Chapter 13 INDEXING – BATCHING APPLICATIONS

Introduction

This chapter discusses an important topic, moving of data and large data manipulation programs.
This includes batching applications as well as the labs at the end of the chapter, Simon Says and
Whack-a-Mole.

Modicon, a rival PLC manufacturer to A-B and Siemens, used three simple instructions with
capabilities to move data from tables to a fixed location, from a fixed location to a table and from
a location in a table to the same location in a second table. These instructions were called:

o Table to Register
o Register to Table
o Table to Table

All PLC manufacturers have instructions with capabilities similar to the Modicon instructions.
A-B has a number of different instructions for moving data from a table. The SLC and PLC/5
instruction set used two different techniques for moving data. Siemens uses an indexer and
matrices. The ControLogix language uses matrices and indexing as well. While RSLogix5000
looks very similar to RSLogix 500, the tag addressing scheme is very different as well as the
instructions that perform indexes and moving data using indexing.

In this chapter, we will attempt to discuss the different indexing instructions presently employed
by A-B and Siemens as well as look back at the older indexing instructions used by A-B with
their SLC and PLC-5 processor lines. In addition, we will look at a specification from ISA
called SP88 and some of its methodologies as to how to build a successful batching application.

SP88 will only be discussed here as to how it allows the PLC programmer to build an application
that has the elements needed by the application but in a somewhat standardized way.

Batching systems vary in type and are pictured in the figures below. The first shows a simple
batch system with various ingredients laid on the transfer belt at programmed rates. The system
here does not include steps but only the process to mix a number of ingredients. More complex
systems include steps after which various activities may occur such as agitation or heating. With
the second figure, this is the case. Various ingredients can be added to a weigh mix tank a step at
a time. This batch system requires the step architecture discussed in this chapter. Both require
recipes. Different processes favor one over the other and some processes can use both.
Obviously the transfer belt does not allow for wet ingredients adds directly on the belt. We will
discuss the software needed to step through a recipe and the processes to program a batch with
the PLC.
Ch. 13 Indexing – Batching Applications 1
 The three figures here show a variety of
batch systems. The batch system at left was
made by Capstone students at the
University of Toledo. It contains three
ingredient tanks and a mix tank. Below the
mix tank is a weigh cell. Ingredients are
added to the mix tank one at a time and
then the combined mix is drained from the
mix tank.
Lower left is a similar system from industry
except the ingredients are solids. Each
ingredient is added to the mix tank through
an auger arrangement. Each ingredient
tank is shown with vibration equipment that
guarantee an even flow of solid into the
auger.

Lower right is a mix system with ingredients

simultaneously laying a weighed amount on
the belt at a controlled rate. There is no mix
tank in this system. The ingredients are
layered onto the belt and then fed into a
melter or other process.

Data Moving - an Example

We will be using an example of a simple batching system to discuss indexing and moving of data
and construction of batching systems. The batch we discuss consists of:

15 recipes for making, as an example, pancake batter:

Each recipe consists of up to 16 steps
Each step consists of 4 integer words
Each recipe is given a 4-digit identifier number 0001-9999 that the operator may enter
into a given location prior to requesting that the batch be made
Ch. 13 Indexing – Batching Applications 2
When the recipe is moved into a batch of batter, the recipe is moved to an active recipe area.
With the start of the recipe, steps are moved one by one from the active recipe area to the active
step area.

As a step is executed, information about the step is collected. For instance, the actual weight
added is found and added to the information already found in the step.

As a step is made, the information about the step including the actual data is saved in a 6 integer
word group with a time stamp in an output table. As a new recipe starts, the time stamp at the
start of the recipe is saved with the recipe number. Then the step information is saved step by
step.

Storage Active Active Recipe

Recipes Recipe Step Report
Recipe 1 Step 1 Word 1 Header
Recipe 2 Step 2 Word 2 Time Step
Recipe 3 Step 3 Word 3 Step 1 W1
Recipe 4 Step 4 Word 4 Step 1 W2
Recipe 5 Step 5 Step 1 W3
Recipe 6 Step 6 Step 1 W4
Recipe 7 Step 7 Step 1 W5
Recipe 8 Step 8 Step 1 W6
Recipe 9 Step 9 etc
Recipe 10 Step 10
Recipe 11 Step 11
Recipe 12 Step 12
Recipe 13 Step 13
Recipe 14 Step 14
Recipe 15 Step 15
Step 16

To selectively move a recipe from storage to the active area, with A-B processors, the COP
command is selected. Moving of large portions of data at a time is referred to as a Copy move.
Many times the computer supervising the process will store the many recipes in the computer
memory and copying these recipes into the PLC. An alternative technique would provide the
PLC with only the recipe presently being made and the next recipe to be made leaving only the
two recipes in the PLC’s memory. In general, it is advisable to use the database capabilities of
the computer to control movement of recipes rather than storing and moving large portions of
data in the PLC and occupying the PLCs memory with recipes that are rarely if ever used.

An Aside:
Data historically was stored in long strings of words, not necessarily in the format of an array.
The user had to know that what was being programmed was an array and the data kept separate
from other data even though there was no barrier between the array and other data. The
programmer had to convey with a data table layout where the array was and its partitions. The
user just had to be aware of where the array was in the data and not over-write data into it
unintentionally.
Ch. 13 Indexing – Batching Applications 3
COP is used for large data table moves:

Storage Active
Recipes Recipe
Recipe 1 Step 1
Recipe 2 Step 2
Recipe 3 Step 3
Recipe 4 Step 4
Recipe 5 Step 5

Contacts that are usually defined as one-shots are selecting large data blocks to be moved. In the
example, B3:2/1, B3:2/2, B3:2/3 are selectively picking recipe 1, 2, or 3 to move to the active
region to make one of the three recipes the active recipe. The active recipe storage area is in area
N7 starting at word 10 and having length of 64 words.

Fig. 13-1 A-B Copy Commands moving large amounts of data

Copy commands and other commands moving large amounts of data had the problem of moving
the data in one scan or multiple scans. If the data was expected to be moved in one scan, care
had to be taken to not over-burden the length of time needed to execute the instruction. When
reading the instruction definition, look into the execution time of the command and what would
happen if the time extends beyond a reasonable scan time.

Ch. 13 Indexing – Batching Applications 4

 N11:0 – N11:63 N7:10 – N7:73

N12:0 – N12:63 N7:10 – N7:73

For Siemens, moving large data blocks involves the following instructions:

MOVE_BLK: Move Block

Move_BLK_VARIANT: Move Block
UMOVE_BLK:Move block uninterruptible

Ch. 13 Indexing – Batching Applications 5

MOVE_BLK

The description for the MOVE_BLK instruction follows:

“You use the "Move block" instruction to move the content of a memory area (source range) to
another memory area (target range). The number of elements to be moved to the target range is
specified at input COUNT. The width of the elements to be moved is defined by the width of the
element at input IN.”

MOVE_BLK_VARIANT

“You use the "Move block" instruction to move the content of a memory area (source range) to
another memory area (target range). You can copy a complete ARRAY or elements of an
ARRAY to another ARRAY of the same data type. The size (number of elements) of source and
destination ARRAY may be different. You can copy multiple or single elements within an
ARRAY.”

UMOVE_BLK: Move Block Uninterruptible

“You use the "Move block uninterruptible" instruction to move the content of a memory area
(source range) to another memory area (target range). The instruction cannot be interrupted. The
number of elements to be moved to the target range is specified with the COUNT parameter. The
width of the elements to be moved is defined by the width of the element at input IN.”
Ch. 13 Indexing – Batching Applications 6
These instructions introduce the new concepts of UDTs, arrays and variants. Earlier, the SLC
examples treated arrays as only a string of numbers in successive data locations with the
programmer having to keep track down the list. Now, the array or UDT indexes the variables by
number. Building an array or UDT will be described later in the chapter.

Description of Variant Type – Siemens (from the Help Screen for MOVE_BLK_VARIANT)

“A parameter of VARIANT data type is a pointer or a reference It can point to tags of various
data types. The VARIANT pointer cannot point to an instance and therefore cannot point to a
multiple instance or ARRAY of multiple instances. The VARIANT pointer can be an object of
an elementary data type, such as INT or REAL. It can also be a STRING, DTL, ARRAY of
STRUCT, UDT, or ARRAY of UDT. The VARIANT pointer can recognize structures and point
to individual structure components. An operand of data type VARIANT occupies no space in the
instance data block or work memory. However, it will occupy memory space on the CPU.

A tag of the VARIANT type is not an object but rather a reference to another object. Individual
elements of the VARIANT type can only be declared on formal parameters within the block
interface of a function in the VAR_IN, VAR_IN_OUT and VAR_TEMP sections. For this
reason, it cannot be declared in a data block or in the static section of the block interface of a
function block, for example, because its size is unknown. The size of the referenced objects can
change.

Using the VARIANT data type, you can in particular create generic, standardized function
blocks (FB) or functions (FC) for various data types. Various instructions in all programming
languages are available to you for this purpose. During the creation of the program, you can
specify which data types the block should be able to process. The VARIANT data type supports
you here by allowing the interconnection of any tags. You can then react accordingly to their
data types in the block. When a block is called, you can connect the parameters of the block to
tags of any data type. When a block is called, the type information of the tag is transferred in
addition to a pointer to the tag. The code of the block can then be executed according to its type
in line with the tag transferred during runtime.

If, for example, a block parameter of a function has the VARIANT data type, then a tag of the
integer data type can be transferred at one point in the program, and a tag of the PLC data type
can be transferred at another point in the program. With the help of the VARIANT instructions,
the function is then in a position to react to the situation without errors.”
Ch. 13 Indexing – Batching Applications 7
Moving Small Amounts of Data:

Indexed Addressing is used to selectively move a step from the active recipe to the active step.
If B3:2/5 is energized (one-shot), the words from the active recipe are moved into locations for
use in the active step. The first word selected moves to N7:30. The second word moves to
N7:31. The third moves to N7:32 and the fourth to N7:33. Again, from the SLC – A/B.

Fig. 13-2 A-B Move

Commands moving small
amounts of data

#N10:13

As the batch program moves through steps of the recipe, the indexing pointer moves starting at
N7:10 and moves through the recipe.

MOV instructions are used for moving smaller amounts of data selectively using indexed or
indirect addressing. Single word MOV statements are used to select individual word groups.

Indexing will be discussed later. For the SLC processors, the index is stored in location S:24.
For Siemens and A-B Compact/Control Logix processors, the index is a word used in the move
instruction. Matrices replace fixed locations for both Logix and Siemens processors.

The following shows words being moved to an active storage area from the steps in a recipe as
the program moves through the steps. First the words of step are moved to the active area. This
is also referred to as the work area or the register area. Next step two data is moved, then step
three, etc. As each step is moved into the active area, a sequence of programming statements is
executed allowing the program to execute the entire step and then move on. The sequence of the
program can easily be displayed in a state diagram. The state diagram may have many parts or
Ch. 13 Indexing – Batching Applications 8
be very simple. The state diagram may be as simple as found in Fig. 13-3.

Active Step
Step 1 Active
Step 1 Step Word 1
Step Word 2
Step Word 3
Step 2 Step Word 4

Step 3

Step 4

Step 5

Active Step

Step 1 Step 2 Active Step Word 1

Step Word 2
Step Word 3
Step 2 Step Word 4

Step 3

Step 4

Step 5

Active Step

Step 1 Step Word 1

Step 3 Active
Step Word 2
Step Word 3
Step 2 Step Word 4

Step 3

Step 4

Step 5

In a similar fashion, Siemens uses the MOVE command to move individual data content. The
definition for the Siemens’ MOVE command follows:

“You use the "Move value" instruction to transfer the content of the operand at the IN input to
the operand at the OUT1 output. The transfer is always made in the direction of ascending
address.”

Ch. 13 Indexing – Batching Applications 9

State Diagram of Step in Batch System

Execution at the step level is accomplished with a state diagram program. Movement through a
recipe is accomplished with a set sequence of options that must be addressed for each step.

Init

Action Check scale and start weighment

1

Action Allow flow into tank to preset weight

2

Action Allow to settle, get actual weight,

3 record actual weight

Action Check if agitation to be turned on Fig. 13-3 Sample State

4 Diagram for Step in Recipe

Action Check if heat to be applied

5

Action Check if product to be dumped,

6 begin flush cycle

Action Flush complete, tank empty

7

After a step is executed, data is collected about what actually happened. If a scale is used, the
target weight is usually not the actual weight of the step. If the operator has an option to choose
an action, the results of the choice are likewise remembered by the collected data. This data
forms a step in the Recipe Report for a recipe. The word count may be equal to, more than or
less than the active step recipe information.
Ch. 13 Indexing – Batching Applications 10
 Active Recipe
Step Report
Word 1 Header
Word 2 Time Step
Word 3 Step 1 W1
Word 4 Step 1 W2
Step 1 W3
Step 1 W4
Step 1 W5
Step 1 W6

A more ordered approach would be to allow the A-B database handler RSSQL handle the data
from recipes. When requested, RSSQL would hand a recipe to the active recipe residing in
storage in the PLC. After an active step is executed, RSSQL hands the data back to a second
database in the computer that keeps track of what actually happened as the result of each step.

RSSQL RSSQL
Database Active Active Database
Recipes Recipe Step Report
Recipe 1 Step 1 Word 1 Time Step
Recipe 2 Step 2 Word 2 Step 1 W1
Recipe 3 Step 3 Word 3 Step 1 W2
Recipe 4 Step 4 Word 4 Step 1 W3
Recipe 5 Step 5 Step 1 W4
Recipe 6 Step 6 Step 1 W5
Recipe 7 Step 7 Step 1 W6
Recipe 8 Step 8
Recipe 9 Step 9 etc
Recipe 10 Step 10
Recipe 11 Step 11
Recipe 12 Step 12
Recipe 13 Step 13
Recipe 14 Step 14
Recipe 15 Step 15
Recipe 16 Step 16
Recipe 17
Recipe 18
Recipe 19
Recipe 20

The older method from A-B was used in the above examples. The pointer in these examples is
the number found in S:24. As this number is incremented, the pointer is moved down the table.
The S:24 value is referred to as the indexer. The rules for indexing with this method are referred
to as indexed addressing. The method was discontinued with the RSLogix 5000 instruction set.
Ch. 13 Indexing – Batching Applications 11
With newer processors from A/B, indexing is accomplished with a matrix and the index is the
number in the matrix [ ] location. Matrices are also standard with Siemens. With each method,
the index value must be controlled or the program will have problems and probably cause the
processor to fault. A pointer out of range is one of the first problems to look for with batching
programs if the processor faults.

Creating Arrays

Creating arrays in Siemens and Allen-Bradley is not complex. For Siemens, follow the
following two figures to create an array. Note that arrays are not available in the M Table.

To create arrays in Siemens PLCs, use the Data Block type for creating a storage array. First,
choose the "Add new block" command and select Global DB. You will then be able to give
information that defines the array desired. Length and data types are necessary. For most
applications, the data type is INT or DINT. You may choose to have multiple arrays for multiple
data types associated with a list of variables. You may also designate a UDT for this purpose.

Fig. 13-4 Matrix defined in Data Block

Ch. 13 Indexing – Batching Applications 12
The array created in the example above shows an array Array with 51 integer values.

Allen-Bradley allows creation of an array with creation of a named tag and then choosing the
data type and dimension. There is no M table with Allen-Bradley and the type and length is
chosen below:

The array length is determined in the boxes below. Multiple array dimensions may be chosen as
well.

Fig. 13-5 Matrix defined in A-B’s Tag Table

Ch. 13 Indexing – Batching Applications 13
A-B Data Handling in ControLogix PLCs

Examples of the types of addressing available in the ControLogix processor will demonstrate
addressing used in the newer A-B processors. In the following, rung 2 turning on a coil out1 is
not as simple as it first may appear. A table table1 is entered in the database seen below. The
table consists of 320 bits. Two separate pointers determine the status of a particular bit. Index1
may vary from 0 to 9 determining the word in the table to view. Index2 may vary between 0 and
31. The value of index2 determines the bit in the word being viewed.

Fig. 13-8 A-B Array Bit

Addressing

table1[0]
table1[1]
table1[2]
table1[3]
table1[4]
table1[5]
table1[6]
table1[7]
table1[8]
table1[9]

Consider the table expanded further as table2[index1,index2],[index3]. The index capabilities of

arrays significantly enhance the power of the PLC to perform complicated operations in an
orderly manner.

Ch. 13 Indexing – Batching Applications 14

The following array in rung 3 uses a toggle bit to execute an ADD block. In this example, the
same 10 word table is used to selectively add one to a second word in the table.

Fig. 13-9 A-B Array

Word Addressing

table1[0]
table1[1]
table1[2]
table1[3]
table1[4]
table1[5]
table1[6]
table1[7]
table1[8]
table1[9]

For instance, if index1 = 1 and index2 = 1, the instruction would add 1 to table1[1]. If index1 = 3
and index2 = 4, the contents of table1[4] would be updated with the contents of table1[3] + 1.
For-Next Loops are not traditionally included in ladder logic for the reason that a scan can
appreciably be lengthened if any loop is executed. For-Next Loops provide a looping control
mechanism that is very useful but is capable of lengthening the loop execution time. They have
been included in the PLC-5 but not in the SLC ladder instruction set. They are also included in
the RSLogix 5000 programming software for both the Control Logix processors as well as the
Compact Logix processors. Excluded from the Control Logix and Compact Logix processors,
however, are the two addressing modes: indexed and indirect.

The For-Next loop requires an indexer that increments each pass the program makes through a
subroutine. The subroutine becomes the program used to execute the logic of the For-Next
operation.

Ch. 13 Indexing – Batching Applications 15

 Fig. 13-10
Subroutine Loop
for CompactLogix

In the above example, the routine MainRoutine executes. Each scan that tag_1 energizes, the FOR
loop Sub_z executes. The program Sub_z executes 10 times with the value of int_point
incremented by 1 from 0 to 9.

Of course, Sub_z allowed to call a subroutine as well with the effect of providing a loop within a
loop. The looping procedure is used for table manipulation similar to the MOV and COP
commands described in this chapter. If the FOR command is not available, a method using a
variable number of scans to execute a subroutine may be employed.

UDT’s

Both A-B and Siemens use UDTs for defining variable arrays of data.

A user-defined structure can contain any base data type (e.g., SINT, INT, DINT, BOOL, REAL)
or structure (either predefined or user-defined). In addition, a single-dimensional array can be
included as a structure member.

To create a user-defined structure, right click on the User-Defined folder in the Controller
Organizer, and choose New Data Type. The Data Type editor will appear, from which you can
define your new data type.

Many control programs require the ability to store blocks of information in tables that can be
traversed at runtime. RSLogix 5000 supports this requirement by providing the ability to create
custom arrays with up to three separate dimensions (i.e., row, column, and depth). Individual
cells within an array may contain any base data type (e.g., SINT, INT, DINT, BOOL, REAL) or
structure (either predefined or user-defined).

The example of a UDT is from the database example of a field. The field defines a set of data of
different data types and allows entry into a table using these data types. UDTs are the same. An
example of a database table ‘employees’ is as follows:

Ch. 13 Indexing – Batching Applications 16

CREATE TABLE employees (
emp_no INT NOT NULL, -- UNSIGNED AUTO_INCREMENT??
birth_date DATE NOT NULL,
first_name VARCHAR(14) NOT NULL,
last_name VARCHAR(16) NOT NULL,
gender ENUM ('M','F') NOT NULL, -- Enumeration of either 'M' or 'F'
hire_date DATE NOT NULL,

Circular Table

One of the file types studied in a programming course that may be useful in the Recipe Report
portion of the program is the circular table structure. The last step executed is presented in an
area with its time stamp and the computer is assumed to pick up the actual step information and
record it. If multiple steps are available for the polling computer, then the circular file structure
becomes more important. For instance, the last few steps of information are kept in the file. The
PLC program continues to increment through the steps working its way down the recipe and
sending the actual step information to the circular table. When the end of the circular table is
reached, the PLC starts again at the top of the table. This approach allows steps to be read
multiple times by the computer. If the polling computer fails to read a record, the table will
continue to fill till the end of the table is reached. Only when the table is full and wraps over old
data will data be lost if the polling computer is still unable to read the data.

An example of a circular table:

Time Stamp
Step 1 W1
Step 1 W2
Step 1 W3
Step 1 W4
Step 1 W5
Step 1 W6
Time Stamp
Step 2 W1
Step 2 W2
Step 2 W3
Step 2 W4
Step 2 W5
Step 2 W6
Time Stamp
Step 3 W1
Step 3 W2
Step 3 W3
Step 3 W4
Step 3 W5
Step 3 W6

Empty, yet to be filled in Step

Ch. 13 Indexing – Batching Applications 17

While data may be stored in the PLC, most large databases are kept in a computer closely linked
to the PLC. The circular table may be used to buffer data if the computer is not responding to
the PLC. A database is useful in organizing large amounts of data. Using a database for
applications such as this offloads the PLC from the burden of data handling, giving the PLC the
flexibility to do what it is designed to do best - control machines.

From the Easy Book “

Ch. 13 Indexing – Batching Applications 18

”

Ch. 13 Indexing – Batching Applications 19

Indirect Addressing for SLC and PLC/5 PLCs (Older Addressing Schemes)

This addressing format allows a storage location to specify the number in the file of the file,
element, or bit in the direct logical address. Up to two address numbers in the direct address are
allowed with indirect addresses.

For example: #F[N7:4]:0 identifies a floating point file whose number is found in the
N7:4location. If this location contains 99, the 99th file would be accessed as element 0. This
would be equal to F99:0.

Rules for using Indirect addressing:

1 Indirect addresses are indicated with brackets

2 Address must be direct logical address with N, T, C, or R types. Type N (Integer) is

recommended but not required.

3 # is not to be used inside brackets

4 The element number must be within the file’s length. A fault will occur if not.

5 When used to store file number, the file number must represent the same type as the
prefix.

Examples:

B3/[ ], B[ ]/[ ], N7:[ ]/8, C[ ]:5.DN

Example:

The following contact in a program would have various values depending on the value in
N7:0.

B3/[N7:0]

N7:0 B3/x Reference

0 B3/0
1 B3/1
10 B3/10
67 B3/67

Ch. 13 Indexing – Batching Applications 20

Example:

Fig. 13-11 A-B Indirect

Addressing Example
from SLC Instruction Set

The example makes the counter variables being added selectable from any of the counters in C5.

Note that addresses are not limited to whole word addresses. Bit addresses may be referenced as
well.

Fig. 13-12 A-B Indirect

Addressing Example
from SLC Instruction Set

The rung references B3/ and then a bit in the B3 table referenced from 0 using N7:10 as that
reference. For example, if N7:10 contained the number 30, the bit reference would be B3/30 or
B3:1/14.

An editorial comment on Indirect Addressing:

It is hard to debug or troubleshoot if you are not the initial programmer. So, don’t use it
unless you find no alternative means to program the task at hand.

It is believed that the use of this addressing method to obscure the logic behind the program led
the designers to discontinue it with the RSLogix 5000 language. Both the indirect and indexed
methods were discontinued with the newer languages.

If one becomes fluent with all the new languages, the procedural STL language may be the best
to be used for indexing program development. Although we predominantly use LAD here, the
STL language has many benefits and should be considered when planning a program with
indexing in mind.

Ch. 13 Indexing – Batching Applications 21

Indexed Addressing for SLC and PLC/5 PLCs

Indexed addressing allows an offset of an address by a number of words stored in location S:24.
To identify indexed addressing, place the # symbol immediately before the file-type identifier in
the address:

For example: #N7:0 refers to word 0 of the N7 file offset by the number stored in S:24.

When using Indexed Addressing:

• Use care to insure that the index value (positive or negative) does not exceed file bounds.

• With instructions using two or more indexed addresses in the same instruction, the offset
will be the same for all addresses.

• Use care to reset the offset to its desired value before enabling an instruction having
indexed addresses.

Example:

The MVM instruction uses indexed addressing as follows:

Fig. 13-13 A-B Indexed

Addressing Example
from SLC Instruction Set

Value Base Offset(Value in S:24) Actual Address

Source N7:10 4 N7:14
Destination N7:50 4 N7:54

N7:10 N7:50
N7:11 N7:51
N7:12 N7:52
N7:13 N7:53
N7:14 N7:54
N7:15 N7:55
N7:16 N7:56
N7:17 N7:57

Ch. 13 Indexing – Batching Applications 22

Using the MOV instruction as a reference, observe that the table of results uses the offset value
found in S:24 to compute a new address for the MOV instruction. The example above moves the
value in N7:14 to N7:54 when the offset in S:24 = 4. Only one word is moved when the rung is
executed. Other program statements should be added to the rung to increment or decrement S:24
to move other locations.

Another example using one offset address and one fixed address:

Fig. 13-14 A-B Indexed

Addressing Example
from SLC Instruction Set

Source Offset (S:24) Actual Source Destination

N7:5 0 N7:5 N7:30
N7:5 1 N7:6 N7:30
2
3
4
20

This is commonly referred to as a Table to Fixed move. This type of rung is used to get a value
sequentially or randomly from a table. It is used in programming recipe routines.

N7:5 N7:30
N7:6
N7:7
N7:8
N7:9
N7:10
N7:11
N7:12
N7:13

An example using a fixed first address and an indexed second address is included. It is used to
get a value from a fixed location into a table. It is used many times to save the status of an event
that happened in sequence. Picture a line of cars with numeric only license plates. The output
table would save the sequential status these numbers starting with N7:50 and sequentially store
the license plates in order as they passed by a point.
Ch. 13 Indexing – Batching Applications 23
 Fig. 13-15 A-B Indexed
Addressing Example
from SLC Instruction Set

Source Destination Offset(S:24) Actual Dest

N7:0 N7:50 0 N7:50
N7:0 N7:50 1 N7:51
2
3
4
20

N7:0 N7:50
N7:51
N7:52
N7:53
N7:54
N7:55
N7:56
N7:57
N7:58
N7:59

To enter a program using Indexed Addressing, build a table as follows and enter the program
listed below:
Address Value
N7:0 5
N7:1 10
N7:2 15
N7:3 20
N7:4 25
N7:5 30
N7:6 35
N7:7 40
N7:8 45

Ch. 13 Indexing – Batching Applications 24

 Fig. 13-16 A-B Indexed
Addressing Example
from SLC Instruction Set

Using the SLC processor to execute a For-Next loop employs a technique that allows a variable
number of scans to access the subroutine code. For instance, the following code could
accomplish the same function as that shown above if timing constraints were considered.

Fig. 13-17

The program called in U:3 may be used to respond in a manner similar to the For-Next program
if the output of the code can wait the number of scans needed to loop through the entire range of
numbers in int_point. Care must be taken to initialize N7:10 to 0 prior to execution of the code
as well. When the final path through the loop is executed a bit usually is set to signal any user

Ch. 13 Indexing – Batching Applications 25

program that data from the loop is available. This is more cumbersome than the program of the
Compact Logix processor. It also does not easily support loops within loops. Extreme care
must be taken when using this program technique. It is important to note that this type of
program control is used by many programmers and the student should be aware of its
implementation in existing automation programming.

Comparing Older AB Addressing Modes

As advances are made from the PLC/5 to SLC to RSLogix 5000 processors, addressing
requirements have been enhanced as well. The RSLogix 5000 processors use indexed arrays to
provide functional equivalent programming to the indexed and indirect methods of the PLC/5
and SLC processors. Modes may be mixed, causing a number of programming types which may
or may not be substituted with the indexed array of RSLogix5000. The following list of
comparisons shows some of the evolution from the PLC/5 to SLC to RSLogix5000 addressing.

Indexed: #N7:0

Supported by PLC/5, SLC

Available in RSLogix5000 by using Indexed Arrays

Indirect Word: (N7:[N7:6])

Supported by PLC/5, SLC

Available in RSLogix5000 by using Indexed Arrays
Indirect File: (N[N7:4]:0)

Supported by PLC/5, SLC

Not available in RSLogix5000

Indexed + Indirect Word: (#N:[N7:2])

Supported by PLC/5, SLC

Available in RSLogix5000 by using Indexed Arrays

Indexed + Indirect File: (#N[N7:8]:0)

Supported by PLC/5, SLC

Not available in RSLogix5000

Indexed + Indirect File + Word: (#N[N7:3]:[N7:4])

Supported by PLC/5, SLC

Not available in RSLogix5000

Ch. 13 Indexing – Batching Applications 26

Nested Indirection: (N7:[N7:[N7:2]])

Supported by PLC/5, SLC

Not available in RSLogix5000

While PLC/5 and SLC processors use various combinations of Indexed and Indirect pointers to
move data, the RSLogix5000 processors use indexed arrays to accomplish the same task.

FOR-NEXT looping is not used in the SLC processor family but is supported by the PLC/5
family. Use of multiple scans is necessary to provide the equivalent functionality to FOR-NEXT
looping when using the SLC processors.

Comparison of MOVE Instructions (with Examples from Siemens and A-B)

The Table to Table Move

The MVM instruction uses indexed addressing as follows:

Fig. 13-18

Value Base Offset(Value in S:24) Actual Address

Source N7:10 4 N7:14
Destination N7:50 4 N7:54

N7:10 N7:50
N7:11 N7:51
N7:12 N7:52
N7:13 N7:53
N7:14 N7:54
N7:15 N7:55
N7:16 N7:56
N7:17 N7:57

Siemens’ Move equivalent of the indexed address move above:

Ch. 13 Indexing – Batching Applications 27

 MOVE_BLK Tag_Out

EN ENO

#IN_Array(index1) IN OUT #OUT_Array(index2)

1 COUNT

Allen-Bradley’s Move equivalent of the indexed address move above:

COP
Copy File
Source IN_Array(index1)
Dest Out_Array(index2)
#IN_Array(index) Length 1

Notice that both the Siemens and A-B newer move statements allow more than one element to be
moved. Also notice that index values for the two arrays may be the same or different.

The Table to Register Move

Another example using one offset address and one fixed address:

Fig. 13-19

Source Offset (S:24) Actual Source Destination

N7:5 0 N7:5 N7:30
N7:5 1 N7:6 N7:30
2
3
4
20

This is commonly referred to as a Table to Fixed move. This type of rung is used to get a value
sequentially or randomly from a table. It is used in programming recipe routines.

Ch. 13 Indexing – Batching Applications 28

 N7:5 N7:30
N7:6
N7:7
N7:8
N7:9
N7:10
N7:11
N7:12
N7:13

Siemens’ Move equivalent of the indexed address move above:

Allen-Bradley’s Move equivalent of the indexed address move above:

MOV
MOV
Source IN_Array(index)

Dest Fixed_Value

The Register to Table Move

An example using a fixed first address and an indexed second address is included. It is used to
get a value from a fixed location into a table

Fig. 13-20

Ch. 13 Indexing – Batching Applications 29

 Source Destination Offset(S:24) Actual Dest
N7:0 N7:50 0 N7:50
N7:0 N7:50 1 N7:51
2
3
4
20

N7:0 N7:50
N7:51
N7:52
N7:53
N7:54
N7:55
N7:56
N7:57
N7:58
N7:59

Siemens’ Move equivalent of the indexed address move above:

Fig. 13-21a

Allen-Bradley’s Move equivalent of the indexed address move above:

MOV
MOV Fig. 13-21b
Source Fixed_Value

Dest OUT_Array(index)

Ch. 13 Indexing – Batching Applications 30

Scale Weighing

Scale Weighing Systems are an important part of a batch system. Siemens provides a load cell
interface system for weighing applications called the SIWAREX WP231. It is pictured in Fig.
13-22 below.

Fig. 13-22

The electronic weighing system has the following characteristics as listed by Siemens:
“
● Uniform design technology and consistent communication in SIMATIC S7-1200
● Parameter assignment by means of HMI panel or PC
● Uniform configuration option in the SIMATIC TIA Portal
● Measuring of weight with a resolution of up to 4 million divisions
● High accuracy, 3000 d, legal for trade according to OIML R76
● Legal-for-trade display with SIMATIC operator panel or PC
● High measuring rate of 100/120 Hz (effective interference frequency suppression)
● Limit monitoring
● Flexible adaptation to varying requirements
● Easy calibration of the scales using the SIWATOOL program
● Automatic calibration is possible without the need for calibration weights
● Module replacement is possible without recalibrating the scales
● Use in Ex Zone 2 / ATEX approval
● Intrinsically safe load cell supply for Ex Zone 1 (SIWAREX IS option)
● Diagnostics functions”

Ch. 13 Indexing – Batching Applications 31

SIWATOOL overview

SIWATOOL does not only offer support when you set the scale but also when you analyze
the diagnostic buffer that can be saved after being read out of the module together with the
parameters. The display of the current scale status can be configured.

Fig. 13-23

Fig. 13-24
Ch. 13 Indexing – Batching Applications 32
A load cell is pictured in the figure below:

Fig. 13-25

A weigh vessel with load cells usually includes four load cells. Some vessels may only include
three load cells, however.

Side View of Weigh Vessel

Load Load
Cell Cell

Load Load
Cell Cell

View from bottom of

weigh Vessel

Load Load
Cell Cell

Fig. 13-26

Ch. 13 Indexing – Batching Applications 33

There are also load cells located under traveling weigh belts. Systems that weigh moving
material include averaging algorithms that weigh the belt and material but tare the weight of the
belt out of the weight.

Fig. 13-27

The following weigh vessels show the location of load cells with the vessel suspended in space.
These weigh vessels show the traditional locating of load cells at four corners of the tank.

Fig. 13-28

The Siemens system is described in the manual:

Weighing systems Electronic weighing system SIWAREX WP231.

Ch. 13 Indexing – Batching Applications 34

Also, the load cell can be terminated in a converter box similar to the Red Lion Strain/Load Cell
Panel Meter pictured below. Since it can be used to interface to a PLC using an optional analog
output, the Red Lion is used simply to pass through a signal from the scale to the PLC after
linearization has occurred with the scale signal.

Fig. 13-29

Since this device only updates every 1/3 second, there must be programs written to articulate
between data points and anticipate when the output should turn off based on the rate of change of
the scale.

From the mathematical calculations of rate of change, a predicted value should allow the
program to turn off a valve very close to the actual turn-off point. This is left as an exercise.

Ch. 13 Indexing – Batching Applications 35

Check List for Writing PLC Batch Application

From the ISA website, the following gives an insight into considerations for the batching
application:

“The ISA88 committee has published a series of standards on batch control in industrial
automation systems.”

They are:

ANSI/ISA-88.00.01-2010, Batch Control Part 1: Models and Terminology

This standard “provides standard models and terminology for defining the control requirements
for batch manufacturing plants”

ANSI/ISA-88.00.02-2001, Batch Control Part 2: Data Structures and Guidelines for Language

This standard “defines data models that describe batch control as applied in industrial automation
systems, data structures for facilitating communications within and between batch control
implementations, and language guidelines for representing recipes”

ANSI/ISA-88.00.03-2003, Batch Control Part 3: General and Site Recipe Models and
Representation

This standard “defines a model for general and site recipes; the activities that describe the use of
general and site recipes within a company and across companies; a representation of general and
site recipes; and a data model of general and site recipes”

ANSI/ISA-88.00.04-2006, Batch Control Part 4: Batch Production Records

This standard “provides a detailed definition for batch production records, establishing a
reference model for developing applications for the storage and/or exchange of batch production
records. Implementations based upon the standard will allow retrieval, analysis, and reporting of
selected batch production record data”

A fifth standard is under development:

Implementation Models & Terminology for Modular Equipment Control

The purpose of the SP88-ISA-88 specification is to provide a common strategy for all batch
applications programmed. These include PLC programs. To be included are the physical and
functional implementations. The functional model includes “the relationships between the five
types of control recipe management, scheduling, sequential control, regulatory control, and
safety interlock systems.”

Examples are the definitions for modes, states and alarms for a typical batch system. They are
Ch. 13 Indexing – Batching Applications 36
defined in the specification as:

• Auto
• SemiAuto
• Manual
• Bypassed
• Controlled
• Reset
• AlarmPresent
• AlarmAcknowledged

As discussed previously, the reporting function is important in that values are required by the
higher level computer. Such values as actual weights by the scale, errors, status of the batch
should be saved and reported for each step of the batch.

While the chemical engineer or mechanical engineer is usually in charge of determining the
equipment design and feeds for the process, the electrical engineer/program designer is
responsible for programming the process. Thus there is a concern and desire to have input in the
process from the beginning. The PLC program should be knowledgeable of the feed rates, the
ingredients to fill, the coordination of when and how to mix and dump the material, when to
apply heat, etc.

With the batching system, scales and other material feed devices are required to monitor and
control the feed rates of the various materials. SP-88 defines the following material feed types:

 FILLING
“The SINGLE transfer (movement) of a specified amount of product from one single
location to another location”

 DOSING
“The SINGLE transfer (movement) of a specified amount of product from one location
into a continuous process”
 FORMULATION
“MULTIPLE transfers (movements) of specified amounts of products from various
locations into a single location”

 BLENDING
“MULTIPLE transfers (movements) of specified amounts of products from various
locations into a single location plus a single ADDITIONAL process phase – mixing”

 BATCHING

“MULTIPLE transfers (movements) of specified amounts of products from various

locations into a single location plus multiple ADDITIONAL process phases – heating,
cooling, wait, mix, agitate, dump etc.”

Ch. 13 Indexing – Batching Applications 37

The different methods of adding material to a batch are discussed. Most involve scales but there
are those that involve a meter or level sensor. Methods for measuring material include:

Material Feed Types

 Gain In Weight Feeders

 Loss In Weight Feeders
 Flow Meter Feed or Metered Feed
 Dump To Empty
 Hand Add

To add material using any of the above methods, a scale or load cell system should probably be
used to accurately weigh the product being added. The scale can be either on the container being
added to or fed from. The steps in weighing are critical in that consistency needs to be
maintained and proper records kept of all transactions. Decisions need to be made as well
whether the weight added is acceptable or not. The SP-88 document divides the weighing cycle
into six states as follows:

 Pre Feed
 Feed Start
 Feed
 Feed Stop
 Feed Finish
 Post Feed

It may be important to the programmer to identify every step and build their program around these
steps. Certainly the steps add order to the program and aid in troubleshooting the system. The
state diagram shown below also helps in identifying areas of concern and giving aid in
programming the feed.

Ch. 13 Indexing – Batching Applications 38

State Diagram of Material Add System

A state diagram is included in the SP88 diagram for each step of adding material and used as a
review of the steps outlined above:

Completed

Reset

Alarm In Alarm

Complete

Reset

Idle Start Requested Transferring

Pause

Pausing
Abort

Resume

Paused
Aborting

Reset Abort

Aborted

Fig 13-30

Alarms are likewise included the presence of an alarm, the setpoint over or under-run of the add
and whether or not the actual weight was acceptable to the operation before proceeding.

REPORTS

The following reports should be considered when weight is added to a mix:

o ActualFeedWeight
o Error
o ExistStatus

Ch. 13 Indexing – Batching Applications 39

Material Transfer Terminology

Some of the terms used in the addition of material using scales or rate feeders include:

Weighing Terminology

Gross
Net
Units
Zero
Center of Zero
Under Zero
Tare
Clear (Tare)
Over Capacity
Motion
Print

Material Transfer Terminology (definitions from SP-88)

“Target ( = Setpoint + Spill)

Set Point (= Target – Spill)
Spill (=Target –Set Point) (preact, in-flight, offset, bias)
 Fixed Spill
 Adaptive Spill
 Predictive Adaptive Spill
Fast Feed ( coarse feed)
Feed (fine feed, slow feed, dribble feed)

Control Methods
 BASIC Control – single speed transfer control

Dribble Setpoint or Dribble Target or Slow Feed Target(slow-feed setpoint,

dribble setpoint)

Flow Rate

Tolerance
Jog (re-dispensing)
 Manual Jog – operator starts jog feed and operator ends jog feed
 Semi-Automatic Jog – operator acks out of tol, starts jog feed and
controller ends jog feed
 Automatic Jog – operator acks selects auto accept out tol, controller starts
jog feed and ends jog feed
 Setpoint Error, Target Error, Feed Error”

Ch. 13 Indexing – Batching Applications 40

The inclusion of this kind of information regarding the addition of a material to a batch may
seem too much to digest but when faced with the task of programming the entire batch system,
many times from no prior program, it is important to ask the right questions and be able to make
the system perform to specification. Many people are depending on the accuracy of the batching
system since the product being made must guarantee accuracy within specifications on the label
of the product in the store. For pancake mix, this is very important, especially for those of us
who like good pancakes.

For a simple batching system with one main mix tank

Now that we have somewhat of an idea about a batching system structure, we could picture the
instructions used by the various PLC’s to provide the step move to an active step. The steps are
activated sequentially starting with step 1, step 2, …

Active Step
Step 1 Active
Step 1 Step Word 1
Step Word 2
Step Word 3
Step 2 Step Word 4

Step 3

Step 4

Step 5

Active Step

Step 1 Step 2 Active Step Word 1

Step Word 2
Step Word 3
Step 2 Step Word 4

Step 3

Step 4
Fig. 13-31
Step 5

Ch. 13 Indexing – Batching Applications 41

How Would You Program This?

The following picture is of a liquid batching system capable of simultaneously mixing batches in
three main mix tanks. In addition, there are six pre-mix tanks – any of which can be mixing a
pre-mix for any one of the main mix batches. Each tank measures addition of weight via scales.

Multiple pre-mixes may be required for each main mix and they mix concurrently in various pre-
mix tanks. They then add to the main mix at a prescribed time.

Begin to plan the programming of how a recipe is to be constructed to handle such a system as
this.

Premix A Premix B Premix C Premix D Premix E Premix F

Main Mix A Main Mix B Main Mix C

Fig. 13-32 Liquid Batch System

This is left as a problem for discussion.

Ch. 13 Indexing – Batching Applications 42

Other Types of Recipes

There are other recipe types not necessarily using scales and mx tanks. The following two
examples give some insight into the diversity of types of recipes.

Valve Nest:

This example requires a number of paths through a number of valves in a valve nest. Each valve
has two limit switches, one closed with a closed valve and one closed with an open valve. Each
valve in the transfer path must be set appropriately and its limit switches closed or opened in a
recipe in order to allow a transfer to occur. With a number of different transfer paths, these paths
may be considered recipes.

Steel Heat/Soak Cycle:

The heating of steel in the hardening process requires a recipe of time and heat setpoint. The
hardness of a piece of steel is determined with a recipe.

Several pieces can be inserted in the oven at the same time if they all support the same setpoints
and soak times. If various types are to be introduced at the same time, then a check must be
performed to determine whether the different recipes can be used at the same time.

This is similar to baking a cake. If one is determined to use the oven to bake a large number of
cakes, if one cake is ready to take out, then another cake can be inserted in the oven even if there
is a longer baking cake still in the oven.

The rules in the steel example are used to determine whether multiple pieces can be inserted at
the same time. These rules can be intricate.

Ch. 13 Indexing – Batching Applications 43

To access the instructions for Recipe and Data logging for Siemens, the following basic
instructions are selected:

From the instruction bar at right on

the TIA portal one can find in
Extended Instructions the entry for
Recipe and data logging, the focus of
this chapter. Expansion of the entry
give the instructions below:

The instructions for Recipe and data

logging are expanded here:

Ch. 13 Indexing – Batching Applications 44

 Using the help box for Recipes
gives the following:

This list gives a more extensive

listing of what can be learned
under the Recipes and data
logging operations.

What do all these do? I don’t

know. I would have to check
each out individually using the
help menu. Someday...

How to save data once it has been entered in an array:

In online mode, toggle ‘Snapshot’ above. Then copy snapshots to start values prior to
uploading and saving. This saves your data recently updated. A nice technique to know.
Ch. 13 Indexing – Batching Applications 45
When beginning a batch process, also consider the vendor. Allen-Bradley offers a toolkit, the
Batch Application Toolkit. Likewise, Siemens offers a Batch Process Control System:

The Siemens approach to batching resembles a kitchen and the baking of a cake or other product,
in this case, spaghetti:
“

Ch. 13 Indexing – Batching Applications 46

 ”

Chapter 31 of the Lab Text Book describes a robotic arm that was programmed to pick up and
place a checker in a box. The robotic arm consists of 4 axes and a suction attachment (not
shown). The entire program was written in a week and used for a capstone group’s display. The
program was written entirely with array storage of the positions of the robot arm. The program
is given in its entirety in Ch. 31 of that text.

Due to the weight of the end effector, the 5th

and 6th servos are removed. The end of arm
tool is replaced with the suction device shown
below. This is attached to servo 4 shown at
right.

Ch. 13 Indexing – Batching Applications 47

The following pages are from the Siemens Text:
Programming Guideline for S7-1200/1500 Entry ID: 81318674, V1.6, 12/2018

They summarize changes and upgrades to the Siemens Portal Language from Version 14 – TIA
and later. These next 10 pages instruct the TIA programmer about changes in the programming
language that improve the languages and make programming more flexible. Other chapters
containing parts of this text are Ch. 15, 16, 18, and 20.

Ch. 13 Indexing – Batching Applications 48

Ch. 13 Indexing – Batching Applications 49
Ch. 13 Indexing – Batching Applications 50
Ch. 13 Indexing – Batching Applications 51
Ch. 13 Indexing – Batching Applications 52
Ch. 13 Indexing – Batching Applications 53
Ch. 13 Indexing – Batching Applications 54
Ch. 13 Indexing – Batching Applications 55
Ch. 13 Indexing – Batching Applications 56
 ”

Ch. 13 Indexing – Batching Applications 57

Summary

This chapter explains a number of data handling instructions and provides applications for their
use in factory automation. An example of a batching application demonstrated the handling of
large amounts of data. The chapter covers topics in:

Recipes to active recipe to active step

State diagram of step logic
Arrays – how created – how manipulated
For Next in ladder – or SCL
UDT
Easy Book – Data Logging
Old Addressing Modes – Indirect, Indexed
R->T, T->R, T->T for Siemens, A-B
Scale systems – Siemens
SP-88
From simple to complex batching
Other uses of recipes
Instructions for Recipe Handling and Data Logging
Upgrade to Siemens Ver 14 for MOVE, etc

Included at the end of the chapter are two important labs using file manipulation to control
simple games. The games Simon Says and Whack-a-Mole are used to provide an experience in
the use of table-to-working register functions. In the MicroLogix 1000 processor, the only
available mode to consider table-to-register moves is the indexed mode. Whether using the
MicroLogix 1000 or other processor, these labs provide valuable experience programming
simple batching applications such as these. The example program was written for the
MicroLogix 1000 processor.

You may be curious how two games, Simon Says and Whack-a-Mole have anything to do with
batch applications. If run as sequences of numbers, the same operations used in these games are
used for batch applications. The games are to be programmed in this way. Do not consider
some form of random number generation but rather use storage of information in tables and then
retrieving the information as the game is being played. The Whack-a-Mole game has the added
similarity to a batching program in that one of the options asks for a report back as to how soon
after the mole popped up that the button was pushed. This is similar to the report of actual
weight added for the batch report. These labs will give experience in how actual batch programs
can be set up.

Several Lab Text Labs expand on the discussions of this chapter. They may be found in the Lab
Text under:

Chapter 12 Simon Says Game

Chapter 13 Whack-a-Mole
Chapter 14 Batch System Programming
Chapter 31 Simple Robot
Ch. 13 Indexing – Batching Applications 58
Lab 13.1 Simon Says

Use four illuminated push buttons to build the game Simon Says.
Use a fifth button to start the game.
Use a sixth light to signal the game is done good.
Use a seventh light to signal the game is done bad.

Simon Says is a sequential game that plays a four-note tune. This lab has no sound so lights will
have to do. After the start button is pushed, one light at a time is turned on. The player must
mimic or push the button attached to the light. First one light is lit, then two, then three, etc.,
until a final number is attained. Assume 15 is the final number of steps in the game. The steps
are repeated each time the game is played. The values are to be stored in a table and re-used.

Lab 13.1A Add a three-position switch to allow for easy, middle, hard ranges varying the
number of steps from 10 to 15 to 20.

Lab 13.1B Automatically rotate through 3 different sets of conditions for each range – easy,
middle, and hard.

Lab 13.1C Vary the speed that the lights are display as the player gets closer to the last step.

Lab 13.1D Create a teach mode using a separate button to teach the game a sequence of
steps.

Use the program starting on the next page as a suggested beginning point for your logic:

Fig. 13-33 Simon

Says Game

The program below is programmed for three, not four buttons and is programmed using
indexed addressing from the SLC architecture PLCs from A-B.

Ch. 13 Indexing – Batching Applications 59

Fig. 13-34a Simon Says Game Program in SLC

Ch. 13 Indexing – Batching Applications 60

Fig. 13-34b Simon Says Game Program in SLC
Ch. 13 Indexing – Batching Applications 61
Fig. 13-34c Simon Says Game Program in SLC
Ch. 13 Indexing – Batching Applications 62
In addition to the program, a table must be filled in starting at N7:0 in the N7 file.

Fig. 13-35 Simon Says Game Program in SLC

The file must also be inserted for the game to work correctly. Set the Radix to Binary and set
each word from N7:0 to N7: with either a 1 in the bit 0, 1, 2 or 3 position. The game will be
played using these entries.

Ch. 13 Indexing – Batching Applications 63

To implement the array and start the Simon program, the following is to be implemented. First,
to build an Array with the Siemens processor, add a new Data Block.

In the Data Block, add an array. We call it ‘arr’ and give it 15 locations. For type, we can chose
either ‘Byte’, ‘Int’ or ‘Dint’. We will choose ‘Byte’.

Ch. 13 Indexing – Batching Applications 64

Finally, expand the table and in the ‘Start value’ column, insert a series of integers.

These integers determine the game pattern. The same number may not be repeated but any series
is acceptable. The game will play the same series each time the game is played.

Ch. 13 Indexing – Batching Applications 65

The following shows the construct of the ‘Move’ instruction using a file to word format:

The following shows the construction of a ‘one shot’ or ‘edge trigger’ instruction.

The first rung of the program shows the ‘running’ of the game being set. Events that terminate
the game are ‘x’ instructions.

Ch. 13 Indexing – Batching Applications 66

With Allen-Bradley, the instructions are similar to Siemens for building an array. We do not
need to include a Data Block, however.

Populating the table is shown here:

The ‘Move’ block:

Ch. 13 Indexing – Batching Applications 67

And the Game Start Logic:

Lab 13.2 Whack-a-Mole

Design a Whack-a-Mole game using only 4 lights. The game is to react to the light by pushing
that particular button before the light turns off. Construct the game so that the time between
lights is pseudo-random (you pick various numbers) and the next light to turn on is pseudo-
random (again, you pick). Count the steps (light turn-ons) and stop at 30. If the person playing
the game is successful 10 of the 30 times, blink all the lights a number of times. The steps are
repeated each time the game is played. The values for buttons and time delays are to be stored
in a table and re-used.

Use a button not part of the game to start the game.

The layout is as follows:

Whack-a-mole buttons

Fig. 13-36

Button used to start game

Lab 13.2A Automatically rotate through 3 different sets of data tables.

Lab 13.2B Create a teach mode using a separate button to teach the game a sequence of steps
which can then be played.

Lab 13.2C Add a table of results including whether the player hit the light while the light was
Ch. 13 Indexing – Batching Applications 68
 on and how long the response was delayed from when the light first turned on.
Results for each hit are to be saved sequentially in the table.

Lab 13.2C1 Implement 13.2C above with a UDT output table. Save sequential hit data for
later display or analysis.

The structure of the two games is shown below:

Whack-a-Mole
Simon Says Game

Show Light Delay

Repeat up to 15
Repeat PB Show Light

Delay

Show Light

Delay

Show Light

Up to 30

Ch. 13 Indexing – Batching Applications 69

Lab 13.3 Liquid Batch Lab

The lab was first built by a capstone group. Since then, it has been used by a two other capstone
groups as well. It has been in storage at other times and is rather large.

Three Ingredient
Batch System

Purpose of the Lab – The purpose of this lab is to introduce students to batching system design.
Earlier lab exercises include games that simulate the same principles of design.

Scale Weighing

Scale Weighing Systems are an important part of a batch system. Siemens provides a load cell
interface system for weighing applications called the SIWAREX WP231.

The electronic weighing system has the following characteristics as listed by Siemens:
“
● Uniform design technology and consistent communication in SIMATIC S7-1200
● Parameter assignment by means of HMI panel or PC
● Uniform configuration option in the SIMATIC TIA Portal
Ch. 13 Indexing – Batching Applications 70
● Measuring of weight with a resolution of up to 4 million divisions
● High accuracy, 3000 d, legal for trade according to OIML R76
● Legal-for-trade display with SIMATIC operator panel or PC
● High measuring rate of 100/120 Hz (effective interference frequency suppression)
● Limit monitoring
● Flexible adaptation to varying requirements
● Easy calibration of the scales using the SIWATOOL program
● Automatic calibration is possible without the need for calibration weights
● Module replacement is possible without recalibrating the scales
● Use in Ex Zone 2 / ATEX approval
● Intrinsically safe load cell supply for Ex Zone 1 (SIWAREX IS option)
● Diagnostics functions”

SIWATOOL overview

SIWATOOL does not only offer support when you set the scale but also when you analyze
the diagnostic buffer that can be saved after being read out of the module together with the
parameters. The display of the current scale status can be configured.

A load cell is pictured in the figure below:

Ch. 13 Indexing – Batching Applications 71
Also, the load cell can be terminated in a converter box similar to the Red Lion Strain/Load Cell
Panel Meter pictured below. Since it can be used to interface to a PLC using an optional analog
output, the Red Lion is used simply to pass through a signal from the scale to the PLC after
linearization has occurred with the scale signal.

Lab 13.4 Simple Robotic Arm

Using the program from Ch. 8 for the servo arm, design a robotic arm that has four degrees of
motion. The arm is to move in a set number of motions with a time delay between motions so as
to pick up a coin and lay it down in another spot.

The four axes control the four servo motors in the robot with PWM output control. The
processor is the S7-1215 DCDCDC model. The axes are set up similar to the code below. The
program can be written to move between various settings for the sp_x variables for the four axes.

Ch. 13 Indexing – Batching Applications 72

The PWM outputs are controlled through configuring PWM1, PWM2, PWM3 and PWM4 below:

Variables that control movement are sp_1, 2, 3, and 4 (setpoints). The program may be tested by
setting ena to 1 and test_1, 2, 3, and 4 to 1. The setpoint variables are the position points.

Ch. 13 Indexing – Batching Applications 73

Configuration of the PWM axes follow. They all resemble PWM1 shown below:

The other outputs are wired as follows:

Axis 2 – Q0.1
Axis 3 – Q0.3
Axis 4 – Q0.4

Ch. 13 Indexing – Batching Applications 74

Output variables to be written to are:

Axis 1 - QW1008
Axis 2 – QW2
Axis 3 - QW1014
Axis 4 – QW8

Each variable is 16 bit (Word length).

Each axis must contain the following logic:

This instruction must be inserted to set up the PWM motion.

This lab may be programmed several different ways. The best would include arrays that have
positional data for the various axes. As the robot moves through various positions, the robot
program moves down through the list of position data at each position. There should also be a
rate of movement for each of the axes (or perhaps just one common rate as programmed here).
The rate of movement is important as well as sequence of the positional data.

At present, only one of these robotic arms is available. The 5 V separate power supply is
extremely important as the current draw by the various axes is large.

Ch. 13 Indexing – Batching Applications 75

The following logic is a timer that either increases or decreases the value to be output to the
PWM. The setpoint determines whether the value is to grow or decrease.

Ch. 13 Indexing – Batching Applications 76

 The power supply shown at left is a
large 5 V supply capable of
supplying current to a number of
different servo controllers.

The remainder of this lab is found

in the Hybrid Lab Text’s Ch. 31.
The entire listing is found there for
a program that takes a number
(command) and moves through up
to 9 different points to execute a
robotic motion. There is a fifth
array with the command to either
pick up or put down a part using
suction.

Ch. 13 Indexing – Batching Applications 77

Exercises:

1. Write logic to move sequential data from a table starting at N7:20 to location B3:20. Use
B3/9 to reset to the top of the file (B3/9 is a one-shot pulse). Use B3/10 to move the data
(B3/10 is also a one-shot pulse).

Use the instructions below to fill in changes in the table:

Source Value Destination Value
N7:0 102 N10:0 0
N7:1 115 N10:1 0
N7:2 210 N10:2 0
N7:3 365 N10:3 0
N7:4 542 N10:4 0
N7:5 9 N10:5 0

Destination Value
2.. MOV N10:0
#N7:0 and s:24 =2 N10:1
N10:0
N10:2
N10:3
N10:4
N10:5

3. MOV
Destination Value
#N7:0 and s:24 =4
N10:0
#N10:0
N10:1
N10:2
N10:3
N10:4
N10:5

4. MOV Destination Value

N7:0 and s:24 =3 N10:0
#N10:0 N10:1
N10:2
N10:3
N10:4
N10:5

5. With the problems 2-4 above, rewrite the logic using Siemens’ LAD equivalent instruction,
Allen-Bradley’s RSLogix 5000 LAD equivalent instruction.

6. Rewrite rungs 9-14 of the Simon Says sample program using A-B RSLogix 5000 LAD code.

7. Review the following from the Chemicals & Petrochemicals Plant Automation Congress
2015 presentation “Batch Process Control Strategy”

Ch. 13 Indexing – Batching Applications 78

8. Review a scale input method and comment on the interface between the scale system and the
PLC.

9. Discuss implementation strategies for programming the batch project in Fig. 13-32.

10. Write a program to successfully turn off a solenoid based on a moving weight for the analog
value when the updated values are only reported every 1/3 second. Use the following graph
as a guide.

11. Using the A-B software and the Siemens software, create a UDT with at least five different
variables and three different types.

12. Provide a network compiled and working using a Variant type variable.

Ch. 13 Indexing – Batching Applications 79

Appendix

Linking PLC UDT Tags to HMI Faceplates and Pop-ups in TIA Portal V13 SP1 (DMC Corp)

A blog posted by Jason Mayes in Front Page, PLC, Automation, Siemens PLC, HMI and
SCADA, WinCC
Please Review for Creating UDTs combining Logic and HMI

User Defined Data Types (UDTs) with A-B

The Controller Organizer has a folder called Data Types > User-Defined with all the UDTs in the
project.

Review this data type from A-B.

Leveraging Siemens MultiUser Engineering for TIA Portal

Posted by Gina Brooks-Zak in PLC, Automation, Siemens PLC, HMI and SCADA

Review this as well:

This work is licensed under a Creative Commons Attribution 4.0 International License.

Ch. 13 Indexing – Batching Applications 80