Chapter 9

© 2011, The McGraw-Hill Companies, Inc.

9.1

Master Control Reset

Instruction
© 2011, The McGraw-Hill Companies, Inc.
Program control instructions are used to enable
or disable a block of logic program or to move
execution of a program from one place to
another place.

Program Control menu tab for the Allen-Bradley

SLC 500 PLC
© 2011, The McGraw-Hill Companies, Inc.
Hardwired master control relays
are used in relay control circuitry
to provide input/output power
shutdown of an entire circuit.

Hardwired
master control
relay circuit.

© 2011, The McGraw-Hill Companies, Inc.

PLC manufacturers offer a form of a master
control relay as part of their instruction set.

MCR (Master Control Reset) -Clears all set

nonretentive output rungs between the paired MCR
instructions.

Because the MCR instruction is programmed, for safety

reasons, it should not be used as a substitute for a
hardwired master control relay, which provides
emergency I/O power shutdown.
© 2011, The McGraw-Hill Companies, Inc.
Programmed Master Control Reset instruction.

© 2011, The McGraw-Hill Companies, Inc.

 Simulated Master Control Reset instruction.

© 2011, The McGraw-Hill Companies, Inc.

 MCR fenced zone with the zone true.

© 2011, The McGraw-Hill Companies, Inc.

 MCR fenced zone with the zone false.

© 2011, The McGraw-Hill Companies, Inc.

 Simulated MCR fenced zone.

© 2011, The McGraw-Hill Companies, Inc.

9.2

Jump Instruction

© 2011, The McGraw-Hill Companies, Inc.

The jump (JMP) instruction is used to jump over
certain program instructions when certain
conditions exist.

The label instruction is used to identify the ladder rung

that is the target destination but does not contribute to
logic continuity.

© 2011, The McGraw-Hill Companies, Inc.

 Jump (JMP) operation program.

© 2011, The McGraw-Hill Companies, Inc.

 Simulated jump (JMP) operation program.

© 2011, The McGraw-Hill Companies, Inc.

Effect on
instructions
of jumped
rungs.

© 2011, The McGraw-Hill Companies, Inc.

 Jump-to-label from two locations.

© 2011, The McGraw-Hill Companies, Inc.

9.3

Subroutine Functions

© 2011, The McGraw-Hill Companies, Inc.

A subroutine is a short program that is used by
the main program to perform a specific function.

JSR (Jump to RET (Return from SBR

Subroutine) Subroutine) (Subroutine)
Jump to a Exits current Identifies the
designated subroutine subroutine
subroutine and returns to program.
instruction. previous condition.

© 2011, The McGraw-Hill Companies, Inc.

When a subroutine is called from the main program,
the program is able to escape from the main program
and go to a program subroutine to perform certain
functions and then return to the main program.

© 2011, The McGraw-Hill Companies, Inc.

 Flashing pilot light subroutine program.

Anytime the weight on the conveyor exceeds a

preset value, the subroutine program is scanned
and pilot light changes from on to flashing.
© 2011, The McGraw-Hill Companies, Inc.
 Main
Program

Subroutine
Program

© 2011, The McGraw-Hill Companies, Inc.

 Simulated subroutine program.

© 2011, The McGraw-Hill Companies, Inc.

 Setting up a
subroutine file.

© 2011, The McGraw-Hill Companies, Inc.

 Passing
subroutine
parameters

© 2011, The McGraw-Hill Companies, Inc.

 Nested subroutines.

© 2011, The McGraw-Hill Companies, Inc.

9.4

Immediate Input and

Immediate Output
Instructions
© 2011, The McGraw-Hill Companies, Inc.
The immediate input and immediate output
instructions interrupt the normal program scan
to update the input and output image table files
with current data.

Immediate input Immediate output

(IIN) (IOT)
PLC-5 instruction PLC-5 instruction
is used to read an is used to update the
input condition status of an output
before the I/O device before the I/O
update is performed.
© 2011, The McGraw-Hill Companies, Inc.
update is performed.
Immediate input
instruction operation.

© 2011, The McGraw-Hill Companies, Inc.

Immediate output
instruction operation.

© 2011, The McGraw-Hill Companies, Inc.

SLC 500 Immediate Input with Mask (IIM)
instruction.

When the rung is true,

the program scan is
interrupted, and data
from a specific input
slot are transferred
through the mask to
the input data file.
© 2011, The McGraw-Hill Companies, Inc.
SLC 500 Immediate Output with Mask (IOM)
instruction.

When the rung is

true, the program
scan is interrupted to
update output data to
the module located in
the slot specified in
the instruction.
© 2011, The McGraw-Hill Companies, Inc.
9.5

Forcing External I/O

Addresses
© 2011, The McGraw-Hill Companies, Inc.
 Forcing allows the PLC
user to turn an external
input or output on or off
from the keyboard of the
programming device.

Forcing is accomplished
regardless of the actual
state of the field device.
© 2011, The McGraw-Hill Companies, Inc.
Forcing an
input on.

© 2011, The McGraw-Hill Companies, Inc.

 Simulating forcing an input on.

© 2011, The McGraw-Hill Companies, Inc.

Forcing an
output on.

© 2011, The McGraw-Hill Companies, Inc.

 Simulating forcing an output on.

© 2011, The McGraw-Hill Companies, Inc.

By forcing outputs off, you can prevent the
controller from energizing those outputs even
though the ladder logic, which normally
controls them, may be true.

© 2011, The McGraw-Hill Companies, Inc.

You can enter and enable or disable forces while
you are monitoring your file offline, or in any
processor mode while monitoring your file online.

Forces version of the data table with bit

I:1/3 forced on.
© 2011, The McGraw-Hill Companies, Inc.
If used incorrectly, force functions can cause
injuries to persons working around a system,
and/or equipment damage.
You must
understand the
potential effect that
forcing given inputs
or outputs will have
on machine
operation in order to
avoid possible
personal injury and
equipment damage.
© 2011, The McGraw-Hill Companies, Inc.
9.6

Safety Circuitry
© 2011, The McGraw-Hill Companies, Inc.
Sufficient emergency
circuits must be
provided to stop
either partially or
totally the operation of
the controller or the
controlled machine or
process.

These circuits should

be hardwired outside
the controller.
© 2011, The McGraw-Hill Companies, Inc.
 Safety wiring
requirements for a
PLC installation.

© 2011, The McGraw-Hill Companies, Inc.

 The master
control relay
must be able
to inhibit all
machine
motion by
removing
power to the
machine I/O
devices when
the relay is
deenergized.

© 2011, The McGraw-Hill Companies, Inc.

Safety PLCs are now available for applications
that require more advanced safety functionality.

© 2011, The McGraw-Hill Companies, Inc.

Both standard and safety PLCs have the ability
to perform control functions but a standard
PLC was not initially designed to be fault
tolerant and fail-safe.
Safety PLCs have redundant (dual) microprocessors.

Safety PLCs have an internal output circuit

associated with each input for the purpose of testing
the input circuitry.

Safety PLCs use power supplies designed specifically

for use in safety control systems and redundant
backplane circuitry between the controller and I/O
modules.
© 2011, The McGraw-Hill Companies, Inc.
The use of the field-
generated starter auxiliary
contact is safer because it
provides positive feedback
to the processor about the
exact status of the motor.

© 2011, The McGraw-Hill Companies, Inc.

All stop buttons should be wired using a
normally closed contact programmed to examine
for an on condition.

Using a normally open contact

programmed to examine for an off
condition will produce the same logic but
is not considered to be as safe.
© 2011, The McGraw-Hill Companies, Inc.
9.7

Selectable Timed
Interrupt
© 2011, The McGraw-Hill Companies, Inc.
The selectable timed interrupt (STI) instruction is
used to interrupt the scan of the main program
file automatically, on a time basis, to scan a
specified subroutine file.

The selectable timed disable

(STD) instruction is generally
paired with the selectable timed
enable (STE) instruction to
create zones in which STI
interrupts cannot occur.

© 2011, The McGraw-Hill Companies, Inc.

The selectable timed
disable (STD)
instruction
is generally paired
with the selectable
timed enable
(STE) instruction to
create zones in which
STI interrupts
cannot occur.

© 2011, The McGraw-Hill Companies, Inc.

9.8

Fault Routine

© 2011, The McGraw-Hill Companies, Inc.

A fault subroutine file, if used, determines how
the processor responds to a programming error.

When the processor detects a major fault, it looks for a

fault routine. If a fault routine exists, it is executed; if one
does not exist, the processor shuts down.

When there is a fault routine, and the fault is

recoverable, the fault routine is executed.

If the fault is non-recoverable, the fault routine

is scanned once and shuts down.
© 2011, The McGraw-Hill Companies, Inc.
9.9

Temporary End
Instruction
© 2011, The McGraw-Hill Companies, Inc.
The temporary end (TND) instruction is used to
progressively debug a program or conditionally
omit the balance of your current program file or
subroutines.

When rung conditions are true,

this instruction stops the
program scan, updates the I/O,
and resumes scanning at rung
© 2011, The McGraw-Hill Companies, Inc.
0 of the main program file.
The TND instruction
lets your program run
only up to this
instruction.

You can move it progressively

through your program as you
debug each new section.

You can program the TND

instruction unconditionally, or
you can condition its rung
according to your debugging
needs.
© 2011, The McGraw-Hill Companies, Inc.
Simulated temporary end instruction program.

© 2011, The McGraw-Hill Companies, Inc.

9.10

Suspend Instruction

© 2011, The McGraw-Hill Companies, Inc.

The suspend (SUS) instruction is used to trap
and identify specific conditions during system
troubleshooting and program debugging.

© 2011, The McGraw-Hill Companies, Inc.

 When the rung is true, the SUS
output instruction places the
controller in the suspend mode
and the PLC immediately
terminates scan cycling.

All ladder logic outputs are de-energized, but other

status files have the data present when the suspend
instruction is executed.

The SUS instruction writes the suspend ID number

(100) to S:7 as it executes.

You can include several SUS instructions in a

program, each with a different suspend ID.
© 2011, The McGraw-Hill Companies, Inc.