This article provides a brief introduction into documenting software programs for Programmable Logic Controllers (PLC). Its aim is to provide clear guidance in the program documentation for PLC’s.
This article is based on the Ladder Logic format of PLC Programming, but many of the points also related to Instruction List (IL) and Function Block Diagram (FBD).
PLC Programs should be written and documented so that they can be easily maintained and modified by others than those who originally wrote the program. All PLC Programming Editors have increased documentation capabilities including Siemens, Modicon, Allen Bradley and Mitsubishi.
Documenting PLC Software
Early Programmable Logic Controllers had little or no capacity for the documentation of programs. For technicians to understand the logic the program had to be followed from inputs to outputs. This made fault finding or modifications to programs difficult.
As PLC’s have developed the programming packages have also improved, allowing for the software to be clearly annotated.
The programming tools available for most PLC’s allow for the following documentation.
Symbols and Symbol Comments.
This article provides a practical guide to using these documentation techniques.
Symbols and Symbol Comments
The purpose of symbolic addressing is to allow the PLC programmer to write the software using meaningful symbols rather than having to remember addresses.
General rules for Input and Output symbols should be to use the tags from Process and Instrumentation Diagrams (P&ID) or electrical drawing references. Where these are not available use of a simple description should be used.
For the above the following could be used.
Symbol Address Description
VAC01_STPB I 0.0 Vacuum Pump Start Pushbutton
VAC01_SPPB I 0.1 Vacuum Pump Stop Pushbutton
VAC01 Q 0.0 Vacuum Pump Run
VAC01_TRAL M 1.1 Vacuum Pump Trip Alarm (Latched)
VAC01_AL M 1.1 Vacuum Pump Alarm Latch (Failed to Start/Stop)
Although many program editors can allow for more characters within the symbols it is recommended to keep the symbol short and use the comments to provide further details. Our recommendation is to build the symbols from the blocks of two characters to represent the the meaning and to keep the length less than 10.
The numbers tell a tale of programmable logic controller ( PLCs ) firm entrenchment in control applications. For instance, hardware sales figures for 2001 show $80 million spent for open control (PCbased control), with $1.1 billion being spent on programmable logic controller ( PLCs ) solutions. Even as the trend is for both figures to grow by 2004, programmable logic controllers ( PLCs ) still have a sizable advantage over PCs.
Engineers these days are calling for networking capabilities. A programmable logic controllers ( PLCs ) are now low-cost dedicated controllers. They offer more processing power and have added networking capabilities with other programmable logic controllers ( PLCs ) through serial connections. A micro programmable logic controller ( PLCs ) has an Ethernet connection with optional DeviceNet or Profibus modules. So the total system is not just a stand-alone controller, but one that can network to bigger programmable logic controllers ( PLCs ). Also, increased processing speeds allow for any given programmable logic controller ( PLCs ) to do more. Because of these changes, the programmable logic controller ( PLCs ) remains a viable control option.