02PLC Programming 2017-01-16

Programming PLCs with
IEC 61131-3
MEI-56206 Production Automation Exercises
Niko Siltala, niko.siltala@tut.fi

PLC = Programmable Logic Controller
16.1.2017
72
Agenda
PLC HW & Operational Principle (Recap)
PLC Programming
Standard IEC 61131-3
Structural components
(Use of) Instance of FB
Details of IEC 61131-3 Programming
languages
From State models to PLC language

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73
Recap of PLC HW
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74
Base parts of PLC

PC +
development App
Power source
Input units
CPU
Output units
Special units
Prg Port
Hand held programming device
Counter inputs
Encoder inputs
Pulse outputs
Potentiometer,
temp. sens.
Barcode reader
Computer,
HMI
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75
About inputs and outputs

IO modules establish interface to sensors and actuators
With use of different kinds of input, output, special, and
fieldbus modules different process signals (type and
magnitude) can be connected to logic
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76
PLCs Operating principle
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Operating principle of logic

Logics executes programs cyclically, where each cycle
consist of sequence of repeated routines
During typical cycle is read inputs, execute whole program
(evaluating all lines), update outputs, monitor state of CPU
and auxiliary devices, and handle HMI and communication
(e.g. ethernet, serial ports)
R Inputs
Exe. Logic
W Outputs
R Inputs
Exe. Logic
W Outputs
Cycle Time = X ms
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78
Real Time & Determinism

RT = fast response & short cycle time
Det = constant cycle time / deviation of CT (t) 0 s
PLC
R Inputs
R Inputs
Exe. Logic W Outputs

Idle
Cycle Time = X ms
Idle time: 0..Z ms

Config:
Cycle time
SoftPLC PC -Based
tOS
Logic time = Y ms
R Inputs
R Inputs
Exe. Logic
Disk UI tasks
Cycle Time = X ms
Config:
Cycle time
tOS max. % Y of X
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Systems Response
Target:
small deviation
(Determinism)
prev. slide t 0 s
AND
Density function of Systems Latency Time
fast response (RT)

Cycle time 0 s
Small deviation is more

important!
Ideal situation: Impulse, at
moment 0 s.
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PLC Programing
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81
PLC Programming
Program can be usually made offline without PLC HW
PLC HW is usually required for testing. PLC is connected to
development environment PC via serial/USB/ethernet port
Establishing connection between PLC and PC; downloading
application program to controller; and performing the testing
procedure.
Dev. Env. Usually offers means for monitoring states, memory,
and execution of PLC program and affecting on it.
Sometimes possible to test program directly on development
environment. However this requires modelling and simulation
of HW (SW in the loop).
Programming device
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Standard IEC 61131

IEC, International Electrotechnical Commission,
prepared by PLCopen (http://www.plcopen.org/)
Standard aiming to harmonise methods and languages for
programming PLCs
Published in December 1993
Objectives and Benefits:

Reduce wasting of (human) resources (education, learning,
changes, problem tracing & solving)
Re-use of code enables focus to solving (new) problems
Minimise misunderstanding and errors
Guarantees widespread use of programming techniques
Enables working (programming) with same projects in
different locations, countries. Cross utilisation of code across
projects.
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Standard IEC 61131

Standard is assembled from nine parts, which defines and
guides use of PLC HW and actions
Part 1 General information

Part 2 Equipment requirements and tests
Part 3 Programming Languages
Part 4 User Guidelines
Part 5 Messaging service specification
Part 6 Functional Safety
Part 7 Fuzzy control programming
Part 8 Guidelines for the application and implementation of
programming languages
Part 9 Single-drop digital communication interface for small sensors
and actuators (SDCI)
i.e. IO-Link
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84
Standard IEC 61131-3

Third part of standard deals with both textual
and graphical PLC programming languages
and data types
It defines several data types, which can be used
for programming
Many actions can be done with data type BYTE,
but in sake of clarity and saving memory specific
data type should be selected according the
usage
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IEC 61131-3 / data types

nimi
tyyppi
koko (bitti)
alue
BOOL
boolean
01
SINT
short integer
-128 127
INT
integer
16
-32768 32767
DINT
double integer
32
-2.1e-9 2.1e9
LINT
long integer
64
-9.2e19 9.2e19
USINT
unsigned short integer
0 255
UINT
unsigned integer
16
0 65536
UDINT
unsigned double integer
32
0 4.3e9
ULINT
unsigned long integer
64
0 1.8e20
REAL
real number
32
LREAL
long real
64
TIME
kesto
DATE
pivys
TIME_OF_DAY
aika
DATE_AND_TIME
pivys ja aika
STRING
string
vaihtelee
vaihtelee
BYTE
8 bitti
WORD
16 bitti
16
DWORD
32 bitti
32
LWORD
64 bitti
64
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Programs, FBs and

instances
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Structure of PLC
Configuration / Program
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Relation of program types

1. PRG = Program
2. FB = Function Block
3. F
= Function
Type
Visibility
Instances
Can call or include other
PRG
FB
PRG
Global
FB
Local
0..N
Global
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PRG, FB and F - interface

FB name
INPUT
Name, data type,
[initial value],
[comment]
OUTPUT
IN_OUT
By reference
VAR
Local variables
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FB Implementation vs.
instance (ilmentym)
Cylinder (1 actuator, 1 control signal, 2 sensors)
FB implementation ~ class description (luokka)
Abstraction of cylinder
Top limit
Functionality, model and logic
Low limit
FUNCTION_BLOCK FB_Cylinder
FB instance (ilmentym)
Activity for single device
Created as variables in memory
Referring the
implementation by the
type of the variable
fbCylinder_A : FB_Cylinder;
fbCylinder_B : FB_Cylinder;

Benefits
Ylraja
Ylraja
Ylraja
Alaraja
Alaraja
Alaraja
Implement once utilise many times
Ease of maintenance
Clear interfaces
Calling an
instance
Functionality is equal to all implemented devices,

B
A
But all implementations can be in different states (see. Cylinders or lifts)
fbCylinder_A (
Ctrl_Close := bCloseA,
Limit_up := I_SensA_Up,
Limit_down := I_SensA_Down,
bDone => bDone,
OutToValve => O_Valve_11);
fbCylinder_A
Ctrl_Close
Limit_up
Limit_down
FB_Cylin
der
16.1.2017
bDone
OutToValve
91
Calling a FB
Calling INSTANCE of FB
= Executing its code
On each PLC cycle or when needed
Call can be partial. All ports (IF inputs/outputs) are
not defined or connections are missing
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Calling a FB
Changing / reading values of a single instance of
FB
Its code is NOT executed or evaluated
no state change occurs
E.g.:
Writing input:
fbDrive.wTarget:= GPOS_LOADING;
Reading output (e.g. in transition condition):
fbDrive.bMoveDone
Reading output and assigning it into another variable:
bMuttuja1 := fbDrive.bMoveDone;
State of input can be read with same method
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93
Function
Global
Does not preserve its state between two
adjacent calls (e.g. values of variables) No
counters or timers!!
Can NOT have VAR_OUTPUT type of
variables, only one (1) return value
For math operations E.g. add, storeToQueue
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Programming Languages
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95
IEC 1131-3 :
Programming
languages
Textual
Instruction List (IL)

[Kskylista]
LD
ANDN
ST
Step 1
Sequential Function
Chart (SFC)
[Sekvenssikaavio]
Structured Text (ST)
[Rakenteellinen teksti]
FILL
Transition 1
Step 2
Empty
Transition 2
Step 3
Graphical
C:= A AND NOT B;
Graphical
Function Block Diagram (FBD) Ladder diagram (LD)

[Tikapuukaavio]
[Toimilohkokaavio]
AND
A
B
A B
-| |--|/|----------------( )
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Programming languages
(IEC 61131-3)
1.
2.
3.
4.
Instruction List (IL) (= Kskylista)

Structured Text (ST) (= Rakenteellinen teksti)
Ladder diagram (LD) (= Tikapuu kaavio)
Function Block Diagram (FBD)
(= Toimilohko kaavio)
5. Sequential Function Chart (SFC)

(= Sekvenssi kaavio)
Higher level sequence description
Others: state model, flow chart, PetriNet,

IEC61499, C
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97
Instruction List (IL)

[Kskylista]
Textual, low level programming language
Relative to: Assembly

(Language for first micro controllers (PC-devices))
Instructions are short and simple text

commands
One operation per row
Users, who wants to

program low level HW
related code
Starting and stopping motor with IL
16.1.2017
98
Ladder diagram (LD)
[Tikapuukaavio, Relekaavio]
LD looks like electrical circuit diagram (relay logic), used
commonly in industry.
Used long before standard was developed
Used a lot (still today)
User, who are familiar with electrical drawings
easy to read, smaller need for training
Input Instruction
Output Instruction
16.1.2017
99
Function Block Diagram (FBD)

[Toimilohkokaavio]
Builds from function blocks and functions which

executes actions
Functionality is hidden inside function blocks, and only
interface is exposed outside (inputs and outputs)
With FBD can be implemented clear and easily
understandable program / part of program
User, who wants program without deep understanding of
programming (more like configuring graphically)
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100
FBD: Chemical Process

Agitator
TempControl
Feed valve
Heat
Acidic reagent
Heat
Alkali reagent
Temp sensor
TempSensor
PV
pH sensor
Heater band
Cool
SetPoint
Cool
pHSensor
pHControl
AddAcid
MainSequence
Harvest valve
SetPoint AddAcid
Start
Stop
Duration
Start
Temp
Stop
pH
Duration
Agitation
PV
AddAlkali
AddAlkali
AgitateControl
MotorSpeed
FillState
SetPoint
MotorSpeed
PV
AgitateSpeed
ValveControl
Fill
Fill
State
ValvePositions
Harvest
Harvest
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Structured Text (ST)
[Rakenteellinen teksti, Strukturoitu teksti]
High level programming language. Block structure

Relative language: PASCAL
Well applicable for processing numerical values
Allows complex structures and nested statements.
Conditional structures (IF-THEN-ELSE; CASE),
Iterations(REPEAT-UNTIL; WHILE-DO)
Math functions (SQRT(), SIN(), .)
For those who are used to high level

programming IF (LIMIT_SWITCH_1 AND BOX) THEN
GATE1 := TRUE;
languages
GATE2 := FALSE;
ELSIF ((LIMIT_SWITCH_2 OR (WEIGHT<>SETPOINT)) THEN
GATE1 := FALSE;
END_IF;
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Example of ST
PROGRAM PRG_Jaa
VAR_INPUT
a : INT;
b : INT;
END_VAR
VAR_OUTPUT
c : INT;
END_VAR
IF b <> 0 THEN
c := a / b;
ELSE
c := 0;
END_IF;
END_PROGRAM
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103
Sequential Function Chart (SFC)

[Sekvenssikaavio, askelkaavio, vuokaavio]
Top level sequence description

Not a programming language per se
Parts must be programmed with one
of four previously listed languages
Aimed for step wise controls
Step 1
FILL
Transition 1
Step 2
Empty
Transition 2
Step 3
Control problem is divided into smaller steps

(state models)
Supports both sequential and parallel steps
Graphical programming method, which defines

problem & solution visually
overall picture, fast diagnostics
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Sequential Function Chart (SFC)

Execution of the program
progress from initial step (Init in
example) to next ones according
the transitions (connected lines).
Each step (state, [tila]), can be
programmed with selected
language, that suites best for
task (e.g. ST or LD).
There is one or more transitions
(conditions) between steps. After
transition gets true, ti will be
triggered and step change
happens.
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1.L
Step Execution Order
2.L
4.L
3.O
5.O
7.L
6.O
8.O
2.L
L =
=
O=
=
Loops until Transition == True

0..N times
Executed exact ones
1..1 time
Loops might lead into trap

e.g. Counter
c := c +1;
9.L
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Proprietary solution
SFC Example
Be careful with S, N, P,
for Booleans
Program parts cannot modify
Use ONLY for flow control
Special case of
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108
From State Model

to PLC code
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SFC Direct graphical transformation

ST + Case & IF structures
States as integers (or enumerations)
drawback: only single state is active at time
LD + applying a systematic method
See:
http://engineeronadisk.com/book_plcs/plc_
sequa2.html#16763
From State Model

to PLC code
Methods for transition, state model and

outputs (2 different methods)
States as integers
Drum sequencer available only in specific environments
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Drum Sequencer (1/2)

Associates to LD programs as external function
http://www.unitronics.com/KnowledgeBase/U90Ladder/Drum/dru
m_sequencer.htm
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Drum Sequencer (2/2)

http://forum.hosteng.com/wndm/HTMLHelp1/Instruction
_Set/DRUM_Drum.htm
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112

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Programming PLCs with

Niko Siltala, niko.siltala@tut.fi

From State models to PLC language

MEI-56206 Production Automation Exercises

Base parts of PLC

Hand held programming device

MEI-56206 Production Automation Exercises

About inputs and outputs

MEI-56206 Production Automation Exercises

PLCs Operating principle

MEI-56206 Production Automation Exercises

Operating principle of logic

MEI-56206 Production Automation Exercises

Real Time & Determinism

Exe. Logic W Outputs

Idle time: 0..Z ms

Exe. Logic W Outputs

Exe. Logic W Outputs

MEI-56206 Production Automation Exercises

Density function of Systems Latency Time

fast response (RT)

Small deviation is more

MEI-56206 Production Automation Exercises

Standard IEC 61131

Objectives and Benefits:

Standard IEC 61131

Part 1 General information

MEI-56206 Production Automation Exercises

Standard IEC 61131-3

MEI-56206 Production Automation Exercises

IEC 61131-3 / data types

unsigned short integer

unsigned double integer

unsigned long integer

MEI-56206 Production Automation Exercises

Programs, FBs and

MEI-56206 Production Automation Exercises

MEI-56206 Production Automation Exercises

Relation of program types

Can call or include other

MEI-56206 Production Automation Exercises

PRG, FB and F - interface

Functionality, model and logic

Implement once utilise many times

Functionality is equal to all implemented devices,

MEI-56206 Production Automation Exercises

MEI-56206 Production Automation Exercises

MEI-56206 Production Automation Exercises

MEI-56206 Production Automation Exercises

Instruction List (IL)

Function Block Diagram (FBD) Ladder diagram (LD)

MEI-56206 Production Automation Exercises

Instruction List (IL) (= Kskylista)

5. Sequential Function Chart (SFC)

Higher level sequence description

Others: state model, flow chart, PetriNet,

Instruction List (IL)

Textual, low level programming language

Relative to: Assembly

Instructions are short and simple text

Users, who wants to

Starting and stopping motor with IL

MEI-56206 Production Automation Exercises