ClassicLadder Programming

Typically ClassicLadder components are placed in the custom.hal file if your working from a StepConf generated configuration. These must not be placed in the custom_postgui.hal file or the Ladder Editor menu will be grayed out.

Loading the ClassicLadder real time module (classicladder_rt) is possible from a HAL file, or directly using a halcmd instruction. The first line loads real time the ClassicLadder module. The second line adds the function classicladder.0.refresh to the servo thread. This line makes ClassicLadder update at the servo thread rate.

The speed of the thread that ClassicLadder is running in directly affects the responsiveness to inputs and outputs. If you can turn a switch on and off faster than ClassicLadder can notice it then you may need to speed up the thread. The fastest that ClassicLadder can update the rungs is one millisecond. You can put it in a faster thread but it will not update any faster. If you put it in a slower than one millisecond thread then ClassicLadder will update the rungs slower. The current scan time will be displayed on the section display, it is rounded to microseconds. If the scan time is longer than one millisecond you may want to shorten the ladder or put it in a slower thread.

It is possible to configure the number of each type of ladder object while loading the ClassicLadder real time module. If you do not configure the number of ladder objects ClassicLadder will use the default values.

Objects of most interest are numPhysInputs, numPhysOutputs, numS32in, and numS32out.

Changing these numbers will change the number of HAL bit pins available. numPhysInputs and numPhysOutputs control how many HAL bit (on/off) pins are available. numS32in and numS32out control how many HAL signed integers (+- integer range) pins are available.

For example (you don’t need all of these to change just a few):

To load the default number of objects:

When you first start up ClassicLadder you get an empty Sections Manager window.

This window allows you to name, create or delete sections and choose what language that section uses. This is also how you name a subroutine for call coils.

When you first start up ClassicLadder you get an empty Section Display window. Displayed is one empty rung.

Most of the buttons are self explanatory:

The Vars button is for looking at variables, toggle it to display one, the other, both, then none of the windows.

The Config button is used for modbus and shows the max number of ladder elements that was loaded with the real time module.

The Symbols button will display an editable list of symbols for the variables (hint you can name the inputs, outputs, coils etc).

The Quit button will shut down the non-realtime program, i.e. Modbus and the display. The realtime ladder program will still run in the background.

The check box at the top right allows you to select whether variable names or symbol names are displayed

You might notice that there is a line under the ladder program display that reads "Project failed to load…". That is the status bar that gives you info about elements of the ladder program that you click on in the display window. This status line will now display HAL signal names for variables %I, %Q and the first %W (in an equation). You might see some funny labels, such as (103) in the rungs. This is displayed (on purpose) because of an old bug- when erasing elements older versions sometimes didn’t erase the object with the right code. You might have noticed that the long horizontal connection button sometimes did not work in the older versions. This was because it looked for the free code but found something else. The number in the brackets is the unrecognized code. The ladder program will still work properly, to fix it erase the codes with the editor and save the program.

This are two variable windows: the Bit Status Window (boolean) and the Watch Window (signed integer). The Vars button is in the Section Display Window, toggle the Vars button to display one, the other, both, then none of the variable windows.

The Bit Status Window displays some of the boolean (on/off) variable data. Notice all variables start with the % sign. The %I variables represent HAL input bit pins. The %Q represents the relay coil and HAL output bit pins. The %B represents an internal relay coil or internal contact. The three edit areas at the top allow you to select what 15 variables will be displayed in each column. For instance, if the %B Variable column were 15 entries high, and you entered 5 at the top of the column, variables %B5 to %B19 would be displayed. The check boxes allow you to set and unset %B variables manually as long as the ladder program isn’t setting them as outputs. Any Bits that are set as outputs by the program when ClassicLadder is running can not be changed and will be displayed as checked if on and unchecked if off.

The Watch Window displays variable status. The edit box beside it is the number stored in the variable and the drop-down box beside that allow you to choose whether the number to be displayed in hex, decimal or binary. If there are symbol names defined in the symbols window for the word variables showing and the display symbols checkbox is checked in the section display window, symbol names will be displayed. To change the variable displayed, type the variable number, e.g. %W2 (if the display symbols check box is not checked) or type the symbol name (if the display symbols checkbox is checked) over an existing variable number/name and press the Enter Key.

This is a list of symbol names to use instead of variable names to be displayed in the section window when the display symbols check box is checked. You add the variable name (remember the % symbol and capital letters), symbol name. If the variable can have a HAL signal connected to it (%I, %Q, and %W-if you have loaded s32 pin with the real time module) then the comment section will show the current HAL signal name or lack thereof. Symbol names should be kept short to display better. Keep in mind that you can display the longer HAL signal names of %I, %Q and %W variable by clicking on them in the section window. Between the two, one should be able to keep track of what the ladder program is connected to!

Starting from the top left image:

A short description of each of the buttons:

The config window shows the current project status and has the Modbus setup tabs.

Represent switches or relay contacts. They are controlled by the variable letter and number assigned to them.

The variable letter can be B, I, or Q and the number can be up to a three digit number, e.g. %I2, %Q3, or %B123. Variable I is controlled by a HAL input pin with a corresponding number. Variable B is for internal contacts, controlled by a B coil with a corresponding number. Variable Q is controlled by a Q coil with a corresponding number (like a relay with multiple contacts). E.g., if HAL pin classicladder.0.in-00 is true then %I0 N.O. contact would be on (closed, true, whatever you like to call it). If %B7 coil is energized (on, true, etc) then %B7 N.O. contact would be on. If %Q1 coil is energized then %Q1 N.O. contact would be on (and HAL pin classicladder.0.out-01 would be true).

Represent new count down timers. IEC Timers replace Timers and Monostables.

IEC Timers have 2 contacts.

There are three modes - TON, TOF, TP.

The time intervals can be set in multiples of 100&8239;ms, seconds, or minutes.

There are also Variables for IEC timers that can be read and/or written to in compare or operate blocks.

Represent count down timers. This is deprecated and replaced by IEC Timers.

Timers have 4 contacts.

The timer base can be multiples of milliseconds, seconds, or minutes.

There are also Variables for timers that can be read and/or written to in compare or operate blocks.

Represent the original one-shot timers. This is now deprecated and replaced by IEC Timers.

Monostables have 2 contacts, I and R.

The I contact is rising edge sensitive meaning it starts the timer only when changing from false to true (or off to on). While the timer is running the I contact can change with no effect to the running timer. R will be true and stay true till the timer finishes counting to zero. The timer base can be multiples of milliseconds, seconds, or minutes.

There are also Variables for monostables that can be read and/or written to in compare or operate blocks.

Represent up/down counters.

There are 7 contacts:

The up and down count contacts are edge sensitive meaning they only count when the contact changes from false to true (or off to on if you prefer).

The range is 0 to 9999.

There are also Variables for counters that can be read and/or written to in compare or operate blocks.

For arithmetic comparison. Is variable %XXX = to this number (or evaluated number)

The compare block will be true when comparison is true. You can use most math symbols:

For example ABS(%W2)=1, MOY(%W1,%W2)<3.

No spaces are allowed in the comparison equation. For example %C0.V>%C0.P is a valid comparison expression while %C0.V > %CO.P is not a valid expression.

There is a list of Variables down the page that can be used for reading from and writing to ladder objects. When a new compare block is opened be sure and delete the # symbol when you enter a compare.

To find out if word variable #1 is less than 2 times the current value of counter #0 the syntax would be:

To find out if S32in bit 2 is equal to 10 the syntax would be:

Note: Compare uses the arithmetic equals not the double equals that programmers are used to.

For variable assignment, e.g. assign this number (or evaluated number) to this variable %xxx, there are two math functions MINI and MAXI that check a variable for maximum (0x80000000) and minimum values (0x07FFFFFFF) (think signed values) and keeps them from going beyond.

When a new variable assignment block is opened be sure to delete the # symbol when you enter an assignment.

To assign a value of 10 to the timer preset of IEC Timer 0 the syntax would be:

To assign the value of 12 to s32out bit 3 the syntax would be:

The following figure shows an Assignment and a Comparison Example. %QW0 is a S32out bit and %IW0 is a S32in bit. In this case the HAL pin classicladder.0.s32out-00 will be set to a value of 5 and when the HAL pin classicladder.0.s32in-00 is 0 the HAL pin classicladder.0.out-00 will be set to True.

Coils represent relay coils. They are controlled by the variable letter and number assigned to them.

The variable letter can be B or Q and the number can be up to a three digit number, e.g., %Q3, or %B123. Q coils control HAL out pins, e.g. if %Q15 is energized then HAL pin classicladder.0.out-15 will be true. B coils are internal coils used to control program flow.

More information on modbus protocol is available on the internet.

https://www.modbus.org/

If there is a communication error, a warning window will pop up (if the GUI is running) and %E0 will be true. Modbus will continue to try to communicate. The %E0 could be used to make a decision based on the error. A timer could be used to stop the machine if timed out, etc.

Lets look at an example of reading one hold register at 8448 Decimal (0x2100 Hex).

Looking in the Modbus protocol reference:

Here is an example sent command as printed in the terminal (all Hex):

Meaning (Hex):

If there is an error response, it sends the function code plus 0x80, an error code, and a checksum. Getting an error response means the slave is seeing the request command but can not give valid data. Looking in the Modbus protocol reference:

Exception code meaning:

Here is an example received command as printed in the terminal (all Hex):

Meaning (Hex):

Looking in the Modbus protocol reference for Response:

*N = Number of registers

Here is an example received command as printed in the terminal (all Hex):

meaning (Hex):

(high and low bytes are combined to create a 16 bit value and then transferred to ClassicLadder’s variable.) Read Registers can be mapped to %W or %QW (internal memory or HAL out pins). Write registers can be mapped from %W, %QW or %IW (internal memory, HAL out pins or HAL in pins). The variable number will start at the number entered in the modbus I/O registry setup page’s column: First variable mapped. If multiple registers are requested in one read/write then the variable number are sequential after the first one.

If you used the StepConf Wizard to add ClassicLadder you can skip this step.

To manually add ClassicLadder you must first add the modules. This is done by adding a couple of lines to the custom.hal file.

This line loads the real time module:

This line adds the ClassicLadder function to the servo thread:

Now start up your config and select "File/Ladder Editor" to open up the ClassicLadder GUI. You should see a blank Section Display and Sections Manager window as shown above. In the Section Display window open the Editor. In the Editor window select Modify. Now a Properties window pops up and the Section Display shows a grid. The grid is one rung of ladder. The rung can contain branches. A simple rung has one input, a connector line and one output. A rung can have up to six horizontal branches. While it is possible to have more than one circuit in a run the results are not predictable.

Now click on the N.O. input in the Editor Window.

Now click in the upper left grid to place the N.O. Input into the ladder.

Repeat the above steps to add a N.O. output to the upper right grid and use the Horizontal Connection to connect the two. It should look like the following. If not, use the Eraser to remove unwanted sections.

Now click on the OK button in the Editor window. Now your Section Display should look like this:

To save the new file select Save As and give it a name. The .clp extension will be added automatically. It should default to the running config directory as the place to save it.

Again if you used the StepConf Wizard to add ClassicLadder you can skip this step.

To manually add a ladder you need to add add a line to your custom.hal file that will load your ladder file. Close your LinuxCNC session and add this line to your custom.hal file.

Now if you start up your LinuxCNC config your ladder program will be running as well. If you select "File/Ladder Editor", the program you created will show up in the Section Display window.