A Project Report On P.L.

C (Programable Logic
Controller)
INDEX

1. Introduction
1. What is PLC?
2. Why use PLC?
3. applications of PLC
2. Plc components
1. Overview
2. Specifications of the PLC
3. Micrologix 1500 system
4. RSLogix 500
3. Ladder logic fundamentals
1. Programming language of PLC
1. Electrical ladder diagram
1. Ladder logic instructions
2. Variable voltage variable frequency drive
1. Introduction
1. Advantages of using VVVF drive
1. Details of VVVF drive
1. PROGRAM MODE
1. Process automation
1. Introduction
2. Description of model
3. Motion Control using PLC
4. Temperature measurement
5. Speed Control of Motor using VVVF Drive
6. Conveyor System
2. Entrepreneurship
3. Bibliography
4. Appendix a
5. Appendix b

1. INTRODUCTION
1.1 WHAT IS PLC?
A programmable logic controller (PLC) is an electronic device that controls machines
and processes. It uses a programmable memory to store instructions and execute
specific functions that include ON/OFF control, timing, counting, sequencing,
arithmetic and data handling.
PLCs development began in 1968 in response to the request from hydromantic
division of general motors. At the time, gm frequently spent days or weeks replacing
inflexible relay-based control systems whenever it changed car models or made line
modifications. To reduce the high cost of rewiring, gm’s control specifications
called for a solid state system that had the flexibility of a computer yet could be
programmed and maintained by plant engineers and technicians. It also had to
withstand the dirty air, vibration, electrical noise, humidity and temperature extremes
found in the industrial environment.
The first PLCs were installed in 1969 and quickly became a success. Functioning as
relay replacements; even the early PLCs were more reliable than relay-based
systems, largely due to the ruggedness of their solid-state components compared
with the moving parts in electrochemical relays. PLCs provided material, installation;
troubleshooting and labour cost savings by reducing wiring and associated wiring
errors. They took up less space than the counters, timers and other control
components they replaced. And their ability to be reprogrammed dramatically
increased flexibility when changing control schemes.
Perhaps the biggest key to industry’s acceptance of the PLCs was based on the
ladder diagrams and electrical symbols commonly used by electricians. Most plant
personnel were already trained in ladder logic, and they easily adopted it for PLCs.
In fact, ladder logic still plays an integral role in programming and troubleshooting;
even though more “advanced” programming languages have been
developed.
1.2 WHY USE PLCs?
During the 1970s and early ‘80s, many engineers, manufacturing managers and
control system designers spent considerable time debating this issue, trying to
evaluate cost effectiveness.
Today, one generally accepted rule is that PLCs become economically viable in
control system that requires three to four or more relays. Given that micro PLCs cost
only a few hundred dollars, coupled with the emphasis manufacturers place on
productivity and quality, the cost debate becomes also immaterial. In addition of cost
savings, PLCs provide many value added benefits:
1.2.1 RELIABILITY
Once a program has been written and debugged. It can be easily transferred and
download to other PLCs. This reduces programming time, minimizes debugging, and
increases reliability. With all the logic existing in the PLCs memory, there is no
chance of making a logic wiring error. The only wiring required is for power and
inputs and outputs.
1.2.2 FLEXIBILITY
Program modifications can be made with just a few key strokes. Advanced functions
PLCs can perform a wide variety of control tasks, from a single, repetitive action to
complex data manipulation. Standardizing on PLCs opens many doors for designers,
and simplifies the job for maintenance department personnel.
1.2.3 COMMUNICATIONS
Communicating with operator interfaces, other PLCs or computers facilities data
collection and information exchange.
1.2.4 SPEED
Some automated machines process thousands of items per minute and objects
spend only a fraction of a second in front of a sensor, hence many automation
applications require the PLCs quick response capability.
1.2.5 DIAGNOSTICS
The troubleshooting capability of programming devices and the diagnostics resident
in the PLCs allow users to easily trace and correct software and hardware problems.
1.3 APPLICATIONS OF PLC
No matter what the application, the use of PLCs helps increase competitiveness.
Process using PLCs include: packaging, bottling and canning, material handling,
machining, power generation building control systems, automated assembly, paint
lines, and water treatment. PLCs are applied in variety of industries including food
and beverages, automotive, chemical, plastics, pulp and paper, pharmaceuticals and
metals. Virtually any application that requires electrical control can use PLCs.

2. PLC COMPONENTS
2.1 OVERVIEW
The main components of PLCs are as follows:

1. Inputs
2. Outputs
3. CPU
4. Memory for program and data storage
5. Programming device
Central
Processing
Unit
Programming / Communication Device
Memory
Program Data
Power Supply
Output Circuits
CR
Input Circuits
Optical Isolation

1. Operator interfaces
2.1.1 INPUTS
The input screw terminals on a PLC from the interface by which field devices are
connected to the PLC. Inputs include the items such as tool buttons, thumbwheels,
limit switches, selector switches, proximity sensors and photoelectric sensors. These
are all discrete devices that provide an ON/OFF status to the PLC. While larger
PLCs can directly accept analog values (variable voltage or current signals). Such as
from temperature or pressure sensors, micro PLCs do not typically possess this
capability.
The electrical signals that field devices send to the PLC are typically unfiltered 120v
a.c. or 24v D.C. The inputs circuitry on PLC takes this field voltage and
“conditions”. It too is usable by the PLC. Conditioning is necessary because
the internal components of PLC operate on 5v D.C. and this minimizes the possibility
if damage by shielding them from voltage spikes. To electrically isolate internal
components from the input terminals, PLCs employ an optical isolator, which uses
light to couple signals from one electrical device to another.
2.1.2 OUTPUTS
Connectors tot the o/p terminals of the PLC are devices such as solenoids, relays,
contractors, motor starters, indicator lights, valve and alarms. Output circuits operate
in a manner similar to i/p circuits: signals from the CPU pass through an isolation
barrier before energizing o/p circuits.
PLC use a variety of o/p circuits to energies their o/p terminals: relays, transistors
and triac.

• Relays are for either ac or dc power. Traditional PLC, electromagnetic relay

typically handle current up to a few amps. Relays can better withstand
voltage spikes, and they have an air gap between their contacts, which
eliminates the possibility of current leakage. However they are comparatively
slow and subject to wear overtime.
• Transistors switch dc power are silent and have no moving parts to wear out
transistors are fast and can reduce response time, but only carry loads of
0.5amps or less. Special types of transistors, such as FET (field effect
transistors) can handle more power, typically up to 1amp.
Triac strictly switch ac power. Like transistors triac o/p are silent, have no moving
parts to wear, are fast and carry loads of 0.5 amps or less.

• USING INPUT AND OUTPUT

This section discusses the various aspects of input and output features of the
micrologix 1500 controller. the controller comes with a certain amount of embedded
I/O, which is physically located on the base unit. The controller also allows for adding
expansion I/O. This section discusses the following I/O functions:

• Embedded I/O
• I/O configuration
• Expansion I/O
• EMBEDDED I/O
All embedded I/O is automatically configured to factory default settings and does not
require setup. If you need to change the input filters for any DC input controller
(1764-24BWA, 1764-28BXB), open RS Logix 1500.

1. Open the controller folder.

2. Open the I/O configuration folder
3. Open slot (MICROLOGIX 1500)
4. Select the I/O configuration tab.
1. You can change the filter settings for any of the input groups and configure
the latching inputs from the screen.
• I/O CONFIGURATION
CONTOLLE INPUT OUTPUT
R
QUANTITY TYPE QUANTITY TYPE
1764- 12 24V DC 12 RELAY
24BWA
1764- 12 120 V AC 12 RELAY
24AWA
1764- 16 24V DC 12 6
28BXB RELAY,6FE
T
DC embedded I/O can be configured for a number of special function that can be
used in your application these are selectable I/N filters, high speed counting, event
interrupts, latching I/N and high speed O/P.
• EXPANSION I/O
If the application requires more I/O then the controller provides, the user can attach
up to eight additional I/O modules. Compact I/O is used to provide discrete inputs
and outputs and in the future specialty modules. The number of compact I/O that can
be attached to the MICROLOGIX 1500 is dependent on the amount of current
required by the I/O modules.
2.1.3 CENTRAL PROCESSING UNIT- CPU
The CPU made up of a microprocessor and a memory system, forms the primary
component of the PLC. The CPU reads the inputs, executes logics as dictated by the
application program, performs calculations and controls the output.
PLC users works with two areas of the CPU: program files and data files. Program
files stores the user application program, subordinate files and the error files. Data
files store data associated with the program such as input, counter/timer preset and
accumulates the valves. Together, these two areas are called application memo0ry
or user memory.
Also the CPU carries an executing program or a system memory that directs and
performs ‘operation’ activities such as executing the user program and co-
ordination scans and output updates. The user cannot access system memory,
which is programmed by the manufacturer.2.1. 4 DATA, MEMORY AND
ADDRESSING Memory is a physical space, data is and information stored in that
space. The CPU operates just like a computer; it manipulates data using binary
digits, or bits. Thus the data is a patter of electrical charges that represents the
numerical values. CPU processes the stored data in 16 bit groups also known as
‘words’.
Each word of data has a specific physical location in the CPU called an address or a
register. When assigned address to input in a program, note that address is related
to the terminal where input and output are connected.
2.1.5 PROGRAMMING DEVICE OPERATING CYCLE
Component of the PLC system, come into play during the operating cycle, which
consist of series of operation performed sequentially and repeatedly.
Major elements of operating cycle are:

• INPUT SCAN
During the input scan, the PLC examine the external input devices for a voltage
present or absent i.e. an OFF or ON condition. The status of input is temporarily
stored in an input image memory file.

• PROGRAM SCAN
During the program scan PLC scans the instructions in the ladder logic program. The
resultant status of the output is written to the ‘output image memory file’.

• OUTPUT SCAN
It is based on the data in the output image file. The PLC energizes or de-energizes
its output circuits, controlling external devices.
2.1.6 OPERATOR INTERFACES
In order to convey information about machine status the front panel of a micro PLC
has a series of indicator lights. For example, power, run, faults etc. To communicate
with PLC i.e. is to enter data or monitor and control machine status. The new
generation of electronic operator interfaces devices is used now a day. These are
not programming devices but graphic or alphanumeric displays and control panel.
These interfaces can output data and display messages about machine status in
descriptive text. They can also be used for data input. These interfaces decrease
need for operator training on machine operation and reduce system component and
installation cost. These products communicate with the PLC through an RS 232
communication port.2.2 SPECIFICATIONS OF THE PLC 2.2.1 MICROLOGIX 1500
1764-24BWA
Description 1764-BWA
Number of I/O 12 Inputs; 12 Outputs
Line Power 85 to 265V a.c.
Power supply inrush 120V ac= 25A for 8 ms; 240V ac= 40A for 4 ms
User power output 24V dc at 400 mA, 400 micro fared max.
Input circuit type 24V dc, sink/source
Output circuit type Relay
Operating Temperature +0 degree cent. to +55 degree cent.
Storage Temperature -40 degree cent. to +85 degree cent.
2.2.2 ANALOG INPUT MODULE (1769-IF4)
Analog normal operating Voltage: +/-10Vd.c, 0to 10V d.c, 0to5V d.c, 1 to
ranges 5 V d.c. Current: 0to20mA, 4to 20mA
Number of inputs 4 Differential or single ended
Rated working voltage 50V a.c. / 50Vd.c
Common mode voltage range +/- 10V max. per channel
Input impedance Voltage terminal: 220killo-ohm (typical) Current
terminal 250 ohm
2.2.3 ANALOG OUTPUT MODULE (1769-OF2)
Number of outputs To single ended
Maximum inductive load (current 0.1Mh
outputs)
Maximum capacitive load (voltage 1micro -farad
outputs)
1. DIGITAL INPUT MODULE-1769-IQ16
Voltage category 24Vd.c (sink/source)
Operating voltage range 10to30Vd.c at 30 deg. Cent. 10 to
26.4Vd.c at 60 deg. Cent.
Off state voltage (Max.) 5Vd.c
Number of inputs 16
Off state current max. 1.5mA
On state voltage min. 10Vd.c
On state current min. 2.0mA
Nominal impedance 3killo-ohm
2.2.5 DIGITAL OUTPUT MODULE (1769-OW8)
Voltage category A.C/D.C normally open relay
Operating voltage range 5 to 265V a.c. and 5 to 125V d.c.
Number of outputs 8
Off state leakage max. 0 mA
On state current min. 10mA at 5Vd.c
Continuous current per common 8Amp
(max.)
Continuous current per module (max) 16Amp
2.3 MICROLOGIX 1500 SYSTEM The PLC used in our lab is purchased by Allen-
BradelTM. The name of the product is MicroLogix 1500. Allen-Bradley TM also
provides the software by which one can interact with the PLC the name of software
is RS Logix 500. This software is installed on the computer by which PLC is
connected through series port (RS.2).the information about the Software and PLC
available on the website of the Allen-BradelTM is as follows:
In a perfect world you would always know what's behind the next door. In the world
of automation, the MicroLogix 1500 controller can help you open up new possibilities
and get you to where you want to go with ease.
This dynamic controller is a more powerful and expandable addition to the
MicroLogix family:

• Application flexibility and versatility with Compact I/O means a small footprint
and expansion to over 100 I/O points.
• Large onboard non-volatile memory
• Real Time Clock (RTC) capabilities allow time scheduling of control
• Program portability allows user programs to be uploaded, downloaded and
transported via Memory Modules
• Built in PID capabilities
• Data Access Tool for data monitoring and adjustment
• Eight Latching (pulse catch) inputs
• Four event interrupts
• Performance
• Approximate scan time for a typical 1K user program (includes timers,
counters, etc.): 1 millisecond
• Simple bit instruction execution: 0.7 microseconds
• 2 millisecond selectable timed interrupt (STI)
• 1 millisecond timers
• Two 20 kHz high-speed counters each with eight modes of operation (up,
down, up/down, quadrature, etc.)
• Two 20 kHz high-speed outputs (PTO or PWM with acceleration/deceleration
profiles)
• Rugged tongue-and-groove package design, to provide strength and system
reliability
• May be expanded to include up to 16 Compact I/O modules
Base Units continue to support up to eight modules (within the power budget
of the base unit) with additional expansion through expansion cables and a
number of expansion power supplies.
• Optional Features
 • Data Access Tool (DAT) plug-in device
• Memory Module
• Real Time Clock (RTC) Module
• Combination Memory & RTC Module
• Expansion I/O modules for discrete and analog applications with a
comprehensive selection of electrical configurations
2.4 RSLogix 500 The RSLogixâ„¢ family of ladder logic programming packages
helps you maximize performance, save project development time, and improve
productivity. This family of products has been developed to operate on
Microsoft’s Windows® operating systems. Supporting the Allen-Bradley SLC
500â„¢ and MicroLogixâ„¢ families of processors, RSLogix 500â„¢ was the first
PLC® programming software to offer unbeatable productivity with an industry-
leading user interface. RSLogix 5™ supports the Allen- Bradley PLC-5® family of
programmable controllers. RSLogix 5000â„¢ provides support for the
Logix5000’s Highly Integrated Motion functionality. RSLogix offers reliable
communications, powerful functionality, and superior diagnostics.
These RSLogix products share:

• Flexible, easy-to-use editors

• Common look-and-feel
• Diagnostics and troubleshooting tools
• Powerful, time-saving features and functionality
RSLogix programming packages are compatible with programs created with
Rockwell Software’s DOS based programming packages for the PLC-5 or SLC
500 and MicroLogix families of processors, making program maintenance across
hardware platforms convenient and easy.
INTEROPERABILITY
Rockwell Software provides you with the most powerful and completes programming
products available today in the RSLogix family. The interoperability between
RSLogix and Rockwell Software’s HMI package, RSView32™, and
communication package, RSLinxâ„¢, positions RSLogix as the ultimate programming
solution. With the Rockwell Software family of products, you have the ability to share
your database with RSView32. You can create schematic drawings of your system
directly from your RSLogix project using RSWireâ„¢, automatically tune PID loops
with RSTuneâ„¢, trend critical application parameters with RSTrendâ„¢, or test and
debug your ladder logic programs using RSLogix Emulate 5â„¢ or RSLogix Emulate
500â„¢.

3. LADDER LOGIC FUNDAMENTALS3.1 Programming Language of PLC A

program is a user developed series of instructions or commands that direct the PLC
to execute actions. A programming language provides rules for combining the
instructions so that they produce the desired actions.
The most commonly used language for programming PLCs is ladder logic. In fact,
more PLC programs are written in ladder logic than any other language. The ladder
logic programming language is an adaptation of an electrical relay wiring diagram,
also known as a ladder diagram. Because ladder logic is a graphical system of
symbols and terms even those not familiar with electrical relay wiring diagrams can
easily learn it.
Other control languages occasionally used to program PLCs include BASIC, C and
Boolean. These computer languages facilities programs that require complex
instructions and calculations too cumbersome to implement with a ladder logic
program. However, micro PLCs that can be programmed with BASIC and C are not
widely available.
The instructions used to program most micro PLCs are based on a combination of
Boolean, ladder logic and mnemonic expressions. A mnemonic expression is a
simple and easy to remember term which represents a complex or lengthy
instruction. For example, “TON” stands for “timer on.” Different PLCs
use slightly different instructions, and these can be found by consulting the
user’s manual.3.2 Electrical Ladder Diagrams Ladder logic programs evolved
from electrical ladders diagrams, which represent how electrical current flows
through devices to complete an electric circuit. These diagrams show the
interconnection between electrical devices in an easy-to-read graphical format that
guides the electrician when wiring.
An electrical diagram consists of two vertical bus lines, or power lines, with current
flowing from the left bus to the right bus. Each electrical circuit in the diagram is
considered a rung. Every rung has two key components: it contains at least one
device that is controlled, and it contains the condition(s) that control the device, such
as power from the bus or a contact from a field device.
A rung is said to have electrical continuity when current flows uninterrupted from left
to right across the rung (i.e. all contacts are closed). If continuity exists, then the
circuit is complete and the device controlled by the rung turns on. If continuity does
not exist, the device stays off.
A PLC ladder logic program closely resembles an electrical ladder diagram. On an
electrical diagram, the symbols represent real world devices and how they are wired.
A PLC program uses similar symbols, but they represent ladder logic instructions for
the application. A ladder logic program exists only in the PLC’s software- it is not
the actual power bus or the flow of current through circuits. Another difference is that
in an electrical diagram. Devices are described as being open or closed (Off or on).
In a ladder logic program, instructions are either True or False (however, the terms
are often used interchangeably).
Each rung in a ladder logic program must contain at least one control instruction
(output) and usually contains one or more condition instructions (inputs). Condition
instructions are programmed to the left of the control instruction. Examples of
condition instructions include signals from connected input devices, contacts
associated with outputs, and signals from timers and counters.
Auxiliary holding contact
M1
Rung
PB1stop
PB2start
Motor
L1
L2
Programmed on the right side of the rung, a control instruction is the operation or
function that is activated/de-activated by the logic of the rung. Examples of control
instructions include output energize (turn on the PLC’s output circuitry to activate
a field device) and instructions internal to the PLC, such as bit commands, timers,
counters and math commands.
The control instructions are energized or de-energized based on the status of the
condition instructions in the rung. The PLC does this by examining a rung for logical
continuity (i.e. all condition instructions are evaluated as True). If logical continuity
exists, the PLC energizes the control instruction. If logical continuity does not exist,
then the PLC maintains the control
pb1stop
pb2start
Auxiliary holding contact
m11
motor
L1
L1
R
u
n
g
Electrical continuity
3.3 LADDER LOGIC INSTRUCTIONS
The most frequently used instructions in a PLC ladder logic program are normally
open instruction, normally closed instruction, output energize instruction, these
instructions are represented as symbols placed on the rungs of the program.
3.3.1 NORMALLY OPEN INSTRUCTION
A normally open instructions examines a PLC memory location for an ON condition
(i.e., it checks to se if the bit element at the instruction’s address is ON.
For example, a NO push button (pb1) is wired to input terminal I/3 is scanned, that
instruction is seen as true and the PLC energizes output O/4 during its output scan.
When PB1 is released, the OFF status is written to address I/3, the no instruction is
now false and the rung lacks logically continuity. During the PLCs output scan, O/4
will be de-energized.
Input terminal on plc I/3
I/3
True
Output terminal on plc
Status of output ON
Normally open instruction
Output terminal on plc
Status of output ON
I/3
O/4
True
False
False
Normally open instruction
Input device
Input terminal on plc
O/4
3.3.2 NORMALLY CLOSED INSTRUCTION:
A normally closed instruction examines the PLC memory for an OFF condition (i.e., it
checks to se if the bit element at the instruction’s address is OFF or 0). If the
PLC detects an OFF condition, the instruction is true and has logical continuity.
For example, a NO pushbutton (PB1) is wired to input terminal I/4 is programmed as
a D.C. instruction.
When PB1 is not pressed (OFF) that OFF status is written to input image memory
location I/O during the PLCs input scan. When the rung containing the D.C.
instruction with address I/O is scanned, that instruction is seen as true (not ON) and
the PLC energizes output O/5 during the output scan.
When PB1 is pressed, the ON status is written to address I/4 the D.C. instruction is
now false and the rung lacks logical continuity. During the PLCs output scan, output
O/5 will be de-energized.
Output terminal on plc
True
True
Normally closed instruction
Input terminal on plc I/3
Normally closed instruction
Input terminal on plc I/3
I/3
O/4
Output terminal on plc
False
False
I/3
O/4
3.3.3 OUTPUT ENERGIZE INSTRUCTION
Controlled by the condition instructions that precede it on a rung, the output energize
instruction (OTE) turns on a bit element in the output image file when rung conditions
are true. Output energize is the ladder logic equivalent of a relay coil on an electrical
diagram.
When logical continuity exists on a rung, the on condition (binary 1) is written to the
location in memory associated with the output energize instruction. If the address is
that of an external output device, the PLC energizes the output during the output
scan. When the rung is False, the PLC de-energizes the output. The output
energizes instruction controls real world devices (solenoid valves, motors, lights,
etc.) or internal bit elements.
Higher Level Instructions
While relay logic is suitable for simple On/Off sensing and control, many applications
require more powerful instructions. To allow this, enhanced ladder language
commands have been developed. These instructions deal with numerical data
beyond simple 1s or 0s by manipulating data in bytes or words. Examples of higher
level instructions include counters, timers, sequencers, math, comparison and other
operations that N.O., N.C., and OTE instructions cannot perform.
To keep the implementation of these operations simple, higher-level instructions are
usually represented in ladder logic programming as function blocks. Function blocks
are literally programmed as blocks on the rung of a ladder program. Depending on
their operation, higher level instructions can be either condition instructions (e.g.
comparison instructions) or control instructions (e.g. timer or counter instructions).
3.3.4 COMBINING INSTRUCTIONS
Two fundamental logic operations- AND and OR- provide the rules for governing
how instructions are combined.
AND Logic
Condition instructions programmed in series are the ladder diagram equivalent of
AND logic. For example, picture a metal stamping operation where the machine
activates only if the operator simultaneously pushes both a left-hand start button (X)
AND a right hand start button (Y).
The output of an AND equation will be True only if all conditions in series are True. If
any condition is False, then the rung does not have logical continuity and the output
will be off.
OR Logic
Condition instructions programmed in parallel are the ladder diagram equivalent of
the OR operation. For example, imagine a conveyor that has two run switches, one
located at each end. The conveyor could be configured to start if an operator
pressed a start button at one end (X) OR the other (Y)
The output of an OR equation will be True if any condition in parallel is True. If all
conditions are False, then the rung does not have logical continuity and the output
will be False.
Branch Operations
The function of a branch is to allow both condition and control instructions to be
programmed in parallel in a single rung.

• Condition instructions programmed in parallel are the equivalent of an OR

operation.
• Control instructions programmed in parallel are the equivalent of an
3.3.5 PROGRAM EXECUTION Before reading how the PLC executes a ladder logic
program, re-reading, “Operating Cycle” may be helpful.
The PLC solves each rung sequentially from top to bottom of the program. Even if
the output of the current rung (e.g., rung 5) affects a previous rung (e.g., rung 2), the
PLC does not go back to solve the earlier rung until the next program scan. For the
output of one rung to affect an instruction in another rung in the same scan, it must
have a lower rung number than the rung it is to affect. That is, the controlling rung
must be programmed before the controlled rung.
While rungs are often ordered to show a sequence of events- the top –most rung is
the first event and so on- this is done purely for organizational convenience. In both
electrical diagrams and ladder logic programs, rung order does not necessarily
dictate the sequence of operation. Remember, the status of the condition instructions
of each rung dictates the sequence in which outputs are controlled. 3.3.5
INSTRUCTION SET PLC has a very big instruction set which is similar to
microprocessor’s instruction set we have studied in 8085.
Categorized Instructions are as follows:

1. Compare Instructions
2. Math Instructions
 3. Relay Type Instructions
4. Timer and Counter Instructions
5. Sequence Instructions
6. PID Control
7. Bit Shift FIFO and LIFO Instructions
Different types of instruction used in PLC which empowers it are as follows:

• XIO (“Examine if closed” or “Normally opened”)

This instruction (also called "examine on" or "normally opened") functions as an input
or storage bit.
If the corresponding memory bit is a "1" (on), this instruction will allow rung continuity
and outputs will be energized.

• XIO (“Examine if Open” or “Normally closed”)

This instruction (also called "examine off" or "normally closed") functions as an input
or storage bit.
If the corresponding memory bit is a "1" (on), this instruction will not allow rung
continuity and outputs on its rung will be de-energized (Note other factors may affect
rung continuity).
If the corresponding memory bit is a "0" (off), this instruction will assume its normal
status and allow rung continuity and outputs on the rung will be energized (Again,
other factors can influence rung continuity).
If used as an input bit, its status should correspond to the status of real world input
devices tied to the input image table by the identical addresses.

• OTE [Output Energize]

This instruction sets the specified bit when rung continuity is achieved (rung goes
true). Under normal operating conditions, if the set bit corresponds to an output
device, the output device will be energized when the rung goes true.
If you are using a 5/02, 5/03, 5/04, 5/05 or MicroLogix processor, you can use
indexed addresses. If you are using a 5/03 OS302, a 5/04 OS401, or a 5/05
processor, you can use indirect addresses.
Output addresses are specified to the bit level.

• TON [Timer On-Delay]

Use the TON instruction to turn an output on or off after the timer has been on for a
preset time interval. This output instruction begins timing (at either one second or
one hundredth of a second intervals) when its rung goes "true." It waits the specified
amount of time (as set in the PRESET), keeps track of the accumulated intervals
which have occurred (ACCUM), and sets the DN (done) bit when the ACCUM
(accumulated) time equals the PRESET time.
As long as rung conditions remain true, the timer adjusts its accumulated value
(ACC) each evaluation until it reaches the preset value (PRE). The accumulated
value is reset when rung conditions go false, regardless of whether the timer has
timed out.

• TOF [Timer Off Delay]

Use the TOF instruction to turn an output on or off after its rung has been off for a
preset time interval. This output instruction begins timing (at either one second or
one hundredth of a second intervals) when its rung goes "false." It waits the specified
amount of time (as set in the PRESET), keeps track of the accumulated intervals
which have occurred (ACCUM), and resets the DN (done) bit when the ACCUM
(accumulated) time equals the PRESET time.
The Accumulated value is reset when rung conditions go true regardless of whether
the timer has timed out.

• RTO [Retentive Timer On-Delay]

An RTO function the same as a TON with the exception that once it has begun
timing, it holds its count of time even if the rung goes false, a fault occurs, the mode
changes from REM Run or REM Test to REM Program, or power is lost. When rung
continuity returns (rung goes true again), the RTO begins timing from the
accumulated time which was held when rung continuity was lost. By retaining its
accumulated value, retentive timers measure the cumulative period during which
rung conditions are true.

• EQU [Equal]
This input instruction is true when Source A = Source B.
The EQU instruction compares two user specified values. If the values are equal, it
allows rung continuity. The rung goes true and the output is energized (provided no
other forces affect the rung's status).
Entering Parameters
Source A must be a word address.
Source B can be a word address or program constant.

• NEQ [Not Equal]

Use the NEQ instruction to test whether two values are not equal. If Source A and
Source B are not equal, the instruction is logically true. If the two values are equal,
the instruction is logically false.

• LES [Less Than]

This conditional input instruction tests whether one value (Source A) is less than
another (Source B). If the value at Source A is less than the value at Source B, the
instruction is logically true. If the value at Source A is greater than or equal to the
value at Source B, the instruction is logically false.
Entering Parameters
Enter a word address for Source A. Enter a constant or a word address for Source B.
Signed integers are stored in two’s complement form.

• LEQ [Less Than or Equal]

This conditional input instruction tests whether one value (source A) is less than or
equal to another (source B). If the value at source A is less than or equal to the value
at source B, the instruction is logically true. If the value at source A is greater than
the value at source B, the instruction is logically false.

Entering Parameters
Enter a word address for source A. Enter a constant or a word address for source B.
Signed integers are stored in two’s complement form.

• GRT [Greater Than]

This input instruction compares two user specified values. If the value stored in
Source A is greater than the value stored in Source B, it allows rung continuity. The
rung will go "true" and the output will be energized (provided no other instructions
affect the rung's status). If the value at Source A is less than or equal to the value at
Source B, the instruction is logically false.
Entering Parameters
You must enter a word address for Source A. You can enter a program constant or a
word address for Source B. Signed integers are stored in two’s complementary
form.

• GEQ [Greater Than or Equal To]

This input instruction compares two user specified values. If the value stored in
Source A is greater than or equal to the value stored in Source B, it allows rung
continuity. The rung will go true and the output will be energized (provided no other
instructions affect the rung's status). If the value at Source A is less than the value at
Source B, the instruction is logically false.

• OR [Inclusive OR Operation]
When rung conditions are true, Sources A and B of the OR instruction are OR bit by
bit and stored in the destination. Sources A and B can be either word addresses or
constants; however, both sources cannot be a constant. You can enter a constant or
a word address for either Source parameter. The destination must be a word
address.

• NOT [Logical Not Operation]

When rung conditions are true, the source of the NOT instruction is NOT bit by bit
and stored in the destination.
The source and destination must be word addresses.
If you are using a 5/02, 5/03, 5/04, 5/05 or MicroLogix processor, you can use
indexed addresses for the source or destination parameters. If you are using a 5/03
OS302, a 5/04 OS401, or a 5/05 processor, you can use indirect addresses for the
source or destination parameters.
NOT Truth Table
Source Destinatio
n
0 1
1 0
• XOR [Exclusive OR Operation]
When rung conditions are true, Sources A and B of the XOR instruction are
Exclusive Oared bit by bit and stored in the destination. Sources A and B can be
either word addresses or constants; however, both sources cannot be a constant.
Floating point values must be within the range of [-102943.7, +102943.7].

• AND [Logical AND Operation]

When rung conditions are true, sources A and B of this output instruction are AND bit
by bit and stored in the destination. Sources A and B can be either word addresses
or constants; however, both sources cannot be a constant. The processor you are
using you may use indexed or indirect addressing in this instruction.

4. VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVE 4.1 Introduction One

of the major factors needed for the automation in industries is the speed control of
the motor without compensating on the efficiency and economy of the operation.
The earliest and simplest method of the motor control was manual control, which
was accomplished by plain knife switches, rotary switches, starting and speed
control rheostats pushbuttons and controller. Since then many changes has come
across in the method of control of motors and with the advancement made in the
field of power electronics the easy control of A.C. motors has become possible, to a
great extent and usage of A.C. motors in industries has increased owing to it’s
light-weight, inexpensive, low maintenance, compared to D.C. motors. Most common
device used for this purpose is the power converters, inverters, and A.C. voltage
controllers.
The latest trend in the industries to control the A.C. motors is to use a variable
voltage variable frequency drive or variable speed controllers. They can control the
frequency, voltage, and/or current to meet the drive requirement. Thus they can
control the speed, direction of rotation of motor, its acceleration and deceleration
time and as well as imply various modes of braking according to the requirement
The Allen-Bradley company (U.S.A.) Company has introduced 160SSC (smart
speed controller) series B, for this purpose and besides this other models are too
available, according to the requirement and voltage/current ratings.4.2 Advantages
of using VVVF drive or SSC 1. Reduceenergyusages and operating cost
Reducing the speed of a centrifugal pump/fan load drastically reduces power
consumption. Both SSC controller models offer the speed control to accomplish this.
In addition the large reduction in starting current can save utility demand charges.
2. Reduces system Noise
Adjustment of PWM switching frequency (up to 8 kHz) provides quite motor
operation and controllers to solutions for electromagnetic noise problem.
3. Prolong equipment: Adjustable acceleration and deceleration time provides
inherent soft starting and stopping. This is further enhanced by the controller’s
programmable “s” curve adjustment. This means a huge reduction in starting
currents and elimination of excessive starting torques.
4. Eliminate electromechanical controls-Reduce system cost
SSC controller allows the user to control the process without the need for:

• Reversing starters
• Reduced voltage starters
• Multi speed starters
• Multi speed motor
5. Integral dynamic braking transistor
The SSC controller has an additional transistor built in for applications that require
extra braking torque. The dynamic brake resister module connects directly to the
controller’s terminals to provide up to 300% braking torque.
 Braking torque depends up on controller rating and motor.
6. Compact design
Attaches directly to front of controller – replacing keypad or Ready/fault panel and
saves valuable panel space.
7. Quick installations
Reduces installation time by allowing the user to configure node address via the
network.
8. Electronic motor over load protection
SSC does not require an over load relay for the operation of one motor. Thus saves
the extra cost and panel space of installing a separate over load relay.
9. Multiple specific speeds
Can be made available for manufacturing and material handling e.g. conveyors,
packaging, winders, mixers, trolleys and for commercial applications examples
laundry machines, automatic doors, automatic car washes, dock levellers. (In case of
preset speed module)
10. Follows analog signal
It can be used in many applications that take advantage of the adjustability and
simple control that comes from an analog signal. Example:

1. Fans and pumps- Refrigeration, paint booths, exhaust, HVAC,

metering.
2. Machine tools- Lathes, milling machines, drill presses, saws,
woodworking, grinders.
4.3 Details of VVVF Drive The A.B. 160 SSC series B comes in two different
models i.e. analog signal follower and preset speed module. The major difference
lying between them is that by using preset speed controller module, we can fix 8
different speeds for the motor by changing the preset frequency by programming it.
It has an option of program keypad module, through which we can change the
parameter required for the control of motor.
The SSC (smart speed controller) is a compact motor speed controller for use on
three-phase induction and synchronous A.C. motors. It is microprocessor controlled
and fully programmable for a variety of applications.
1 3 Output Input Dynamic Power Coolin
phas phas ratings ratings braking torque Dissipati g
e e (%) on Watt meth
inpu inpu od
t t
50/6 50/6
0 Hz 0 Hz
KW HP O/P Amps Operating KVA Without With
Voltage external exter
range resistor nal
resist
or
160s 160- .37 1/2 2.3 180-265 1.1 10 30 2 Convecti
- AA0 0 0 0 on
AA0 2
2
Control Inputs (analog signal follower model only)
Analog input (4 to 20 mA) Input impedance 250 ohm
Analog input (-10 to +10V DC) Input impedance 100k ohm
External speed potentiometer 1k ohm to 10 k ohm, watt minimum
Program keypad module
Features:
The program keypad module is located on the front panel of the controller. It features
the following:
# Five key on the module for display or programming controller parameter
# Three keys for control inputs to the controller
# Directional LEDs
# six digit, seven segment LED display
Four digits, seven segments LED display this four digit display the parameter value
or fault code number
Two digit, seven segment LED display– These two digit display the active
parameter number for both display and program parameter, which are designated as
P## throughout this manual.
Escape key- It allows you to toggle between the display mode and program mode.
When in program mode, this key also disables the editing of parameter value.
Select key – It is not only used while in program mode. It enables the editing of a
parameter values. When you press this key the program mode indicator flashes.
Up/down arrow keys - Are used to scroll through a list of parameters, or increase and
decrease the parameter values. Press and hold either key to increase scrolling
speed.
Enter key – When pressed, while in programming mode causes the current value
displayed to be entered into memory. When you press this key the program mode
indicator remains on, but stops fleshing.
Starts Key - Initiates a start command when the controller is programmed for local
start/stop control. (When P46- (input mode) is set to “2”).
Stop key- Initiates the motor to “coast”, “ramp” or “D.C. brake”
to stop the motor depending on the setting of P 34 – [stop mode].
Reverse key – Pressing it causes the motor to ramp down to zero hertz and then
ramp up to its set speed in the opposite direction.
Directional LEDs to indicate the direction of rotation – counter clockwise and
clockwise LEDs.
The counter clockwise Led eliminates constantly when the motor rotates in reverse
direction.
The clockwise LED eliminates constantly when the motor rotates in forward
direction.
Four-digit parameter display – these four digits display the parameter value or fault
code number.
Display mode
The controller always powers up in the display mode. While in this mode you may
view all read only controller parameters, but not modify them.
4.4 PROGRAM MODE
You enter the program mode by pressing the escape key (ESC). While in program
mode, you can edit any programmable controller’s parameters.
Display and Program Parameters Descriptions
Display Parameters
Parameter Paramet Descriptio Units
er name n
1 Output 0.0 to 0.1 Hz
frequenc 240 Hz
y
2 Output 0 to max. 1 volt
voltage Voltage
3 Output 0 to 2 .01
current times amps
controller
rated
output
current
4 Output 0 to 2 .01
power times KW
controller
rated
output
power
5 Bus 0 to 410v 1 volt
voltage for 230v
controller
s
6 Frequenc 0.0 to 0.1 Hz
y 240 Hz
comman
d
7 Last fault Retains Numer
fault for ic
trouble value
shooting
8 Heat sink 0 to 150 1degr
temperat degree ee
ure cent cent.
9 Controlle Running, Binary
r status forward, numbe
accelerati r
ng,
decelerati
ng
10 Controlle Used by Numer
r type Allen- ic
Bradley value
field
service
personal
11 Control Display Numer
version firm wire ic
version value
12 Input Displays Binary
status the status numbe
of start, r
stop, and
reverse
discrete
inputs
13 Power 0.00 to .01
factor 90 degre
angle degrees es
14 Memory Used by Numer
probe Allen- ic
display Bradley value
field
service
personnel
15 Preset Displays Binary
status the status numbe
of speed r
discrete
inputs
Program parameters
Parameter Paramet Descripti Factor
er on y
Name Defaul
t
30 Accel 0.1 to 10
time 1 600 sec.
31 Decel 0.1 to 10
time 1 600 sec.
32 Min. 0 to240 0
Frequen Hz
cy
33 Max. 0 to240 60
Frequen Hz
cy
34 Stop Three Ramp
mode settings
selectio 1) Ramp
n 2) Coast
3) D.C.
injection
braking
35 Base 10 to 60
frequen 240 Hz
cy
36 Base 20 to 230
Voltage 230 V for
230V
controlle
rs
42 Motor 20 to 115%
over 200% of
load controlle
current r rated
current
46 Input Four 3 wire
mode settings-
keypad,
2wire,
3wire,
moment
ary run
fwd/run
reverse
47 Output Nine 0
configur different
e settings
for a
variety
of
controlle
r
condition
s
54 Clear Resets 0
fault fault
56 Reset Resets 0
default controlle
r to
factory
default
settings
57 Progra Protects 0
m lock users
settings
59 Frequen Selects Extern
cy source of al
select frequenc
y
 (internal
or
external)
5. PROCESS AUTOMATION
5.1 INTRODUCTION
Digital computers were first applied to the industrial process control in late
1950’s to automate the processes like to control temperature, pressure, flow etc.
The use of computer increased and dedicated microcontrollers were then used. One
of the most ingenious devices ever devised to advance the field of industrial
automation is the Programmable Logic Controller. Broadly, the PLC performs tasks
like - acquisition of process data, processing of collected data, plant hardware
monitoring, system check and diagnosis, and generates control actions.
Industrial automation is being done in nearly every type of industry. Underlying most
of this automation of big process is much more mundane tasks: turning equipment
(pumps, conveyor belts etc.) on or off; opening and closing of valves; checking
sensors to be certain they are working; sensing alarms when monitored signals go
out of range etc. These logical functions can be implemented by PLCs
In this project we are demonstrating some of the industrial process control with the
help of programmable logic controller. Such processes which we are controlling have
applications in domains of electroplating, painting electro reforming, drying, heating,
drying and any such type of industrial processes The processes which are
demonstrating in this project are:

1. Lowering and raising a job

2. Moving job laterally.
3. Synchronizing the opening and closing of tank with lowering and rising of job.
4. Controlling start/stop and speed of conveyer motor using VVVF drive.
5. Counting of job using proximity switch.
6. Synchronizing finished job placement on conveyer belt.
7. Measurement of temperature using thermocouple.
8. Displaying of temperature on digital indicator.
5.2 DESCRIPTION OF MODEL
To demonstrate the above objectives we have constructed a model, the details of
which are given systematically below. In this model we are using following items:
S.NO ITEM SPECIFICATION QUANTITY
1 Container Tin(19”height,28cm diameter) 1
2 DC gear motor 24 volts separately excited with permanent 2
magnet
3 Pulley and Gear 2,1
4 Relay( 8 24 volts 2
terminals)
Diagram of the model
5.2.1 CONTAINER
We have used a tin circular container of 30 centimeter diameter and forty five
centimeter height for containing the useful liquid or device for the desired purpose
.The lead of container is open one forth only. A sliding lead is riveted to main lead
which meshes with gear of motor.
5.2.2 DC GEAR MOTOR
We used a 24 volt DC motor for the desired operation.D.C motor can rotate in both
the direction by changing the polarity. We used gear motor because of smooth
operation and high torque. One motor is synchronized with the cap of container as
well as job piece and second motor rotates with the arm of the model.
5.2.3 PULLEY AND GEAR
Gear is used to mesh with the cap of container. It opens and closes the container
cap. Pulley is used to wrap the rope of the job piece. Both are mounted on same
shaft. The diameter of pulley is 3.5 cm which transmit power to another pulley of
diameter of 1cm and increase the number of revolution per minute. Another pulley of
3.5 cm diameter is mounted on same shaft on which rope is mounted. The pitch
circle diameter of gear is 4.5 cm which open and close the lid.
5.2.4 RELAY
We used 24 volts relay for reversing the direction of motor, having six terminals for
reversing the direction of motor and two terminals for energizing the coil. The centre
terminals is used to input supply and outer four terminal is cross connected and
output is taken from their. when coil is energies then polarity is reverse and coil is
deaneries then its output of same polarity.
5.2.5 WOODEN STRUCTURE
We used shisham wood for the structure which gives the desired construction of the
model. A flat base is used to put the container and proper standing of model
5.2.6 ROPE
We use nylon thread for the carrying of job. It is rolling on the 3.5 diameter pulley.
OUTPUTS GIVEN OUT FROM PLC
OUTPUT ADDRESS
Motor 1 O:2/6
Motor 2 O:2/5
Relay 1 O:2/7
Relay 2 O:2/4
Digital controller O:4/0
Temperature hi alarm O:0/11
VVVF drive O:2/1
INPUTS GIVEN TO PLC
INPUT ADDRESS
To control the starting of operation I:0/0
Accept I:1/1
Test I:1/3
Proximity sensor I/P I:1/7
Emergency switch I:1/0
5.3 MOTION CONTROL USING PLC
Object To lower and raise a job in a container by means pulley and motor and place
the job on the conveyor belt using an arm control.
Basic Idea
The basic idea behind this program is to control the direction of rotation of the motor.
The placement of the motor should also be such that the transmission of mechanical
power to the pulley can be done using belt drive. The job then can be raised or lower
logically through the PLC.
Implementation
In this project we are controlling a typical industrial processes by the PLC in this
project we are controlling our model with the help of DC gear motors. The step of
operation as follow:
STEP 1
We put job on the arm and arm motor start rotation for 2.48sec. & rest above the
container for starting the operation to be perform on the job.
STEP 2
Motor1 rotate in anti-clock wise direction with the help of relay 1 for 10.4sec. The
container will open & job moves into the container.
STEP 3
The motor -1 rotates clock wise without relay for 10.42sec. The container will close
and the job will comes out.
STEP 4
Arm motor rotates in anti clockwise direction with out relay for 2.9sec & the arm goes
over the conveyer belt and drop the job on it.
STEP 5
Arm motor rotate clock wise for 5.3sec and bring arm to its initial position.
After that the next cycle starts after 4.5sec.
OPERATION:-
In this process we have used the timer instruction for performing the operation for
the specified duration. In all we have used 9 timers T4:1-T4:9.The output of timer
T4:2 goes to T4:1 whose output comes back to T4:2 for initializing the whole process
after 43sec.
T4:3 timers are used for the pause of 2.48 sec. After that T4:4 timers are used for
rotating the motor 1 for 10.42sec with relay. T4:5 are used for pause of 5sec for
completing the process to be done on the job.T4:6 are used for closing the lid of
container. It takes 10.42sec.T4:7 are used for rotation of the arm motor for
2.9sec.T4:8 are used for the pause of 2.3sec.T4:9 are used to bring the arm in its
initial position for 5.35sec.This cycle is repeated sequentially and continuously for
desired number of times.
5.4 TEMPERATURE MEASUREMENT
Object To sense the temperature of any particular device and simulation for the
condition of fault occurrence in the device.
Basic Idea
The basic idea behind this program is to basically indicate the temperature of any
device through the digital indicator and to sense the temperature value for the faulty
condition and to stop the process automatically so that the fault can be removed and
then again restart the process.
Implementation
To implement the above program we have a temperature sensor which senses the
temperature of particular device and sends it to the CPU through the RTD converter
and the CPU calibrate it and gives the output to the digital indicator so that the
temperature of that device can be measured. In case of any faulty condition the CPU
which is continuously sensing the temperature and giving the output senses the high
temperature and stops the process and activates an indicator which is a flasher so
that it can be known that which fault has occurred in the process. And the process
remains stop until the fault is accepted and removed.
Operation
In the given program at rung 0 the input scaling of the temperature is done so that
the reading of the temperature from the RTD converter goes to the CPU and at the
very next rung the reading is calibrated according to the scale so gives the output at
the digital indicator.
If the temperature increases more than the prescaled value the function GRT will
give the high output to the flasher (O: 0/11). This flasher is used in the series of
every output for suddenly stop the operation.
The above conditions remain as it is until the temperature remains below the
presettable limit. It has preset value one so it’s done bit goes high in first
increment and which stops the blinking of LED and glow it constantly. and the
process is going on
Now to again restart the whole process the fault has to be removed and the
temperature should become to its desired value.
We have used a thermocouple for measuring of temperature that will convert in the
digital signal and indicated on the temperature indicator.
5.5 SPEED CONTROL OF MOTOR USING VVVF DRIVE
Object To control the speed of a motor by the help of variable voltage and variable
frequency drive controlled by the PLC.
Basic Idea
The basic phenomenon to control the speed of any motor is to control its input
voltage or to control its frequency and this job is performed by the VVVF drive.
Implementation
To implement this program as ladder logic firstly its scaling has to be done so that it
may run with the desired speed given in the computer. To scale any output or input
the SCP (Scale w/parameters) instruction is used.
Operation
When the control switch TG#1 which is addressed at I:0/0 is switched on which gives
the output to the VVVF drive and the motor connected to the this drive starts running.
There is also an emergency stop button which can be pressed in case of any
emergency occurred while the process is running.
In the SCP (Scale w/parameter) instruction the scaling is done to control the speed
of motor the input given to it is the percentage value of the scaled values. And what
ever may be the input is given in the SCP instruction the speed of the motor
becomes high and low according to it.
5.6 CONVEYOR SYSTEM
Object To implement the conveyor system on a VVVF controlled motor and to count
the number of the pieces passing through the conveyor.

Basic Idea
The basic idea behind this program is to count any number of pieces passing
through the conveyor belts which are sensed by the proximity switch.
Implementation
To implement this program the proximity switch is placed to the suitable distance
from the conveyor belt. When any piece passes through the proximity sensor it gives
a high pulse which is fed to the PLC and the counter placed in the program counts
the number of pieces moving on it up to the preset value given to the counter.
Operation
When the motor is started by the switch TG#1 the conveyor starts to move in forward
direction along with the pieces kept on it. The proximity switch inputs to the PLC
when it senses any ferrous material passing through it at the address I:1/7 which
increments the counter C5:0 by one and also glows a RED LED addressed at O:0/0
as per the count.
After one count of the counter C5:0 the another counter C5:1 is incremented by one
and since its preset value is one so its done bit goes high in one increment and thus
it stop the motor and also activates a timer T4:0 associated with it which counts for
the given time period and then resets the counter C5:1 and thus motor is again
started. Thus the delay of desired time period can be obtained with the help of this
timer after each count so that any operation can be performed to the job counted by
the proximity switch and after that operation the motor automatically restarts.
When the counter C5:0 counts 10 pieces the RED LED glows which is addressed at
O:0/3. And after it counts 20 pieces another LED glows next the above LED and the
very next to this glows after 30 count and similarly the LED addressed at O:0/8 glows
after 40 pieces.
After the done bit of counter C5:0 goes high a RED LED addressed at O:0/10 glows
and the counter stops counting the pieces.

7. BIBLIOGRAPHY

1. User Manual, Allen – BradleyTM Micro Logix 1500 Programmable

Controller
2. User Manual, Allen – BradleyTM 160 SSC Variable Speed Controller
3. Allen – BradleyTM’s URL http://www.ab.com/plclogic/
4. Rockwell Automation’s URL www.rockwellautomation.com
5. MicroMentor, Allen – BradleyTM, Rockwell International Company

8. APPENDIX A
INSTRUCTION DESCRIPTION

1. XIC Examines a bit for an ON condition

2. XIO Examines a bit for an OFF condition
3. OTE Turn ON or OFF a bit(non-retentive)
4. OTL Latch a bit ON (retentive)
5. OTU Unlatch a bit OFF (retentive)
6. OSR Detects an OFF to ON transition [It sets a bit for false to true (one scan)]
7. OSF It sets a bit for true to false (one scan)
8. TON Delay turning ON an output on a true rung
9. TOF Delay turning OFF an output on a false rung
10. RTO Delay turning on an output from a true rung. The accumulator is
retentive.
11. CTU Count Up
12. CTD Count Down
13. RES Reset the RTO and counter’s ACC and status bits (not used with
TOF timers)
14. EQU Test whether two values are equal (=)
 15. NEQ Test whether one value is not equal to a second value.
16. GRT Test whether one value is greater than a second value.
17. GEQ Test whether one value is greater than or equal to a second value.
18. LEQ Test whether one value is less than or equal to second value.
19. MEQ Test portions of two values to see whether they are equal.
20. LIM Test whether one value is within the range of two other values.
21. ADD Add two values.
22. SUB Subtract two values.
23. MUL Multiply two values.
24. DIV Divide one value by another.
25. NEG Change the sign of the source value and place it in the destination.
26. CLR Set all bits of a word to zero.
27. SCL Scale a value.
28. SCP Scale value to a range determined by creating a linear relationship.
29. SQR Find the square root of a value.
30. DCD Decodes a 14-bit value (0 to15), turning ON the corresponding bit in the
16-bit
destination

1. ENC Encodes a 16-bit source to a 4-bit value. Searches the source from the
lowest to
the highest bit, and looks for the first set bit. The corresponding bit position is
written to the destination as an integer.

1. FRD Converts the BCD source value to an integer and stores, in the
destination.
2. TOD Converts the integer source value to BCD format and stores it in the
destination.
3. AND Performs an AND operation
4. OR Performs an inclusive OR operation
5. XOR Performs an exclusive OR operation
6. NOT Performs a NOT operation
7. MOV Move the source value to the destination.
8. MVM Move data from a source location to a selected portion of the
destination.
9. COP Copy a range of data from one file location to another.
10. FLL Load a file with a program constant of a value from an element address.
11. BSL Load and unload data into a bit array one at a time.
12. BSR. Load and unload data into a bit array one at a time.
13. FFL Load words into a file and unload them in the same order (first in, first
out).
14. FFU Load words into a file and unload them in the same order (first in, first
out).
15. LFL Load words into a file and unload them in reverse order (last In, last Out)
16. LFU Load words into a file and unload them in reverse order (last In, last Out)
17. SQC Compare 16-bit data with stored data.
18. SQO Transfer 16-bit data to word addresses
19. SQL Load 16-bit data into a file.
20. JMP Jump forward/backward to a corresponding label instruction.
21. LBL Jump forward/backward to a corresponding label instruction.
22. JSR Jump to a designated subroutine and return.
23. SBR Jump to a designated subroutine and return.
24. RET Jump to a designated subroutine and return.
25. SUS Debug or diagnose your user program.
26. TND Abort current ladder scan
27. END End a program or subroutine
28. MCR. Enable or inhibit a master control zone in your ladder program.
29. IIM Update data prior to the normal input scan
30. IOM Update outputs prior to the normal output scan.
31. REF Interrupt the program scans to execute the input/output scan