Programmable

Logic Controllers
Getting Started Student Workbook

Allen Bradley V2019-AB-1695

Micro 820 Series PLC www.golearnlab.com
All rights reserved. No part of this document may be
reproduced, stored in any retrieval system, or
transmitted, in any form or by any means electronic,
mechanical, photocopy, recording, or otherwise, without
the permission of Industrial Training Unlimited, Inc.

2
 Course Objectives

Understand the History of PLCs

Understand PLC Fundamentals
Understand PLC Programming Basics
Understand how to Troubleshoot PLCs
Understand Micro820 Basics
Understand and Demonstrate
Software Requirements Micro820
Setting up communications Micro 820
Basic Control Program Lab #1
Basic Control Program Lab #2
Basic Control Program Lab #3
Basic Timer Program Lab #4
Timer & Counter Program Lab #5
Timer & Counter Program Modification Lab #6
Explore Real World PLC Application

3
Notes

4
 Part 1: History

What Is A PLC?
A
Programmable Logic Controller
is a computer
that is specially designed
to make industrial
equipment and processes
easier to control

5
Notes

6
 Part 1: History

PLCs originated from a simple control component called

an electromagnetic relay.

Most maintenance personnel understood

relay operation and how to read basic relay
control diagrams, often referred to as “ladder
diagrams”.
7
Notes

8
 Part 1: History

Ladder Diagrams: The Language of Control

Control

9
Notes

10
 Part 1: History

Ungrounded Grounded
Conductor Conductor

Rungs

Power Grounded
Rail Rail

11
Notes

12
 Part 1: History

Disadvantages of relays:

• Size
• Speed (20 to 60 milliseconds)
• Not easy to make changes
(must re-wire to make
changes)

13
Notes

14
 Part 1: History

And then came TTL Gates

But they used Boolean Algebra instead of Ladder

Diagrams

AND Operations (X)

OR Operations (+)
NOT Operations (')

Logic designers also had to use various

laws associated with Boolean Algebra and
theorems to work with logic gates:

15
Notes

16
 Part 1: History

Maintenance electricians also had to learn

Boolean Algebra to be able to read the logic
gate diagrams and troubleshoot these
systems.....

So most companies kept the relays.....

until.....

17
Notes

18
 Part 1: History

The first PLC…

1968
Bedford Associates (Bedford, MA) developed
the first PLC known as the Model 084, It was
there 84th project.
They named it the MODICON 084

Modicon = Modular digital controller

“We had some real problems convincing people that this box of
software and cast iron could do the same thing as 50 feet of
cabinets with associated relays and wiring.”
Richard “Dick” Morley
Credited with inventing the first PLC but Allen-Bradley
copyrighted the letters “PLC”

19
Notes

20
 Part 2: PLC Fundamentals

Current PLCs

• Since the late ’60s PLCs have

grown in:
• Number of I/O points in
regards to size of PLC
• Amount of memory
• Processor Speed
• Ability to communicate with
other devices
• Networking

21
Notes

22
 Part 2: PLC Fundamentals

The Future of PLCs

• The automation in manufacturing

and industrial applications must
be able to be maintained by
people who have a knowledge of
how to troubleshoot with standard
meters.

• While some PLCs can be

programmed in many different
programming languages nearly
all PLCs can display relay ladder
logic diagrams.

23
Notes

24
 Part 2: PLC Fundamentals

Types of PLC Configurations

With the modular configuration, everything is a separate

unit. Each component is installed into a slot in a rack.

INPUT OUTPUT OUTPUT INPUT OUTPUT INPUT

P
O
CPU MODULE MODULE MODULE MODULE MODULE MODULE
8xDC12V 8xDC24V 8xDC5V 8xDC5V 8xDC12V 8xDC24V
W 00 00 00 00 00 00
E POWER E
RUN M
R FAULT
01 01 01 01 01 01
P
S 02 02 02 02 02 02 T
U 03 03 03 03 03 03
Y
P
P 04 04 04 04 04 04 S
L L
Y 05 05 05 05 05 05 O
06 06 06
T
L1 06 06 06

L2 07 07 07 07 07 07
GND

Advantages:
Disadvantages:
• Repairable with modular
• More expensive
replacement
up front.
• Can be reconfigured with
• Larger in size,
system modifications
may not always fit.
• Flexible I/O
• Easily expandable

25
Notes

26
 Part 2: PLC Fundamentals

With the integral configuration, also referred to as a

brick or shoebox, everything is in one box. PLC’s of
this configuration are usually supplied by the OEM with
the equipment.

The I/O is expandable in some units of this configuration

through the use of expandable modules.

A B C
X0 X1 X2 X3 COM X4 X5 X6 X7 COM X10 X11 COM

POWER INPUTS
RUN
L1 FAULT OUTPUTS
Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7
L2 D E
COM COM
GND

Advantages: Disadvantages:
• Less expensive • Not usually considered
repairable
• Smaller in size
• Cannot reconfigure with
system modifications
• I/O is not as flexible
• Limited types of input and
output modules 27
Notes

28
 Part 2: PLC Fundamentals

PLC replaces relay control

Real-World Real-World
PLC
Input Devices Output Devices

MS

CR

Basic PLC Set-Up

Present with or without the PLC

29
Notes

30
 Part 2: PLC Fundamentals

Input Output
Modules Processor Modules
Digital 1 2 3 Digital
Inputs Outputs

Analog Analog
Inputs Outputs

Power Programming
4 Supply Device
5 Parts to PLC
5
POWER
SUPPLY
POWER PROGRAMMING
ON
DEVICE

INCOMING
POWER

L1
INPUT CPU OUTPUT L2

00 RUN 00 M1

01 CPU 01 G
FAULT
I/O CR
02 FORCE 02

03 BATTERY 03 R
LOW
04 04 CR

05 05

06 06

07 07

REAL WORLD INPUT PROCESSOR OUTPUT REAL WORLD 31

INPUTS MODULE (CPU) MODULE OUTPUTS
Notes

32
Part 2: PLC Fundamentals

Central Processing Unit

The CPU (processor) controls the PLC operations

• It can be referred to as the brains

• The CPU reads input conditions
• The processor controls the machinery or process
(via the outputs).
• A programming device can be interfaced with the
CPU to allow the operator access to
programming functions

CPU The CPU:

RUN • Looks at the Input(s)
• Runs the Program
COMM
• Activates the Output(s)
CPU
FAULT
I/O
FORCE
BATTERY
LOW
From Input To Output
Modules RUN Modules
PROGRAM
RUN
HALT
DISABLE
OUTPUTS

33
Notes

34
 Part 2: PLC Fundamentals

Input Modules
• The input module interfaces with inputs from the
machinery or process that is being controlled.

• Makes ON and OFF conditions available to the CPU

• They are available in many AC and DC voltage ratings

and various configurations

L1
INPUT
00

01

02
TO CPU
03

04

05

06

07

N
Termination
Indication Isolation
35
Notes

36
Part 2: PLC Fundamentals

Why Isolation?
• The module acts as a messenger for the CPU
• The CPU is operating on a low voltage DC
• There must be isolation between the real world
and the CPU

Inside the PLC module this circuit

isolates the PLC from the real
world devices. It acts as a
protection form problems from
How It Works
harming the PLC. • There is no electrical connection
from the control voltage to the low
voltage DC processor
• The communication is done through
light in the opto-
coupler shown above
• An opto-coupler is more or less a
light sensitive switch

37
Notes

38
Part 2: PLC Fundamentals

Output Modules
The output module interfaces with the outputs of the
machinery or process that is being controlled.

• The output module is controlled by the CPU

• It is the interface between the CPU and the real
world
• Output modules are available in many AC and
DC voltage ratings, and many configurations

L1 OUTPUT

00 M1

01 G

02 CR

03 R

04 CR
FROM CPU
05

06

07

Isolation Termination
N
Indication 39
Notes

40
Part 2: PLC Fundamentals

• The output module acts as a messenger for the CPU

• The processor is operating on a low voltage DC
• There must be isolation between the real world and
the CPU

Basically How It Works

• There is no electrical connection from the control voltage to the low
voltage DC processor
• The communication is done through light in the opto-coupler shown
above
• An opto-coupler is more or less a light sensitive switch

41
Notes

42
 Part 2: PLC Fundamentals

Changing the battery…

You must consult the manufacturers procedure to replace

the PLC CPU battery. When the battery low light is on, it’s
time to replace it!
If you don’t, YOU CAN LOSE THE PROGRAM!

The battery is usually located on the front

or on the CPU main board. Again use the
manufacturers procedures to locate and
change the battery…Play It Safe!

The battery holds the program

in memory when the PLC is not
powered by an outside power
source. Such as when the
machine is turned off, or
powered down, or “re-booted”

43
Notes

44
Part 2: PLC Fundamentals

Here a battery is located on

the front of the CPU. It can
be changed very easily.
Some units are as easy as
just un-plugging the battery
while the PLC is powered up
and replacing it with a new
battery.

The battery may be

located on the actual
Printed circuit board.
This may require
have to remove the
CPU card to replace
the battery. AGAIN,
you should refer to
the factory
procedures to
replace any battery.
45
Notes

46
Part 2: PLC Fundamentals

The Micro820 has the option

of using a Micro SD card for
project backup and restore.

47
Notes

48
Part 2: PLC Fundamentals

Backup and restore can

only occur in PROGRAM
mode.

On power-up it will be done

automatically if the “Load
Always” or “Load on Memory
Error” selection has been
configured in the Controller
Options.

49
Notes

50
 Part 2: PLC Fundamentals

Programming Devices
The programming device allows the PLC programmers
and/or technicians the ability to develop, monitor, and edit
the operating program.

PC (Laptop)
Computer

51
Notes

52
Part 3: PLC Programming
Basics

Logic Instructions
Even though they look like relay contacts and coils,
they are not.

3 Main Instructions

The address must be ON (=1)

for the instruction to be true.

The address must be OFF (=0)

for the instruction to be true.

If there is a true logic path to the

output, the address will be ON (=1)

53
Notes

54
Part 3: PLC Programming
Basics

Logic Instructions
When the PLC scans the program, it looks at the
ON/OFF state of the instructions to verify if the rung
is true.
X3 X1 X4 Y0

The object is to get a complete logic path through

the rung to make the output a 1 (High)

55
Notes

56
 Part 3: PLC Programming
Basics

Logic Instructions
Boolean Math

Boolean math lets us do some vary basic functions with the

bits in the registers. These basic functions typically include
AND, OR and XOR functions.

AND- The only time the Result is true (=1) is when both
operators A AND B are true (=1).
The AND instruction is useful when the plc doesn't have a
masking function.
See the truth table below to figure out what we mean. (1 AND
1 = 1, 0 AND 0= 0)

57
Notes

58
 Part 3: PLC Programming
Basics

Logic Instructions
Boolean Math

OR- the result is true (=1) is when operator A OR B is true

(=1).

59
Notes

60
 Part 3: PLC Programming
Basics

Logic Instructions
Boolean Math

EXOR- the result of this function is true (=1) when A and B

must be one or the other case, exclusively.
In other words, they must be opposites of each other.
When they are both the same the result is false (=0).

This is sometimes useful when you want to compare bits in

2 registers and highlight which bits are different. It's also
needed when we calculate some checksums. A checksum
is commonly used as error checking in some
communications protocols.

61
Notes

62
 Part 3: PLC Programming
Basics

Logic Instructions
Boolean Math

AND symbol
The instructions above typically have a symbol that looks
like that shown here. Of course, the word AND would be
replaced by OR or XOR.

In this symbol, The source A is DM100, the source B is

DM101 and the destination is DM102. Therefore, we have
simply created the equation DM100 AND DM101 =
DM102. The result is automatically stored into DM102.

Please note that we are using a

one-shot instruction. If we didn't
use it, the plc would execute the
instruction on every scan. Odds
are good that we'd only want to
execute the function one time
when input 0000 becomes true

63
Notes

64
 Part 3: PLC Programming
Basics

Logic Instructions
Boolean Math
The dual instruction method would use a symbol similar to
that shown above. In this method, we give this symbol only
the Source B location. The Source A location is given by the
LDA instruction. The Destination would be included in the
STA instruction.

The results are the same as the single instruction method

shown above. It should be noted that although the symbol
and ladder diagram above show the AND instruction, OR
or EXOR can be used as well. Simply substitute the word
"AND" within the instruction to be either "OR" or "EXOR".
The results will be the same as shown in their respective
truth tables.

65
Notes

66
 Part 3: PLC Programming
Basics

PLC Programs
Most PLC's present their program in ladder logic.

Rails

Addresses

X1 X3 Y1

X2
Conditional Output
Instructions Rungs
Instructions

X2 Y2

**NOT DEVICES**

67
Notes

68
 Part 3: PLC Programming
Basics

PLC Programs
Some PLC's use a format called statement list.

Instructions Addresses
STR X1
OR X2
AND X3
OUT Y1

STR NOT X2
OUT Y2

69
Notes

70
Part 3: PLC Programming
Basics

The Purpose of Addressing

Addressing serves two basic purposes:

1. It identifies the physical location where a real- world device is

connected to the I/O.

2. It lets the processor know what storage area in memory to

read from or write to.

Physical Location Instructional Identification

No matter what input device Since the instruction has been
was hooked up to a terminal labeled X2, it is referring to
it’s address will be X2 to the whatever is hooked to the
PLC. input location X2.

A B C
X0 X1 X2 X3 COM X4 X5 X6 X7 COM X10 X11COM
POWER INPUTS
RUN
L1 FAULT OUTPUTS
Y0 Y1 Y2 Y3 E Y4 Y5 Y6 Y7
L2 D
COM COM
GND

71
Notes

72
Part 3: PLC Programming
Basics

Rack System Addressing

RACK TYPE PLC
SLOTS 00 01 02 03 04 05 06 07

P INPUT INPUT INPUT OUTPUT OUTPUT OUTPUT

CPU MODULE MODULE MODULE MODULE MODULE MODULE
O
W
00 00 00 00 00 00
E POWER E
R RUN
01 01 01 01 01 01 M
FAULT
P
S 02 02 02 02 02 02 T
U Y
03 03 03 03 03 03
P
P 04 04 04 04 04 04 S
L L
Y 05 05 05 05 05 05 O
T
06 06 06 06 06 06
L1
L2 07 07 07 07 07 07

GND

Identify: Input in slot 01 terminal 05

73
Notes

74
Part 3: PLC Programming
Basics
Rack System Addressing
2nd digit
1ST digit identifies
input or output identifies the
I = In slot in the rack
O = Out

Not all OEM’s use

this system. I:1/05
For Example:

Siemens Uses:
The remaining
E = In digits identify
A = Out the terminal on
the module in
GE, Siemens, the slot
and others use:
I = In I:1/ I:1/ O:4/
Q = Out
00 01 03

Koyo, TI & O:4/

Others use:
03
X = In
Y = Out
I:1/ O:5/

06 07
75
Notes

76
Part 3: PLC Programming
Basics
Modular Addressing
2nd digit
1ST digit identifies identifies the
input or output Terminal block/strip
I = In
O = Out
The remaining
I:0/05 digits identify
the terminal on
block/strip

77
Notes

78
 Part 3: PLC Programming
Basics

The instruction set is all of the different commands

that a particular model of processor can understand

LOGIC INSTRUCTIONS

TIMERS AND COUNTERS

I
CNT OR TMR N CNT
P
U OR
Relay TMR
T Output
Type S
( ) Function Block
Type
LOTS OF OTHER INSTRUCTIONS
SEQUENCERS
COMPARISON; <, >, = MATH: +, -, *, /
CONVERSION FUNCTIONS

COMMUNICATIONS 79
Notes

80
 Part 3: PLC Programming
Basics
Internal Relay Instructions work the same as Output Instructions.
These instructions do not use your real I/O points.

Bit Identifies which bit is

B3/0 used (0 - 4095)

Data file number

3 is the default for
SLC-500
B3/0
Rung 0

Door Air Hydraulic Light Start

Guard Pressure Pressure Curtain OK
OK OK
4 Rungs Later

Rung 4

B 3/0 Stop Start Cycle

Start

23 Rungs Later
Rung 27

B 3/0 Jog Press Ram

Extend
Auto 81
Notes

82
Part 3: PLC Programming
Basics

Remember!
3 Main Instructions

The address must be ON (=1)

for the instruction to be true.

The address must be OFF (=0)

for the instruction to be true.

If there is a true logic path to the

output, the address will be ON (=1)

Identify what happens on this rung….

X3 X1 X4 Y0

83
Notes

84
Part 3: PLC Programming
Basics

• The scan cycle is the sequence of events of

operation that the CPU follows.

• The amount of time that it takes the CPU to

complete one cycle is referred to as scan time.

1. Housekeeping
Housekeeping Allows the CPU to organize and
manage file information.

2. Read Inputs
Read The CPU looks at the input
Inputs modules and writes the status of those
modules to the input module storage
area.

Execute Program 3. Execute Program and Write Outputs

& The CPU compares a specific program to
Write Outputs the input information and writes the output
information in the output image storage
area to the output modules
Update
Outputs 4. Update Outputs
The output module activates the
appropriate output device as directed by
the CPU.
85
Notes

86
Part 4: Troubleshooting PLCs

Multimeters
Review
Auto Ranging: Manual Range: The
The meter Ranging: highest value
automatically Range is set that the meter
determines the by the operator can measure on
scale. of the meter a particular
They usually can setting
operate in
manual mode.

Digital meters
are available
in Manual or
Auto ranging.

87
Notes

88
 Part 4: Troubleshooting PLCs

Reading What is the value of the following?

Multimeters Display: 16.7
Dial on 20K __________

Manual Ranging Display: 2.3

Dial on 20M __________
Selector Dial will indicate range
Display: 156.4
Dial on 200 __________

Display: - 0.L -
OL Dial on 2K __________

M = Mega = millions (X 1,000,000)

K = kilo = thousands (X 1,000)
m = milli = thousandths (X .001)
 = micro = millionths (X .000001)

Autoranging
Display will indicate range
What is the value of the following?

Display: 4.8 M __________

Display: 13.5 K __________

Display: 7.3 __________

Display: - 0.L - __________

89
Notes

90
Part 4: Troubleshooting PLCs

OL Manual Ranging
Selector Dial will indicate range

Meter is set to read Volts DC

What is the value of the following?

Display: 135.8
Dial on 200 __________

Display: 2.36
Dial on 20 __________

Display: OL
Dial on 20 __________

Autoranging
Display will indicate range
What is the value of the following?

Display: 24.84 __________

Display: 233.5 __________

__________
Display: - 0.L -

91
Notes

92
 Part 4: Troubleshooting PLCs

Input Module Troubleshooting

L1 - 120VAC INPUT

00
01
02
03
04
05
06
07 N

L1 N
PROBLEM -
when pressing NO pushbutton
terminated at 00: What would the meter read set on VAC?

Open in field wiring for Terminal 00 - Neutral on Terminal strip = ____VAC

pushbutton Terminal 00 - Neutral on Card = ____VAC
Would indicating light be on or off?

Open in neutral Terminal 00 - Neutral on Terminal strip = ____VAC

between card and Terminal 00 - Neutral on Card = ____VAC
terminal strip Would indicating light be on or off?

93
Notes

94
 Part 4: Troubleshooting PLCs

OUTPUT Output Module

Relay Output
VAC1
00 M1
Troubleshooting
01 G

02 CR

03 R
VAC2
04 CR

05

06

07
120VAC

L1 N
Problem - M1, hooked up
to output 00, is not energized
and the PLC is telling it to
come on. What would the meter read set on VAC?
Open in field wiring to **Terminal 00 - Neutral on Terminal strip = ____VAC
M1 Would indicating light be on or off?

Open in L1 between Terminal 00 - Neutral on Terminal strip = ____VAC

card and terminal strip VAC1 - Neutral = ____VAC
Would indicating light be on or off?

Blown fuse on card Terminal 00 - Neutral on Terminal strip = ____VAC

VAC1 - Neutral = ____VAC
VAC2 - Neutral = ____VAC
Terminal 05 - Neutral = ____VAC
Would indicating light 00 be on or off? 95

**This reading will change depending on the type of module.

Notes

96
Part 4: Troubleshooting PLCs

Sinking and Sourcing

Sourcing Sinking
Proximity Input Module
Switch
+ BLACK
BROWN

Input 00
- BLUE

Common Terminal
-

+ -
24VDC

Sinking Sourcing
Proximity Input Module
Switch
BLUE - BLACK

Input 00
+ BROWN

Common Terminal
+

97
- +
24VDC
Notes

98
Part 4: Troubleshooting PLCs

Some basic directions to finding a problem…

IDENTIFY THE FUNCTION

THAT IS NOT OPERATING

Look at the input or output that is

associated with that function
Is the light functioning?

YES NO

CHECK THAT PROGRAM

CONDITIONSARE MET TO ALLOW
THE DEVICE TO OPERATE
The component that is associated
With the output may be defective
Check it.

CHECK FOR CORRECT VOLTAGE AT

THE SOURCE TO THE MODULE OR DEVICE

CHECK FOR
FAULTY DEVICE

CHECK FOR
FAULTY WIRING

CHECK FOR
FAULTY WIRING
CHECK FOR
FAULTY DEVICE

99
Notes

100
Part 4: Troubleshooting PLCs

E-Stop Circuits
• A hard wired MCR provides a means for
emergency shutdown of machines.
• NEVER wire an e-stop to a PLC output!
• Place MCR contacts in series with power supply
to inputs/outputs – this way PLC stays on, but
machines are off.

101
Notes

102
Part 5: Micro820

Micro820 Series PLC

103
Notes

104
Part 5: Micro820

Micro820 Series PLC

105
Notes

106
 Part 5: Micro820

Micro820 Series PLC

Pre-wired Power Supply Wiring

Connect 2 wires from

the power supply to Then, run 2 additional
the +DC24 and –DC24 wires from the +24DC
terminals on the PLC and -24VDC on the
power supply to the
small terminal strip.

107
Notes

108
Part 5: Micro820

Micro820 Series PLC

Input and Output Wiring Examples

The input signal comes

from the 24VDC
supply is built into the
power supply for the 109
PLC unit
Notes

110
Part 5: Micro820

Micro820 Series PLC

Input and Output Wiring Examples

The outputs
are powered
by the 24Vac
supply built
into the
111
trainer.
Notes

112
 Part 5: Micro820

Micro820 Series PLC

Input and Output Wiring Reference Sheet

These connections should be on the small terminal

strip to the right of the PLC on your trainer.

113
Notes

114
Part 6: Application

Micro820 Series PLC

Hands-On Labs
The student will complete one or
more of the following using the
information provided:
• wire input & output devices to
the PLC
• Create the program in the PLC
software
• Set up communications
between the PLC & PC
• Download the program to the
PLC
• Demonstrate circuit operation
• Troubleshoot PLC and circuit
operation

115
Notes

116
 Part 6: Application

Micro820 Series PLC

For each of the Labs in this workbook, you will need to

complete any or all of the following steps:

1. Wire the PLC on your training panel as shown or

described in each Lab.
2. Construct a Ladder Logic program in the
Connected Components Workbench
programming software that is described in each
Lab.
3. Download the program to the PLC
4. Test to see if your Lab project functions as it
should.
5. Notify the Instructor that you have finished
setting up the Lab.

117
Notes

118
 Part 6: Application

Setting Up Communications
Prior to beginning any of the labs in this workbook, you
will need to set up communications between the PLC
and your computer.

Connect a standard Ethernet communication cable with

an RJ-45 connector from the port on your computer to the
port located on the bottom of the controller

119
Notes

120
 Part 6: Application

Setting Up Communications
Launch Connected Components Workbench software

Then, click “New”

121
Notes

122
 Part 6: Application

Setting Up Communications
The “New Project” window pops-up. Give your project a
name, and designate a location to save it on your
computer.

Then, click the “Create” button.

123
Notes

124
 Part 6: Application

Setting Up Communications
The software will then prompt you to select a device

Expand the “Controllers” menu

Then expand the “Micro820” menu

125
Notes

126
 Part 6: Application

Setting Up Communications
The software will then prompt you to select a device

Select the “2080-LC20-20QWB(R)

Then click the “Select” button

127
Notes

128
 Part 6: Application

Setting Up Communications

The screen should look like this

Then, click the “Add To Project” button

129
Notes

130
Part 6: Application

Setting Up Communications
The screen should look like this

Now it is time to configure your project for

Ethernet communications.

On the device configuration tree, expand

the “Controller” property, and then click on
“Ethernet”

131
Notes

132
 Part 6: Application

Setting Up Communications
The right side of the screen will display the configuration
set up for Ethernet

Under “Internet
Ensure the checkbox
Protocol (IP) Settings
“Detect duplicate IP
make sure the
address” is selected
“Obtain IP address
automatically using
DHCP” choice is
selected.

133
Notes

134
Part 6: Application

Setting Up Communications

Leave the Port Settings

at defaults:
1. Port State Enabled
& Auto-Negotiate
Speed and Duplex
Mode checkbox
selected

135
Notes

136
 Part 6: Application

Setting Up Communications

Go to the “Communications” menu and select “Configure Drivers”

You should see the

default Ethernet driver
running.

Click the “Close” button.

Now you are ready to

wire the trainer!

137
Notes

138
 Part 6: Application

Lab #1:

Start by wiring the

Once you have PLC & Panel
completed wiring components as
the red Stop PB shown
and the green
Start PB to the
PLC as shown,
you will be able to
power the panel
up and watch the
input indicators
change as you
press the
switches.

Also, you will

notice that
because you have
wired a “Normally
Closed” switch to
input 5, the
indicator is on
when the switch is
not being
pressed.

Call your instructor

to your trainer to
demonstrate.
139
Notes

140
 Part 6: Application

Lab #2:

You will need to construct the PLC Program below to make the CR1
relay energize and stay energized when the Start PB is momentarily
pressed. The relay should de-energize when the red Stop PB is
pressed. 141
Notes

142
Part 6: Application

Lab #2:

Right-click “Programs”
in the Project Organizer
area, then move the
mouse over “Add”, then
select “New LD:
Ladder Diagram”

143
Notes

144
Part 6: Application

Lab #2:

A new ladder diagram

should appear in the
Project Organizer.

Double click “Prog1” to

enter the ladder
diagram window.

This is where you will

begin inserting
instructions to create
the program for Lab #2.

145
Notes

146
 Part 6: Application

Lab #2:

If the “Toolbox” contain

instructions does not
appear on the right side
of the screen

Select “View” from the top menu,

and then select “Toolbox”

Now you are ready to begin clicking and dragging instructions

into your program…

147
Notes

148
 Part 6: Application

Lab #2:
The green Start PB is wired to Input #4, so you will need to
assign this address to your instruction.

#1 Begin by clicking on the rung

(it should turn blue).

Next, click the “Direct Contact”

instruction, and drag it over to the rung.
When you see a “+” symbol, release the
mouse. The Variable Selector window
will pop-up.

149
Notes

150
 Part 6: Application

Lab #2:
Select the “I/O Micro820” tab

Next,
choose
Input 4 by
selecting Then, assign a
“IO_EM_DI name to the
_04”. instruction by
clicking in the
“Alias” area, and
then type
“START”

To save, 151

click “OK”.
Notes

152
 Part 6: Application

Lab #2:
The instruction should now appear in the rung with the correct
address and name.

Repeat this same sequence for the red STOP PB.

CR1 coil is wired

to Output 0.
Use the “Direct
Coil” instruction,
and use the
same sequence
of steps to
assign the 153
address.
Notes

154
 Part 6: Application

Lab #2:
Now we are going to use the address from the CR1 output
instruction to control an input instruction in order to form an
interlock in the program to keep CR1 true (=1).

Click and drag

the “Branch”
instruction from
the Toolbox all
the way to the far
left of the rung so
that the branch
will encompass
the START
instruction

155
Notes

156
 Part 6: Application

Lab #2:
Click and drag a “Direct Contact” instruction to the branch, and
then select “IO_EM_DO_00 CR1” as the address.

Now both addresses should be the same.

157
Notes

158
 Part 6: Application

Lab #2:
Save your project by selecting “File”, then “Save Project As”
from the top menu. The Save Project As pop-up window
appears.
Choose a name and location for your project.

Once saved, the software will return to the “Micro820” tab. This is
because the software anticipates the downloading the project to the PLC

159
Notes

160
 Part 6: Application

Lab #2:
Click “Download”, and the software should show a message
“Building” along the top of the screen

The Connection Browser pop-

up window appears. Expand
the “AB ETHIP-1, Ethernet”
driver and select the Micro820
PLC.

NOTE: If you have previously

connected to the PLC it will go
directly to the “Downloading”
window (as shown on the next
page)

161

Then click “OK”.

Notes

162
 Part 6: Application

Lab #2:
The Download Confirmation pop-up window appears. You will
select “Download with Project Values”

When the download is

complete, the software will ask
if you want to put the PLC in
the Remote Run mode. Select
“Yes”.
163
Notes

164
 Part 6: Application

Lab #2:
Your project is now running in the PLC.

If you wish to monitor the program instructions, double-click

“Prog1” in the Project Organizer.

165
Test your program. If it is working properly, notify your instructor.
Notes

166
 Part 6: Application

Lab #2:
To monitor the inputs and outputs double-click the “Global Variables” in
the Project Organizer

All input and output data will be displayed in real time.

167
Notes

168
 Part 6: Application

Lab #3

For this lab you will add instructions to the program to make the lights that
are connected to the PLC outputs energize.

• Make the Red light energize when the relay is off.

• Make the Green light energize when the relay is on.

Draw out the instructions above including the

addressing.
Hint: Look at the wiring diagram on the next page
for addressing.

169
Notes

170
 Part 6: Application

The limit switches will be

used in a later lab. Lab #3

171
Notes

172
 Part 6: Application

Lab #3

You will need to “Disconnect” the communication link in order to modify the
program

1. Save and download your edited

program.
2. Call your instructor to your trainer
when your program is functioning
correctly.
173
Notes

174
Part 6: Application

Lab #4

In this lab, you will re-wire the outputs. Leave

CR1 and the PBs in place.

The contacts from the relays will energize

the lights. NOTE: The lights are no longer
175
wired to the PLC.
Notes

176
 Programming
Part 6: Application

Lab #4
Once you have completed wiring the diagram on the previous page you will
modify the logic instructions in the project to reflect what is shown in the
program on the next page.

Remember to “Disconnect” the communication link in order to modify the

program

177
Notes

178
 Programming
Part 6: Application

Lab #4
This program uses Timers to make the outputs alternate. You will need to
assign the addresses and variables in the Connected Components
Workbench software. Follow the instructions on the following pages.

179
Notes

180
 Part 6: Application

Lab #4
Alternating Lights Program
This alternating lights uses the same stop/start circuit seen on the last lab, but
in addition we have added two timer instructions. Each are set at a short
time interval so as to switch back and forth. We are also using a control bit or
virtual coil “C1” in this program.

Virtual Coil C1
“BOOL” data type

DIRECT
CONTACT
REVERSE CONTACT
Timers set at .5
seconds each
(500ms)
Looking at the
condition
of TMR 1

Looking at
the
condition
of TMR 0
Real World
Outputs

181
Notes

182
 Programming
Part 6: Application

Lab #4
C1 is an internal memory location – not a physical output.
To input this type of instruction and address into the PLC program, click
and drag a “Direct Coil” into the program from the Toolbox.
When the Variable Selector pop-up window appears:
1. Ensure that you are in the “Local Variables” tab
2. Type “C1” in the Name field
3. Ensure that the Type is “BOOL”
4. Then click “OK” to save.
3

Now you can use this variable on all the other

instructions labeled “C1” in the program.
183
Notes

184
 Programming
Part 6: Application

Lab #4
In order to use a timer in the Connected Components Workbench software,
you must create two variables:
1. A variable named “Red_Light_Timer” with a “TIME” data type
2. A variable named “Red_Light_Preset” with an “INT” data type

Use a similar sequence of steps that you took to create the “C1” variable.
1. Double click the “Local Variables” in the Project Organizer
2. Click the “Name” field in the bottom row containing the “*” symbol
3. Type “Red_Light_Timer” in the Name field
4. Ensure that the Type is “TIME”
5. Then hit “Enter” to save the variable. Another “blank” row will appear

3 4

5
185
Notes

186
 Programming
Part 6: Application

Lab #4

6. Go through the same steps to create the variable

“Red_Light_Preset” with a “INT” data type

7. Then, repeat the steps to create another two variables

that will be used with the Green Light

Type the number 500 into the “Initial Value” for both the
Red and Green Light Preset values. This is 500ms, or .5
seconds. You can change this value at any time.

187
Notes

188
 Programming
Part 6: Application

Lab #4
TMR1 & TMR 2 are timer instructions.

To input this into the PLC program, click and drag an “Instruction Box”
instruction into the program.

189
Notes

190
 Programming
Part 6: Application

Lab #4

When the Variable Selector pop-up window appears scroll down and select
TON (on delay timing).

Then click “OK”

191
Notes

192
 Programming
Part 6: Application

Lab #4
TON_1 should now appear in your program

Move the mouse into the rectangle near the PT parameter (it should
turn blue) and click the box. A drop down menu appears. Scroll down
and select “Red_Light_Timer”

193
Notes

194
 Programming
Part 6: Application

Lab #4
In order to control the preset time, an INT variable must be used. The
number placed in this variable will be transferred to the preset value of the
timer using an ANY_TO_TIME Instruction Block.

1. Click and drag another rung into your program, and then click and drag
another Instruction Block. This time choose the ANY_TO_TIME type.

Then click “OK”

195
Notes

196
 Programming
Part 6: Application

Lab #4
Now you must specify:

1. Which variable contains the preset value of the timer

2. Which variable that number will be placed into in order to control the
timer.

Click the box near Click the box near

“i1” and select “o1” and select
Red_Light_Preset Red_Light_Timer
from the drop from the drop
down menu down menu

Now, whatever number you place in the Red_Light_Preset

variable will become the preset time of TON_1
NOTE: Timer values are always expressed in milliseconds 197
Notes

198
 Programming
Part 6: Application

Lab #4
Your completed program should look similar to this:

Save and download your program.

The next few pages will walk you through the
199
sequence of the program logic.
Notes

200
 Programming
Part 6: Application

Lab #4
The sequence of the program begins:

1. Start PB is momentarily pressed, C1 value becomes true (=1)

2. All instructions with C1 address become true (=1)

201
Notes

202
 Programming
Part 6: Application

Lab #4
The sequence of the program continues:

1. TON_1 begins timing

2. RELAY 1 becomes true (=1) and that energizes CR1
3. CR1A contact closes, Red Light on

203
Notes

204
 Programming
Part 6: Application

Lab #4
The sequence of the program continues:

1. When TON_1 times out, TON_1.Q becomes true (=1), this triggers:
1. TON_2 starts timing
2. Relay 1 becomes false (=0), and CR1 deenergizes, then Red
Light off
3. Relay 2 becomes true (=1), and CR2 energizes, then Green
Light on

205
Notes

206
 Programming
Part 6: Application

Lab #4
The sequence of the program continues:

1. When TON_2 times out, TON_2.Q becomes true (=1), this triggers:
1. TON_1 rung becomes false, resets TON_1
2. TON_1.Q becomes false (=0), resets TON_2, RELAY 2
becomes false, CR2 deenergizes, Green Light off
3. TON_2.Q becomes false (=0), this makes rung 2 true, and
the cycle begins again

This bit
creates a
“domino
effect” in
the
program,
and sets
off a chain
of events
that resets
the
sequence

When it is functioning correctly, call your

instructor to your trainer. 207
Notes

208
 Programming
Part 6: Application

Lab #5

Alternating Lights with Counter

X4 X5 CNT0 C1

C1

C1 T1
TMR 0 This lab
incorporates a
T0 Counter
TMR 1 Instruction
Block

T0 Y2

C1 T0 Y3

T0

X4 CTR 0

END

No additional wiring is needed for this lab.

209
Notes

210
 Programming
Part 6: Application

Lab #5

Alternating Lights with Counter

X4 X5 CNT0 C1

C1
Stops the
sequence when
T1 the Counter
C1
reaches its
TMR 0 preset value.

T0
TMR 1

T0 Y2

C1 Counter preset to
T0 Y3
10 increments.

T0

X4 CTR 0
Resets the
counter to
zero.
END

211
Notes

212
 Programming
Part 6: Application

Lab #5

Alternating Lights with Counter

Challenge: Use the knowledge you have gained from Labs #1-4
and apply to this application.

Program Considerations:

1. The Counter Instruction will need a variable to hold the preset

value – ensure it is a “DINT” data type
2. The Counter’s Q bit functions the same as Q bit from a Timer
Instruction -- it will become true (=1) when the Counter preset
value = current value.
3. A Counter Instruction differs from a TON Instruction in two
ways:

• It will need to be reset manually. In this case, the Start

PB will reset the Counter Instruction every time it is
pressed

• Counter Instructions must be “pulsed” or “triggered” with a

change in logic level (true-false). We are using TON_1.Q to
pulse the Counter Instruction

213
Notes

214
 Programming
Part 6: Application

Lab #5
Your finished program should look similar to this:

215
Notes

216
 Part 6: Application

Now that you

have
completed the
Lab 5 that
makes the
PLC count
cycles and
shut down,
you will need
to incorporate
two limit
switches wired
to inputs 9 &
10.

Program Description:

If either limit switch is OPENED, the process will stop, but only pause
until both limit switches are closed again (hint: counter does not reset).

This will simulate a safety precaution logic situation that if either door
switch is opened, the machine will stop.

217
Notes

218
Part 6: Application

Draw out the modified rung logic

219
Notes

220
Part 6: Application

Real World
Examples of PLC
Operated
Machines

221
 Part 6: Application

Let’s look at an actual machine used to bend Lawn Chair Legs. This
machine uses an Allen Bradley PLC and the program is included. Look
step by step through the program and see if you recognize the
statements.

Hydraulic Leg Bender

(Top View)
PRS 1, GUARD OPEN PRS 2, GUARD CLOSED

PRS 3, CYL RETRACTED

HYD CYLINDER

GUARD

HYDRAULIC PUMP
MANUAL POWER
START PUMP
RETRACT ON
ON
Note:
STOP READY E-STOP
The hydraulic pump,
solenoid valves, and
Control Cabinet pressure switch are
located underneath.

222
 Part 6: Application

Hydraulic Leg Bender

(Top View)
PRS 1, GUARD OPEN PRS 2, GUARD CLOSED

PRS 3, CYL RETRACTED

HYD CYLINDER

GUARD

HYDRAULIC PUMP
MANUAL POWER
START PUMP
RETRACT ON
ON

STOP READY E-STOP

Control Cabinet

Sequence of Operation
1. Insert Metal
2. Close Guard
3. Hydraulic cylinder extends until it engages
and activates the pressure switch.
4. Cylinder retracts
5. Open Guard
6. Repeat 223
Notes

224
 Part 6: Application

L1 L2 L3

01

02

03 1030FU

1040 1041 1042

04

05

1060FU
1060
06 201

1070
07 202

08

09 1090FU

10

4030 MS
11

12 1120 1121 1122

T1 T2 T3
13

14 HYDRAULIC
1140M PUMP MOTOR
15

DATE DRAWN BY PG NO. TOTAL PAGES

1 4
225
Notes

226
 Part 6: Application

1060
01 106

1070
02 107

2030T
03 1KVA

2040 X4 X2 X3 X1 2041
04

2050 2060 PB 2061 PB 2060 ESR

05 FU
E-STOP POWER ON EMERGENCY
STOP RELAY
2061 2062
2060
06 ESR 207, 213
2060 ESR-1

07

08
2090 PLC
SLOT 0 SLOT 1 SLOT 2 SLOT 3
09
CPU 120 120
VAC VAC
POWER IN OUT E
10
SUPPLY M
P
T
11 H
Y
N
12

13 2060 ESR-2
2130

14

2130 2041
15
301 301

DATE DRAWN BY DRAWING NO. PG NO. TOTAL PAGES

227
2 4
Notes

228
 Part 6: Application

215 215

01 2130 2041

120 VAC INPUT

SLOT 1
02
3030 HYDRAULIC PUMP START
PB
3030
03 IN0 I:1/0

3040 HYDRAULIC PUMP STOP

PB
3040
04 IN1 I:1/1

4030 HYD PUMP MOTOR STARTER AUXILLARY

MS
3050
05 IN2 I:1/2
3060 GUARD OPEN PROXIMITY SWITCH
PRS
3060
06 IN3 I:1/3
3070 GUARD CLOSED PROXIMITY SWITCH
PRS
3070
07 IN4 I:1/4
3080 HYD CYLINDER RETRACTED PROX SWITCH
PRS
3080
08 IN5 I:1/5

3090 MANUAL CYLINDER RETRACT

PB
3090
09 IN6 I:1/6

3010 CYLINDER EXTENDED PSI SWITCH

PS
3010
10 IN7 I:1/7

11 AC COM

12 AC COM

13

14

15 2130 2041

401 401

DATE DRAWN BY PG NO. TOTAL PAGES

229
3 4
Notes

230
 Part 6: Application

120 VAC OUTPUT

315 SLOT 2 315

01 2130 2041

02 VAC 1
4030 MS 4030 OL
HYD PUMP MS
03 4030 111,
O:2/0 OUT0 305

HYD CYL ADV SOL 4040 SV

4040
04 O:2/1 OUT1

HYD CYL RET SOL 4050 SV

4050
05 O:2/2 OUT2
4060 LT
4060
HYD PUMP ON LT
06 O:2/3 OUT3 G

07 VAC 2
4080 LT
4080
READY LT
08 O:2/4 OUT4 G

09 O:2/5 OUT5

10 O:2/6 OUT6

11 O:2/7 OUT7

12

13

14

2130 2041
15
301 301

DRAWN BY PG NO. TOTAL PAGES

231
4 4
Notes

232
Part 6: Application

+--------------------------------------------------+
| |
| |
| Allen-Bradley Co. |
| 1747 Series Software |
| APS Release 4.01 |
| Documentation Utility |
| Program Listing |
| |
| SUNBEAM |
| |
| Processor File: SUNBEAM.ACH |
| March 09, 2000 - 21:24 |
| |
+--------------------------------------------------+

233
Notes

234
 Part 6: Application
SUNBEAM March 09, 2000 Page 1
Program Listing Processor File: SUNBEAM.ACH Rung 2:0

Rung 2:0
| HYD PUMP HYD PUMP | HYD PUMP |
| START PB STOP PB | MS |
| I:1 I:1 O:2 |
|-+----] [-----+----] [------------------------------------------------( )-----|
| | 0 | 1 0 |
| | HYD PUMP | |
| | MS AUX | |
| | I:1 | |
| +----] [-----+ |
| 2 |

Rung 2:1
| HYD PUMP | HYD PUMP |
| MS | ON LIGHT |
| O:2 O:2 |
|----] [---------------------------------------------------------------( )-----|
| 0 3 |

Rung 2:2
| HYD CYL |GUARD HYD PUMP | READY |
| RET PROX |OPEN PROX MS | LIGHT |
| I:1 I:1 O:2 O:2 |
|-+----] [--------] [-----+----] [-------------------------------------( )-----|
| | 5 3 | 0 4 |
| | READY | |
| | LIGHT | |
| | O:2 | |
| +----] [----------------+ |
| 4 |

Rung 2:3
| HYD CYL |HYD CYL READY |CYCLE | ADVANCE |
| EXT PRESS |ADV SV LIGHT |COMPLETE | COMPLETE |
| SW | |
| I:1 O:2 O:2 B3 B3 |
|-+----] [--------] [-----+----] [--------]/[--------------------------( )-----|
| | 7 1 | 4 2 0 |
| | ADVANCE | |
| | COMPLETE | |
| | B3 | |
| +----] [----------------+ |
| 0 |

Rung 2:4
| GUARD |READY |ADVANCE | HYD CYL |
| CLOSED |LIGHT |COMPLETE | ADV SV |
| PROX | |
| I:1 O:2 B3 O:2 |
|----] [--------] [--------]/[-----------------------------------------( )-----|
235
| 4 4 0 1 |
Notes

236
 Part 6: Application

SUNBEAM March 09, 2000 Page 2

Program Listing Processor File: SUNBEAM.ACH Rung 2:5

Rung 2:5
| HYD CYL |HYD CYL READY |CYCLE | RETRACT |
| RET PROX |RET SV LIGHT |COMPLETE | COMPLETE |
| I:1 O:2 O:2 B3 B3 |
|-+----] [--------] [-----+----] [--------]/[--------------------------( )-----|
| | 5 2 | 4 2 1 |
| | RETRACT | |
| | COMPLETE | |
| | B3 | |
| +----] [----------------+ |
| 1 |

Rung 2:6
| READY |ADVANCE |RETRACT GUARD |HYD CYL | HYD CYL |
| LIGHT |COMPLETE |COMPLETE CLOSED |RET PROX | RET SV |
| PROX | |
| O:2 B3 B3 I:1 I:1 O:2 |
|-+----] [--------] [--------]/[-----+----] [--------]/[---------------( )-----|
| | 4 0 1 | 4 5 2 |
| | MANUAL |READY | |
| | RET PB |LIGHT | |
| | I:1 O:2 | |
| +----] [--------]/[----------------+ |
| 6 4 |

Rung 2:7
| GUARD |RETRACT | CYCLE |
| OPEN PROX |COMPLETE | COMPLETE |
| I:1 B3 B3 |
|----] [--------] [----------------------------------------------------( )-----|
| 3 1 2 |

Rung 2:8
| |
|-------------------------------------+END+------------------------------------|
| |

237
Notes

238
Part 6: Application

+--------------------------------------------------+
| |
| |
| Allen-Bradley Co. |
| 1747 Series Software |
| APS Release 4.01 |
| Documentation Utility |
| Cross Reference |
| |
| SUNBEAM |
| |
| Processor File: SUNBEAM.ACH |
| March 09, 2000 - 21:24 |
| |
+--------------------------------------------------+

239
 Part 6: Application
SUNBEAM March 09, 2000 Page 1
Cross Reference Processor File: SUNBEAM.ACH
Address Symbol / Comment /
Instruction File Number:Rung Number

B3/0 ADVANCE COMPLETE

-] [- 2:3 2:6
-]/[- 2:4
-( )- 2:3

B3/1 RETRACT COMPLETE

-] [- 2:5 2:7
-]/[- 2:6
-( )- 2:5

B3/2 CYCLE COMPLETE

-]/[- 2:3 2:5
-( )- 2:7

I:1/0 HYD PUMP START PB

-] [- 2:0

I:1/1 HYD PUMP STOP PB

-] [- 2:0

I:1/2 HYD PUMP MS AUX

-] [- 2:0

I:1/3 GUARD OPEN PROX

-] [- 2:2 2:7

I:1/4 GUARD CLOSED PROX

-] [- 2:4 2:6

I:1/5 HYD CYL RET PROX

-] [- 2:2 2:5
-]/[- 2:6

I:1/6 MANUAL RET PB

-] [- 2:6

I:1/7 HYD CYL EXT PRESS SW

-] [- 2:3

O:2/0 HYD PUMP MS

-] [- 2:1 2:2
-( )- 2:0

O:2/1 HYD CYL ADV SV

-] [- 2:3
-( )- 2:4

O:2/2 HYD CYL RET SV

-] [- 2:5
-( )- 2:6

O:2/3 HYD PUMP ON LIGHT

-( )- 2:1 240
 Part 6: Application

SUNBEAM March 09, 2000 Page 2

Cross Reference Processor File: SUNBEAM.ACH
Address Symbol / Comment /
Instruction File Number:Rung Number

O:2/4 READY LIGHT

-] [- 2:2 2:3 2:4 2:5 2:6
-]/[- 2:6
-( )- 2:2

241
 Glossary

A
•AC input module: This is a module that converts a real-world AC input signal to the
logic level required by the PLC processor.
•AC output module: Module that converts the processor logic level to an AC output
signal to control a real-world device.
•Accumulated value: Applies to the use of timers and counters. The accumulated value
is the present count or time.
•Accuracy: The deviation between the actual position and the theoretical position.
•Actuator: Output device normally connected to an output module. An example would
be an air valve and cylinder.
•Address: Number used to specify a storage location in memory.
•Ambient temperature: Temperature that naturally exists in the environment. For
example, the ambient temperature of a PLC in a cabinet near a steel furnace is very
high.
•Analog: Signal with a smooth range of possible values. For example, a temperature
that could vary between 60 and 300 degrees would be analog in nature.
•ANSI: American National Standards Institute.
•ASCII: American Standard Code for Information Interchange. A coding system used to
represent letters and characters. Seven-bit ASCII can represent 128 different
combinations. Eight-bit ASCII (extended ASCII) can represent 256 different
combinations.
•Asynchronous communications: Method of communications that uses a series of bits
to send data between devices. There is a start bit, data bits (7 or 8), a parity bit (odd,
even none, mark, or space), and stop bits (1, 1.5, or 2). One character is transmitted at
a time. RS-232 is the most common.

242
 Glossary

B
•Backplane: Bus in the back of a PLC chassis. It is a printed circuit board with sockets
that accept various modules.
•Baud rate: Speed of serial communications. The number of bits per second
transmitted. For example, RS-232 is normally used with a baud rate of 9600. This
would be about 9600 bits per second. It takes about 10 bits in serial to send an ASCII
character so that a baud rate of 9600 would transmit about 960 characters per second.
•BEUG (BITBUS European Users Group): BEUG is a nonprofit organization devoted to
spreading the BITBUS technology and organizing a basic platform where people using
BITBUS can share application experiences.
•Binary: Base two number system. Binary is a system in which ones and zeros are
used to represent numbers.
•Binary-coded decimal (BCD): A number system. Each decimal number is represented
by four binary bits. For example, the decimal number 967 would be represented by
1001 0110 0111 in BCD.
•Bit: Binary digit. The smallest element of binary data. A bit will be either a zero or a
one.
•BITBUS: It is one of the most widely used fieldbuses. It was promoted as a standard
in 1990 by a special committee of the IEEE (standard IEEE-1118 1990).
•Boolean: Logic system that uses operators such as AND, OR, NOR, and NAND. This
is the system that is utilized by PLCs, although it is usually made invisible by the
programming software for the ease of the programmer.
•Bounce: This is an undesirable effect. It is the erratic make and break of electrical
contacts.
•Branch: Parallel logic path in a ladder diagram.
•Byte: Eight bits or two nibbles. (A nibble is 4 bits.)

243
 Glossary

• C
• Cascade: Programming technique that is used to extend the range of timers and
counters.
• CENELEC: European Committee for Electrotechnical Standardization. It develops
standards which cover dimensional and operating characteristics of control
components.
• Central processing unit (CPU): Microprocessor portion of the PLC. It is the portion of
the PLC that handles the logic.
• Color mark sensor: Sensor that was designed to differentiate between two different
colors. They actually differentiate on the basis of contrast between the two colors.
• Complement: The complement is the inverse of a digital signal.
• CMOS (complementary metal-oxide semiconductor): Integrated circuits that
consume very little power and also have good noise immunity.
• Compare instruction: PLC instruction that is used to test numerical values for equal,
greater than, or less than relationships.
• Contact: Symbol used in programming PLCs. Used to represent inputs. There are
normally open and normally closed contacts. Contacts are also the conductors in
electrical devices such as starters.
• Contactor: Special-purpose relay that is used to control large electrical current.
• CSA (Canadian Standards Organization): Develops standards, tests products and
provides certification for a wide variety of products.
• Current sinking: Refers to an output device (typically an NPN transistor) that allows
current flow from the load through the output to ground.
• Current sourcing: Output device (typically a PNP transistor) that allows current flow
from the output through the load and then to ground.
• Cyclic Redundancy Check (CRC): A calculated value, based on the content of a
communication frame. It is inserted in the frame to enable a check of data accuracy
after receiving the frame across a network. BITBUS uses the standard SDLC CRC.

244
 Glossary

• D
• Dark-on: Refers to a photosensor's output. If the sensor output is on when no object
is sensed, it is called a dark-on sensor.
• Data highway: This is a communications network that allows devices such as PLCs
to communicate. They are normally proprietary, which means that only like devices
of the same brand can communicate over the highway.
• Data table: A consecutive group of user references (data) of the same size that can
be accessed with table read/write functions.
• Debugging: Process of finding problems (bugs) in any system.
• Diagnostics: Devices normally have software routines that aid in identifying and
finding problems in the device. They identify fault conditions in a system.
• Digital output: An output that can have two states: on or off. These are also called
discrete outputs.
• Distributed processing: The concept of distributed processing allows individual
discrete devices to control their area and still communicate to the others via a
network. The distributed control takes the processing load off the "host" system.
• Documentation: Documentation is descriptive paperwork that explains a system or
program. It describes the system so that the technician can understand, install,
troubleshoot, maintain, or change the system.
• Downtime:The time a system is not available for production or operation is called
downtime. Downtime can be caused by breakdowns in systems.
• E
• EEPROM: Electrically erasable programmable read only memory.
• Energize: Instruction that causes a bit to be a one. This turns an output on.
• Examine-off: Contact used in ladder logic. It is a normally closed contact. The
contact is true (or closed) if the real-world input associated with it is off.
• Examine-on: Contact used in ladder logic programming. Called a normally open
contact. This type of contact is true (or closed) if the real-world input associated with
it is on.
• Expansion rack: A rack added to a PLC system when the application requires more
modules than the main rack can contain. A remote rack is sometimes used to permit
I/O to be remotely located from the main rack.

245
 Glossary

• F
• False: Disabled logic state (off).
• Fault: Failure in a system that prevents normal operation of a system.
• Firmware: A series of instructions contained in read-only memory (ROM) that are used
for the operating system functions. Some manufacturers offer upgrades for PLCs. This
is often done by replacing a ROM chip. Thus the combination of software and
hardware lead to it being called firmware.
• Flowchart: Used to make program design easier.
• Force: Refers to changing the state of actual I/O by changing the bit status in the PLC.
In other words, a person can force an output on by changing the bit associated with
the real-world output to a 1. Forcing is normally used to troubleshoot a system.
• Frame: Packet of bits that will be transmitted across a network. A frame contains a
header, user data and an end of frame. The frame must contain all the necessary
information to enable the sender and receiver(s) of the communication to decode the
user's data and to ensure that this data is right.
• Full duplex: Communication scheme where data flows in both directions
simultaneously.
• G
• Ground: Direct connection between equipment (chassis) and earth ground.
• H
• Half duplex: Communication scheme where data flows in both directions but in only
one direction at a time.
• Hard contacts: Physical switch connections.
• Hard copy: Printed copy of computer information.
• HDLC (High-level Data Link Control): Standard protocol of communication oriented in
message transmission (frames). The user's data field in an HDLC-frame can be of a
free number of bits. The SLDC is a subset of the HDLC that defines the whole protocol
in more detail and is byte-oriented.
• Hexadecimal: Numbering system that utilizes base 16.
• Host computer: One to which devices communicate. The host may download or
upload programs, or the host might be used to program the device. An example would
be a PLC connected to a microcomputer. The host (microcomputer) "controls" the PLC
by sending programs, variables, and commands. The PLC controls the actual process
but at the direction and to the specifications of the host.
• Hysteresis: A dead band that is purposely introduced to eliminate false reads in the
case of a sensor. In an encoder hysteresis would be introduced in the electronics to
prevent ambiguities if the system happens to dither on a transition.
246
 Glossary

• I
• IEC (International Electrotechnical Commission): Develops and distributes
recommended safety and performance standards.
• IEEE: Institute of Electrical and Electronic Engineers.
• Image table: Area used to store the status of input and output bits.
• Incremental: This term typically refers to encoders. Encoders provide logic states of 0
and 1 for each successive cycle of resolution.
• Instruction set: Instructions that are available to program the PLC.
• Intelligent I/O: PLC modules that have a microprocessor built in. An example would be
a module that would control closed-loop positioning.
• Interfacing: Connection of a PLC to external devices.
• I/O (input/output): Used to speak about the number of inputs and outputs that are
needed for a system, or the number of inputs and outputs that a particular
programmable logic controller can handle.
• IP rating: Rating system established by the IEC that defines the protection offered by
electrical enclosures. It is similar to the NEMA rating system.
• Isolation: Used to segregate real-world inputs and outputs from the central processing
unit. Isolation assures that even if there is a major problem with real-world inputs or
outputs (such as a short), the CPU will be protected. This isolation is normally
provided by optical isolation.
• K
• Abbreviation for the number 1000. In computer language it is equal to two to the tenth,
or 1024.
• Keying: Technique to ensure that modules are not put in the wrong slots of a PLC. The
user sets up the system with modules in the desired slots. The user then keys the
slots to assure that only a module of the correct type can be physically installed.

247
 Glossary
• L
• Ladder diagram: Programmable controller language that uses contacts and
coils to define a control sequence.
• LAN: See Local area network.
• Latch: An instruction used in ladder diagram programming to represent an
element that retains its state during controlled toggle and power outage.
• Leakage current: Small amount of current that flows through load-powered
sensors. The small current is necessary for the operation of the sensor. The
small amount of current flow is normally not sensed by the PLC input. If the
leakage is too great a bleeder resistor must be used to avoid false inputs at
the PLC.
• LED (light-emitting diode): A solid-state semiconductor that emits red, green,
or yellow light or invisible infrared radiation.
• Light-on sensor: This refers to a photosensor's output. If the output is on
when an object is sensed, the sensor is a light-on sensor.
• Linear output: Analog output.
• Line driver: A line driver is a differential output driver intended for use with a
differential receiver. These are usually used where long lines and high
frequency are required and noise may be a problem.
• Line-powered sensor: Normally, three-wire sensors, although four-wire
sensors also exist. The line-powered sensor is powered from the power
supply. A separate wire (the third) is used for the output line.
• Load: Any device that current flows through and produces a voltage drop.
• Load-powered sensor: A load-powered sensor has two wires. A small leakage
current flows through the sensor even when the output is off. The current is
required to operate the sensor electronics.
• Load resistor: A resistor connected in parallel with a high-impedance load to
enable the output circuit to output enough current to ensure proper operation.
• Local area network (LAN): A system of hardware and software designed to
allow a group of intelligent devices to communicate within a fairly close
proximity.
• Lockout: The placement of a lockout device on an energy isolating device, in
accordance with an established procedure, to ensure that the energy isolating
device and the equipment being controlled cannot be operated until the
lockout device is removed.
• Lockout device: A device that utilizes a positive means such as a lock, either
key or combination type, to hold an energy isolating device in the safe
position and prevent the energizing of a machine or equipment.
• LSB: Least significant bit.

248
 Glossary
• M
• Machine language: Control program reduced to binary form.
• MAP (manufacturing automation protocol): "Standard" developed to make
industrial devices communicate more easily. Based on a seven-layer model of
communications.
• Master: The master on a network is the device that controls communication
traffic. The master of a network usually polls every slave to check if it has
something to transmit. In a master-slave configuration, only the active master
can place a message on the bus. The slave can reply only if it receives a
frame from the master that contains a logical token that explicitly enables the
slave to reply.
• Master control relay (MCR): Hardwired relay that can be deenergized by any
hardwired series-connected switch. Used to deenergize all devices. If one
emergency switch is hit it must cause the master control relay to drop power
to all devices. There is also a master control relay available in most PLCs.
The master control relay in the PLC is not sufficient to meet safety
requirements.
• Memory map: Drawing showing the areas, sizes, and uses of memory in a
particular PLC.
• Microsecond: A microsecond is one millionth (0.000001) of a second.
• Millisecond: A millisecond is one thousandth (.001) of a second.
• Mnemonic codes: Symbols designated to represent a specific set of
instructions for use in a control program. An abbreviation given to an
instruction: usually an acronym that is made by combining the initial letters or
parts of words.
• MSB: Most significant bit.

249
 Glossary

• N
• NEMA (National Electrical Manufacturers Association): Develops standards that
define a product, process, or procedure. The standards consider construction,
dimensions, tolerances, safety, operating characteristics, electrical rating and so on.
They are probably best known for their rating system for electrical cabinets.
• Network: System that is connected to devices or computers for communication
purposes.
• Node: Point on the network that allows access.
• Noise: Unwanted electrical interference in a programmable controller or network. It
can be caused by motors, coils, high voltages, welders, and so on. It can disrupt
communications and control.
• Nonretentive coil: A coil that will turn off upon removal of applied power to the CPU.
• Nonretentive timer: Timer that loses the time if the input enable signal is lost.
• Nonvolatile memory: Memory in a controller that does not require power to retain its
contents.
• NOR: The logic gate that results in zero unless both inputs are zero.
• NOT: The logic gate that results in the complement of the input.
• O
• Octal: Number system based on the number 8, utilizing numbers 0 through 7.
• Off-delay timer: This is a type of timer that is on immediately when it receives its
input enable. It turns off after it reaches its preset time.
• Off-line programming: Programming that is done while not attached to the actual
device. For example, a PLC program can be written for a PLC without being
attached. The program can then be downloaded to the PLC.
• On-delay timer: Timer that does not turn on until its time has reached the preset time
value.
• One-shot contact: Contact that is only on for one scan when activated.
• Operating system: The fundamental software for a system that defines how it will
store and transmit information.
• Optical isolation: Technique used in I/O module design that provides logic separation
from field levels.
• OR: Logic gate that results in 1 unless both inputs are 0.

250
 Glossary

• P
• Parallel communication: A method of communications where data is transferred on
several wires simultaneously.
• Parity: Bit used to help check for data integrity during a data communication.
• Peer-to-peer: This is communication that occurs between similar devices. For
example, two PLCs communicating would be peer-to-peer. A PLC communicating to
a computer would be device-to-host.
• PID (Proportional, integral, derivative) control: Control algorithm that is used to
closely control processes such as temperature, mixture, position, and velocity. The
proportional portion takes care of the magnitude of the error. The integral takes care
of small errors over time. The derivative compensates for the rate of error change.
• PLC: Programmable logic controller.
• Programmable controller: A special-purpose computer. Programmed in ladder logic.
It was also designed so that devices could be easily interfaced with it.
• Pulse modulated: Turning a light source on and off at a very high frequency. In
sensors the sending unit pulse modulates the light source. The receiver only
responds to that frequency. This helps make photo-sensors immune to ambient
lighting.
• PPR (Pulses per revolution): This refers to the number of pulses an encoder
produces in one revolution.
• Q
• Quadrature: Two output channels out of phase with each other by 90 degrees.
• R
• Rack: PLC chassis. Modules are installed in the rack to meet the user's need.
• Radio frequency (RF): Communications technology in which there is a
transmitter/receiver and tags. The transmitter/ receiver can read or write to the tags.
There are active and passive tags available. Active tags are battery powered.
Passive tags are powered from the RF emitted from the transmitter. Active tags have
a much wider range of communication. Either tag can have several K of memory.

251
 Glossary

• R
• RAM (random access memory): Normally considered user memory.
• Register: Storage area. It is typically used to store bit states or values of items such
as timers and counters.
• Repeatability: The ability to repeat movements or readings. For a robot it would be
how accurately it would return to a position time after time. Repeatability is unrelated
to resolution and is usually 3 to 10 times better than accuracy.
• Resolution: A measure of how closely a device can measure or divide a quantity. For
example, in an encoder resolution would be defined as counts per turn. For an analog
to digital card it would be the number of bits of resolution. For example, for a 12-bit
card the resolution would be 4096.
• Retentive coil: A coil that will remain in its last state, even though power was
removed.
• Retentive timer: Timer that retains the present count even if the input enable signal is
lost. When the input enable is active again, the timer begins to count again from
where it left off.
• Retroreflective: Photosensor that sends out a light which is reflected from a reflector
back to the receiver (the receiver and emitter are in the same housing). When an
object passes through it breaks the beam.
• RF (radio frequency): See radio frequency.
• ROM (read-only memory): This is operating system memory. ROM is nonvolatile. It is
not lost when the power is turned off.
• RS-232: Common serial communications standard. This standard specifies the
purpose of each of 25 pins. It does not specify connectors or which pins must be
used.
• RS-422 and RS-423: Standards for two types of serial communication. RS-422 is a
balanced serial mode. This means that the transmit and receive lines have their own
common instead of sharing one like RS-232. Balanced mode is more noise immune.
This allows for higher data transmission rates and longer transmission distances. RS-
423 uses the unbalanced mode. Its speeds and transmission distances are much
greater than RS-232 but less than RS-422.
• RS-449: Electrical standard for RS-422/RS-423. It is a more complete standard than
the RS-232. It specifies the connectors to be used also. RS-485: Similar to the RS-
422 standard. Receivers have additional sensitivity which allows for longer distances
and more communication drops. Includes some extra protection for receiver circuits.
• Rung: Group of contacts that control one or more outputs. In a ladder diagram it is the
horizontal lines on the diagram.

252
 Glossary

• S
• Scan time: Amount of time it takes a programmable controller to evaluate a ladder
diagram. The PLC continuously scans the ladder diagram. The time it takes to
evaluate it once is the scan time. It is typically in the low-millisecond range.
• SDLC: Serial Data Link Control, subset of the HDLC used in a large number of
communication systems like Ethernet, ISDN, BITBUS, and others. This protocol
defines the structure of the frames and the values of a number of specific fields in
these frames.
• Sensitivity: Refers to a device's ability to discriminate between levels. If it's a sensor it
would relate to the finest difference it could detect. If it were an analog module for a
PLC, it would be the smallest change it could detect.
• Sensor: Device used to detect change. Normally it is a digital device. The outputs of
sensors change state when they detect the correct change. Sensors can be analog or
digital in nature. They can also be purchased with normally closed or normally open
outputs.
• Sequencer: Instruction type that is used to program a sequential operation.
• Serial communication: Sending of data one bit at a time. The data is represented by a
coding system such as ASCII.
• Slave: On a master-slave configured network, there is usually one master and several
slaves. The slaves are nodes of the network that can transmit informations to the
master only when they are polled (called) from it. The rest of the time a slave never
transmits anything.
• Speech modules: Used by a PLC to output spoken messages to operators. The
sound is typically digitized human speech stored in the module's memory. The PLC
requests the message number to play it.
• T
• Tagout: The placement of a tagout device on an energy isolating device, in
accordance with an established procedure, to indicate that the energy isolating device
and the equipment being controlled may not be operated until the tagout device is
removed.
• Tagout device: A prominent warning device, such as a tag and a means of
attachment, which can be securely fastened to an energy isolating device in
accordance with an established procedure, to indicate that the energy isolating device
and the equipment being controlled may not be operated until the tagout device is
removed.
• Thermocouple: A thermocouple is a sensing transducer. It changes a temperature to a
current. The current can then be measured and converted to a binary equivalent that
the PLC can understand.

253
 Glossary

• T cont’d
• Thumbwheel: Device used by an operator to enter a number between 0 and 9.
Thumbwheels are combined to enter larger numbers. Thumbwheels typically output
BCD numbers to a device.
• Timer: Instruction used to accumulate time until a certain value is achieved. The timer
then changes its output state.
• TOP (technical and office protocol): Communication standard that was developed by
Boeing. Based on the contention access method. The MAP standard is meant for the
factory floor and TOP is meant for the office and technical areas.
• Transitional contact: Contact that changes state for one scan when activated.
• True: This is the enabling logic state. Generally associated with a "one" or "high" state.
• U
• UL (Underwriters Laboratory): Organization that operates laboratories to investigate
systems with respect to safety.
• User memory: Memory used to store user information. The user's program,
timer/counter values, input/output status, and so on, are all stored in user memory.
• V
• Volatile memory: Memory that is lost when power is lost.
• W
• Watchdog timer: Timer that can be used for safety. For example, if there is an event or
sequence that must occur within a certain amount of time, a watchdog timer can be set
to shut the system down in case the time is exceeded.
• Word: Length of data in bits that a microprocessor can handle. For example, a word for
a 16-bit computer would be 16 bits long, or two bytes. A 32-bit computer would have a
32-bit word.

254
VISIT OUR WEBSITE
www.goitu.com
FREE SAFETY DOWNLOADS!

Contact us at:

Industrial Training Unlimited, Inc.

Arc Flash Engineering Group
8184 Station Street
Dugger, IN 47848

Phone: 800.381.4389
Fax: 812-961-8811

Email: [email protected]

255