Industrial Automation

Second Semester 2019/2020

Lecturer: Dr Mohannad Jreissat

Chapter 8: Programming Counters

Textbook:
Petruzella, Frank D., Programmable Logic Controllers. McGraw
Hill Companies Inc., 5th edition

Email: [email protected]
Office: E3088
 Counters
Common applications of counters include keeping track
of the number of items moving past a given point, and
determining the number of times a given action occurs.

A preset counter can control an

external circuit when its
counted total matches the
user-entered preset limits.
Mechanical Counters

Programmed counters can serve

the same functions as mechanical
counters.

Every time the actuating lever is moved

over the counter adds one number,
while the actuating lever returns
automatically to its original position.
Resetting to zero is done with a
pushbutton located on the side of the
unit.
 Electronic Counters
Electronic counters can count up, count down, or be combined
to count up and down. They are dependent on external
sources, such as parts traveling past a sensor or actuating a
limit switch for counting.

Counter
Applications
 Coil-Formatted Counter Instruction
The coil is assigned an
address as well as being
identified as a counter

Increments Like the timer, preset and

counter by 1 for accumulated values are
every false-to-true included
transition

When the accumulated count equals the preset count, the

output is energized and the counter output is closed. The
counter contact can be used as many times as you wish
throughout the program as an NO or NC contact.
Coil-Formatted Counter And Reset Instruction

Same address

Resets counter when true

 Block-Formatted Counter Instruction

Count line Type of

counter Output
line
Preset value

Reset line Accumulated

value

PLC counters operate or count on the leading edge of the

input signal. The counter will either increment or decrement
whenever the count input transfers from an "off" state to an
"on" state. The counter will not operate on the trailing edge,
or on-to-off transition of the input condition.
 Counter Counting Sequence

PLC counters are normally retentive. Whatever

count was contained in the counter at the time of a
processor shutdown will be restored to the counter on
power-up. The counter may be reset, however, if the
reset condition is activated at the time of power
restoration.

PLC counters can be designed to count up to a preset

value or to count down to a preset value.
 Counter Counting Sequence
The up-counter is incremented by 1 each time the rung
containing the counter is energized.

The counter will increment until the accumulated value is

equal to or greater than the preset value, at which time an
output will be produced.
 Counter Counting Sequence
The down-counter decrements by 1 each time the rung
containing the counter is energized.

A counter reset is always provided to cause the counter

accumulated value to be reset to a predetermined value.
Simple Up-counter Program

7
Up-counter Program Timing Diagram
 C5 Counter Data File
Each counter address is made of a 3-word element

•Bit 0-9: Internal Use

•Bit 10:
Specifies the value, UAthe
which - Update
counteraccumulation value. the controller
must reach before
This is the number
•Bit of
11:times
UN ofUnderflow
false to true transitions that have occurred
sets the done bit. When the-accumulated bit.
value becomes equal to or
since the counter was
•Bit 12:last
OV reset.
- Overflow
greater than the preset value, the donebit.
status bit is set. You can use this
•Bit
bit to control an 13: DN
output - Done
device.
•Bit 14: CD - Count down is enabled.
•Bit 15: CU - Count up is enabled.
PLC-5 And SLC 500 Count-Up Counter Instruction
 ControlLogix Count-Up Counter Instruction

For example,
The counter address it to say
in the PLC-5 that
and SLC 0-9999
500 is
is a data table
16-bit BCD(binary coded decimal) and
address, whereas Because
Why
in
that
the the most
toweird
ControlLogix
-32,768 plc's
32767 numbers?! have
it is0ato
and
predefined
65535 is
16-bit counters.
16-bit binary.
structure of the data type.

In the PLC-5 and SLC 500, the max value for the preset and
accumulated values is 32,767 and the min value is –32,768; for
the ControlLogix controller the max value is 2,147,438,647 and
the min value is –2,147,438,648.
 RSLogic Counter Commands

Command Name Description

Decrements
Increments
Resets the the
the accumulated
accumulated
accumulated
Counts high-speed pulses
RES
HSC
CTD
CTU Count-Down
Count-Up
High-Speed
Reset value
value ataand
at
value each
each false-to-true
false-to-true
status bit of
from fixed controller
Counter transition
transition andinput
and
the counter
high-speed retains the
retains the
accumulated value
accumulated value when
when
power cycle
power cycle occurs
occurs
 Parts Counting Program

Counter C5:2 counts the

total number of parts coming
off an assembly line for final
packaging

Each package must contain 10 parts

When 10 parts are detected, counter C5:1 sets bit B3/1 to
initiate the box closing sequence

Counter C5:3 counts the total number of packages filled per day

A pushbutton is used to restart the total part and package count

from zero daily
Parts Counting Program

10
9
15

10
59

1
 One-Shot, Or Transitional, Contact Program
The transitional or one shot contact program can be used to
automatically clear or reset a counter. The program is designed
to generate an output pulse that, when triggered, goes on for
the duration of one program scan and then goes off.
 One-Shot, Or Transitional, Contact Program
The transitional or one shot contact program can be used to
automatically clear or reset a counter. The program is designed
to generate an output pulse that, when triggered, goes on for
the duration of one program scan and then goes off.

The one-shot can be

triggered from a
momentary signal, or
one that comes on and
stays on for some time.
 Types Of Transitional Contacts
Off-To-On Transitional Contact
Is programmed to
On provide a one-shot
pulse when the
Off referenced trigger
signal makes a
On positive (off-to-on)
Symbol One
transition
Off scan

On-To-Off Transitional Contact

On Is programmed to
provide a one-shot
Off pulse when the
referenced trigger
On signal makes a negative
Symbol One
scan
(on-to-off) transition
Off
 Conveyor Motor Circuit That Uses A
Programmed One-Shot Reset Circuit
Proximity
switch Sequential Task:

The start button is pressed

Case
to start the conveyor motor

Cases move pass the proximity

switch and increment the
Count reset
Conveyor motor
button
counter's accumulated value
Start/Stop station

After a count of 50, the conveyor motor stops automatically

and the counter's accumulated value is reset to zero
The conveyor motor can be stopped or started manually at
anytime without loss of the accumulated count
Conveyor Motor Circuit That Uses A
Programmed One-Shot Reset Circuit

50
 One-Shot Rising (OSR) Instruction

• Triggers a one-time event.

• The OSR instruction is a retentive input instruction
that triggers an event to occur only one time. Use the
OSR instruction when an event must start based on
change of state of the rung from false to true.
• When the input instruction goes from false to true, the
OSR instruction conditions the rung so that the output
goes true for one scan. The output goes false and
remains false for successive scans until the input makes
another false to true transition.
 Alarm Monitor Program

▪ The alarm is triggered by the closing of liquid level switch

LS1

▪ The light will flash whenever the alarm condition is triggered

and has not been acknowledged, even if the alarm condition
clears in the meantime

▪ The alarm is acknowledged by closing selector switch SS1

▪ The light will operate in the steady mode when the alarm
trigger condition exists but has been acknowledged
Alarm Monitor Program
 Down-Counter
The down-counter output instruction will count down
or decrement by 1 each time the counted event occurs.
Each time the down-count event occurs, the
accumulated value is decremented. Normally the down-
counter is used in conjunction with the up counter to
form an up/down counter.

Generic up/down
counter program
Up/Down Counter Timing diagram

Preset Value = 3
 Parking Garage Counter Program

➢ As a car enters, it triggers the up-counter output instruction and

increments the accumulated count by 1.
➢ As a car leaves, it triggers the down-counter output
instruction and decrements the accumulated count by 1.
➢ Since both the up- and down-counters have the same address,
the accumulated value will be the same in both.
➢ Whenever the accumulated value equals the preset value, the
counter output is energized to light up the Lot Full sign.
Parking Garage Counter Program

50
38
150

50
150
38
 PLC-5 And SLC-500
Count-Down Counter Instruction

If the accumulation value is below the

minimum range then the underflow
(UN) bit will be true.
 Up/Down-Counter Program

1
10

1
10

When
Whenthe the CTU
CTD instruction
theaccumulated
instruction
When
is true, C5:2/CU will be value
true
isgreater
true,CC5:2/CD
isInput going
than true
or will beto
will
equal true
cause
the
causing
causing output
output A
B to
to be
be true
true
both counter
preset instructions
value, C5:2/DN will to
be
resetcausing output C to be
true,
true
 In-Process Monitoring System

After processing,
Before start-up, finished
the parts
system is appearing empty
completely at the out-feed
of parts, sensor
and
When the
generate operation
down begins,
counts, raw parts
so the accumulated move through the in-feed
count of the counter
the counter is reset manually to zero.
sensor, with each
continuously part generating
indicates the numberan ofup count. parts.
in-process
In-Process Monitoring System

58

8
5
 Counter Speed

The maximum speed of transitions you can count is

determined by your program's scan time. Any counter
input signal must be fixed for one scan time to be
counted reliably.

If the input changes faster

than one scan period, the
count value will become
unreliable because counts
will be missed. When this is
the case you need to use a
high-speed counter.
Cascading Counters

Depending on the
application, it may be
necessary to count events
that exceed the maximum
number allowable per
counter instruction. One way
of accomplishing this is by
interconnection, or
cascading, two counters.
Counting Beyond The Maximum Count

15000
 Counting Beyond The Maximum Count

The output of the

first counter is
programmed into
the input of the
The status second counter
bits of both
counters are
These two
programmed
counters allow
in series to
twice as many
produce an
counts to be
output
measured
Cascading Counters For Extremely Large Counts

500
0

Whenever counter C5:1

reaches 500, its done bit
resets counter C5:1 and
1
increments counter C5:2
by 1

The output light turns

on after 500 x 500, or
250,000 transitions of
the count input
24 Hour Clock Program
The timer times for a 60 s period,
after which its done bit is set. This,
in turn cases C5:0 to increment 1
count. On the next processor scan,
the timer is reset and begins timing
again.

Whenever C5:0 reaches its preset

value of 60, its done bit is set. This, in
turn causes it to reset itself and C5:1
to increment 1 count.

Whenever C5:1 reaches its preset

value of 24, its done bit is set to reset
itself.
Program For
Monitoring
The Time
Of An Event
 Incremental Encoder
An incremental encoder creates a
series of square waves as its shaft
is rotated.
The encoder disk interrupts the light
as the encoder shaft is rotated to
produce the square wave output
waveform.
Incremental Encoder

The number of square waves obtained

from the output of the encoder can be
made to correspond to the mechanical
movement required.

To divide a shaft revolution into 100

parts, an encoder could be selected to
supply 100 square wave cycles per
revolution. By using a counter to
those cycles, we could tell how far
the shaft has rotated.
 Cutting Objects To A Specific Size

The object is advanced for a specific distance and measured

by encoder pulses to determine the correct length for
cutting.
 Counter Used For Length Measurement
Count input pulses are generated by the magnetic sensor, which
detects passing teeth on a conveyor drive sprocket. If 10 teeth per
foot of conveyor motion pass the sensor, the accumulated count of
the counter would indicate feet in tenths.

The photoelectric sensor monitors a reference point on the

conveyor. When activated, it prevents the unit from counting,
thus permitting the counter to accumulate counts only when bar
stock is moving.
Counter Used For Length Measurement

10

Photo sensor activated, therefore,

accumulated count remains at 10
Combining Counter And Timer Functions
When the start button is pressed,
conveyor M1 begins running.

After 15 plates have been stacked,

conveyor M1 stops and conveyor
M2 begins running.

After conveyor M2 has been

operated for 5 s, it stops and the
sequence is repeated
automatically.

The done bit of the timer resets

the timer and counter, and
Automatic Stacking Process provides a momentary pulse to
automatically restart conveyor
M1.
Automatic
Stacking
Program
 Motor Lock-Out Program
Designed to prevent The normally open (OL) relay
a machine operator contact momentarily closes
from starting a each time an overload current
motor that has is sensed.
tripped off more Every time the the motor
than 5 times in an stops due to an overload
hour. condition, the motor start
circuit is locked out for 5 min.

If the motor trips off more

than 5 times in an hour, the
motor stat circuit is
permanently locked out and
cannot be started until the
reset button is actuated.
Motor
Lock-Out
Program
 Product Flow Rate Program

Parts This program is designed to indicate how

many parts per minute pass a given
process point.
Sensor
When the start switch is closed, both the counter and timer
are enabled.
The counter is pulsed for each part passing the sensor.
The counting begins and the timer starts timing through its
1-min time interval.

At the end of 1 min, the timer done bit causes the counter
rung to go false. Sensor pulses continue but do not affect the
PLC counter. The number of parts for the past minutes are
represented by the accumulated value of the counter.
Product Flow Rate Program

60

28
Timer Driving A Counter For Long Time-Delay Period

0
10,000

Each timer T4:0

input closes for
1
10,000 s, its done
bit resets itself
and increments
C5:0 by 1.

The output light turns on 10,000 x

100, or 1,000,000 seconds after the
timer input contact closes.