232 14-1 142 THE PLC SKIP AND MASTER CONTROL RELAY FUNCTIONS INTRODUCTION Both the SKIP (SK) and MASTER CONTROL RELAY (MCR) functions are programming tools. The SK function allows us to skip, or bypass, a chosen portgee ti ladder sequence. The coils and functions skipped remain in the state they were in dunt? las scan before SK was enabled. SKIP enables us to effectively branch ta differs = ™ tion ofthe program. In some programming systems, SKIP is called ZCL (zone conn state). In many PLCs the SKIP function is carried out by a JUMP programming sy which is covered in chapter 15. ‘em, MCR operates similarly. When MCR is enabled on, the ladder diagram function, normally. When MCR is not enabled. a specified number of coils and functions are frre in the off position. Coils in the frozen section will then stay off even if their indivgua enable lines are turned on. In some systems, MCR means Master Control Reset (ny Relay). The difference between the two functions is that SKIP leaves the next specified num. ber of ladder lines in their previous on or off state. MCR turns the next specified number of ladder lines to the off state. Another difference is that SKIP is active when enabled and MCR is active when not enabled, which makes it fail-safe. THE SKIP FUNCTION AND APPLICATIONS The SKIP (SK) function, illustrated in figure 14~1, allows a portion of a PLC program to be bypassed when its coil is enabled. The enable line of the function is energized when the skip of one or more subsequent lines is desired. In addition to programming a coil number in the usual manner, the number of lines to be skipped is also specified and programmed as shown. Figure 14-2 shows a basic application of the SKIP function in a program. The eight- Jine program used for illustration has seven lines with output functions. A SKIP function is included on the third line of the eight-line program. When the SK function is off, the other seven functions operate in the normal manner, When the seven lines corresponding to inputs are on, their outputs are on, and when inputs are off, outputs are off. For this illustration, the value for number of lines to be skipped will be set at 3. When the SKIP function (set at 3) is turned on, the first two lines will function as usual. However, the next three lines, 4 through 6, will stay on or off in their previous state. With SKIP on, changing the input on-off status feeding the coils on lines 4 through 6 will FIGURE 14-1 - SKIP Function (77 Sell Number sk0216 R013 0003 | «—— Number of Enable lines to be skippedTHE SKIP FUNCTION AND APPLICATIONS 233 FIGURE M42 Enabling Contacts ‘SKIP Function PLC Operation Line No. INOOS4 RO083 ‘pa —__ 6 'Nooss croges 4 b+ skooa6 |INoos6 or 3 }—4}-—___ , INoos7 4-4 Three lines INo0s8 skipped when 5 SK0046 is on Coils remain in last state - on 5 | iNonse aad INoo60 7h ype INoos1 cRoO89 . st 4 have no effect on output coils 4 through 6, Coils on lines 4 through 6 wil! retain their Previous states. Lines 7 and 8 will continue to operate normally. unaffected by the SKIP function's operation. Lines 7 and 8 could also be skipped if we had inserted a $ in place of 3.8 the number of lines to be skipped by the function, When SKIP is turned off, the ladder will operate normally. For an illustration of the SKIP funct production line has eight stations, Product comes down the line. De ion, we apply it to a production line. The each of which can perform an assembly operation as the Pending on the individual part number, all of the eight Operations may or may not be set up and carried out. The pattern of whether or not she operations are to be set up and performed is stored in registers, as expl chapter 18. Each of the eight stations is set uy statuses. A bit of I says turn the setup on, an AU the third station, an inspection takes place. If the part is good, it continues down the operating line: iit is bad, iis shunted to a side conveyor and repaired, After repair, the Part reenters at the beginning of the conveyor. The product flow and conveyor layout are shown in figure 14~3 When a part arrives at the be; ence of the parts at the be; for operation. The sensor ained in detail in Ip LO Operate or not, according to register bit id a 0 says turn the setup off. ginning of the line, a sensor (not shown) detects the pres- Binning of the conveyor and causes the eight stations to be set up r causes register contents to turn each of the eight setup switch14-3 FI PLE SKIPAND MASTER CONTROL RELAY FUNCTIONS Product Flow Set Up: 110 8 Set Up: 4108 Skip 1103 Reenter Station | Start Numbers Station Numbers ‘Check Point Product Flow Station Layout FIGURE 14-3 ‘SKIP Function Application Layous contacts (the BP/IR contacts) on or off. Figure 14-4 shows this setup system on the left. The setup functions are CRO041 through CROO48. As the part proceeds down the conveyor, each operation is performed (if set up) when the part is detected by sensors at each station. These sensors are INOO21 through IN0028, as shown on the right of figure 14-4. The operations are CROO61 through CRO068. If partis rejected at station 3, it is shunted to repair. Later, when the repaired part reenters the conveyor, the setups of stations 1 through 3 do not have to be reset. Unneces- Sary retest is prevented by the two SK functions, 0011 and 0060. The two SK functions are ‘ured on by a sensor at the repair reentry point. THE MASTER CONTROL REL, FUNCTION AND APPLICATIONS ‘The MASTER Pica, nae RELAY (MCR) function operation is similar to the SK turns on. When MCR is ee ‘ara MCR function. When its enable line is energized, it » Ihe number of following ladder diagram lines specified are| Set Up Operate 1307 | | oP skoott kiran. st | Nos INoOS* | — Station | Skip After on pP0001 Repair 1R0307 'Nooa1 Only ot | —I al P0002 180307 INooz2 on | 2 P0003 1R0307 CHS §Nooz3 on & Ft P0004 190307 INoo2s ot }—t 4 1 P0005 1R0307 Sapoas INooes on k 5 } BP0008 1R0307 INoo26 on 6 -4 BPOO07 1R0307 iNoo27 of 7 1 BP0008 1RO307 iNoozs oF a i Set-Up Operate Switches Proximity ‘ ‘Switches 4 ‘Typical Register - 10307 (8 Bit) es— 2 Nit 1010 1701 FIGURE 14-4 SKIP Application Program FIGURE 14-5 uoRaae 7 Call Number = MRotit 1Noo73 0003 eae Number of lines to be turned offFIGURE 14.6 MCR Function PLC Operation J iNo201 THE PLC SKIP AND MASTER CONTROL RELAY FUNCTIONS turned off, In contrast to the SK operation, where lines were skipped, the MCR ty following specified number of lines to the off state. In many PLCs, the MCR fein off only the nonretentive outputs in the zone, All retentive functions are unaffected won’ this system dep Figure 14-6 shows how the MCR function operates in a program. There are eigh lines, The third line is the MCR function, The other seven lines are comtact-coil furs, tions, For fail-safe reasons, the MCR must be turned on to be inactive. If the function goes off for some reason, itis active and turns the specitied lines off, also. When MCR is on, the other seven lines operate normally. When MCR is off, the next three lines, 4 through 6, are turned off. Lines 1, 2, 7, and 8 are unaffected, With MCR off, there is no way to turn on coils 4 through 6 by energizing their enable lines. When MCR is turned on, the ladder operates in the normal manner. ‘A production line example similar to the SK example will be used for the MCR ight production stations. Whether each station application illustration. There are again operates for a given part number as the part goes past depends on the setup (not shown), Each station's operation is ied by proximity switches at each station. The proximity switches are INOO81 through INOO88, Figure 14-7 shows the production line layout and product flow. Line No. cRO031 Inoz02 cRo032 McRO132 (0003 iNoz03 INoz04 cR0033 cROg34 Three lines irevocably turned off when MCRO132 is off 'Nozos, cRO037TROUBLESHOOTING PROBLEMS rrr Set Up: 1 08 Product Fiow ure 7 eit a Setup 6108 Station | Start Pinang Skip 1 105 Numbers 1 - : 2 é 3 4 Reject 5 fe] ¥ Check Point 7 8 Product Flow Station Layout Station 5 is an inspection station. Rejected parts are shunted to a repair conveyor. ‘After repair, the part reenters the conveyor. When it renters, it turns on INOOL1, which ; turns on and seals an MCR relay, CROO21. The first five steps are therefore not repeated for the part, because the first five operations are prevented by the MCR. When the part ‘gets to station 5, the MCR is unsealed. The part then continues through stations 6, 7, and 8, These last three steps were not performed the first time through, but are now performed to complete the process. The MCR program for these operations is shown in figure 14-8. TROUBLESHOOTING PROBLEMS TS 14-1 You have set up a SKIP program similar to that shown in figure 14-2, The three lines are skipped when the program is first turned on. What could be wrong? ‘TS 14-2 You have set up an MCR program similar to that shown in figure 14-6, The three lines are still on when the program is turned on. What could be wrong?