HACKS TO CRUSH PLC PROGRAM FAST & EFFICIENTLY EVERYTIME... : CODING, SIMULATING & TESTING PROGRAMMABLE LOGIC CONTROLLER WITH EXAMPLES

HACKS TO CRUSH PLC PROGRAM FAST & EFFICIENTLY EVERYTIME
https://freeplcbook.plcguide.com/
Coding, Simulating & Testing Programmable Logic Controller
With Examples
About The Authors
is a PLC Control programmer. With over 20 years of experience in the
industrial automation field. With deep appreciation for his friend who introduced him
to this in 1997 after finishing his diploma program in Electrical & Electronics.
Farouk Idris
Over the years, he has engaged with many system integrators and companies in
Singapore. Utilizing self-taught skills, networking, and leverage mentality, he works
with the industry's best tools, people, and companies.
By joint venture between him , who possesses a similar capacity,
they are taking up a key role in teaching PLC programming to as many people as
possible, cutting short the learning curves and fears.
and Michael Blake
All rights reserved and Disclaimer.
No part of this publication shall be reproduced or stored in any retrieval system
mechanical or electronic, or transmitted in any form or by any means; electronic,
mechanical, recording, or otherwise, without the author's prior written permission.
Hacks to Crush Plc Program Fast & Efficiently Everytime…

Although the author has made every effort to ensure that the information in this
book is correct at present, the authors and publisher do not assume and hereby
disclaim any type of liability to any party for any loss, damage, or disruption caused
by any errors or omissions, whether such errors or omissions resulting from
negligence, accident, or any other possible cause. This book cannot assume any
responsibility whatsoever. All contents are original contents by Michael Blake and
Farouk Idris. CoDeSys is the Copyright of 3S - Smart Software Solution GmbH. This
book is not authorized or endorsed by 3S - Smart Software Solution GmbH.
This book serves as a best practices guide. The results are unique. Our track record
has shown those who contribute effort follow the best practices guide shown here
and continue to work on it, achieving sustainable and long-term results.
It is essential that you have the PLC programming App in your PC. Click the link below
to download it.
https://plcguide.com/funnel/view/AppDownload
Table of Content
About The Authors
All rights reserved and Disclaimer.
Preparation before Inputting Contacts in LD (Ladder Diagram)
Insert New Rung before in LD.
Insert New Rung after in LD.

Variables Declaration in LD
Input a Normally Open Contact in LD
Input a Normally Closed Contact (negated) in LD
Input a Parallel Contact' in LD
Input a Parallel Contact (negated) in LD
Moving all the contact elements in the LD-Editor
Input an Output Coil in LD
Input a Set coil in LD.
Input a Reset coil in LD.
Input a Function Block instruction in LD.
Input a Rising edge detect Instruction in LD.
Input a Falling edge detect instruction LD.
Changing the SET/RESET output with S/R in LD
Input Box with EN instruction in LD
Input MOVE instruction in LD

Input a POU Block in LD
Input AND contact in LD
Input OR contact in LD
Ladder Diagram in the Online Mode
Input GT instruction in LD
Input EQ instruction in LD
Input SR instruction (Flip Flop) in LD
Input RS instruction (Flip Flop) in LD
Input CTU instruction in LD
Input TOF instruction in LD
Input CTUD instruction in LD
Controlling a Traffic Light Signal Example
Create a POU (Program Organization Unit)
TRAFFIC_LIGHT.pro Simulation
TRAFFIC_LIGHT.pro variable declaration

The result
PLC_PRG
Visualization for a Traffic Signal
Summary

This command on the toolbar inserts a rung or network in the Ladder editor. If there
are rung already then, the new one will be inserted before the currently selected.
Insert New Rung after in LD.
Network (after):
Network (before):
Insert New Rung before in LD.
Preparation before Inputting
Contacts in LD (Ladder Diagram)

Click this button in the LD editor to insert a contact.
The contact now shows "???". You can click on this text and change it to the desired
variable shown at “Declared Variable Image.”
Normally open contact:
Input a Normally Open Contact in LD
Variables Declaration in LD
Declare variables.
This command on the toolbar inserts a rung or network in the Ladder editor. If there
are rung already then, the new one will be inserted after the currently selected.

Parallel (OR) Normally open contact:
Use this command in the LD Editor to insert a contact parallel to the marked position
in the network.
Input a Parallel Contact' in LD
This command inserts a negated contact. The same is true for the commands' Insert'
'Contact' and 'Extras' 'Negate,' which in combination also could be used to insert a
negated contact.
Input a Normally Closed Contact (negated)
in LD
Normally Closed Contact:

This command inserts a negated parallel contact. The same is true for the
commands' Insert 'Parallel Contact' and 'Extras' 'Negate,' which in combination also
could be used to insert a negated parallel contact.
Moving all the contact elements in the LD-
Editor
Input a Parallel Contact (negated) in LD
Parallel (OR) Normally close contact:
The contact is preset with the text "???". This means you can change the text and
desired variable name.

Move the element to one of these positions and let off the mouse key: the element
will be inserted at the new position. If you, however, move the element to the name
(variable name) of another element, the name field will be shaded green. If you then
let off the mouse key, the previous name will be replaced by the "dragged" one. If
additional addresses and comments are displayed (options), the copying also will
apply to those. Here we’ll demonstrate that. First, click on the contact that you wish
to move.
All elements in the editor can be moved around to a different position within an LD
POU by "drag&drop."
To do this, just select the any elements that is, contacts, coils, function blocks and
drag it – remember to keep pressing the mouse select key button – and move it away
from the current position. Thereupon all possible positions within all networks in the
editor, to which the element can be moved, will be indicated by a mirage of grey-
filled rectangles.

Input a Set coil in LD.
Input an Output Coil in LD
Output Coil:
Use this command in the LD Editor to insert a coil in a run. If clicked again, a new coil
will be inserted in parallel to the previous coils.
All the small boxes indicated by the BLUE arrow will be highlighted when dragging the
contact. Thus, you can drop it anywhere indicated by the small box.

This command will insert a Set coil. Another way is to go through the Insert 'Coil' and
in Extras 'Set/Reset,' which could also get a Set coil.
Input a Function Block instruction in LD.
Input a Reset coil in LD.
Change output coil to Reset:
This command will insert a Reset coil. Another way is to go through the Insert 'Coil'
and in Extras 'Set/Reset' could be used to get a Reset coil.
Change output coil to Set:

For this example, choose TON.
In this example, we will add a Timer Function Block (TON):
After clicking on it:
Adding a Function Block.

Write the name Timer1 then click OK.
Finally, put in the timer input count to T#5s which means 5 seconds.

This command inserts a R_TRIG function block, which will detect a rising edge (FALSE
-> TRUE) by the incoming signal. You can do the same through the command 'Insert'
'Function Block,' which can be used to insert any available function block.
Input a Rising edge detect Instruction in
LD.
Rising Up detect Instruction:

Input a Falling edge detect instruction LD.
Falling Down detect Instruction:
Input the variable name, then click OK.

This command inserts a F_TRIG function block, which detects a rising edge (TRUE ->
FALSE) at the incoming signal. You can do the same by the command 'Insert'
'Function Block,' which can be used to insert any available function block.
Input the variable name, then click OK.

Changing the SET/RESET output with S/R in
LD
Click this command repeatedly. The coil will alternate between set, reset, and normal
coil.
Input Box with EN instruction in LD
Use this command to insert a function block, an operator, a function, or a program
with EN input into an LD network.
The EN Box is inserted parallel to the coils that are underneath them. Initially, it
contains the instruction "AND." Then, after that, just rename it to instructions to
your liking.

Input MOVE instruction in LD
Declare the variables beforehand. We have assigned Source with 15. So, when we run
the code 15 will be loaded to the Source variable.
Insert a box with EN.

Rename the default AND instruction to MOVE instruction.
Another way is to right-click and click the “Box with EN.”

Rename the default AND instruction to MOVE instruction or any other instruction
based on your code design
Input a POU Block in LD

Here we will input the Demo_Ladder_Diagram program to the PLC_PRG program,
which is the main program in this project. But you may ask, why is that? If you don’t
do that, then the Demo_Ladder_Diagram program will not run. Meaning all the codes
in Demo_Ladder_Diagram will be idle or no operation.
This is another way to input the Demo_Ladder_Diagram program here.
Just delete the word AND in the box, then enter in the period (.) then, you can scroll
to find the program you want to input here. But you need to make sure you rebuild
the programs by going to Project -> Rebuild all.

We don’t need the output for this box, so delete the output line.
The final looks like this.
Rebuild all the programs.

Input AND contact in LD
Click this button to add in a normally open contact in series.
Clicking again will place another normally open contact in front of it (in series). This is
an AND logic. Meaning input1 AND input2 must be ON for the output coil to be ON.

Input OR contact in LD
This button will add in contact in parallel. Let the cursor or selector be at input1
normally open contact, then just click on the Parallel Contact button.
Once a new parallel contact (OR) appears, then rename the variable. This is OR logic.
Output7 will be On if either input1 OR input3 is ON.
Ladder Diagram in the Online Mode
It is necessary now that we show how to go in the online mode. The upcoming
example will showcase why this is the better option.
All the contacts and coils in the Ladder Diagram (LD) in the "ON" state are colored
blue. And all the lines over which the "ON" state is carried are also colored blue. At
the inputs and outputs of function blocks, the values of the corresponding variables
are indicated in the LD diagram and at the variable fields.

To start to simulate, just go Online and log in.
It is essential that you have the PLC programming App in your PC. Click the link below
to download it.
https://plcguide.com/funnel/view/AppDownload
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Next is to click the Run or press F5.

Now double click the Demo_Ladder_Diagram program to allow it to appear on the
screen. Next, click the boolean you want to update the value as shown by the arrow
in the below picture.

When double-clicked, you can see what next is going to happen to the variable. This
means you can turn this variable ON (TRUE). Clicking on it again will change it to
FALSE.
If Write Values (Ctrl+F7) is selected, the value will be updated to the variable.

Input GT instruction in LD
This is a Greater than comparing instruction. Click the Box with EN.
A new AND box will be inserted. First, delete the AND and rename the GT. Then,
start to put in a number on the instruction input and a boolean variable at the
output.

The input we put in a 10 (Top input) & a 9 (Bottom input), then the output variable is
Level_Up.
It will return the value TRUE when the value of the first (top ones) operand is greater
(this case is 10) than that of the second (bottom ones, which is now 9). The Level_Up
boolean will be TRUE (Turned ON) when input1 contact is ON.

Input EQ instruction in LD
This is equal to comparing instruction. This instruction will return the value TRUE
when the operands are equal.
Input new box with EN with either right-click on a rung or clicking the icon on the
toolbar.

A new AND instruction BOX with EN is inserted
Edit and change the AND to EQ. instruction

Add in the variable Source and the value 15 on the EQ instruction inputs. The output
of EQ is the variable name Same_Level. A normally open contact has been added in
the next rung.
Now, let us simulate it. First, as in the previous example, update the value of the
variable input1 to 1 (ON).
The variable Destination will be updated with a value 15. The variable Same_Level is
turned ON now because it is equal to the value 15.

Input SR instruction (Flip Flop) in LD
This instruction is provided by standard.lib. Making a Bistable Function Block.
The SR truth table:

No S R Q Description
1 1 0 1 Q is set to ON
2 1 1 1 No change
3 0 1 0 Q is set to OFF
5 0 0 1 No change
Input SR instruction

Declare it as
Another way is to click.
Then choose the bistable function.

Then click OK.
Declare variable to

Notice here there are two types of SR instructions. Next, we will plug in all the
variables and simulate them.
All variables have been added.

Right after running the simulation, the SR_Demo2 output with Q1 is turned ON. This
is because the SET1 input is already ON
If SrInp3 is turned ON, the output Q1 is still not OFF, as shown by the truth table.
Therefore, we suggest you test the logic as shown by the truth table.

The SrInp1 is turned ON for SR_Demo, but the Q1 (SrOut1) is OFF. This is because the
EN input is not ON.
Now when input3 turns ON, the Q1 (SrOut1) is ON. So, all the behavior of this SR
instruction can be demonstrated as shown by the truth table.
Overall, the SET1 input will make Q1, ON regardless if RESET input is On or OFF
Input RS instruction (Flip Flop) in LD
Provided by the standard.lib. Resetting Bistable Function Blocks
The RS truth table:

No S R Q Description
2 1 1 0 Q is set to OFF
3 0 1 0 No change
5 0 0 1 No change
We have created the two types of RS instructions here
Let us start to simulate it. First, it would appear that the RS instruction is the
opposite of SR instruction. Why is that?

This is because whenever the RESET1 input is ON, the output will be OFF. Try it
yourself.
Input CTU instruction in LD
This is provided by standard.lib. Counter Up Function block Incrementor:
Type BOOL is input variables CU, RESET and the output variable Q. Whereas, type
WORD is input variable PV, and the output variable CV.
If RESET is TRUE the counter variable CV will be set to 0. If CU input detect a
transition from 0 to 1 Or from FALSE to TRUE, CV value will be incremented by 1. Q
will return TRUE when CV is greater than or equal to the upper limit PV.
Below in the example, we have added a 1-second clock represented by Clock1 and
Clock2 TON timers. Each TON timer's PT parameters are set to 0.5 seconds.

The R_TRIG detects the rising edge of Clock2.Q output and feeds the input CTU
counter instruction.
The counter PV is set to 10, and RESET input is set to input3.
Below shows the CV value at 8 now.
Now you can see the CV is over the value of 10, and the output of the counter is ON.

The input3 is ON now, which reset CV to zero. The Counter1 output is also OFF now.
Input TOF instruction in LD
This is provided by standard.lib. TOF function block implements a turn-off delay.
When input1 is ON, the TOF_Demo output is ON as well.

When the variable input1 is OFF, the TOF starts to count.
Now the TOF timer output is OFF now.

Input CTUD instruction in LD
Provided by the standard.lib. Function Block of a Counter Up and Down
(Incrementor/Decrementer)
For this example, the previous clock has been reduced to 0.2 seconds (Combining
Clock1 & Clock2)

Create a new set of timers for this. You can see here Clk_Short is at 3 seconds, and
Clk_Long is at 5 seconds. Use the Clk_Short output AND with Clock_Pulse.Q to drive
Up_Count output.
One this Normally-Close Clk_Long with Clock_Pulse.Q to drive Down_Count output.

Below is the Trend plotting on CTUD_Demo.CV. You can see the value of
CTUD_Demo.CV going up and down but eventually trending up.
Controlling a Traffic Light Signal
Example
Now we will write our own version of traffic light signal unit controlling the two
traffic light signals at a traffic intersection.
The red/green phases of both traffic signals must be alternate to avoid accidents.

In this example, we will see how time-dependent programs can be shown with the
language resources of the IEC1131-3 standard. But for now, we only focus on Ladder
Logic (LD) with the help of CoDeSys, and how one can easily connect them while
becoming familiar with the simulation of CoDeSys.
Create a POU (Program Organization Unit)
Starting is always easy by just Start CoDeSys and choose 'File' 'New.'
In the dialog box which appears, the first POU has already been given the default
name PLC_PRG. Keep this name, and the type of POU should be a program. Each
project needs a program with this name. In this case, we choose as the language of
this POU the Ladder Logic (LD)

TRAFFIC_LIGHT.pro Simulation
Now we will check and test the program in simulation mode. Compile ('Project'
'Build') and load ('Online' 'Login'). Then click ('Online' 'Run'). This will set the virtual
PLC to run and execute the code we wrote in PLC_PRG.
TRAFFIC_LIGHT.pro variable declaration

There are two declarations made in the program. One in the PLC_PRG POU, and the
other is in the Global_Variables.
In the declaration editor, we will declare inputs, outputs, and local variables (between
the keywords VAR and END_VAR in the POU) and (between the keywords
VAR_GLOBAL and END_VAR in the Global_Variables) in the resource tab.
In the Global_Variables we have put all the lights output variables in it. Whereas in
PLC_PRG POU will have all the local variables used for the logic. The declaration will
look like these:

The result
In our hypothetical situation, the traffic signal cycle starts upon running the virtual
PLC in simulation mode.
Light 1 will start from the green light, whereas Light 2 will start from the red light.
After the cycles are completed, the traffic light unit turns itself on, and the entire
process starts again from the beginning.
We do a test of the current version of your program in simulation mode before we go
on to create the POU PLC_PRG.

PLC_PRG
The Ladder Logic program for Controlling a Traffic Signal.

To start, we have added an NC boolean contact. This contact is not being triggered
anywhere in the program. When the simulation is run, a pulse trigger will be available
at POWER_UP_PLS, Q output which will latch variable INIT. This will start the Traffic
Signal lighting sequence. Remember, there are many ways you can program this
logic. But in this book, we have specifically used Ladder Diagram (LD) or Ladder
Logic. We have a great plan to teach you all the five programming languages
available in IEC 61131-3 standard. Michael and I have committed to teaching you
what we have learned for 20 years in customizing automation machines and
systems.
Just follow what we have written below. This is the beginning of the code where
initialization takes place.
L1, L2 & L3 are for Light 1, where L1 is for the Green, L2 is for the Yellow, and L3 is for
the Red.

L1DONE means the Light 1 sequence is done. The TON timer L3DELAY1.Q will initiate
the start for the Light 2 sequence.
L11, L21 & L31 are for Light 2, where L11 is for the Green, L21 is for the Yellow, and
L31 is for the Red.

MASTER_RESET TON timer is used to reset the if both light sequences are done.
Output LIGHT1RED (For Light 1) is the start of the output I/O’s.
Output LIGHT2RED (For Light 2) is the start of the output I/O’s.

Visualization for a Traffic Signal
With the visualization in CoDeSys, you can quickly and easily bring projects to life.
We will now draw two traffic signals which will illustrate the switching process. Here
we have made it quite simple for you.
You just have to put in the global variable with a logical NOT in front of it. This means
in the normal case, the lights will be invisible. However, when it is triggered or
latched, then it will be visible.
The below image shows how we do the variable setup in the visualization tab.

This is how it looks when the simulating starts. First, the green light of Light 1 will
light up.

After a few seconds, then the yellow of Light 1 will light up.

Then later, the red of Light 1 will light up.

At this time Light 1 sequence is done. Then after a few seconds, the green light of
Light 2 starts to light up.

Then later, the yellow of Light 2.

Then finally, the Light 2 sequence is done where the red light will be on.
After this, the MASTER_RESET TON timer will restart the whole process again.

Summary
This was not meant to be an exhaustive guide, but we hope it becomes a great
baseline. Additionally, you can use the quick references and other information to
build on as you become more adept in this programming language and functionality.
Other books Special Offers
https://plcguide.com/funnel/view/paperbackboxset

HACKS TOCRUSH PLC PROGRAM
FAST &EFFICIENTLY
EVERYTIME... :CODING,
SIMULATING &TESTING
PROGRAMMABLE LOGIC
CONTROLLERWITH EXAMPLES
★ Hacks To Crush PLC Programs From Beginning. Start Designing,
Building, Simulating and Testing Programs in IEC Languange (This book
guides only on LD (Ladder Diagram)★ This book will get you crushing
PLC-HMI programming environment as well as familiarize you with
(LD) ladder logic programming. You'll gain a deeper understanding of
the LD programming and the editing interface, the practical methods
used to build a PLC program, and how to . We also cover the basics of
ladder logic programming that every beginner should know, and
provide ample practical examples to help you gain a better
understanding. By the end of this book you will be able to create a
PLC-HMI program from start to finish, that can take on any real-world
task. If you know how to write & test the PLC-HMI codes then you're
on your way to work on any PLC environment.

HACKS TO CRUSH PLC PROGRAM FAST & EFFICIENTLY EVERYTIME... : CODING, SIMULATING & TESTING PROGRAMMABLE LOGIC CONTROLLER WITH EXAMPLES

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