Chapter 10

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10.1

Data Manipulation

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Data manipulation instructions allow numerical
data stored in the controller’s memory to be
operated on within the control program.
There are two Word Data
classes of data
manipulation
instructions:
instructions that File Data
operate on word
data and those that
operate on file data,
which involve
multiple words.
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 Data files, words, and bits.

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The data manipulation instructions are output
instructions which allow the movement,
manipulation, or storage of data.

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10.2

Data Transfer Operations

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Data transfer instructions involve the transfer of
the contents from one word or register to another.

Original data are in

register N7:30 and N7:20

After the data transfer

has occurred register
N7:20 now holds a
duplicate of the
information that is in
register N7:30.
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The move MOV instruction is used to copy the
value in one register or word to another.

When the rung is true, this instruction copies data

from a source register to a destination register.
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 SLC 500 move instruction program.

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 Simulated move instruction program.

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With the move with mask (MVM) instruction
the data being moved must pass through a
mask word to get to their destination address.

Masking refers to the action of hiding a portion of a

binary word before transferring it to the
destination address.
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Move with mask (MVM) instruction program.

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Simulated move with mask (MVM) program.

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The bit distribute (BTD) instruction is used to move
bits within a word or between words.

Moving bits
within words

Moving bits
between words

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Move instruction used to change the preset time
of a timer program.

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Simulated
move
instruction
used to
change the
preset time
of a timer
program.

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Move
instruction
used to
change the
preset count
of a counter
program.

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Simulated
move
instruction
used to
change the
preset count
of a counter
program.

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A file is a group of related consecutive words in
the data table that have a defined start and end
and are used to store information.
Moving data using file instructions

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 SLC 500 word and file addressing.
Address #N7:30 represents the starting address of
a group of consecutive words in integer file 7.

The length is eight words, which is determined by

the instruction where the file address is used.
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The file arithmetic and
logic (FAL) instruction is
used to copy data from
one file to another and to
do file math and file logic.
Control word uses four control bits: enable bit, done bit,
error bit, and unload bit.

Length represents the file length in words.

Position points to the word being operated on.

Mode (All, Numeric or Incremental) represents the

number of file elements operated on per program scan.
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Destination is the address at which the processor
stores the result of the operation.

Expression contains addresses, program constants,

and operators that specify the source of data and the
operations to be performed. The expression entered
determines the function of the FAL instruction.
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File-to-file copy function program using the FAL
instruction.

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 File-to-word copy function using the FAL
instruction.

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 Word-to-file copy function using the FAL
instruction.

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 Copying recipes and storing values for timer
presets.

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The file copy (COP) instruction and the fill file
(FLL) instruction are high-speed instructions that
operate more quickly than the same operation
with the FAL instruction.

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There is no control element to monitor and data
conversion does not take place, so the source and
destination should be the same file types.

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Using the FLL instruction to change all the data
in a file to zero.

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10.3

Data Compare
Instructions
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Data compare instructions are input instructions
used to compare numerical values.

These instructions compare the data stored in two

or more words (or registers) and make decisions
based on the program instructions.
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Comparison instructions are used to test pairs of
values to determine if a rung is true.

LIM (Limit test) —Tests whether one value is within

the limit range of two other values.

MEQ (Masked Comparison for Equal) —Tests

portions of two values to see whether they are equal.
Compares 16-bit data of a source address to 16-bit
data at a reference address through a mask.
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 EQU (Equal) —Tests whether two values are equal.
NEQ (Not Equal) —Tests whether one value is not
equal to a second value.
LES (Less Than) —Tests whether one value is less
than a second value.
GRT (Greater Than) —Tests whether one value is
greater than a second value.
LEQ (Less Than or Equal) —Tests whether one
value is less than or equal to a second value.
GEQ (Greater Than or Equal) —Tests whether one
value is greater than or equal to a second value.
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 The equal (EQU) instruction rung compares
the value of source A to that of source B.

When source A is equal to source B, the instruction

is logically true and PL1 is switched ON.

When source A is not equal to source B, the instruction

is logically false and PL1 is switched OFF.
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Simulated equal (EQU) instruction program rung.

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The not equal (NEQ) instruction is logically true
when source A is not equal to source B, otherwise
it is logically false.

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Simulated not equal (NEQ) instruction program
rung.

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The greater than (GRT) instruction is logically
true when source A is greater than source B,
otherwise it is logically false.

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 Simulated greater than (GRT) instruction
program rung.

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 The less than (LES) instruction is logically true
when source A is less than source B, otherwise it is
logically false.

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Simulated less than (LES) instruction program
rung.

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The greater than or equal (GEQ) instruction is
logically true when source A is greater than or
equal to source B, otherwise it is logically false.

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 Simulated greater than or equal (GEQ)
instruction program rung.

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The less than or equal (LEQ) instruction is
logically true when source A is less than or equal
to source B, otherwise it is logically false.

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Simulated less than or equal (LEQ) instruction
program rung.

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The limit test (LIM) instruction is used to test
whether values are within or outside the
specified range.

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 The low limit is less than the high limit.

Instruction is true for test values 25 through 50.

Instruction is false for test values less than 25 or

greater than 50.
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 Simulated limit test (LIM) instruction rung.

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The low limit is greater than the high limit.

Instruction is true for test values of 50 and less than

50 and for test values of 100 and greater than 100.
Instruction is false for test values greater than 50
and less than 100.
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 Simulated limit test (LIM) instruction rung.

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 The masked comparison for equal (MEQ)
instruction compares a value from a source
address with data at a compare address and
allows portions of the data to be masked.

The MEQ instruction can be used to compare

the correct position of up to 16 limit switches when the
source contains the limit switch address and the compare
stores their desired states.
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 MEQ instruction rung.

When the data at the source address match the data at

the compare address bit-by-bit (less masked bits), the
instruction is true.
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 Simulated MEQ instruction rung.

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10.4

Data Manipulation
Programs
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Hardwired relay-operated, time-delay circuit.

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 Equivalent programmed time-delay circuit.

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 Simulated programmed time-delay circuit.

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 Timer program implemented using the EQU
instruction.

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Simulated timer program implemented using the
EQU instruction.

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Counter program implemented using the LES
instruction.

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Simulated counter program implemented using
the LES instruction.

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 Vessel filling
operation.

➢The receiving vessel has its

weight monitored continuously
by the PLC program as it fills.

➢When the weight reaches a

preset value, the flow is cut off.

➢Should the system leak additional material into the

vessel, the total weight of the material could rise above
the preset value causing an equal instruction, if used, to
go false and the vessel to overfill.
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10.5

Numerical Data I/O

Interfaces
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 Multibit interfaces allow a
group of bits to be input or
output as a unit.
Each one of the switches provides
four binary digits at its output
that correspond to the decimal
number selected on the switch.

The BCD input module

allows the processor to accept
the 4-bit digital codes and
input their data into specific
register or word locations.
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The seven-segment LED
display is a typical Binary
Coded Decimal output device.

It displays a decimal number that

corresponds to the BCD value it
receives at its input.

The BCD output module is used

to output data from a specific
register or word location.

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 Program for monitoring the setting of a
thumbwheel switch.

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Simulated program for monitoring the setting of
a thumbwheel switch.

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Analog modules convert analog signals to 16-bit
digital signals (input) or 16-bit digital signals to
analog values (output).

An analog I/O will allow

monitoring and control
of analog voltages and
currents.
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The analog output interface module receives
numerical data from the processor.

These data are then translated into a

proportional voltage or current to control an
analog field device.
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10.6

Closed loop Control

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In open-loop control, no feedback loop is
employed and system variations which cause the
output to deviate from the desired value are not
detected or corrected.

A closed-loop system utilizes feedback to

measure the actual system operating parameter
being controlled.
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 PLC closed-loop control system.

Adjustments are
made continuously
by the PLC until
the difference
between the
desired and actual
output is as small
as is practical.

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With on/off PLC control the output is either
on or off.

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Proportional controls are designed to eliminate the
hunting or cycling associated with on/off control.

Proportional control
allows the control
element to take
intermediate
positions between on
and off.

The PLC analog output module controls the amount of

fluid flow by adjusting the percentage of valve opening.
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Proportional-integral-derivative (PID) control is
the most sophisticated and widely used type of
process control.

PID controllers produce outputs that depend on the

magnitude, duration, and rate of change of the system
error signal.
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PID control loop

➢Operating information from the machine is called the

process variable or feedback.

➢Input from the operator that tells the controller the

desired operating point is called the set-point .

➢The difference between the set-point and the process

variable is called the error.
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Programmable controllers are either equipped
with PID I/O modules that produce PID control
or have sufficient mathematical functions of their
own to allow PID control to be carried out.

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