V3 Master MEUK IQR PLC INtro

iQ-R PLC Intro

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Introduction

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Firstly, hello! Welcome to this digital learning experience, designed to help you learn online and in your own time. This course is interactive and (hopefully) easy to navigate. This is why we have created this quick tour of how to get around and get what you need.

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Contents

Welcome

Navigation 101

Selecting Your Hardware

Quick overview of the course

Get the best of this interactive experience

From power supplies to CPU's

GX Works 3 Basics

Placing/Addressing Modules

Basic Programming Theory

The key layout and essential features

PLC Configuration modules and slots

Get started and identify basic techniques

Level 4

Sequencing & Design

Basic Program Elements

Timers & Counters

Key approaches & problem solving

From inputs and outputs to references

How do these work in a program

Learning Assessment

What Do You Remember?

Introduction

Why do this? Scenario 1

The plant manager has just walked into the office. The machines are not functioning properly and must be shut down and re-programmed. That's a cost of £10,000 per hour to your business. What if that scenario didn't ever need to happen?

Per Hour Lost or Saved by good training

10K

Each number or stat reveals more info. Click to discover more.

Introduction

Why do this? Scenario 2

The Production Manager is always looking for cost savings and improvements and to maximise equipment availability. You explain your points and state you are sure that using a PLC can bring big benefits. You are then asked to go away and develop a plan around hardware and software.

Cost savings through the correct hardware selections

£££

Each number or stat reveals more info. Click to discover more.

Introduction

Why do this?

Most factories and buildings have some sort of automation functionality in 2024. No matter how much AI continues to change the world, this does not impact the fact that a PLC needs to be programmed or it will not function well. That's why we have created this interactive learning experience. To help you develop your skills at an introductory level and journey to becoming a skilled programmer.

Key areas of your journey; Knowledge and Skills

Each number or stat reveals more info. Click to discover more.

Introduction

How Does It Work?

This experience has been designed for both interest and flexibility. The course is split across modules by key or core topic. Each module features instructional videos, interactive images, reflection exercises and a summary of the key points from each module to help prepare you for the learning assessment in Module 8.

Key Modules Videos Interactive Resources Key Take Aways

Introduction

Content Disclaimer

As part of the development of this interactive resource, AI technology has been used in creating video avatars and audio playbacks. Each module features fictitious characters and persons who may bear a similarity to someone you know. However, it is purely coincidence. If you have any questions, comments or concerns please contact a member of the delivery team.

AI

Has been used in video, audio and several areas across the development of this resource.

Introduction

How Does It Work?

You can pick the topics you are interested in to start, and your progress bar will show you what you have left to complete the course. On the next screen are what we call learner outcomes. It's not designed to catch you out. It is visibility between you and the training team as to whether we have designed learning that is both impactful and helpful. The learning assessment in Module 8 will help both you and the team understand that further.

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Monitor Your Progress Start with your interest Outcome Driven Let us know if you like it

Section 3

Your Learning Journey

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Enrolment

So, what's the plan?

You Are Here

Placing & Addressing

Selecting Hardware

GXWorks3 Basics

Week 1

Basic Program Elements

The format is what we call a 'flipped classroom'. You have 2 weeks to complete this online experience. You can learn at your own pace in your own time. Some people go straight through. Others do a module every other day. From there, the onboarding team will book your 1-day classroom training. Then? You're done.

Basic Program Theory

Sequencing & Design

Learning Assessment

Counters& Timers

End Of Online Course (Theory)

Week 2

Classroom (Practice

What Will You Learn?

Outcome 3

Outcome 1

Outcome 2

Demonstrate an understanding the configuration of a PLC and the addressing of any type of module in any position (slot) in a PLC

Demonstrate an awareness of the key layout options in GX Works3 and how to access essential features

Identify how to to select a suitable Power Supply, CPU, base and sufficient digital input and output modules to suit the external circuits

Outcome 7

Demonstrate an understanding of the settings of Timers and Counters and how they should be incorporated into a program

Outcome 4

Outcome 5

Outcome 6

Define the 5 key approaches to designing a sequence and apply problem-solving techniques when required

Recognise different ways to start creating programs and identify different techniques to help with the process

Demonstrate an understanding of the basic input and output types and how they are referenced in a program

iQ-R PLC Intro

Selecting Your Hardware

What To Expect?

Video Learning

In this video, Rob gives you an overview of what to expect from your learning experience in Module 1.

What Is A PLC?

PLC 101 Basics

What is a PLC?

PLC stands for programmable logic controller. The iQR range of PLCs is the most advanced PLC that Mitsubishi offers. When we buy a PLC and switch it on it does nothing, all the clever things it can do are what we make it do. It’s very much, like a computer in that we write a program and it runs the program. It doesn’t have a keyboard or mouse or monitor and doesn’t get slowed down like a computer does when data is buffering. That would not be good if it happened at a sewage treatment works!

A PLC is designed to operate 24 hours a day, 7 days a week and 365 days a year.

What Is A PLC?

Click to listen to an audio synopsis

Input Modules

Output Modules

CPU

Power Supply

Battery

Base

Click to listen to an audio synopsis

Section 3

What Can A PLC Do?

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Lorem Ipsum

A PLC is a machine, it’s not to be feared but to be mastered.ks.

A PLC can perform complex tasks quickly. You can choose what these tasks are and their order. A program is a list of decisions and actions that the PLC runs over and over in ‘run’ mode. This is called the ‘Scan’, and it can be very fast, taking only a few milliseconds.

Click to listen to an audio synopsis

Video Series - Selecting Your Hardware

Choosing Outputs

Selecting Hardware

Choosing Inputs

Maria talks you through the part numbers to look at and your options on outputs.

Rob helps explain how you go about choosing inputs for the PLC

Rob takes you through an overview of what goes into making the right choices.

Deep Dive - Sink Or Source

Sink Or Source

What is it?

The terms Positive Common, Negative Common, Sink, and Source are all about how to hook up the input terminals to 24V so they work. Negative Common and Source need the terminals connected to +24V, while Positive Common and Sink need them connected to 0V or Ground to operate. Choosing between Positive or Negative common depends on the input devices, and you also need to consider the choices you make with Outputs. Modules cannot be switched during operations. Simple switches or buttons can work with either setup, but for semiconductor devices with 'transistor' connections, it's key to pick the right one.

Choosing between Positive or Negative common depends on the input and output devices

Deep Dive - Sink Or Source

Input Module Wiring

What is it?

An external power supply (24 V DC) is separately required in addition to the base unit power supply module. It has a single common signal, which can be wired as a positive (common positive rail is used) or negative (common negative rail is used) common. The different wiring types can be switched accordingly.

Choosing between Positive or Negative common depends on the input and output devices

Deep Dive - Sink Or Source

Output Module Wiring

What is it?

Depending on the external devices used, there are two distinctive ways to wire the output module. It has a single common terminal (COM), sink wiring when the negative rail is used and source wiring when the positive rail is used as the common. Each wiring method requires a different type of module. The output module requires an external supply, which should be connected to the +V or OV terminals accordingly.

Choosing between Positive or Negative common depends on the input and output devices

Video Series - Selecting Your Hardware

Choosing A Main Base

Choosing a PSU

Choosing A CPU

Known by 3 different terms, the main base is like a car chassis. Reema elaborates.

The CPU is the brain of the PLC. Our coach Yemi explains more.

Power Supply units are essential to power the PLC. Jackie explains how and why.

FILL IN THE BLANKS - Reflection exercise

Program Life Controller

PLC stands for... _____

Programmable Logic Controller

Programmable Logic Controller

Program Logic Controller

Activities

Automations

Actions

A program is a list of decisions and ___________

Actions

Run

A PLC runs the program over and over all the while it is in ‘run’. We call that the ________

Sequence

Scan

Scan

What Do You Remember?

True

False

A PLC always runs a program from top to bottom...

Servo Motor

What do you remember?

Congrats. You are getting the hang of this.

What Do You Remember?

Not quite what we are looking for? Fancy another go?

Module Wrap Up

Section 3

Three

Anatomy

Next?

Key Take Aways

Of A PLC

Placing/Adressing Modules

1. PLC stands for Programmable Logic Controller. In this case, the iQR PLC.
2. Know how to choose the type and number of modules to create the optimum PLC configuration for the application.
3. A PLC is a machine. It's not to be feared, but mastered.

Up next, you will take a closer look at what you need to consider when placing and addressing modules. Click Next to Progress and Complete Module 1:)

• Inputs
• Outputs
• CPU
• PSU
• Main Base

iQ-R PLC Intro

Placing/Addressing Modules

What To Expect?

Video Learning

In this video, Clare gives you an overview of what to expect from your learning experience in Module 2.

Placing/Addresing Modules

Video Tutorial

In this video, Clare goes into what you need to consider when placing and addressing modules.

Video Key Moments

Key Take Aways03.40

Welcome00.01

Topic 3Head Addressing02.22

Topic 2 Hexadecimal Numbering01.22

Topic 1What can go where?00.26

Deep Dive - Rules Of Configuration

Section 3

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Rules Of Configuration

Always configure the module in the GXWorks3 project. PLC modules, except the power supply and CPU, can be placed anywhere on the base, but we must understand how the CPU recognizes each slot. The slot numbering is hexadecimal, meaning blocks of 16. By default, each slot is one block of 16 memory points.

Deep Dive - Hex Numbering

Hexadecimal Numbering

What is it?

The hexadecimal number system is a type of number system, that has a base value equal to 16. It is also pronounced sometimes as ‘hex’. Hexadecimal numbers are represented by only 16 symbols. These symbols or values are 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E and F. Each digit represents a decimal value. For example, D is equal to base-10 13. Hexadecimal number systems can be converted to other number systems such as binary numbers (base-2), octal numbers (base-8) and decimal number systems (base-10).

Hexadecimal numbers are represented by only 16 symbols.

Source - BYJUS

What Do You Remember?

True

False

Modules can be placed anywhere on the PLC?

What Do You Remember?

Spot on. You will be building them next:)

What Do You Remember?

Not quite what we are looking for on this one. Fancy another go?

Module Wrap Up

Section 3

Three

One

Next?

Clare's Take Aways

Numbering System

GX Works 3 Basic

1. Modules can be placed anywhere else but a logical approach is worthwhile for fault-finding purposes.
2. Be clear on your understanding of the configuration of a PLC and the addressing of any type of module in any position (slot) in a PLC.
3. GX Works3 is a programming tool you will use for your programming. It has a very useful feature that allows easy checking of the Head address.

Up next, you will take a closer look at the basics of getting started with GXWorks3. Click Next to Progress and Complete Module 2:)

The numbering system is Hexadecimal which is a computing derived number system and allows 16 items to be represented with a single digit from 0 to 9 then letters from A to F.

iQ-R PLC Intro

GX Works 3 Basics

What To Expect?

Video Learning

In this video, Jackie gives you an overview of what to expect from your learning experience in Module 3.

What To Expect?

Video Tutorial

In this video, Paul takes you through getting started with GX Works3 and its basic elements.

Video Key Moments

Summary06.14

Welcome00.01

Topic 3Creating A New Project 02.33

Topic 2 Laying Out The Working Area00.37

Topic 1Starting The Program Tool 00.27

What Do You Remember?

iQ-F & L Series

iQ-R & L Series

What are the 2 PLC types that GX Works3 supports?

iQ-R & iQ-F Series

What Do You Remember?

Spot on. You will be building them next:)

What Do You Remember?

Not quite what we are looking for on this one. Fancy another go?

Module Wrap Up

Section 3

Three

What?

Next?

Paul's Take Aways

Is GX Works 3?

Basic Programming Theory

1. GX Works3 only works with iQ-R and iQ-F PLCs.
2. ‘Navigation’ and ‘Element Selection’ are ‘Docking Windows’ and can be positioned anywhere or left floating by clicking and dragging.
3. Knowing how to set up the working area in GX Works3 is key to effective programming.

Up next, you will take a closer look at how to go about creating your first program and where to start. Ready For Module 4? Click Next to Progress and Complete Module 3:)

GX Works3 is the program you will use for your programming. GX Works3 is the latest generation of programming and maintenance software offered by Mitsubishi Electric specifically designed for the MELSEC iQ-R and MELSEC iQ-F Series control system.

iQ-R PLC Intro

Basic Programming Theory

What To Expect?

Video Learning

In this video, Yemi gives you an overview of what to expect from your learning experience in Module 4.

Basic Programming Theory

Video Tutorial

In this video, Yemi introduce techniques for starting the process of creating a program.

Video Key Moments

Key Take Aways04.33

Welcome00.01

Topic 3Creating A Flow Chart03.55

Topic 2 Choosing Techniques02.18

Topic 1Choosing The Right Approach00.54

What Do You Remember?

False

A PLC will only do what we program it to do.

True

What Do You Remember?

Enough said. You know your stuff.

What Do You Remember?

Not quite what we are looking for on this one. Fancy another go?

Module Wrap Up

Section 3

Three

Start

Next?

Yemi's Take Aways

Right For Best Results

Basic Programming Elements

1. A PLC will only do what we program it to do, it will not think like us unless we program it that way.
2. It doesn’t matter that there is more than one way to solve a problem, what is important is to appreciate that there are different ways.
3. A flowchart is a good way to start a program. It’s a good idea to make the flowchart as detailed as possible.

Up next, you will be introduced to the simple input and output elements of a PLC and how they are used in a program. Click Next to Progress and Complete Module 4:)

Getting the approach right from the outset is crucial otherwise one can end up down a ‘dead end’ with no way to go other than back out. The most obvious solution might not be the best choice in the long term.

iQ-R PLC Intro

Basic Program Elements

What To Expect?

Video Learning

In this video, May gives you an overview of what to expect from your learning experience in Module 5.

Basic Program Elements

Video Tutorial A

In this video, Mai introduces the simple input and output elements of a PLC and how they are used in a program.

Video Key Moments

Key Take Aways04.26

Welcome00.01

Topic 3Combining Inputs & Outputs 03.13

Topic 2 Outputs02.33

Topic 1Inputs01.12

Basic Program Elements

Video Tutorial B

In this video, Mai introduces the scenarios you need to consider when using buttons and switches as basic program elements.

Video Key Moments

Key Take Aways09.24

Welcome00.01

Buttons & Switches04.25

Switches02.56

How Is A Button Handled?01.07

Deep Dive - PLC Memory Allocation

PLC Memory

What is stored?

Any CPU device relies on memory for it to operate and in a PLC the memory is divided into three main areas. Some of the areas can be adjusted, others are fixed. The Program memory is where the program is written to. It’s a fixed size and cannot be altered. The Devices area is where the states of the inputs, outputs, timers, counters, registers and so on are held. The Label area is for things like the results of calculations.

The iQ-R has way more memory than our other PLCs have ever done.

Deep Dive - Latch In Programming

PLC Ladder Latch

What are Latches?

Latches are digital circuits that store a single bit of information and hold its value until new input signals update it. They are used in digital systems as temporary storage elements to store binary information. Latches can be implemented using various digital logic gates, such as AND, OR, NOT, NAND, and NOR. Latches are widely used in digital systems for various applications, including data storage, control circuits, and flip-flop circuits. They are often used in combination with other digital circuits to implement sequential circuits, such as state machines and memory elements. Source - Geeks For Geeks - Latches In Digital Logic

Latches are digital circuits that store a single bit of information and hold its value until new input signals update it

FILL IN THE BLANKS - Reflection exercise

Mind Map

A _____ is a good starting point when creating a program.

Flowchart

Flowchart

Gaant Chart

Infinite

Less

More

The iQR has ___________ memory than other Mitsubishi PLC's.

More

Programs

This area is where the states of the inputs, outputs, timers, counters, registers and so on are held ________

Devices

Devices

Labels

What Do You Remember?

Inputs & Outputs

Coils & Relays

What are the 2 main input types in basic programming?

Buttons & Switches

What Do You Remember?

Spot on. You will be building them next:)

What Do You Remember?

Not quite what we are looking for on this one. Fancy another go?

Module Wrap Up

Section 3

Three

Five

Next?

Key Take Aways

Key Points

Sequencing & Design

1. A basic input from a button appears in a program with a symbol referring to a ‘Normally Open’ contact and wording called a Label.
2. A rung must always have a valid format: a beginning, a middle and an end.
3. A PLC program, first and foremost, is written to control the machine or process.

Up next, you will be introduced to some typical concepts which can be applied to create sequences Click Next to Progress and Complete Module 5:)

Of Programming Elements

iQ-R PLC Intro

Let's Check In Shall We?

Introduction

How Does It Work?

Congrats! You're over halfway. Take a break and refresh some modules. What's left? 2 Modules, 1 Assessment. Let's have a quick recap with some fast facts.

2/1

Key Modules Confirmation of Learning Assessment

Section 3

Section 4

Section 3

PLC Fast Facts - Quick Recap

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Write a subtitle here

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Key Hardware Choices

Main Areas PLC Memory

Inputs/Outputs/CPU/PSU/Main Base

Programs - Devices - Labels

4096

Maximum Inputs

Software Programme

A PLC Can Accept

GX Works3 To Create/Manage Programs

Section 3

Mid Way Check In

Write a subtitle here

How's it going?

Placing & Addressing

Selecting Hardware

GXWorks3 Basics

Basic Program Elements

You Are Here

This is a reminder of your learning and where you are. Keep going. And we hope you like the robots:)

Basic Program Theory

Sequencing & Design

Learning Assessment

Counters& Timers

End Of Course (Theory)

iQ-R PLC Intro

Sequencing & Design

What To Expect?

Video Learning

In this video, Justin gives you an overview of what to expect from your learning experience in Module 6.

Sequencing & Design

Video Tutorial

In this video, Justin introduces some typical concepts which can be applied to create sequences.

Video Key Moments

Key Take Aways04.38

Welcome00.01

Topic 3Programming Options 03.55

Topic 2 Designing A Sequence01.46

Topic 1Understanding & Choice Of Approach00.48

Deep Dive - Types Of Timers

Master Timer

Sequential Timer

Cascading Timer

A single Timer is used to control the complete sequence.

Timers all start simultaneously but complete one-by-one in a progression.

Timers in a ‘chain’ where a Timer can only start when the previous Timer has completed

Deep Dive - Types Of Timers

Oscillator Clocked

Clocked Timer

Uses a short timer and a counter. When the counter hits a set value, it changes the state of the lights.

A Timer and Counter counts seconds and refers to devices inside the CPU.

FILL IN THE BLANKS - Reflection exercise

Sequential Timers

Timers in a ‘chain’ where a Timer can only start when the previous Timer has completed _____

Cascaded Timers

Cascaded Timers

Master Timer

Cascaded Timer

Master Timer

Clocked Sequence

This sequence uses a short timer and a counter. ___________

Clocked Sequence

Master Timer

Timers all start simultaneously but complete one-by-one in a progression ________

Sequential Timers

Cascaded Timers

Sequential Timers

iQ-R PLC Intro

Timers & Counters

What To Expect?

Video Learning

In this video, Reema gives you an overview of what to expect from your learning experience in Module 7.

Timers & Counters

Video Tutorial

In this video, Reema introduces Timers and Counters in the PLC and looks at their properties and how they can be used.

Video Key Moments

Welcome00.01

Implement An'On Delay' Timer04.14

Adding Timers Into A Program01.40

Timer Properties00.56

Counter Properties07.07

Implementing A Counter08.49

Resetting ACounter10.42

Key Take Aways11.20

Timers and Counters

How do they work?

Timers are basic building blocks in a PLC, a CPU has hundreds of them. They all behave the same way: On Delay.

There are four key elements to a Timer:

1. An input to drive it.
2. A delay value.
3. A current value.
4. A contact to indicate when the timing is complete.

Timers need to be placed in programs with a particular format

What Do You Remember?

On Delay

Off Delay

Look at the image. What type of timer delay set up is this?

One Shot

What Do You Remember?

Great work. You know your stuff.

What Do You Remember?

Not quite what we are looking for on this one. Fancy another go?

What Do You Remember?

Indicates Completion

Activates The Timer

Look at the image. What does the upper rung do?

What Do You Remember?

The factory called. They want that PLC back:)

What Do You Remember?

Not quite what we are looking for on this one. Fancy another go?

What Do You Remember?

Indicates Completion

Activates The Timer

Look at the image. What does the lower rung do?

What Do You Remember?

Well done. Last question ahead.

What Do You Remember?

Not quite what we are looking for on this one. Fancy another go?

FILL IN THE BLANKS - Reflection exercise

Target Value

Counters have four elements which can be/must be referenced correctly in the program. What drives it? _____

Input To Drive It

Current Value

input

Target Value

Contact

A ________ is needed to indicate the target reached.

Current Value

Contact

Module Wrap Up

Section 3

Three

Five

Next?

Reema's Take Aways

Rules

Test Yourself

1. Timers are basic building blocks in a PLC, a CPU has hundreds of them. They all behave in the same way, On Delay.
2. There are four key elements to a Timer; An input to drive it, a delay value, a current value and a contact to indicate when the timing is complete.
3. Counters are entered into a program similar to Timers and driven with an ‘On-Off’ signal.
4. Labels for counters can be set up in 3 ways.
5. Counter’ target values need to be varied rather than fixed numbers.

That's the end of the modules. Feel free to go back to any of them, anytime you like. It's time to complete your confirmation of learning assessment. Click Next to Progress and Complete Module 7:)

For Entering Counters Into A Program

iQ-R PLC Intro

Learning Assessment

What is the learning assessment?

Section 3

Write a subtitle here

Confirmation Of Learning

Let's make sure all this learning has not been for nothing. The assessment will help meet the learner outcomes explained at the start of this course. Most questions are multiple-choice or true/false and take about 20 minutes. There is a score at the end which will be shared with your tutor/classroom coach. Ready? Click the next screen button to begin.

Section 3

iQ-R PLC Intro

Assessment Complete

What To Expect?

Video Learning

Congratulations, you have finished the online part of your learning journey. In this video, Finn explains what happens now, and next, and what you need to do to prepare.

Course Finish

iQ-R PLC Introduction

Click To Finish

Congratulations

You have completed this interactive learning experience.

Next up, you will move back into the main LMS 360 pathway and get access to wider resources.

Module 1 - Video 1 - Choosing A CPU. Control the playback speed and play in full screen using the playback controls.

Module 1 - Video 1 - Choosing A CPU. Control the playback speed and play in full screen using the playback controls.

Module 1 - Video 3 - Choosing Outputs. Control the playback speed and play in full screen using the playback controls.

The PLC not only runs the program but also monitors inputs and manages output changes. At the end of the program, it updates outputs in 'Refresh mode'. There's a slight delay between input activation and output response, which is usually acceptable.

Module 1 - Video 1 - Selecting Hardware. Control the playback speed and play in full screen by using the playback controls.

Module 1 - Video 1 - Choosing A Main Base. Control the playback speed and play in full screen using the playback controls.

Module 1 - Video 1 - Choosing A Main Base. Control the playback speed and play in full screen using the playback controls.

Remind yourself of the journey with our welcome video. You can control the playback speed and subtitles using the control bar.

Input modules are a similar construction, all types are the same width. The part numbers have a similar format; they all start with the letter ‘R’ to denote iQ-R PLC then a letter ‘X’ to indicate Inputs.

Bases are available in two versions: Main and Extension. The Main base is the ‘top level’ and is the mounting place for the CPU(s). All PLCs must have a Main base.

Part numbers for output modules all begin with the letter ‘R’ for iQ-R PLC and then the letter ‘Y’ to denote outputs. There are three main categories and four types of output.

Module 1 - Video 1 - Choosing A PSU. Control the playback speed and play in full screen using the playback controls.

The CPU is the brain of the PLC it runs the program we write to it. There is a wide range of CPU types from basic to advanced plus some special variants for safety applications and redundant systems.

All CPUs can have a battery installed and for all but the basic models of CPU a battery is essential and supplied fitted. The battery doesn’t power the CPU, its purpose it to keep the program in the CPU.

A power supply is essential to power the PLC and a few options are available. The purpose of the power supply is to provide power to all the modules mounted on the PLC, it does not provide power to external circuits.

What are they?

Here are some rules to consider

1. The counts are on the rising edge.
2. They do not exceed the target.
3. The counter must be reset with a ‘RST’ instruction.

It’s important to note that a Counter will ‘max out’ when it reaches its target and won’t count any further. If there are products still coming down a conveyor, for example, they will be missed.

Module 1 - Video 1 - Choosing Inputs. Control the playback speed and play in full screen using the playback controls.

Module 1 - Video 1 - Choosing A PSU. Control the playback speed and play in full screen using the playback controls.

Module 1 - Video 2 - Choosing Inputs. Control the playback speed and play in full screen using the playback controls.

Module 1 - Video 1 - Selecting Hardware. Control the playback speed and play in full screen using the playback controls.

Module 1 - Video 1 - Choosing Outputs. Control the playback speed and play in full screen using the playback controls.