1. L12 - Basic PLC Programming with Micro800® Controllers
Hands-on Lab

2. Agenda Introduction to Terms / Concepts Micro800® Family
Connected Components Workbench™ software
Application Examples
Hands-on Lab

3. What Is a PLC?
A solid-state (electronic) device that controls output devices that are based on control program and input signals
Inputs
Outputs
Control
Program

4. Two Types of I/O (Inputs and Outputs)
Digital
Also called Discrete
Has two possible states
Represented by “1” or “0”
Electrically:
“0” is usually 0 Volts (AC or DC)
“1” is a fixed voltage value such as 5VDC, 24VDC, 120VAC,.
Technology: Relays, Triac, Transistor, MOSFET, TTL
Analog
Has many possible states between two values.
Example: Temperature sensor.
Range of values between two limits. For example:
0°F represented by “0”
100°F represented by “4095” (example)
Electrically: 4-20mA, 0-5VDC, -10VDC to 10VDC
4095 1

5. This is a simple rung of logic, from a PLC program:
Ladder Logic Example
This is a simple rung of logic, from a PLC program:
Start_Button
Light
The rung is read as:
If the Start Button is on, turn ON the Light. If the Start Button is off, turn OFF the Light. 17

6. Simple PLC Instructions (IEC 1131)
Contacts
Direct
Reverse
Coils
Set
Reset
Instruction Blocks
Arithmetic (+ - * / COS SIN TAN)
Binary (Mask, Shift)
Boolean (AND,OR,NOT,XOR)
Comparator (< > = CMP)
Counter (CTD, CTU, CTUD)
Data Conversion (ANY_TO_**)
Process (PID, SCALER, more…)
String (FIND, REPLACE, more…)
Time (TON,TOF,TONOFF) S R

7. PLC Control Program Program
Instructions that are used to process inputs and set outputs
Primarily written as (Relay) Ladder Diagram:
Programs can also be written in other languages
Function Block or Structured Text
Data (Variables)
Examples
Start_Button is assigned to a digital input
Light is assigned to a digital output
Start_Button
Light

8. I/O Addressing
Often, a descriptive name of the device that is connected to the I/O point is used and, or in place of the I/O variable that describes the physical location on the controller.
Example of user-defined
name
Start Button
Light
_IO_Embedded_Digital_Input_0
_IO_Embedded_Digital_Output_0
Example of system-defined
I/O variable

9. Applications Today Require a High Level of Control Capability and Advanced Features
Arithmetic (Addition, Subtraction, Multiplication, Division, etc...)
Data Comparison (Equal, Greater Than or Equal, Less Than or Equal)
Word Manipulation (Copy, Move, etc...)
Communications or Messaging data between PLCs
Sequencing
Data Manipulation
Motion and Process Control (Used for Temperature, Pressure, Speed, Flow regulation)
Stop light is a perfect example of Discrete I/O Control. It requires Inputs such as street sensors, outputs (the lights themselves), Timers, even counters…
Example of PID control is a dryer section of a Paper machine or more simple: the temperature control of boiler.
PLC Basics - Automation Fair 2006

10. Agenda Introduction to Terms / Concepts Micro800® Family
Connected Components Workbench™ software
Application Examples
Hands-on Lab

11. Micro800® Controller Family
Nano PLC Micro PLC
Each controller is cost and performance that is optimized for specific applications
24-132pts
Performance/Features
Local I/O
10-88pts
20-36pts
12pts
Micro850®
For standalone machines with motion and more I/O and Ethernet connectivity.
Micro810®
Programmable relay replacer and timer
8A relay outputs,
Analog inputs
Micro830®
For standalone machines with motion
Micro820™
For smaller standalone machines and remote automation
EmbeddedAnalog I/O

12. Micro800® PLCs

13. Agenda Introduction to Terms / Concepts Micro800® Family
Connected Components Workbench™ software
Application Examples
Hands-on Lab

14. Connected Components Workbench™ Single Software for All Your Component Devices
Notes about free SW from competitors:
Major competitors do not provide free software for download and they require a license serial number.
Competitors may provide free licenses to customers but you still have to get the SW on DVD and maintain those licenses. If your PC fails, you must find that license serial number to install it on the replacement PC. With CCW SW you can always download the latest version from RA download site and install it.
Competitors may allow you to install a single copy of the software on several PCs with a single serial number but with CCW’s license agreement, you can install it legally as many times as you want.

15. Connected Components Workbench™ Software
Lower the cost to Design, Develop and Deliver your machine
Easy to Configure
Single software package for all your essential components reduces time to create and maintain your machine design
PowerFlex® drive wizards make configuration easier
Guardmaster® configurable safety relay editor make safety logic intuitive
Easy to Program
Micro800® controller supports your choice of IEC PLC programming languages (Ladder Diagram, Function Block Diagram, Structured Text) to suit your application
User-defined function blocks speed machine development
Standard PLCopen motion instructions with PTO Motion Axis and HSC Feedback Axis removes the complexity from simple positioning applications
Easy to Visualize
Micro800 variable names can be directly referenced by HMI tags, which results in less complexity and time-saving benefits

16. Connected Components Workbench™ Software
Comparison of Standard versus Developer Editions
Standard Edition
Developer Edition
Price
Free for download or on DVD
Contact local distributor
Common environment to configure all your common devices
Yes
Project import/export
Archive manager No
Micro800 Programming
- IEC ladder diagram, function block diagram, structured text
- User-defined function block
- Run mode change
- User-defined data types
No*
- Spylist Used
Existing lists
New lists can be created
- Intellectual Property Protection
No**
Developer Edition is for machine developers to reduce their time to Design, Develop and Deliver
Standard Edition is meant to be installed on many PCs to ensure availability for simple debugging and configuring devices
* – requires Developer Edition to create new data types, which can be used in Standard Edition.
**- requires Developer Edition to create passwords, which can be used in Standard Edition.

17. Agenda Introduction to Terms / Concepts Micro800® Family
Connected Components Workbench™ software
Application Examples
Hands-on Lab

18. So Where Could You Use a PLC?
Conveyor control
Printed circuit board handling equipment
SCADA(Supervisory Control And Data Acquisition)
Remote pump/lift station (water/wastewater)
Flow monitoring for leak detection (Oil & Gas)
Strapping machinery / trash compactors
Palletizers
Compressor control
Amusement park rides and attractions
Hard-wired relay panels or Single Board Computers
Many more…
PLC Basics - Automation Fair 2006

19. Application Animations
Virtual demo of our application includes voiceover and Connected Components Workbench™ solution drawings
Solar Tracking
Adhesive Labeler
VFFS
Stretch Wrapper
Shearing Machine
Air Handling Unit
Material Handling Unit
Water Pump

20. Typical Configurations including Performance Limitations
Micro800® Popular Configuration Drawings Helps OEMs Size and Design Their Machines To avoid Issues Before They Happen
Drives and I/O on DeviceNet
Safety and Motion
Typical Configurations including
Test Data to highlight
Performance Limitations

21. Agenda Introduction to Terms / Concepts Micro800® Family
Connected Components Workbench™ software
Application Examples
Hands-on Lab