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http://www.bin95.com PLC Programming Example

                                     Program File List

Name         Number   Type           Rungs   Debug   Bytes


[SYSTEM]     0        SYS             0      No        0
             1        SYS             0      No        0
MAIN         2        LADDER          5      No       87
PRESS CNTR   3        LADDER          7      No       271
XREF         5        LADDER          16     No       250
DIAG         6        LADDER          1      No        3
SPARE        7        LADDER          1      No        3




                               (This program for training only)
http://www.bin95.com PLC Programming Example

       LAD 2 - MAIN - Main subroutine (allways scanned) by BIN95.com --- Total Rungs in File = 5

                                                           BIN95.com Training Example - (Not for use in actual equipment)
       This pogram is not to be placed in machine unless a qualified engineer has approved and in any case bin95.com and related initieis are not responsable for the use of
       this training example. Feel free to share and link to this programming example. If you would like a copy of the actual .RSS file you can load in a PLC for training,
       contact BIN95@BIN95.com and request it. Also see our website for more PLC programming examples.
                   START               STOP         E_STOP                                                                                                      AUTO
                    B3:0                B3:0           B3:0                                                                                                       B3:0
0000
                    0                   1              3                                                                                                             2

                  AUTO
                   B3:0

                    2

       IF NOT in Auto, you must be in Manual.
           AUTO                                                                                                                                             MANUAL
            B3:0                                                                                                                                             B3:0
0001
              2                                                                                                                                                 10

       Jump to Real-World I/O cross reference subroutine. Having all Real-World I/O in a separate subroutine is a best-practices technique. To learn more best-practices
       see BIN95.com instructor based training. If you are about to purchase a machine and it's program does not have an XREF Sub, you should question the quality of
       it's programming.
                                                                                                                             Real world
                                                                                                                             io cross ref
                                                                                                                                       JSR
0002                                                                                                                              Jump To Subroutine
                                                                                                                                  SBR File Number            U:5


       What does this rung do? Use comment area to answer and refer to rung number and program file number when doing so. Then read on to learn more!
                                                                                                                       Main Press
          AUTO                                                                                                         Control
           B3:0                                                                                                                 JSR
0003                                                                                                                        Jump To Subroutine
             2                                                                                                              SBR File Number           U:3



0004                                                                                                                                                             END




                                                           (This program for training only)
http://www.bin95.com PLC Programming Example

       LAD 3 - PRESS CNTR - Simple Example Press Control by BIN95.com --- Total Rungs in File = 7

                                                        BIN95.com Training Example - (Not for use in actual equipment)
       This program is not to be placed in machine unless a qualified engineer has approved and in any case bin95.com or related entities are not responsible for the use of
       this training example. This program was to give the general public an idea how we teach proper PLC programming structure.

       This first rung, # zero in subroutine 3 (also referred to as "ladder 3" or "program file 3" is a seal-in or latching rung. As there is an actual latch instruction, to limit
       confusion bin95.com training refers to it as seal in rung. Proper PLC programming should be a sequence of events in order of sequence. So our first rung is Boolean
       logic "IF LS1 (Press in home position at top) AND operator presses cycle start button AND in auto move press down at high speed as long as NOT in slow speed
       mode.
                                                                                         Move Down                                                                Move Down
                   Top Limit Switch                                                      Slow speed                                                               High speed
                   LS1                      CYCLE_START                    AUTO          DWN_SLOW               E_STOP                                            DWN_FAST
                         B3:4                      B3:0                     B3:0              B3:0                B3:0                                                 B3:0
0000
                            0                        5                       2                  7                  3                                                  6

                 Move Down
                 High speed
                 DWN_FAST
                    B3:0

                        6

       IF Jog down pushbutton is pressed AND in manual mode AND NOT bottom limit switch (LS3) is made OR LS3 timer is still timing, THEN move press down in
       slow speed. OR IF moving down in fast mode (Auto) AND middle limit switch (LS2) is made AND NOT bottom LS3 made AND NOT Emergency Stop tripped,
       THEN move press down in slow mode. OR IF machine is already in move down in slow mode AND in Auto, THEN continue to move down in slow mode
       (Seal-in/latch branch).
                  Manual Jog                                                                                                                Move Down
                  DOWN                                                Bottom Limit Switch                                                   Slow speed
                  JOG_DWN          MANUAL                             LS3                                   E_STOP                          DWN_SLOW
                      B3:0            B3:0                                     B3:4                          B3:0                               B3:0
0001
                       8                 10                                               2                                     3                                     7

                 Move Down            Middle Limit Switch                        Extra time press
                 High speed           (Speed Control)                            down motion applied
                 DWN_FAST             LS2                                        after bottom limit
                    B3:0                     B3:4                                switch (LS3) is
                                                                                 made.
                        6                        1                               EXT_DWN_PRESSURE/TT
                                                                                             T4:0
                 Move Down
                 Slow speed                                                                   TT
                 DWN_SLOW               AUTO
                     B3:0                B3:0

                        7                 2

       The above rung descriptions described the rungs more detail than you will typically see. As we move on, we will describe less and in a more typical fashion.

       As long as LS3 is made then timer T4:0 starts timing, OR IF the timer is already timing, it continues to time (seal-in). When timer is done in ¼ second, it's "TT"
       (timer timing) bit is no longer true and breaks seal-in. If the rung is not true, the timer resets to zero and would require LS3 to be made again. This rung allows press
       to travel down ¼ second past the bottom LS.
                                                                                                                                  Extra time press
                                                                                                                                  down motion applied
                                                                                                                                  after bottom limit
                                                                                                                                  switch (LS3) is
                  Bottom Limit Switch                                                                                             made.
                  LS3                                                                                                             EXT_DWN_PRESSURE
                           B3:4                                                                                                             TON
0002                                                                                                                                   Timer On Delay                 EN
                             2                                                                                                         Timer              T4:0
                                                                                                                                       Time Base          0.01        DN
                  Extra time press                                                                                                     Preset               25<
                  down motion applied                                                                                                  Accum                 0<
                  after bottom limit
                  switch (LS3) is
                  made.
                  EXT_DWN_PRESSURE/TT
                               T4:0

                                TT




                                                             (This program for training only)
http://www.bin95.com PLC Programming Example

       LAD 3 - PRESS CNTR - Simple Example Press Control by BIN95.com --- Total Rungs in File = 7

       IF Jog_Up OR Manual AND NOT LS1 AND NOT E_Stop THEN Up_Slow
            Manual Jog                                                                                                                                        Move Up
            UP                         Top Limit Switch                                                                                                       Slow speed
            JOG_UP        MANUAL       LS1               E_STOP                                                                                               UP_SLOW
               B3:0         B3:0            B3:4          B3:0                                                                                                   B3:0
0003
                9                  10                    0                   3                                                                                    11

       IF Ext_Dwn_Pressure timer is done OR Up_Fast AND Auto AND NOT LS1 AND NOT E_Stop THEN Up_Fast

       Question: What is another name for this type of rung? (Use comment area to answer)
                 Extra time press
                 down motion applied
                 after bottom limit
                 switch (LS3) is                                                                                                                              Move Up
                 made.                                                 Top Limit Switch                                                                       High speed
                 EXT_DWN_PRESSURE/DN                       AUTO        LS1                          E_STOP                                                    UP_FAST
                              T4:0                          B3:0             B3:4                    B3:0                                                        B3:0
0004
                              DN                               2                   0                    3                                                         12

                 Move Up
                 High speed
                 UP_FAST
                    B3:0

                     12

       This rung does nothing … or does it? There is a common practice by PLC programmer to actually place a rung in programs that does nothing, sometimes the bit is
       described as a "Dummy" bit. I may be there just to place extra comments in the program like this one, or the bit replaces a bit that would be their if the end-user
       ordered a certain option. We will use this rung for extra advice. First advice, if you do not know what AFI stands for and how it is used in a program, it is
       absolutely critical you seek our bin95.com instructor based training. Second tip, just like an professor obtained his/her position by reading a lot of books, the more
       PLC programs you study, the better a PLC programmer you will be.
                                                                                                                                                                     AFI
                                                                                                                                                                      B3:0
0005                                                                                                                                                                   U
                                                                                                                                                                       13


0006                                                                                                                                                               END




                                                             (This program for training only)
http://www.bin95.com PLC Programming Example

         LAD 5 - XREF - Realworld I/O cross reference by BIN95.com --- Total Rungs in File = 16

                                                        BIN95.com Training Example - (Not for use in actual equipment)
       This pogram is not to be placed in machine unless a qualified engineer has approved and in any case bin95.com or related initieis are not responsable for the use of
       this training example.
            Safety Gate             Safety Photoeye                                                                                                           E-Stop
            Proximity Switch        Curtain                                                                                                                   Auxiliary
                    I:1                    I:1                                                                                                                   B3:0
0000
                   3                       4                                                                                                                      4
              1746-IV16               1746-IV16

           E-Stop
           Auxiliary                                                                                                                                           E_STOP
             B3:0                                                                                                                                               B3:0
0001
               4                                                                                                                                                   3

                                                                                                                                                    E-Stop
                                                                                                                                                    Activated
                                                                                                                                                    (Check safety light
                                                                                                                                                    curtain or safety
           E_STOP                                                                                                                                   gate)
            B3:0                                                                                                                                            O:2
0002
               3                                                                                                                                             0
                                                                                                                                                        1746-OW16




                                                           (This program for training only)
http://www.bin95.com PLC Programming Example

       LAD 5 - XREF - Realworld I/O cross reference by BIN95.com --- Total Rungs in File = 16

                              Above was safety rungs. Safety first! Use page titles like this to organize rung
        Top Limit Switch
        for Hydraulic Press
        (User refers to as                                                                                          Top Limit Switch
        "C1")                                                                                                       LS1
                I:1                                                                                                      B3:4
0003
                 0                                                                                                            0
            1746-IV16

        Middle Limit Switch
        for Hydraulic Press
        -SPEED CONTROL-                                                                                          Middle Limit Switch
        (User refers to as                                                                                       (Speed Control)
        "C2")                                                                                                    LS2
                  I:1                                                                                                   B3:4
0004
                  1                                                                                                       1
             1746-IV16

        Bottom Limit Switch
        for Hydraulic Press
        (User refers to as                                                                                       Bottom Limit Switch
        "C3")                                                                                                    LS3
                 I:1                                                                                                    B3:4
0005
                 2                                                                                                       2
            1746-IV16




                                       (This program for training only)
http://www.bin95.com PLC Programming Example

       LAD 5 - XREF - Realworld I/O cross reference by BIN95.com --- Total Rungs in File = 16

                                 ^^^ Above Limit Switches ... Below Operator Push Buttons VVV
                                                                                                   Manual Jog
        Manual                                                                                     DOWN
        Jog Down                                                                                   JOG_DWN
            I:1                                                                                      B3:0
0006
              8                                                                                          8
        1746-IV16

                                                                                                   Manual Jog
        Manual                                                                                     UP
        Jog Up                                                                                     JOG_UP
            I:1                                                                                       B3:0
0007
              9                                                                                          9
        1746-IV16

        START
        Push Button                                                                                      START
            I:1                                                                                           B3:0
0008
             6                                                                                               0
        1746-IV16

        STOP
        Push Button                                                                                      STOP
            I:1                                                                                           B3:0
0009
             7                                                                                               1
        1746-IV16

        Cycle Start
        Push Button                                                                             CYCLE_START
            I:1                                                                                     B3:0
0010
             5                                                                                       5
        1746-IV16




                                    (This program for training only)
http://www.bin95.com PLC Programming Example

       LAD 5 - XREF - Realworld I/O cross reference by BIN95.com --- Total Rungs in File = 16

                                                Below Outputs
        Move Up                                                                         Up
        Slow speed                                                                      Speed 1
        UP_SLOW                                                                         (Slow speed)
           B3:0                                                                             O:2
0011
           11                                                                                2
                                                                                        1746-OW16

        Move Down                                                                       Down
        Slow speed                                                                      Speed 1
        DWN_SLOW                                                                        (Slow speed)
            B3:0                                                                            O:2
0012
             7                                                                               3
                                                                                        1746-OW16

        Move Down                                                                       Down
        High speed                                                                      Speed 2
        DWN_FAST                                                                        (High speed)
           B3:0                                                                             O:2
0013
             6                                                                               1
                                                                                        1746-OW16

        Move Up                                                                         UP
        High speed                                                                      Speed 2
        UP_FAST                                                                         (High speed)
           B3:0                                                                             O:2
0014
           12                                                                                4
                                                                                        1746-OW16


0015                                                                                          END




                                   (This program for training only)

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PLC Programming Example - Hydraulic Press

  • 1. http://www.bin95.com PLC Programming Example Program File List Name Number Type Rungs Debug Bytes [SYSTEM] 0 SYS 0 No 0 1 SYS 0 No 0 MAIN 2 LADDER 5 No 87 PRESS CNTR 3 LADDER 7 No 271 XREF 5 LADDER 16 No 250 DIAG 6 LADDER 1 No 3 SPARE 7 LADDER 1 No 3 (This program for training only)
  • 2. http://www.bin95.com PLC Programming Example LAD 2 - MAIN - Main subroutine (allways scanned) by BIN95.com --- Total Rungs in File = 5 BIN95.com Training Example - (Not for use in actual equipment) This pogram is not to be placed in machine unless a qualified engineer has approved and in any case bin95.com and related initieis are not responsable for the use of this training example. Feel free to share and link to this programming example. If you would like a copy of the actual .RSS file you can load in a PLC for training, contact BIN95@BIN95.com and request it. Also see our website for more PLC programming examples. START STOP E_STOP AUTO B3:0 B3:0 B3:0 B3:0 0000 0 1 3 2 AUTO B3:0 2 IF NOT in Auto, you must be in Manual. AUTO MANUAL B3:0 B3:0 0001 2 10 Jump to Real-World I/O cross reference subroutine. Having all Real-World I/O in a separate subroutine is a best-practices technique. To learn more best-practices see BIN95.com instructor based training. If you are about to purchase a machine and it's program does not have an XREF Sub, you should question the quality of it's programming. Real world io cross ref JSR 0002 Jump To Subroutine SBR File Number U:5 What does this rung do? Use comment area to answer and refer to rung number and program file number when doing so. Then read on to learn more! Main Press AUTO Control B3:0 JSR 0003 Jump To Subroutine 2 SBR File Number U:3 0004 END (This program for training only)
  • 3. http://www.bin95.com PLC Programming Example LAD 3 - PRESS CNTR - Simple Example Press Control by BIN95.com --- Total Rungs in File = 7 BIN95.com Training Example - (Not for use in actual equipment) This program is not to be placed in machine unless a qualified engineer has approved and in any case bin95.com or related entities are not responsible for the use of this training example. This program was to give the general public an idea how we teach proper PLC programming structure. This first rung, # zero in subroutine 3 (also referred to as "ladder 3" or "program file 3" is a seal-in or latching rung. As there is an actual latch instruction, to limit confusion bin95.com training refers to it as seal in rung. Proper PLC programming should be a sequence of events in order of sequence. So our first rung is Boolean logic "IF LS1 (Press in home position at top) AND operator presses cycle start button AND in auto move press down at high speed as long as NOT in slow speed mode. Move Down Move Down Top Limit Switch Slow speed High speed LS1 CYCLE_START AUTO DWN_SLOW E_STOP DWN_FAST B3:4 B3:0 B3:0 B3:0 B3:0 B3:0 0000 0 5 2 7 3 6 Move Down High speed DWN_FAST B3:0 6 IF Jog down pushbutton is pressed AND in manual mode AND NOT bottom limit switch (LS3) is made OR LS3 timer is still timing, THEN move press down in slow speed. OR IF moving down in fast mode (Auto) AND middle limit switch (LS2) is made AND NOT bottom LS3 made AND NOT Emergency Stop tripped, THEN move press down in slow mode. OR IF machine is already in move down in slow mode AND in Auto, THEN continue to move down in slow mode (Seal-in/latch branch). Manual Jog Move Down DOWN Bottom Limit Switch Slow speed JOG_DWN MANUAL LS3 E_STOP DWN_SLOW B3:0 B3:0 B3:4 B3:0 B3:0 0001 8 10 2 3 7 Move Down Middle Limit Switch Extra time press High speed (Speed Control) down motion applied DWN_FAST LS2 after bottom limit B3:0 B3:4 switch (LS3) is made. 6 1 EXT_DWN_PRESSURE/TT T4:0 Move Down Slow speed TT DWN_SLOW AUTO B3:0 B3:0 7 2 The above rung descriptions described the rungs more detail than you will typically see. As we move on, we will describe less and in a more typical fashion. As long as LS3 is made then timer T4:0 starts timing, OR IF the timer is already timing, it continues to time (seal-in). When timer is done in ¼ second, it's "TT" (timer timing) bit is no longer true and breaks seal-in. If the rung is not true, the timer resets to zero and would require LS3 to be made again. This rung allows press to travel down ¼ second past the bottom LS. Extra time press down motion applied after bottom limit switch (LS3) is Bottom Limit Switch made. LS3 EXT_DWN_PRESSURE B3:4 TON 0002 Timer On Delay EN 2 Timer T4:0 Time Base 0.01 DN Extra time press Preset 25< down motion applied Accum 0< after bottom limit switch (LS3) is made. EXT_DWN_PRESSURE/TT T4:0 TT (This program for training only)
  • 4. http://www.bin95.com PLC Programming Example LAD 3 - PRESS CNTR - Simple Example Press Control by BIN95.com --- Total Rungs in File = 7 IF Jog_Up OR Manual AND NOT LS1 AND NOT E_Stop THEN Up_Slow Manual Jog Move Up UP Top Limit Switch Slow speed JOG_UP MANUAL LS1 E_STOP UP_SLOW B3:0 B3:0 B3:4 B3:0 B3:0 0003 9 10 0 3 11 IF Ext_Dwn_Pressure timer is done OR Up_Fast AND Auto AND NOT LS1 AND NOT E_Stop THEN Up_Fast Question: What is another name for this type of rung? (Use comment area to answer) Extra time press down motion applied after bottom limit switch (LS3) is Move Up made. Top Limit Switch High speed EXT_DWN_PRESSURE/DN AUTO LS1 E_STOP UP_FAST T4:0 B3:0 B3:4 B3:0 B3:0 0004 DN 2 0 3 12 Move Up High speed UP_FAST B3:0 12 This rung does nothing … or does it? There is a common practice by PLC programmer to actually place a rung in programs that does nothing, sometimes the bit is described as a "Dummy" bit. I may be there just to place extra comments in the program like this one, or the bit replaces a bit that would be their if the end-user ordered a certain option. We will use this rung for extra advice. First advice, if you do not know what AFI stands for and how it is used in a program, it is absolutely critical you seek our bin95.com instructor based training. Second tip, just like an professor obtained his/her position by reading a lot of books, the more PLC programs you study, the better a PLC programmer you will be. AFI B3:0 0005 U 13 0006 END (This program for training only)
  • 5. http://www.bin95.com PLC Programming Example LAD 5 - XREF - Realworld I/O cross reference by BIN95.com --- Total Rungs in File = 16 BIN95.com Training Example - (Not for use in actual equipment) This pogram is not to be placed in machine unless a qualified engineer has approved and in any case bin95.com or related initieis are not responsable for the use of this training example. Safety Gate Safety Photoeye E-Stop Proximity Switch Curtain Auxiliary I:1 I:1 B3:0 0000 3 4 4 1746-IV16 1746-IV16 E-Stop Auxiliary E_STOP B3:0 B3:0 0001 4 3 E-Stop Activated (Check safety light curtain or safety E_STOP gate) B3:0 O:2 0002 3 0 1746-OW16 (This program for training only)
  • 6. http://www.bin95.com PLC Programming Example LAD 5 - XREF - Realworld I/O cross reference by BIN95.com --- Total Rungs in File = 16 Above was safety rungs. Safety first! Use page titles like this to organize rung Top Limit Switch for Hydraulic Press (User refers to as Top Limit Switch "C1") LS1 I:1 B3:4 0003 0 0 1746-IV16 Middle Limit Switch for Hydraulic Press -SPEED CONTROL- Middle Limit Switch (User refers to as (Speed Control) "C2") LS2 I:1 B3:4 0004 1 1 1746-IV16 Bottom Limit Switch for Hydraulic Press (User refers to as Bottom Limit Switch "C3") LS3 I:1 B3:4 0005 2 2 1746-IV16 (This program for training only)
  • 7. http://www.bin95.com PLC Programming Example LAD 5 - XREF - Realworld I/O cross reference by BIN95.com --- Total Rungs in File = 16 ^^^ Above Limit Switches ... Below Operator Push Buttons VVV Manual Jog Manual DOWN Jog Down JOG_DWN I:1 B3:0 0006 8 8 1746-IV16 Manual Jog Manual UP Jog Up JOG_UP I:1 B3:0 0007 9 9 1746-IV16 START Push Button START I:1 B3:0 0008 6 0 1746-IV16 STOP Push Button STOP I:1 B3:0 0009 7 1 1746-IV16 Cycle Start Push Button CYCLE_START I:1 B3:0 0010 5 5 1746-IV16 (This program for training only)
  • 8. http://www.bin95.com PLC Programming Example LAD 5 - XREF - Realworld I/O cross reference by BIN95.com --- Total Rungs in File = 16 Below Outputs Move Up Up Slow speed Speed 1 UP_SLOW (Slow speed) B3:0 O:2 0011 11 2 1746-OW16 Move Down Down Slow speed Speed 1 DWN_SLOW (Slow speed) B3:0 O:2 0012 7 3 1746-OW16 Move Down Down High speed Speed 2 DWN_FAST (High speed) B3:0 O:2 0013 6 1 1746-OW16 Move Up UP High speed Speed 2 UP_FAST (High speed) B3:0 O:2 0014 12 4 1746-OW16 0015 END (This program for training only)