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11/19/2017 Building a PLC Program That You Can Be Proud Of Part 6 | Acc Automation

ACC, COMMUNICATION, DIGITAL, HMI, MANUFACTURING, MODBUS TCP, PLC, PROGRAMMABLE LOGIC CONTROLLER,
PROGRAMMING, PROGRAMMING EXAMPLE, UNCATEGORIZED

BUILDING A PLC PROGRAM THAT YOU CAN BE


PROUD OF PART 6
JANUARY 23, 2016 | GARRYS | LEAVE A COMMENT

We will continue the series by looking at a sequencer controlling seven cylinders that can be taught. The
cylinders can be operator programmed from the AdvancedHMI screen. You will be able to select what
cylinders to activate at each step and program in 500 steps. Our PLC will be the Do-More from

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Automation Direct.

Here is a quick review of the programming series so far. If you are new to the site, we recommend
reviewing the other parts in the series rst.
Inpart 1we looked at writing PLC programs to control a traf c light using discrete bits and then using
timed sequencing using indirect addressing.
Part 2 used indirect addressing for inputs as well as output to control the sequence of pneumatic (air)
cylinders in the program. Part 3 and 4 we returned to the traf c light application and expand our
program signi cantly. We looked at the sequence of operation using Input, output and mask tables.
In part 5 we used the AdvancedHMI software to create the game of Simon. A round in the game consists
of the device lighting up one or more buttons in a random order, after which the player must reproduce
that order by pressing the buttons. As the game progresses, the number of buttons to be pressed
increases.

We will be using AdvancedHMI to communicate Modbus TCP to the Automation Direct Do-More
Designer Software Simulator. The following is the sequence of operation:
Watch on YouTube : Running the Cylinder Sequence (PLC / HMI)

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Building a PLC Program that You can be Proud Of Part 6 - Runnin

Note:All of the programsused areprovided free of charge and are an excellent way to learn PLC / HMI
programming.

The following table is the Modbus TCP memory map to the Do-More PLC:

Coil/Register Numbers Data Addresses Type Do-More PLC Table Name

00001-09999 0000 to 270E Read-Write MC1 to MC1023 Discrete Output Coils

10001-19999 0000 to 270E Read-Only MI1 to MI1023 Discrete Input Contacts

30001-39999 0000 to 270E Read-Only MIR1 to Analog Input Registers


MIR2047

40001-49999 0000 to 270E Read-Write MHR1 to Analog Output Holding


MHR2047 Registers

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Here are the inputs and outputs we will be using for our program:

Device Data Addresses Type Do-More PLC Description

Start Pushbutton 00011 Input MC11

Stop Pushbutton 00012 Input MC12

Jog Pushbutton 00013 Input MC13

Reset Pushbutton 00014 Input MC14

Run/ Jog Selector 00008 / 00015 Input/ Output MC8 / MC15 MC8 is the value and
MC15 is the click

Light Stack 00010 / 00009 / Output MC10 / MC9 / Red / Green / Amber
00008 MC8

SetPushbutton 00071 Input MC71

Jog / Teach Selector 00070 Input MC70 MC70 on is teach mode

Sequence Step (Panel 40001 Output MHR1 Current step in the


Meter) sequence

Inputs Actual 40002 Input MHR2 Show the actual inputsin


binary format

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OutputSequence 40003 Output MHR3 Show the actual outputs in


a binary format

Input Sequence 40004 Input MHR4 Show the input sequence


bits in a binary format

Cylinder 1 to 7 value 00001 to 00007 Output MC1 to MC7 Determine if cylinder is


on/off

Cylinder 1 to 7 set 00041 to 00047 Input MC41 to MC47 Set the cylinder button
(click)

Cylinder 1 to 7 retract 00021 to 00027 Input MC21 to MC27 Indicate cylinder has
indicators retracted

Cylinder 1 to 7 extend 00031 to 00037 Input MC31 to MC37 Indicate cylinder has
indicators extended

Cylinder 1 to 7 extend 00050 to 00063 Output MC50 to MC63 Indicate cylinder input
/ retract error indicators error when jogging

The rst thing we will do is design the HMI. We have three main areas on the screen. Basic Controls,
Cylinder Visualization and the Sequence Step/Teach area. Please refer to the above reference chart for
the inputs and outputs programmed on the screen.

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Basic Controls:
This area will allow us to see what mode we are in via the stack light. Red Stop
Yellow Jog / Teach Mode Troubleshooting
Green Run

Cylinder Visualization:
Each cylinder will have indication lights to determine status of the cylinder. (Extended / Retracted)
The cylinder will also have red indication lights to re ect the differences between the current sequence
and the next sequence step. This is visible when we are in jog mode.

Sequence Step/Teach:
When in jog or teach mode the sequence step is visible, which indicates the current step that we are on.
The inputs and outputs are displayed as a binary value which represents the actual inputs and outputs.
This is valuable when troubleshooting and nding errors in the system. The set button is visible when in
teach mode. When pushed the outputs and inputs are set for that step and the sequence will then

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increment.

The following is the code for each of the words that the DataScribers are reading. This includes the code
to change the word into a 16 bit binary value.

Private Sub DataSubscriber1_DataChanged(sender As Object, e As Drivers.Common.PlcComEventArgs)


Handles DataSubscriber1.DataChanged
'Label1.Text = Hex(DataSubscriber1.Value)Dim i As Integer = DataSubscriber1.Value
Label1.Text = Convert.ToString(i, 2).PadLeft(16, "0") '16 bits
End Sub

Private Sub DataSubscriber2_DataChanged(sender As Object, e As Drivers.Common.PlcComEventArgs)


Handles DataSubscriber2.DataChanged
'Label2.Text = Hex(DataSubscriber2.Value)
Dim i As Integer = DataSubscriber2.Value
Label2.Text = Convert.ToString(i, 2).PadLeft(16, "0") '16 bits
End Sub

Private Sub DataSubscriber3_DataChanged(sender As Object, e As Drivers.Common.PlcComEventArgs)


Handles DataSubscriber3.DataChanged
Dim i As Integer = DataSubscriber3.Value
Label3.Text = Convert.ToString(i, 2).PadLeft(16, "0") '16 bits
End Sub

Private Sub DataSubscriber4_DataChanged(sender As Object, e As Drivers.Common.PlcComEventArgs)


Handles DataSubscriber4.DataChanged
If DataSubscriber4.Value = True Then
Label1.Visible = True
Label2.Visible = True
Label3.Visible = True

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Label4.Visible = True
Label5.Visible = True
Else
Label1.Visible = False
Label2.Visible = False
Label3.Visible = False
Label4.Visible = False
Label5.Visible = False
End If
End Sub

We will now look at the PLC ladder program. The program is broken down into several parts as follows:

ACC Automation
This is the main start / stop circuit of the program.
If we are in run mode the green light will be on. (MC9)
If we are not in jog mode (MC8) this circuit will be functional.

If we are not run mode (MC9) or in jog mode (MC8) then the stop mode is active.
This will turn on the red light. (MC10)

Run / Jog Toggle Circuit


Flip Flop circuit to set the jog function

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Move the outputs to the physical outputs when we go to run mode.

Indirect Addresses for the Program


V0 Input pointer 100 499
V1 Output pointer 500 999
V2 Input pointer last step in sequence
V3 Output pointer last step in sequence
V10 Inputs to the sequencer
V20 Outputs from the sequencer

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Jog Mode Jog Pushbutton

Reset the sequencer pointers. This will happen automatically in run mode or by hitting the reset button
in jog or stop mode.

Teach Function
This rst rung will activate the values so we can manually turn them off/on with the HMI screen.

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This will reset the pointers when going into teach mode.

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This will set the teach point and increment to the next step.

Show the current step of the sequence.


Note: 0 is the rst step

Set the inputs for cylinders.


The actural physical input points would be inserted here.
HMI inputs from the cylinders have a 500ms delay to simulate the movement of the actual cylinder.
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Set the actual inputs / sequencer inputs / sequencer outputs so we can monitor this on the HMI.

Set the outputs for cylinders.


This will set the physical output points Y1 to Y7.
This will also set the HMI cylinders MC1 to MC7 (00001 to 00007)

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Diagnostic Bits for indicating the difference for the inputs to the PLC. This will show up as a red
indication light on the cyclinder represented on the HMI.

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This section of PLC logic will mimic the inputs from the cylinders.
Cylinder 1 Retract MC21 (00021) Extend MC31 (00031)
Cylinder 2 Retract MC22 (00022) Extend MC32 (00032)
Cylinder 3 Retract MC23 (00023) Extend MC33 (00033)
Cylinder 4 Retract MC24 (00024) Extend MC34 (00034)
Cylinder 5 Retract MC25 (00025) Extend MC35 (00035)
Cylinder 6 Retract MC26 (00026) Extend MC36 (00036)
Cylinder 7 Retract MC27 (00027) Extend MC37 (00037)

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Between each funtion of the cylinder there is a time delay for the input to turn on and off of 500msec.

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Cylinder 2 Retract MC22 (00022) Extend MC32 (00032)

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Cylinder 3 Retract MC23 (00023) Extend MC33 (00033)

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Cylinder 4 Retract MC24 (00024) Extend MC34 (00034)

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Cylinder 5 Retract MC25 (00025) Extend MC35 (00035)

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Cylinder 6 Retract MC26 (00026) Extend MC36 (00036)

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Cylinder 7 Retract MC27 (00027) Extend MC37 (00037)

This is the end of the PLC program. You can see that the program is not very complicated once you break
down the individual steps.

Download the PLC program and the Bin directory for the AdvancedHMI screen.

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Watch on YouTube : Building a PLC Program that You can be Proud Of Part 6b Explaining the

Building a PLC Program That You Can be Proud of - Part 6b - Expl

Program
If you have any questions or need further information please contact me.
Thank you,
Garry

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