PLC Basics

Tech Notes
Welcome to CIMON Education
Part 1

Basics of PLC
Part One

Definition of PLC

Programmable Logic Controller (PLC)

○ A PLC is an industrial digital computer that has been
ruggedized and adapted for the control of manufacturing
processes, such as assembly lines, robotic devices, or
any activity that requires high reliability, ease of
programming, and process fault diagnosis.
○ Controls various types of machines and processors.
Part One

Relay vs PLC
Existing Relay Panels
Part One

Relay vs PLC
CIMON PLC Applied Panel
(Korea Rural Community Corporation)
Part One

Relay vs PLC
Category Relay PLC

Functionality Large amount of relays are required for complex control. Capable of any complex control by programming.

Changeability of
Rewiring only. Freely changeable by programming.
Control Logic

There can be contact failure and a limit on the product

Reliability High reliability since the core is made up of a semiconductor.
lifespan.

Applicable to any device according to the configuration of the

Versatility Difficult to utilize with the other devices once configured.
program.

After the configuration, it cannot be used to control other

Extendibility Capable of free extension.
devices

Maintenance A heavy workload is required for extension and improvement. Capable of online repair. Easy unit replacement.

Technological Easier to understand due to the simple hardware Have to learn programming method for individual
Understanding construction. manufacturer.

Period of Design Requires complex design. Time-consuming to assemble and Easy to design even with complex control. Can be
and Manufacture test the equipment. manufactured in a short time period.
Part One

Application Example
Part One

PLC Applied Areas

Pollution Prevention
○ Wastewater treatment system, waste incineration, and septic tank system.

Distribution Industry
○ Automatic warehouse system to control the adequate production and supply.

- Digital I/O devices are mostly used. At certain sites, high-speed counter
modules and positioning modules are used for precise control.

Water Supply and Sewage

○ PLCs can be used for the whole process of water management.

- Controls the motor and amount of water intake.

- Controls the amount of chemicals fed to the water through PID.

Part One

PLC Applied Areas

Textile Industry
○ Applied to the base material mixer, filature, weaving and dyeing.

○ For the exact chemical reaction, a temperature-controlling module and PID control
is used. A calculus module can control temperature and chemical reaction rate.

○ Especially, tension control used for the textile. In this case, the analog module

and positioning module are used to wind thread in constant tension.

Food Industry
○ Automatic food & beverage production line, unit process production line,

conveyor system raw material mixer, raw material examination equipment,

raw material processing system, etc.

○ In this industry, the temperature, timing, and weight are usually controlled.

The analog I/O modules are used for this purpose.

Part One

PLC Applied Areas

Automotive Industry
○ In general, the industry is composed of the frame, press, painting,

assembling and designing plants. In these plants, PLC is used for the

equipment, conveyor, JIG control and robot, interlock processes, etc.

○ Digital I/O and communication/network related modules are mostly used.

Network related functions are becoming the most important factor.

Steel Manufacturing Industry

○ The PLC is applied to the electricity and automation facilities. Keeping

precise sizes and temperatures is important in the process of iron-melting

and product manufacturing (steel sheet, pipe, line, etc.).

○ The positioning module is used for the control of precise size and the thickness.

○ Paper industry, oil industry, etc.

Part One

Smart Factory Field Application Case

 Part One

Structure of PLC

● Hardware + Software
○ Hardware
■ Base (except CM3 series)
● Also referred to as a chassis or
backplate.
■ CPU
■ I/O and Special Modules
■ Power
● Software
■ CICON
■ Free
■ Universal for CIMON PLCs
Part One

CPU Processing

Input Refresh Reads the input status of the input module.

Program Execution/END Operates the program from the first step to the last END in order (series processing method).

Self-diagnosis Checks for abnormalities.

Output Refresh Executes the calculation result of logic.

Stands for the time to operate the execution of a project from the beginning to end once.
Scan Time
 Part One

CIMON PLC Types

● Micro-S Brick Type PLC
○ Power, CPU, and I/O compose a single unit.
○ HSC, PID, and servo control.
○ No expansion.
○ Used for simpler controls.

● Modular Type PLC

○ Base, CPU, and I/O are separated.
○ Various expansion capabilities.
○ Used for small to large-sized applications.
Part One

CIMON PLC Types

World Standard Industrial Controller Developed PLC based on IEC 61131

Suitable from Small Machines to Large Plants

XP Series (Large-Scale) CP Series (Moderate-Scale) PLC-S Series (Small-Scale)

Speed 28–75 ns/step 84–200 ns/step 300 ns/step

I/O Up to 8192 Up to 1536 Up to 384

Program Memory Up to 128k steps Up to 64k steps Up to 10k steps

Data Memory 7 MB Up to 512 KB 256 KB

CPU, Power, and I/O all-in-one.

Redundancy available with CM1-XP1S Scaled-down version of XP series. Does not
Notable Feature Built-in HSC, PID w/ auto-tuning, Servo control,
CPU. support floating arithmetic.
Modbus RTU/TCP, and User Protocol.
Part One

PLC-S Anatomy
Part One

CIMON Power Standard

Item CM1-SPC CM1-SP2B CM1-SPW CM1-SPR

100–240 VAC, 50/60 100–240 VAC,

Input Voltage 19–28 VDC 70–110 VDC
Hz 50/60 Hz

1.71 A (110 V) 1.8 A (110 V)

Input Current 1.9 A (24 V) 0.6 A (100 V)
0.85 A (220 V) 0.95 A (220 V)

Input Inrush Current 50 A Peak

Efficiency 65%

Power
Disturbance 10 ms
Susceptibility

+24 V (0.3 A) +24 V (0.3 A)

+5 V (3.5 A)
Output Voltage +5 V (3.5 A) +5 V (3.5 A)
Output +15 V (0.5 A)
(Output Current) +15 V (0.5 A) +15 V (0.5 A)
-15 V (0.3 A)
-15 V (0.3 A) -15 V (0.3 A)

Voltage Indicator LED ON When Output Voltage is Normal

Part One

CIMON PLC Modules

● Analog
○ AD, DA
● Communication
○ Serial, Ethernet, Fieldbus
● I/O
○ Relay, Sink, Source
● Load Cell
● Temperature
○ RTD, TC, Thermistor
● High-Speed Counter
● Data Logger
● Positioning
Part One

Device Memory of I/O Modules

● I/O Area CPU Module I/O Module
○ X (input) & Y (output) area.

○ Displays request for setup and errors. Bit Process I/O Area
○ Uses bit process instruction.
SCAN
● Buffer Memory Area PROGRAM
○ Stores the module’s setting values and results of
Buffer
data processing. FROM/TO
Memory
○ Use FROM/TO instructions to communicate with.
Part One

PLC Programming Language

● Instruction List (IL)
○ Assembly language type.
○ Compatibility with spreadsheets (i.e. Excel).
Part One

PLC Programming Language

● Ladder Diagram (LD)
○ Relay logic display type language.
○ Expresses PLC program with graphic symbols such as

coils and contacts (widely used syntax).

Part One

PLC Programming Language

● Sequential Function Chart (SFC)
○ Using symbols such as Step and Transition.
○ Allows for parallel processing.
Part One

PLC Programming Language

● Function Block Diagram (FBD)
○ An instruction block with a group of instructions which are frequently used.
Part One

PLC Programming Language

● Structured Text (ST)
○ Has a lingual structure of selection, repetition, etc. ST is a structural

text language similar to PASCAL.

○ ST is an advanced language for industrial control, which substitutes

the difficulties of LD (numeric data process).

Part 2

PLC Introduction
Part Two

Device Memory & Notation

Bit
0 or 1, 2 possible expressions

4 Bits = Nibble
24 = 16 possible expressions

8 Bits = Byte
28 = 256 possible expressions

16 Bits = 2 Bytes = 1 Word

216 = 65,536 possible expressions

32 Bits = 4 Bytes = 2 Words = Double Word (DWORD)

232 = 4,294,967,296 expressions

Part Two

Device Area
Device Description Read/Write

X Input contact that receives signals from the input module. R

Y Output contact that delivers the operation result to the output module. R/W

M Auxiliary relay used in the PLC internally. R/W

K Similar use as M device. Supports latching by default. (Non-Volatile Memory) R/W

Special contact area when used with computer/data link module (i.e. Modbus).
L R/W
Without a link, this area can be used same as M area.

F Internal flag relay for the PLC state, time, date or other special contacts. R

T Auxiliary relay for Timer instructions. R

C Auxiliary relay for Counter instructions. R

S Step control relay. R/W

D Capable of 16/32-bit data. R/W

Z Similar to the D device, but is ideally used with subroutines. Cannot have an alias or description. R/W

Index register used to indirectly indicate the address of device memory. CIMON PLC CPU provides 16 index registers.
R R/W
Each register can store offset value in 16-bit.
Part Two

Data Memory Capacity of Each CPU

Device CM1-XP1F/S CM1-XP2F CM1-XP3F CM1-CP3x CM1-CP4x CM3-SP32MDx (PLC-S)

X 8192 4096 2048 1024 384 1024

Y 8192 4096 2048 1024 384 1024

M 16000 16000 8192 8192 8192 8192

K 16000 16000 2048 2048 2048 4096

L 16000 16000 2048 2048 2048 4096

F 2048 2048 2048 2048 2048 2048

T 4096 4096 4096 1024 1024 512

C 4096 4093 4096 1024 1024 512

S 100*100 100*100 100*100 100*100 100*100 100*100

D 32000 32000 32000 10000 5000 10000

Z 2048 2048 2048 2048 2048 1024

Part Two

Device Notation
● Bit Device Notation ● Word Device Notation
(T, C, D, Z)
○ Using Bit of Bit Device

(X, Y, M, K, L, F)

● Using Word of Bit Device

Part Two

Base Base

Pow Slo Slo Slo Slo Slo Slo Slo Slo Slo Slo Slo Slo
er t t t t t t t t t t t t

3 Slot
Base
4 Slot
Base
5 Slot
Base
8 Slot
Base
10 Slot
Base
12 Slot Base
Part Two

Base
Redundancy Base

5 Slot Redundancy Base

8 Slot Redundancy Base

10 Slot Redundancy Base

Part Two

I/O Address Assignment

● Each module occupies 16 points by default.
Part Two

Expansion & Address Assignment

● Connect the local base and expansion bases in order.
● Use the rotary switch of the expansion module to assign
order of the expansion bases.

Base No. Rotary Switch

1st Expansion Base(#1) 0

2nd Expansion Base(#2) 1

3rd Expansion Base(#3) 2

…… ……

15th Expansion Base(#15) E

16th Expansion Base(#16) F

Part Two

Redundancy
Redundancy Comm.

● CPU Redundancy
○ Two CPUs operate as primary and standby. Expansion Comm.
(Single Power)
○ Synchronizes with CPU at each scan.
Expansion 1
(Redundancy Power)

● Power Redundancy Expansion 2

(Redundancy Power)
○ Basic redundancy for a PLC system.
○ Two power supplies can be mounted Expansion 3
(Redundancy Power)
on a single base.
Part 3

CICON Program Structure

Part Three

Create a New Project

Part Three

Password Setting
● Password Setting
○ Secure the project.
■ Partial protection available.
○ Prohibit program upload.
○ PLC security.
Part Three

New Program

● Scan
○ A signal process which repeats regularly at each scan.

● Subroutine
○ A group of programs which are executed by a ECALL
instruction in the scan program.

● Periodic Interrupts
○ A program which is executed by the user-defined period
and order (10–60,000 ms).
Part Three

New Program
● COLD Start Initialization
○ A program executed only when PLC power is ON or the
CPU mode switches to RUN.
○ The Scan program is executed after the operation of the
initialization program.
○ A program for setting initial data for the initialization of
peripheral devices.
Part Three

New Program
● HOT Start Initialization (HOT)
○ In a sudden black out, the HOT Start Initialization program will execute and maintain

the previous values (when power is OFF), then the Scan program will begin.

○ Check the [Hot Restart] option in [PLC Parameter] and set the time.
Power must be restored in the assigned time, or the values will be lost.

Momentary
Blackout

Initialization PROGRAM
Part Three

PLC Operation Mode

● RUN

● PAUSE / REMOTE

RUN Mode Remote

Mode

● STOP
Pause STOP
Mode Mode
Part Three

Connection Option
Part Three

Program Download / Upload

Part Three

PLC Status
Part Three

Ladder Diagram Tools

Instruction Hot Key Description

ESC Selects object to control.

DEL Deletes the selected object.

F2 Draws a horizontal line between symbols.

Shift + F2 Draws a vertical line between symbols.

F4 Inverses the result.

F5 Adds a Normally Open Contact symbol.

F6 Adds Normally Closed Contact symbol.

F7 Adds Positive Transition-Sensing Contact symbol.

F8 Adds Negative Transition-Sensing Contact symbol.

F9 Outputs the operation result.

Shift + F9 Adds a function block.

F10 A contact which operates an application instruction.

F12 Enters a comment for the understanding of a program.
Ctrl + F2 Deletes a vertical line.
Part Three

Contact
● A Contact
○ Normally Open contact

● B Contact
○ Normally Closed contact

● Pulse ON
○ Positive Transition-Sensing Contact

● Pulse OFF
○ Negative Transition-Sensing Contact
Part Three

Variable Editor
Part Three

Variable Editor
Using Excel
Part Three

Find & Replace

Part Three

Memory Monitor
Double click to Double click to
modify (Bit) modify (Word)
Part Three

Online Edit
Part 4

LD Program Instruction
Part Four

Comparison Operation
● Comparison
○ Operators to compare devices S1 and S2.

Comparison Operator Expression Result

= S1=S2 ON

<= S1≤S2 ON

>= S1≥S2 ON

<> S1≠S2 ON

< S1<S2 ON

> S1>S2 ON
Part Four

Arithmetic Operation
● Arithmetic
○ Arithmetic operation between devices S1 and S2, then save the result at device D.

Command Expression Result (D)

ADD S1+S2 WORD

SUB S1-S2 WORD

MUL S1*S2 DWORD

DIV S1/S2 DWORD

Part Four

MOV, MC, INC, DEC

● MOV
○ The MOV instruction moves X to device D.
○ When you want to move consecutive address data at
the same time, use the BMOV command.

● MC
○ Controls any amount of rungs to operate up to an MCR instruction.

● INC
○ Increase device D by 1 for every scan the rung is true.

● DEC
○ Decrease device D by 1 for every scan the rung is true.
Part Four

Time Process Instruction (Read)

● DATERD
○ Read data from RTC (Clock Device) and store in devices D–D+6.
Part Four

Time Process Instruction (Write)

● DATEWR
○ Write time data to RTC (Clock Device) from S–S+6.
Part Four

Timer
● Timer ON (TON) Delay
○ When the input signal is ON, the timer device sets after a designated time V.
○ Timer unit is 100 ms or 10 ms, and can be adjusted within “PLC Parameter”.
○ Example below should be understood as follows: 50 * 100 ms = 5000 ms = 5 s.

ON
M20
OFF
← t = 5 seconds →
ON
T1, M30
OFF
Part Four

Timer
● Timer OFF (TOFF) Delay
○ When the input signal turns OFF after being ON, the timer device sustain during designated time V.

○ Timer unit is 100 ms or 10 ms, and can be adjusted within “PLC Parameter”.

ON
M40
OFF
← t = 5 seconds →
ON
T2, M50
OFF
Part Four

Counter
● CTU (Counter Up)
○ CTU counts the number of ON status execution conditions, and turns ON
a counter contact when the current value reaches the setting value.
○ Maximum 65535

M100

10

M101

C1
Part Four

Counter
● CTD (Counter Down)
○ CTD counts down the number of ON status execution conditions,

and turns ON a counter contact when the current value becomes 0.

M110

M111

C2
Part Four

All Together Now

Part Four

HMI Simulation
Part 5

PLC Setting Application

Part Five

PLC Parameter - Basic

● Action
● Timer
● Communication
● Watch Dog Timer
● Upload
● Hot Restart
● Expansion Setting
Part Five

PLC Parameter - Latch Area Setup

● Device K is always non-volatile (latch device).
Part Five

PLC Parameter - Interrupt

Part Five

PLC Parameter - Error Manipulation

Part Five

PLC Parameter - Comm Port

● RS-232C & RS-485/422 availability.
Part Five

PLC Parameter - Modbus

Part Five

Reserved I/O
● Possible to assign larger or lower amount of I/O points.
Part 6

Communication
Part Six

Communication Configuration
Part Six

Communication Configuration
Part Six

Communication Configuration
Part 7

Analog Module
Part Seven

AD Module
Items CM1-AD04VI CM1-AD08V CM1-AD08I CM1-AD16VI

Analog Input Points 4 Points 8 Points 8 Points 16 Points

0–5 V (0–20 mA)

0–5 V (0–20 mA) 0–5 V
0–20 mA 1–5 V (4–20 mA)
Analog Input 1–5 V (4–20 mA) 1–5 V
4–20 mA 0–10 V
0–10 V 0–10 V
-10–10 V
-10–10 V -10–10 V

Voltage: 0–10 V
Temperature Input to A/D
Transducer
0–1000°C Conversion
Module

Time
Part Seven

AD Module Wiring
Part Seven

Setting AD Module
Part Seven

Setting AD Module
Part Seven

Example of DA
Expansion No. + Slot No. Device Destination

1 3

2 4
Buffer Memory No. of
Address Words

① Expansion No. & Slot No. ② Buffer Memory Address

Part 8

Convenient Function
Part Eight

PLC Simulator
Part Eight

Cross Reference
Part Eight

Permission Mode
Part Eight

PLC Status Monitoring

PLC Remote Control

Error Message
Part Eight

PLC Diagnosis
Part Eight

Device Monitoring
Part Eight

Device Trend
Part Eight

F (Flag): PLC Internal Flag Area

Thank You
● 1-800-300-9916
● [email protected]
[email protected]
● www.cimon.com