 changes to ON, condition for comparing the
values of memory locations IR200+IR2001 and HR00+HR01 is fulfilled. If

110
 value of the first operand is greater, state of bit IR010.00 changes to ON. If
value of the first operand is lesser, state of bit IR010.02 changes to ON. In
case of equal values, state of bit IR010.01 changes to ON.

E.26 BLOCK COMPARE - Block compare

Descriptio Instruction BCMP compares the value of memory location

n CD with values of memory locations CB - CB+31. The
method consists of finding the pair of CB locations where
the value of CD location fits in between. Upon locating
that area, the appropriate bit is set in the result word R.
Based on this information, the programmer knows the general area of value
of location CD.

Ladder
symbol

Limitations Values of CB block must be in order, so that the value of location CB is

lesser than value of CB+1.

Flag It has no effect on any particular flag.

Example

Comparation will be executed for as long as the state of condition is ON. If

value of location HR00 equals “0210”, then it will be set between DM0014
and DM0015 correspoding to the second bit of the result word LR05.

111
E.27 TABLE COMPARE - Table compare

Descriptio Instruction TCMP compares value of memory location CD with values of

n memory locations TB, TB+1, TB+2, TB+3 ... TB+15. If value of location CB
is equal to one of TB values, the appropriate bit of the result word R is set.
Based on this information, the programer knows which TB value matches
the value of location CD.

Ladder
symbol

Limitations Locations DM 6144 - DM6655 cannot be used for the result word.

Flag It has no effect on any particular flag.

112
Example

Comparation will be executed as long as the state of bit IR000.00 is ON. If

value of location HR00 is “0210”, then it equals the values of locations
DM0002, DM0006, DM0010 and DM0014. Accordingly, the appropriate bits
of the word IR216 change states to ON (they are set).

E.28 MOVE - Moves the contents of one memory location to

another

Description Instruction MOVE is used for moving the contents of one memory location
to another. The operand S represents the word whose contents should be
moved to a word that is operand D. Operand S can be a constant, if the
character “#” is placed ahead of four-digit value.

113
Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand D. The current state
of timer or counter also cannot be used as operand D. Instruction BSET(17)
should be used for that purpose.

Flag Flag EQ from TC area changes state to ON when all zeros are written into
operand D. Therefore, flag EQ provides us with information if the moved
value equals zero. In case of error, state of flag ER changes to ON.

Example

Upon fulfilling the condition on bit IR00.00, instruction moves the contents
of memory location IR001 to memory location HR05. Every bit of word
IR001 is copied to the appropriate bit of word HR05. Instruction MOV can
be very helpful when reading the signals controller sends or receives from
peripheral devices. Input states are moved to a working area, where they
are processed and then they are sent to the output points of PLC controller.

E.29 MOVE NOT - Moves the complement

Description Instruction MOVE NOT is used for moving the complemented (inverted bits,
bit “0” becomes “1”and vice versa) contents of one memory location to
another. The operand S represents the word whose complemented contents
should be moved to a word that is operand D. Operand S can be a
constant, if the character “#” is placed ahead of four-digit value.

114
Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand D. The current state
of timer or counter also cannot be used as operand D. Instruction BSET(17)
should be used for that purpose.

Flag Flag EQ from TC area changes state to ON when all zeros are written into
operand D. Therefore, flag EQ provides us with information if the moved
value equals zero. In case of error, state of flag ER changes to ON.

Example

Upon fulfilling the condition on bit IR00.00, instruction moves the

complemented contents of memory location IR001 to memory location
HR05. Every bit of word IR001 is complemented and copied to the
appropriate bit of word HR05.

E.30 BLOCK TRANSFER - Copies one block of words to another

Description Instruction BLOCK TRANSFER copies the contents of one memory block of
words to another. Parametar “N” represents the number of memory
locations copied, “S” is the address of starting source memory location,
while “D” represents the address of the starting destination memory
location.

115
Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand D. S and S+N have to
be from the same memory area. D and D+N also have to be from the same
memory area. N has to be a BCD number.

Flag State of ER flag changes to ON if N is not a BCD number or in case that S

and S+N, D and D+N are not from the same memory area.

Example

Upon fulfilling the condition on bit IR00.00, instruction moves the contents
of ten memory locations IR200 - IR210 to memory locations HR00 - HR10.

116
E.31 BLOCK SET - Copies the contents of one memory location to
multiple locations

Description Instruction copies the contents of one memory location S to a block of

memory locations from St to E. Parameter St contains the starting address
of the block and parameter E contains the ending address of the block. It is
possible to change the contents of the current timer/counter values with
this instruction, unlike with instructions MOV and MVN. Operand S can be a
constant, if the character “#” is placed ahead of four-digit value.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operands St and E. Address in

the operand St has to be lesser than the addreess in operand E. Both the
operands St and E have to be from the same memory block.

Flag State of ER flag changes to ON if St and E do not belong to the same

memory block or in the case that the second parameter is greater than
first.

117
Example

Upon fulfilling the condition on bit IR00.00, instruction moves the contents
of memory location IR000 (zero) to locations HR00 - HR05. In this way, it is
possible to clear the memory block or to set it to a certain value. Same
effect could be achieved if constant “#0000” was used instead of memory
location IR200 containing all zeros.

E.32 DATA EXCHANGE - Exchanges values of two memory

locations

Description Instruction exchanges the values of memory locations E and E1.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operands E1 and E2.

Flag State of ER flag changes to ON if non-existing indirect address of location

from DM area is used as an operand.

118
Example

Upon fulfilling the condition on bit IR00.00 instruction exchanges the

contents of memory locations IR000 (all zeros) and IR201 (all ones). As a
result, memory location IR201 contains all ones and memory location
IR200 contains all zeros.

E.33 SINGLE WORD DISTRIBUTE - Creates a stack

Descriptio Instruction can be used in two ways depending on the states of bits 12, 13,
n 14 and 15 of memory location in parameter C. If these 4 bits have value
between 0 and 8, then the instruction copies the word from parameter S
(or a constant if it is given with character “#” ahead) to an address
calculated by adding the base address from parameter DBs and the shift
defined in the rest of the word of parameter C.
When bits 12-15 in memory location of parameter C form the number 9,
then the instruction is used for stack operations. The rest of the value of
word of parameter C now defines number of the words in stack (from 000
to 999) and the contents of DBs represent the stack pointer.

119
Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand DBs. Address of the
operand DBs has to be in the same memory block with BDs + shift. The
argument C has to be BCD number.

Flag EQ flag changes state to ON when the contents of memory location in

parameter S equal zero. State of ER flag changes to ON in case of error.

Examples

Bits 12-15 in the word LR10 from parameter C formthe number “0011”,
which is in 0 - 8 range. Therefore, the instruction is used in the first form.
Upon fulfilling the condition on bit IR00.00, instruction copies the constant
#00FF to an address calculated by adding the base address (in this case
HR10) and three lower numbers from the word LR10.

120
 Bits 12-15 in the word IR216 from parameter C form the number “0101”,
which exceeds 8. Therefore, the instruction is used in the second form. The
example above shows how to create a stack between memory locations
DM0001 and DM0005. Location DM0000 is used as a pointer marking the
top of the stack.

E.34 DATA COLLECT - FIFO, LIFO stack

Descriptio Instruction can be used in three different ways depending on the states of
n bits 12-15 in the word of parameter C:
1. If four bits have value between 0 and 7, the instruction copies the word
D to an address calculated by adding the address of the word SBs with the
rest of the word C.
2. If value of four bits of word C equals 9, instruction creates the FIFO
stack (First In First Out). The rest of the bits of the word C determines the
number of the words in stack (000 to 999), while SBs represents the
pointer marking the top of the stack.
3. If value of four bits of word C equals 8, instruction creates the LIFO
stack (Last In First Out). The rest of the bits of the word C determine the

121
 number of the words in stack (000 to 999), while SBs represents the
pointer marking the top of the stack.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand DBs. Parameter C has
to be a BCD number. SBs and SBs + shift have to be from the same
memory block.

Flag EQ flag changes state to ON when the contents of memory location in

parameter S equal zero. State of ER flag changes to ON in case of error,
such as overflow or assigning non-BCD contents to parameters S or D.

Examples

Bits 12 - 15 in the word IR200 form “0”, while the rest of the word forms
value 005, defining stack size to be 5 locations. Upon fulfilling the condition
on bit IR000.00, instruction copies the contents of word LR00 to an address
calculated by adding the address DM0000 with the shift defined in the word
IR200 (lower three digits) : DM0000 + 005 = DM0005.

122
Bits 12 - 15 in word IR216 form a number “9”, while the rest of the word
forms value 005, defining the stack size to be 5 locations. Number “9” as
the first digit of word IR216 determines that the instruction works with
FIFO stack. Upon fulfilling the condition on bit IR000.00, instruction moves
the contents of the stack by one address, so that the element that first
came into the stack (“AAAA”) is copied to the word IR001, while the stack
pointer decreases by one.

123
 Bits 12 - 15 of the word IR216 form a number “8”, while the rest of the
word forms value 005, defining the stack size to be 5 locations. Number “8”
as the first digit of the word IR216 means that the instructions works with
LIFO stack. Upon fulfilling the condition on bit IR000.00, instruction copies
the value of the last word that came into stack to the location IR001, while
the stack pointer decreases by one.

E.35 MOVE BIT - Copies a bit from one word to another

Descriptio Instruction copies a specified bit from the word S to a specified bit of word
n D. The word Bi determines the positions of bits in question. The upper 2
digits determine the destination bit, while lower 2 determine the source bit.

124
Ladder
symbol

Limitations Values of destination and source bits has to be between 0 and 15. Words
DM6144 - DM6655 cannot be used as operands Bi or D.

Flag

Example

E.36 MOVE DIGIT - Moves a digit from one word to another

Descriptio Instruction copies a specified digit from the word S to a specified digit of
n the word D. The word Di determines the positions of digits in question.

125
Ladder
symbol

Limitations Value of destination and source bit has to be between 0 and 15. Words
DM6144 - DM6655 cannot be used as operands Bi or D.

Flag ER flag changes state to ON if at least one of three digits in the word Di
isn’t in the specified range (between 0 and 3).

Example The examples below show copying digits from one word to another
depending on the value of word Di.

126
E.37 SHIFT REGISTER - Shifts the contents of a word for 1 bit to
the left

Descriptio Instruction shifts the contents of word St for 1 bit to the left. The highest
n bit of the word St moves to the place of the lowest bit in the word St+1,
the highest bit of the word St+1 moves to the position of the lowest bit in
the word St+2 and so forth, up to the word E. The highest bit of the word E
is irreversibly lost with every shifting. Input I defines whether “0” or “1” fills
the lowest bit position. If the state of I line is ON, value is one, while OFF
defines zero. Input P is used as clock for the instruction and switching it
from OFF to ON changes the bit shift. State on R line can be OFF when the
instruction can be executed and ON when all the bits within word range
from St to E are set to “0”. As long as the state of R line isn’t set to OFF
state, instruction cannot be executed.

Ladder
symbol

Limitations E has to be greater or equal to the address in parameter St.

Flag ER flag changes state to ON if St is lower address than E or if they are not
in the same memory area.

Example

Upon fulfilling the condition on bit IR000.00, instruction uses one-second

clock on bit 255.02 in order to move the contents of the word HR00. Bit
IR200.00 will be ON every time the bit HR00.07 equals one.

127
E.38 WORD SHIFT - Shifts whole words

Descriptio Instruction shifts the whole contents of the word St to an address greater
n by one than the current. Value of the word from the parameter St is moved
to St+1 up to the the word defined with parameter E. Word that equals
zero fills the place on the right for every shifting. Value of the word on the
address from parameter E is irreversibly lost.

Ladder
symbol

Limitations E has to be greater or equal address to the one from parameter St. Words
DM6144 - DM6655 cannot be used as operands St and E.

Flag ER flag changes state to ON if St is lower address than E or if they are not
from the same memory area.

E.39 ARITHMETIC SHIFT LEFT - Arithmetic shift left

Descriptio Instruction shifts the contents of the word Wd for one bit to the left. The
n lowest bit becomes “0”, while the highest bit is moved to carry bit.

Ladder
symbol

128
Limitations Words DM6144 - DM6655 se ne mogu koristiti za operand Wd.

Flag EQ flag changes state to ON if the contents of the word Wd equal zero. CY
flag takes the value of the highest bit of theword Wd and changes state
accordingly.

E.40 ARITHMETIC SHIFT RIGHT - Arithmetic shift right

Descriptio Instruction shifts the contents of the word Wd for 1 bit to the right. The
n highest bit takes value “0”, while the lowest bit moves to carry bit (CY).

Ladder
symbol

Limitations Words DM 6144 - DM6655 cannot be used as operand Wd.

Flag EQ flag changes state to ON if the contents of the word Wd equal zero. CY
flag takes the value of the lowest bit of the word Wd and changes state
accordingly.

E.41 ROTATE LEFT - Rotates the contents of a word for 1 bit to

the left

Description Instruction shifts the contents of the word Wd for one bit to left, using the
carry bit CY. Bit from CY is then moved to the lowest bit to close the circle.

Ladder
symbol

129
Limitations Word DM6144 - DM6655 cannot be used as operand Wd.

Flag EQ flag changes state to ON if the contents of the word Wd equal zero. CY
flag takes value of the highest bit of the word Wd and changes state
accordingly.

E.42 ROTATE RIGHT - Rotates the contents of a word for 1 bit to

the right

Description Instruction shifts the contents of the word Wd for one bit to the right, using
the carry bit CY. Bit from CY is then moved to the highest bit to close the
circle.

Ladder
symbol

Limitations Word DM6144 - DM6655 cannot be used as operand Wd.

Flag EQ flag changes state to ON if the contents of the word Wd equal zero. CY
flag takes value of the lowest bit of the word Wd and changes state
accordingly.

E.43 ONE DIGIT SHIFT LEFT - Shifts word for one digit to the
left

Description Instruction shifts the contents of the word St for one digit to the left. The
highest digit of the word E is irreversably lost and the lowest digit of the
word St takes zero value.

130
Ladder
symbol

Limitations Words DM 6144 - DM6655 cannot be used as operands St and E. Operands

St and E have to be in the same memory area, while the address of
operand E has to be greater or equal to the address of operand St.

Flag ER flag changes state to ON if St and E are not from the same memory
area or in case that the address of parameter E is lower than the address of
parameter St.

E.44 ONE DIGIT SHIFT RIGHT - Shifts word for one digit to the
right

Description Instruction shifts the contents of the word St for one digit to the right. The
lowest digit of the word E is irreversably lost and the lowest digit of the
word St takes zero value.

Ladder
symbol

Limitations Words DM 6144 - DM6655 cannot be used as operands St and E. Operands

St and E have to be in the same memory area and the address of the
operand E has to be lower or equal to the address of the operand St.

Flag ER flag changes state to ON if St and E are not from the same memory
area or in case that the address of parameter E is higher than the address

131
 of parameter St.

E.45 REVERSIBLE SHIFT REGISTER - Shifts words to the left

or to the right

Description Instruction is used for shifting one or several words in both directions,
according to the states of the highest 4 bits in the control word C. The control
word determines shifting direction, input value, clock and reset input.

Ladder
symbol

Limitations Words DM 6144 - DM6655 cannot be used as operands C, St and E. Operands

St i E have to be from the same memory area and the address of the
operand St has to be lower or equal to the address of the operand E.

Flag ER flag changes state to ON if St and E are not from the same memory area
or the address of parameter St is higher than the address of parameter E. CY
changes according to the state of the lowest bit of the word St or the highest
bit of the word E, depending on the shifting direction set in the control word
C.

132
Example

First instruction line determines the shifting direction, second determines

input, third determines the clock and fourth determines reset. The shifting
direction depends on the bit 12 of the control word. Depending on it, data bit
moves to CY carry bit, while the opposite end becomes “0” or “1” depending
on bit 13 of the control word. Condition for executing this instruction is
located in the bit IR000.04, but besides this it is necessary to have the clock
(bit 14 of the control word) ON. If the instruction is being executed with reset
bit (bit 15 of the control word) OFF, all data bits as well as carry bit CY are
set to “0”.

E.46 BCD INCREMENT - Increases the contents of a word by 1

Description Instruction increases the contents of the word Wd by one when the
condition is fulfilled. Incrementation does not affect the carry bit.

Ladder
symbol

133
Limitations Words DM 6144 - DM6655 cannot be used as operand Wd.

Flag ER flag changes state to ON if the contents of the word Wd are not BCD.
EQ flag changes state to ON when the result of incrementation equals “0”.

E.47 BCD DECREMENT - Decreases the contents of a word by 1

Description Instruction decreases the contents of the word Wd by one when the
condition is fulfilled. Decrementation does not affect the carry bit.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand Wd.

Flag ER flag changes state to ON if the contents of the word Wd are not BCD.
EQ flag changes state to ON when the result of decrementation equals “0”.

E.48 BCD ADD - Adds two values

Description Instruction adds the contents of words Au and Ad (Au + Ad + CY) and
stores the result in location R. If the result is greater than 9999 carry bit CY
is set.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON if the contents of words Au and Ad are not
BCD.
EQ flag changes state to ON if the result equals “0”.
CY flag changes state to ON if the result is greater than 9999.

Example Upon fulfilling the condition on bit IR000.02, carry bit is cleared and the
value of memory location IR200 is added to the constant 6103. The result
is stored in the memory location DM0100. The example further shows how
to save the carry bit if the result was greater than 9999. If the result

134
 exceeded 9999, memory location DM0101 will take value “1” and if not it
will take value “0”. In this way, locations DM0100 and DM0101 form one
32-bit word, which may prove to be useful.

E.49 SUBTRACT - Subtracts two values

Descripti Instruction subtracts the contents of the word Su and a value of carry bit CY
on from the contents of the word Mi. The result is stored in the memory location
R If the result is negative, carry bit CY is set and a 10’complement of the
result is stored into R. To get the real result, just subtract the value in R from
zero.

135
Ladder
symbol

Limitatio
Words DM 6144 - DM6655 cannot be used as operand R.
ns

Flag ER flag changes state to ON if the contents of words Mi and Su are not BCD.
EQ flag changes state to ON if the result equals “0”.
CY flag changes state to ON if the result is negative.

136
Example

Carry bit status should be checked before the subtraction. It is best to clear
it with CLC instruction. The check is more necessary after the subtraction,
because there is chance of misinterpretation. If the carry bit is set (value is
“1”) the result of subtraction is negative and the result word contains 10’
complement of the real result.
When the condition is fulfilled on bit IR000.02, carry bit is cleared and the
value of memory location DM0100 is subtracted from value of location IR201.
The result is stored in the location HR10. Upon subtraction, carry bit CY is
checked. If it is set, condition on SR255.04 (the very carry bit) will be
fulfilled, clearing it anew and commencing the new subtraction in order to get
the real result of the first subtraction. The second subtraction instruction
subtracts the value of the result word HR10 from zero, storing the result into
HR10 again.
It is useful to set a certain bit for a programmer to have information on

137
 negative result. In the following example this bit is HR1100. Changing the
state of carry bit to OFF doesn’t change the state of bit HR1100.

Character “@” ahead of SUB(31) represents the differencial form of the

instruction, or simply put, this instruction will not execute non-stop while the
condition is fulfilled. Only changing the condition from OFF to ON executes
the instruction. This means that the second subtraction instruction won’t take
place immediately after the first one. Before executing the second
instruction, it is necessary that bit IR000.02 changed state from OFF to ON
at least once.

E.50 BCD MULTIPLY - Multiplies two values

Descriptio Instruction multiplies values of locations Md and Mr and stores the result
n into memory locations R and R+1.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON if the contents of words Mr and Md are not
BCD.
EQ flag changes state to ON if the result equals “0”.
CY flag changes state to ON if the there is a carry in the result.

138
Example

Upon fulfilling the condition on bit IR000.00, instruction multiplies the

values of memory locations IR013 and DM0005. The result is stored into
two sequential memory locations HR07 and HR08. The result is stored so
that HR08 contains higher bits and that HR07 contains lower bits.

139
APPENDIX E Ladder diagram instructions (3/3)

E.51 BCD DIVIDE - Divides two values

Descriptio Instruction divides the contents of location Dd with contents of location Dr.
n The result of division is stored in locations R and R+1. The first contains the
rounded off result of division, while R+1 contains the fraction.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON if the contents of words Dd and Dr are not
BCD.
EQ flag changes state to ON if the result equals “0”.

Example

Upon fulfilling the condition on bit IR000.00, instruction divides the value of
memory location IR216 by the value of memory location HR09. The result

140
 is stored into two sequential memory locations DM0017 and DDM0018. The
result is stored so that DM0017 contains round number and DM0018
contains the fraction.

E.52 DOUBLE BCD ADD - Adds two 32-bit words

Description Instruction adds values from addresses Au and Au+1 to values from
addresses Ad, Ad+1 and carry bit CY. If the result exceeds 99999999 carry
bit CY is set.

Ladder
symbol

Limitations Word DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON if the contents of words Au and Ad are not
BCD.
EQ flag changes state to ON if the result equals “0”.
CY flag changes state to ON if there is a carry in the result.

E.53 DOUBLE BCD SUBTRACT - Subtracts two 32-bit words

Description Instruction subtracts the contents of two words Su+1 and Su with carry bit
CY added from the contents of words Mi+1 and Mi. The result is stored into
memory locations R+1 and R. If the result is negative, carry bit CY is set
and 10’complement of the result is stored into R. To get the real result,
contents of R should be subtracted from zero.

141
Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON if the contents of words Mi, Mi+1, Su, Su+1
are not BCD.
EQ flag changes state to ON if the result equals “0”.
CY flag changes state to ON if the result is negative.

E.54 DOUBLE BCD MULTIPLY - Multiplies two pairs of words

Description Instruction multiplies values of locations Md, Md+1 with the values of
locations Mr, Mr+1. The result is stored into 4 locations: R, R+1, R+2 i
R+3.

142
Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON if the contents of words Mr, Mr+1, Md and
Md+1 are not BCD.
EQ flag changes state to ON if the result equals “0”.
CY flag changes state to ON if there is a carry in the result.

E.55 DOUBLE BCD DIVIDE - Divides two pairs of words

Description Instruction divides the contents of locations Dd, Dd+1 by the contents of
locations Dr i Dr+1. The result is stored into locations R and R+1 while
locations R+2 and R+3 contain the fraction.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON in two cases, if the contents of words Dd,
Dd+1, Dr and Dr+1 are not BCD or if the contents of locations Dr and Dr+1
equal zero.
EQ flag changes state to ON if the result equals “0”.

143
E.56 BINARY ADD - Binary addition

Description Instruction executes binary addition of words Au and Ad with carry bit and
stores the result into memory location R. If the result is greater than FFFF
the carry bit CY is set.

Ladder
symbol

Limitations Words DM 6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON in case of error.

EQ flag changes state to ON if the result equals “0”.
CY flag changes state to ON if the result is greater FFFF.
OF flag changes state if the result is greater than +32.767 (7FFF).
UF flag changes state if the result is lower than od +32.768 (7FFF).

144
Example The example demonstrates how the binary addition
works. As A6E2+80C5 equals 127A7, carry bit CY is
set and the value of location R+1 (which is, in this
case, on HR11) changes to “1” to enable easier
handling of the result on addresses R and R+1 later
in the program. If overflow occurs, carry bit CY will
be set, fulfilling the condition on bit SR255.04. This
condition controls the lower MOV instruction, which
sets “1” to location HR11.

E.57 BINARY SUBTRACT - Binary subtraction

Description Instruction subtracts values Su+CY from the value Mi and stores the result

145
 into location R. If the result is negative, carry bit CY is set and the
2’complement of the real result is stored into location R.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON in case of error.

EQ flag changes state to ON if the result equals “0”.
CY flag changes state to ON if the result is negative.
OF flag changes state if the result is greater than +32.767 (7FFF)
UF flag changes state if the result is lower than +32.768 (7FFF).

Example
The example subtracts the value of location LR00
increased by the state of carry bit CY from the
value of location IR200. As the result is positive,
carry bit CY will not be set. In case of negative
result, location HR01 would contain 2’complement
of the result, so that a conversion would be
necessary for getting the real result.

146
E.58 BINARY MULTIPLY - Binary multiplication

Description Instruction multiplies values of location Md by the value of location Mr. The
result is stored in two memory locations R and R+1.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state u ON in case of error.

EQ flag changes state u ON if the result equals “0”.

E.59 BINARY DIVIDE - Binary division

Description Instruction divides the value of location Dd with the value of location Dr.
The result is stored into location R, while the fraction is stored in R+1.

147
Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R and the instruction
cannot be used for dividing signed numbers.

Flag ER flag changes state to ON in case that Dr contains value “0”.

EQ flag changes state to ON if the result equals “0”.

E.60 BCD TO BINARY - Converts decimal number to a binary

number

Description Instruction converts binary representation of decimal number from the

word S to binary number in the word R. Contents of the word S remains
unchanged.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON if the contents of the word S are not BCD.
EQ flag changes state to ON if the result equals “0”.

148
Example

Upon fulfilling the condition on bit IR000.00, instruction changes the

contents of memory location IR200 so that its numerical value remains
unchanged; in other words, only the representation of the location’s
contents changes. If the contents of the location IR200 is “164” decimal,
this instruction would convert it to “0000000010100100”. One of the
purposes of this instruction is preparing the contents of memory location
for one of the binary operations.

E.61 BINARY TO BCD - Converts binary number to a decimal

number

Description Instruction converts binary represented number from the word S to a

decimal number in the word R. Contents of the word S remains unchanged.

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symbol

Limitations Word DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON in case of error.

EQ flag changes state to ON if the result equals “0”.

Example

Upon fulfilling the condition on bit IR000.00, instruction changes the

contents of memory location IR200 so that its numerical value remains
unchanged; in other words, only the representation of the location’s
contents changes. If the contents of location IR200 is “000000101100100”
binarny, this instruction would convert it to “740” decimaly. One of the
purposes of this instruction is preparing the contents of memory location
for one of BCD operations.

150
E.62 4 TO 16 DECODER - 4 to 16 decoder

Description Instruction converts up to four 4-bit hexadecimal digits of values from 0 to

15. The result of the instruction is stored into memory locations from
address R to R+3, depending on how many digits was converted. Converted
digit in the result is represented with a set bit on a position corresponding
to the value of a digit. If the value of a digit is “C” (12 decimaly) the twelfth
bit of the result word will be set.

The first digit to be converted, as well as the number of digits to be

converted, is determined in the control word Di. If the number of digits for
conversion is greater than the number of digits remaining in the word S,
then the missing digits are taken from the starting digit anew. The
structure of the control word Di is shown on the picture below.

Some of the combinations of control word values along with their meaning
are given below:

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symbol

Limitations Two rightmost digits of the word Di have to be between 0 and 3. Words
DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON in case that (R + number of digits) exceeds the
range of a given memory block.

Example

Upon fulfilling the condition on bit IR000.00, instruction converts three

digits from the digit no.1 in the word DM0020. As there are three digits to
be converted, the result will take three memory locations starting from
HR10. Digit 0 in the word DM0020 is not converted.

152
E.63 16 TO 4 ENCODER - 16 to 4 encoder

Description Instruction determines the highest set bit in SB and according to it, stores
the 4-bit hexadecimal value to a certain place in the result word R.
In the example below, bit 12 of the location on address SB is set, which
would be “C” in a hexadecimal representation.

Precise place for storing the converted value in the word R is determined by
a control word Di. The same word also determines the number of words to
be converted, starting from the address of the word SB. For this example,
the control word would be “0001”.

The first digit to be converted, as well as the number of digits to be

converted, is determined in the control word Di. If the number of digits for
conversion is greater than the number of digits remaining in the word S,
then the missing digits are taken from the starting digit anew. The
structure of the control word Di is shown on the picture above.

Some of the combinations of control word values along with their meaning
are given below:

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symbol

Limitations Two rightmost digits of the word Di have to be between 0 and 3. Words
DM6144 - DM6655 cannot be used as operands R, SB and Di.

Flag ER flag changes state to ON if (SB + number of digits) exceeds the range of
a given memory block or if the word to be converted equals zero.

154
Example

Upon fulfilling the condition on bit IR000.00, first DMPX instruction converts
two words, IR200 and IR201. The control word is “0010”, meaning that two
words are converted (digit 1) and stored starting from the zero digit in the
result (rightmost digit 0). After the first DMPX instruction, the second one is
executed, converting two words from addresses LR10 and LR11 and storing
them in the result word HR10, starting from the digit no.2. Therefore, the
word HR10 contains four converted words in the following order: IR200,
IR201, LR10, LR11. More detailed explanation of how the instruction works
is given on the following picture.

155
 Presuming that binary value is the one from locations IR200, IR201, LR10
and LR11, as in example, the result of conversion in the result word HR10
would be “5B7D”.

E.64 ASCII CONVERT - Converts to ASCII code

Description Instruction converts digits from the word S to their ASCII equivalent and
stores the result in the words starting from the address D. The control word
Di determines the first converted digit, the number of digits to be converted
and which half of the word D contains the first 8-bit ASCII converted code.
IIf the number of digits for conversion is greater than the number of digits
remaining in the word S, then the missing digits are taken from the starting
digit anew from the word S. Digit with the highest position of the word Di
has a role of parity bit and it can take values between 0 and 2 - not having
parity, parity and non-parity. Parity bit is actually a highest bit of the 8-bit
ASCII code. When the third digit of the word Di equals zero, this bit is
always zero. If the third digit of the word Di equals one, then this bit
represents parity, or simply put, this bit is set when the number of ones in
the other 7 bits of ASCII is odd making the number of ones even. If the
ASCII value equals “31” (binary “0011 0001”), even parity would change
the highest bit to one, changing the ASCII number to “1011 0001” or “B1”.
The status of parity bit does not affect the interpretation of ASCII code.
Odd parity bit behaves in similar fashion, but with the opposite function.
It’s purpose is to ensure that the number of ones in ASCII code is always

156
 odd. The following picture represents interpreting the value of word Di and
the picture after that gives several versions of values of the word Di and
how they affect the instruction.

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symbol

157
Limitations Two lower digits of the words Di must have values betweenmoraju imati 0
and 3. Words DM6144 - DM6655 cannot be used as operand D.

Flag ER flag changes state to ON if two rightmost digits of the word Di do not fall
within the specified range (0-3) or the result word exceeds the boundaries
of memory area.

E.65 COMPLEMENT - Complements a word

Description Instruction executes the second complement of the word Wd and stores it
into word Wd again. The second complement means that ones become
zeros and vice versa.

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symbol

Limitations Words DM6144 - DM6655 cannot be used as operand Wd.

Flag ER flag changes state to ON in case of error.

EQ flag changes state to ON if the result equals zero.

E.66 LOGICAL AND - Operation logical "AND" on the contents of

a word

Description Instruction executes the operation logical “AND” on words I1 and I2. The
result of the operation is stored into word R. Operation logical “AND” puts
one in the result only if the same position of words I1 and I2 also contain
one.

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symbol

Limitations Words DM 6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON in case of error.

EQ flag changes state to ON if the result equals zero.

E.67 LOGICAL OR - Operation logical "OR" on the contents of a

word

Description Instruction executes the operation logical “OR” on words I1 and I2. The
result of the operation is stored into the word R. Operation logical “OR” puts
the one in the result if at least one of the words I1 and I2 contains one on
that position.

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Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON in case of error.

EQ flag changes state to ON if the result equals zero.

E.68 EXCLUSIVE OR - Operation "EXCLUSIVE OR" on the

contents of a word

Description Instruction executes operation “EXCLUSIVE OR” on the words I1 and I2.
The result of the operation is stored into the word R. Operation exlusive
“OR” puts one in the result only if the same position of the words I1 and I2
contains different values.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON in case of error.

EQ flag changes state to ON if the result equals zero.

160
E.69 EXCLUSIVE NOR - Operation "EXCLUSIVE NOR" on the
contents of a word

Description Instruction executes operation “EXCLUSIVE OR” on the words I1 and I2.
The result of the operation is stored into the word R. Operation exclusive
“NOR” puts one in the result only if the same position of words I1 and I2
contains the same value, whether it is “0” or”1”.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R.

Flag ER flag changes state to ON in case of error.

EQ flag changes state to ON if the result equals zero.

E.70 BIT COUNTER - Counts the number of ones in a given word

Description Instruction counts the number of bits with the state “1” in words from
address SB to SB+(N-1) and puts the result on the address of the word R.

161
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symbol

Limitations Words DM6144 - DM6655 cannot be used as operand R. Word N cannot

have zero value.

Flag ER flag changes state to ON in case that N isn’t BCD number or in case that
SB and SB+(N-1) don’t belong to the same memory area.
EQ flag changes state to ON if the result equals zero.

E.71 SUBROUTINE ENTRY - Enters the subroutine

Description Instruction changes the course of the main program towards subroutine, at
the instruction line of the main program which contains the instruction SBS.
Number of instructions N has to be in 000 - 049 range. When the
instruction condition is fulfilled, all the instructions between SBN(92) and
the first RET(92) instruction are executed. Upon processing the RET
instruction, program returns to the line immediately following the
instruction SBS which called the subroutine in the first place. The same
subroutine may be called from several places in the program.

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symbol

Limitations Number of subroutine has to be in 000 - 049 range.

Flag ER flag changes state to ON when non-existing subroutine is called, when

the subroutine calls itself or when the subroutine being executed at the
moment is called.

E.72 SUBROUTINE DEFINE - Beginning of a subroutine

Description Instruction marks the beginning of a subroutine. Each subroutine is defined

with its number N. All subroutines have to be placed after the main
program and instruction END has to follow the last RET instruction of the
last subroutine SBN.

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symbol

Limitations Number of the subroutine has to be in 000 - 049 range. Each number may
be used only once.

Flag It has no effect on any particular flag.

E.73 SUBROUTINE RETURN - Return from a subroutine

Description Instruction executes the return from the subroutine to the main program.
Each subroutine must contain the RET instruction. This instruction jas on
number of its own, naturally assuming that it belongs to the previous SBN
instruction.

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symbol

Limitations Number of the subroutine has to be in 000 - 049 range. Each number may
be used only once.

Flag It has no effect on any particular flag.

E.74 MACRO - Macro

Description Instruction MCRO enables one subroutine to substitiute several subroutines

having the same structure, but different operands. Instruction has 4 input
words SR232 to SR235 and 4 output words SR236 to SR239 used for
sending or receiving the subroutine parameters. Upon fulfilling the
condition, the instruction copies the contents of locations I1 - I3 to words
SR232 - SR235. Upon execution of subroutine N, values of the words
SR236 - SR239 are copied to words O1 - O3.

Ladder
symbol

Limitations Number of the subroutine has to be in 000 - 049 range. Each number may
be used only once.

165
Flag ER flag changes state to ON when non-existing subroutine is called, when
the subroutine calls itself or when the subroutine, being executed at the
moment, is called.

Example

Instruction MCRO calls the subroutine with the number 010. Contents of
words DM0010 - DM0013 is copied to SR232 - SR235 and upon execution
of the instruction, contents of words SR236 - SR239 is copied to the words
DM0020 - DM0023.

E.75 INTERRUPT CONTROL - Interrupt control

Descripti Instruction controls the interrupts and executes one of the seven functions
on presented in the table below, according to the value of the word C1.

C1 Function
000 Mask/unmask interrupts
001 Clear the interrupt input
002 Read the current mask for interrupt inputs
003 Reset decrement counter and unmask interrupts
004 Reset increment counter and unmask interrupts
100 Mask all interrupts
200 Unmask all interrupts NOTE:
Value of the word C1 004 refers to models CPM2A/CPM2C of PLC controller, so it will not be detailed
here.

C1=000
Function is used for masking and unmasking the interrupt inputs 00003 -
00006. Masked interrupts are registered, but the part of the program
assigned to them will not be executed until the mask is off. Upon unmasking
interrupt input, interrupt routine will immediately take place (unless, in the

166
meantime the bit corresponding to that interrupt input is reset with the
instruction INT, parameter C1=001). The input being masked or unmasked is
determined by parameter C2 according to the following scheme (bear in mind
that we work with bits and not with digits of the word C2). Bits 4, 5, 6...15
should be set to zero. All interrupt inputs are masked upon starting the PLC
controller.

C1=001
Function resets the registered interrupts, so that interrupt routine cannot
take place upon unmasking the interrupt input. Bits 4, 5, 6...15 of the word
C2 should be set to zero.

C1=002
Function reads the status of the mask for interrupt inputs 00003 - 00006 and
stores the read state into the word C2. Interrupt input is masked if the state
of the corresponding bit equals “1”. Bits 00 - 03 correspond to interrupt
inputs 00003 - 00006.

C1=003
Function restarts the interrupt inputs in the counter mode. The current
counter value (SR240 - SR243) is set to the starting state and the interrupt is
unmasked. If C1=003, decremental counter is restarted, while in the case of
C1=004 incremental counter is restarted. As CPM1A model of PLC does not
feature incremental counter, this option should not be used. When using the
options C1=003 or C1=004 differencial form of the instruction shoud be used
@INT or else the current counter state (PV) will be reset to the starting state

167
 (SV) and the interrupt will never be generated. Writing the value “0000” to
the starting counter state and executing the INT instruction with parameter
C1=003 stops the counter and disables interrupts.

To start the counter again, non-zero value should be written to a starting

value SV and the instruction INT executed. Interrupts in the counter mode
can be masked by executing the instruction INT with parameter C1=000 and
set corresponding bit in C2. If same is done, but with “0” for the appropriate
position in the word C2 interrupt input will behave as a regular interrupt ulaz
and not as counter interrupt input.

C1=100
Function masks all the interrupts including the interval timer interrupts and
the high-speed counter interrupts. Masked interrupts are registered, but are
not executed. This function is also called a global interrupt mask and it does
not affect the masks of specific interrupts. This option should be used for
temporary disabling all the interrupts. It is cmmonly used in pair, one function
masks all the interrupts and the other one unmasks them. Function cannot be
used within the interrupt routine.

C1=200
Function unmasks all the interrupts including the interval timer interrupts and
the high-speed counter interrupts. If the specific interrupt is masked, global
unmasking does not affect the state of the specific interrupt input state.
Function cannot be used within the interrupt routine.

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symbol

Flag ER flag changes state to ON if:

C1 is not 000, 001, 002, 003, 004, 100 or 200.
C2 is not in 0000 - 000F range.
INT instruction is executed with C1=100 or 200 within the interrupt routine.
INT instruction is executed with C1=100 when all inputs are already masked.
INT instruction is executed with C1=200 when all inputs are already
unmasked.

E.76 INTERVAL TIMER - Interval timer

Descriptio Instruction is used for controling the timer interrupt. Instruction mode is
n determined according to the value of the word C1.

C1 Function
000 Start the interrupt timer with only one timer
003 Start the timer with periodical interrupts
006 Read the current timer value
010 Stop the timer
C1=001 or 003
C2 can be either a constant or an address of a word in PLC controller
memory.

C2=constant

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 If C2 is a constant, then it represents the starting value of decremental
counter in BCD format (form 0000 to 9999 which is equivalent to 0 - 9.999
ms) and C3 represents the number of the interrupt routine (from 000 to
049).

C2=address of a word in memory

If C2 is a word in PLC controller memory, then its contents is a starting
value of decremental counter in BCD format. Cotents of the word C2+1
represents the measurement unit (BCD, 0005 - 0320) in 0.1s decrements.
Interval is, in that case, 0.5 - 32ms. Starting value of the timer is
calculated as C2 * (C2+1) * 0.1s. C3 represents the number of the
interrupt routine.

C1=006
Function reads the current timer state. Parameter C2 represents the
memory address where the read timer state is stored, while C2+1 stores
the measurement unit. Parameter C3 reresents the memory address where
the data concerning the time passed since the last decrementation of timer
in BCD format is stored in 0.1s units.

C1=010
Function stops the timer. Parameters C2 and C3 are without function and
should be set to “0000”.

Ladder
symbol

Flag ER flag changes state to ON if C1 is not 000, 003, 006 or 010 or in case
that the number of interrupt routine is not within 0000 - 0049 range.

E.77 7-SEGMENT DECODER - Seven-segment decoder

Descriptio Instruction translates the digits of the word S to 8-bit 7-segment code and
n stores it into destination word D. The control word Di determines the first digit
of S to be translated, number of digits to be translated and which half of the
word D will contain the result of the first translation. The following picture
interprets the values of digits of the word Di and the picture after that displays
a few versions of the word Di and how they affect the instruction.

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symbol

Limitations Words DM6144 - DM6655 cannot be used as operand D.

Flag ER flag changes state to ON in case of error.

171
Example

E.78 I/O REFRESH - Premature writing to I/O table

Description Instruction checks the states of words from the address St to the address E
and refreshes them according to the current state of the program.
Instruction is used when we want to know the state of certain bit without
waiting it to be refreshed in the course of regular cycle of refreshing the
inputs and outputs of PLC controller (IR000 - IR019).

172
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symbol

Limitations Address of the word St has to be lower or equal to the address of the word
E.

Flag ER flag changes state to ON if words St and E do not belong to IR000 -

IR019 range or in case that the address of the word St is greater than the
address of the word E.

E.79 MESSAGE - Displays message in the programming console

Description Instruction reads the contents of eight words from the address FM and
displays them in the program console. Contents of the word has to be in
ASCII format, with every word containing 2 ASCII characters. If not all the
words are to be displayed in the console, displaying can be stopped if the
string “OD” is put into following word.

Ladder
symbol

Limitations Words DM6144 - DM6655 cannot be used as operand FM.

Flag ER flag changes state to ON in case of error.

E.80 MODE CONTROL - Controls the high-speed counter or the

pulse output

Description Instruction controls the high-speed counter. There are several functions
depending on parameters P, C and P1. Parameter P defines if either high-
speed counter or pulse output will be controlled with this instruction.

173
 P Function
000 Designates the input of PLC controller that will be used as
high-speed counter (000.00, 000.01 and 000.02).
Determines mono-phase signal of logical zero with no
acceleration/deceleration (outputs 010.00 and 010.01)

Determines mono-phase signal of logical zero with

trapezoid acceleration/deceleration (output 010.00)
010* Determines mono-phase signal "1" with no
acceleration/deceleration (output 010.01)
100* Designates interrupt input 0 in counter mode (input
000.03)
101* Designates interrupt input 1 in counter mode (input
000.04)
102* Designates interrupt input 2 in counter mode (input
000.05)
103* Designates interrupt input 3 in counter mode (input
000.06)
NOTE: * refers to CPM2A/CPM2C PLC controller models.

C P1 Function
Starts comparing the current value
000 000 with the values from comparison table
(CTBL)
Stops comparing the current value with
001 000 the values from comparison table
(CTBL)
Changes the current value PV of high-
New value of the
002 current state (PV) speed counter or interrupt input in
counter mode
003 000 Stops the pulse output
New value of the Changes the current state of pulse
005* current state (PV) output
006* 000 Stops the synchronized pulse output
NOTE: * refers to CPM2A/CPM2C PLC controller models.

C=000 or C=001
Function starts or stops comparing the current value of high-speed counter
PV with the values from the comparison table created with instruction
CTBL. If the comparison table wasn’t created ahead of executing the INI
instruction, the error occurs. Generally, when INI instruction with C=000 is
used, differential form @INI is recommended, because one set of starting
comparisons is sufficient.

C=002
Function changes value of the current state of the high-speed counter or
the interrupt in the counter mode.

174
 Fast counter PV ( P=0 )
Function changes the contents of PV to 8-digit BCD number contained in
the words P1 and P1+1. If differential-phase mode or ”up/down “ input
mode is used, PV can have value between F838 8608 and 0838 8607,
where “F” as the first digit is treated as a minus sign. PV can have value
between 000 0000 and 1677 7215 in incremental mode.

Interrupt counter input PV ( P=100, P=101, P=102, P=103)

Function changes the contents of PV to 4-digit hexadecimal number from
the word P1 (from 0000 to FFFF).

C=003
Function stops the pulse output.

C=004
Function changes the value of the current PV pulse output state to an 8-
digit BCD value in the words P1 and P1+1. Change cannot be done while
the pulse output is in function. New value can be from -16.777.215 to
+16.777.215. Bit no.15 of the word P1+1 behaves like a sign: “0” stands
for positive, “1” stands for negative number.

C=003
Function stops the synchronized pulse output.

Ladder
symbol

Limitations If CPM1 or CPM1A PLC controller is used, parameter P has to be 000 and
parameter C has to be 000, 001, 002 or 003. P1 has to be 000 if C is not
002 or 004. If an address from DM memory area is used as parameter P1,
reading and writing to that location has to be enabled.

Flag ER flag changes state to ON if comparison table exceeds one memory area.

175
E.81 HIGH-SPEED COUNTER PV READ - Reads the current
value of high-speed counter

Description Instruction controls the current state of high-speed counter, pulse output,
interrupt input in counter mode or input frequency for synchronized input.
There are several functions depending on parameters P, C and D.

Parameter P defines if either high-speed counter or pulse output will be

controlled with this instruction.

P Function
000 Designates the input of PLC controller that will be used as
high-speed counter (inputs 000.00, 000.01 and 000.02).
Designates input frequency for synchronized pulse input
(inputs 000.00, 000.01 and 000.02). Determines mono-
phase signal of logical zero with no
acceleration/deceleration (outputs 010.00 and 010.01)

Determines mono-phase signal of logical zero with

trapezoid acceleration/deceleration (output 010.00)
010* Determines mono-phase signal "1" with no
acceleration/deceleration (output 010.01)
100* Designates interrupt input 0 in counter mode (input
000.03)
101* Designates interrupt input 1 in counter mode (input
000.04)
102* Designates interrupt input 2 in counter mode (input
000.05)
103* Designates interrupt input 3 in counter mode (input
000.06)
NOTE: * refers to CPM2A/CPM2C PLC controller models.

Control word determines the type of data to be accessed.

176
 Destination
C Function
word
Reads the current state of high-speed counter,
000 D and D+1 of interrupt input in counter mode or input
frequency of synchronized pulse control
Reads the status of high-speed counter or
001 D
pulse output
Reads the results of comparing with values
002 D
from comparison table
003 D and D+1 Reads the current value of pulse output
NOTE: * refers to CPM2A/CPM2C PLC controller models.

C=000
Function reads the current value of PV of the specified high-speed counter
or the interrupt input in counter mode.

Fast counter PV or input frequency (P=000)

When the output is used as the high-speed counter, instruction reads the
current value of the specified fast counter and writes an 8-digit BCD value
to D and D+1.
If differential-phase mode or ”up/down “ input mode is used, PV can have
value between F838 8608 and 0838 8607, where “F” as the first digit is
treated as a minus sign. PV can have value between 000 0000 and 1677
7215 in incremental mode. When the input is used as synchronic pulse
input, the instruction reads the input frequency and writes an 8-digit BCD
value to D and D+1. Range of the input frequency is 0000 0000 - 0002
0000.

Interrupt counter input PV ( P=100, P=101, P=102, P=103)

Function changes the contents of PV to 4-digit hexadecimal number from
the word D (from 0000 to FFFF).

C=001
Function reads the status of the high-speed counter or the pulse input and
stores the data into D.

Status of the high-speed counter or the pulse input 0 (P=000)

The table below shows the function of bits in the word D when P=000. Bits
not mentioned are not used and are always zero.

177
 For... Bit Function
High-speed counter Status of comparing high-speed
00 counter with values from
comparison table (0: not compared,
1:compared)

High-speed counter below/above

01 the specified value (0: in range, 1:out of
range)

Pulse output Total number of pulses defined for

05 pulse output 0 (0: number of pulses not
defined, 1:number of pulses defined)

Defined number of pulses on output

06
0 executed (0: not executed, 1:executed)

07 Pulse output 0 state (0: stopped,

1:executing)

08 Current state PV of pulse output (0:

in range, 1:out of range)

09 Rate on pulse output 0 (0: constant,

1:accelerates/decelerates)

Status of the pulse output 1 (P=010)

The table below shows the function of bits in the word D when P=010. Bits
not mentioned are not used and are always zero.

Bit Function

05 Total number of pulses defined for pulse output 1 (0: number

of pulses not defined, 1:number of pulses defined)

06 Defined number of pulses on output 1 executed (0: not

executed, 1:executed)

07 Pulse output 1 state (0: stopped, 1:executing)

08 Current state PV of pulse output (0: in range, 1:out of range)

09 Rate on pulse output 1 (0: constant, 1:accelerates/decelerates)

C=002
Function reads the result of comparing the current value PV with 8 areas
defined by instruction CTBL and stores data into D. Bits 0 to 7 contain the
results of comparing with 8 ranges from the comparison table (0: not in
range, 1: in range).

C=003
Function reads the value of current state of PV pulse output and stores it to
8-digit BCD value in words D and D+1. PV can have value from
-16.777.215 to +16.777.215. Bit no.15 of the word D+1 behaves like a
sign: “0” stands for positive, “1” stands for negative number.

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Ladder
symbol

Limitations If CPM1 or CPM1A PLC controller is used, parameter D has to be 000 and
parameter C has to be 000, 001 or 002. If an address from DM memory
area is used as parameter D, reading and writing to that location has to be
enabled.
D and D+1 have to belong to the same memory area.

Flag ER flag changes state to ON if an error concerning the value of instruction

operand occurred.

E.82 COMPARISON TABLE LOAD - Defines a comparison table

Description Instruction forms the comparison table for working with high-speed
counter. Depending on parameter C, comparison can be immediate or it can
be called upon with instruction INI.

C Function
Registers comparison table containing values and starts
000
comparing
Registers comparison table containing ranges and starts
001
comparing
Registers comparison table containing values. Comparing
002
starts with INI instruction
Registers comparison table containing ranges. Comparing
003
starts with INI instruction
When the current value of PV matches some of the specified table values or
it belongs to one of the specified ranges, the appropriate subroutine is
called. If the high-speed counter is not enabled in PC area (DM6642)
instruction CTBL cannot be executed.

Comparing with values

Comparison table can have up to 16 values. Each of these values is
assigned a number of subroutine that is called when the current value
matches the table value. With CPM1 and CPM1A models, comparison is
done one at a time in each cycle, while with models CPM2A and CPM2C
comparison is done for all table values simultaneously. After comparing with
the last table value, comparison starts from the first value again. The table

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 below shows the structure of the comparison table containing values.
Each value is assigned three words in the table. If the value “FFFF” is used
as the number of subroutine, no subroutine will be executed in case of a
match.

Number of values that current value is compared with

TB
(0001 to 0016, BCD)
TB+1 Value no.1 (lower four digits in BCD format)
TB+2 Value no.1 (higher four digits in BCD format)
TB+3 Number of subroutine for matching the first value
...
Comparing with a range of values
Comparison table with ranges contains 8 ranges, which the current value
PV is compared with. Ranges can overlap, allowing that the current value
PV falls into several of these; in this case, the subroutine of the first
matching area is called. If the value “FFFF” is used as the number of
subroutine, no subroutine will be executed in case of a match.

TB Lower value no.1 (lower four digits in BCD format)

TB+1 Lower value no.1 (higher four digits in BCD format)
TB+2 Higher value no.1 (lower four digits in BCD format)
TB+3 Higher value no.1 (higher four digits in BCD format)
Number of subroutine in case that the current value PV is
TB+4
within range no.1
...
TB+35 Lower value no.8 (lower four digits in BCD format)
TB+36 Lower value no.8 (higher four digits in BCD format)
TB+37 Higher value no.8 (lower four digits in BCD format)
TB+38 Higher value no.8 (higher four digits in BCD format)
Number of subroutine in case that the current value PV is
TB+39
within range no.8

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Limitations In each area lower border has to be lower than the upper border. Number
of subroutine can be used for several ranges.
Table has to belong to a single memory area. Parameter D has to be 000
and the parameter C has to be 000, 001, 002 or 003.

Flag ER flag changes state to ON if an error concerning the value of instruction

operand occurred.

E.83 FAILURE ALARM AND RESET - Generates error code

Description Instruction generates the code of an error that took place, so that the
programmer can use that information for debugging or program
maintenance. Error code is stored in the first 8 bits of the word SR253 and
has value between 01 and 99.

In case of multiple errors, only one code will be displayed. To display the
other codes, it is necessary to reset bits 00-07 of the word SR253 via
instruction FAL with parameter N=00. Upon each reset, new error code will
be displayed (if there is more than one error). Error code remains in PLC
controller memory after the power is off. When error occurs, besides the
code, programmer will be notified with blinking diode on the casing of PLC
controller.

Instruction FAL with parameter N=0 may be used for resetting the message
created with the instruction MSG.

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E.84 SEVERE FAILURE ALARM - Generates fatal error code

Description Instruction generates the code of an error that took place, so that the
programmer can use that information for debugging or program
maintenance. Error code is stored in the first 8 bits of the word SR253 and
has value between 01 and 99. Upon occurence of fatal error, diode
ALARM/ERROR turns on on the casing of PLC controller and the PLC stops
operating.

PLC controller continues the program execution only when cause of error is
removed. Error code remains written and may be read.

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E.85 SET CARRY - Sets carry bit

Description Instruction changes the state of carry bit CY to ON. Carry bit is an integral
part of the word SR255, and its address is SR255.04.

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E.86 CLEAR CARRY - Resets carry bit

Description Instruction changes state of carry bit CY to OFF. Carry bit is an integral part
of the word SR255, and its address is SR255.04.

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