PROGRAMMABLE LOGIC CONTROLLER (PLC)

(Short Report / Long Report)

Student Name
Wong Shin Chien (0317415)
Date of Experiment:
12/5/2016

Group Members
Jane Lee Song Ern
Yap Yi Wei

Report due date:17/6/2016

Report submission date:
17/6/2016
Checked by:

Item/marks
Format/10

School of Engineering
Taylors University
Malaysia
12 May 2016

Abstract and
Introduction/10
Figures and
Diagrams/15
Materials and
Method/10
Results
Discussions/45
References/10
Total

Table of Contents

Abstract

1.0 Introduction 4
2.0 Experimental Design

2.1 Materials and Apparatus 6

2.2 Methodology 6
2.3 Experimental Procedure 7
3.0 Results and Discussion

10

4.0 Error Analysis 20

5.0 Conclusion 21
Reference 22

Abstract
This report consist of 4 discussion from 4 different experiment done on the same
machine which is the PLC OMRON SYSMAC CS1G-CPU42H (Programmable
Controller) by using CX programmer as the executing tool for the program that
students wrote. The PLC trainer is tested with inputs such as simple PB start switch,
Timer switch, sensors switch, and relay switch. The first experiment allow us to
understand that the circuit will still continue to flow when the relay switch is turned
on even after the PB start switch is deactivated again. Experiment 2 allow students to
understand that there is a delay for the circuit to flow through parallel circuit when the
parallel timer switch is switched on after certain amount of time that is set by students
usually in seconds. 3rd Experiment shows the combination of components such as
relay switch and timer switch. The relay switch is off when the main path of the
circuit which is controlled by the timer switch is open after the timer ends. It shuts
down the only path that completes the circuit therefore the lamp is off after the timer
ends. Experiment 4 is a more sophisticated experiment which includes transformation
of electrical signals into mechanical movement with controlled time and direction of
movement of the car. The sensors switches on and off after the car passing through the
sensor which will activate the related switch and the car changes direction. The
experiment is done successfully with the steps carefully followed by students
according to the lab sheet.

1.0

Introduction

Programmable Logic Controller (PLC) is a device that take inputs from user and gives
desired output which is programmed by the user. PLC can perform task such as receiving
signal generated by sensors which is stimulated by physical stimuli.
A programmable logic controller (PLC) is used for automation process in industry such as
assembly lines, temperature control, lighting control etc[1]. PLC are designed for multiple
input and outputs. It should withstand harsh environment which can function under extended
temperature ranges, resistance to vibration and impact, etc[2].
Early PLCs were designed to replace relay logic systems[3].Ladder logicis the programming
language for PLC which looks like a diagram of relay logic. This is to reduce the difficulties
for existing technicians.
Modern PLCs can be programmed in a variety of ways such as specially adapted dialects
of BASIC and C[4]. They also used state logic which is a very complex and high level
programming language specially designed to program PLCs.
PLC is a computer, it has a CPU which carry out function such as:

Store user commands in a non-volatile memory which will not be erased even there is

an electrical breakdown.
Communicate with other devices such as sensors, actuators etc.
Perform house-keeping activities including communications, internal diagnostics and
etc.

A basic PLC system follows 4 steps of operation which is stated in the table below:
Table1: Operational Steps and its functions

Process

Functions

Input Scan
Program Scan
Output Scan
House-Keeping

Detects the state of input devices

Executes logic created by user
Energize/de-energize state of output devices
Internal diagnostics, communications, programming
terminals, etc

For our experiment, the programming software that we are using is CX programmer to
execute our commands and programming diagram on the PLC.
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Figure 1.2 CX programmer software [5]

It creates advanced programs using data blocks of identical data types (Arrays), or different
data types (Structures. It also create symbols quicker as it has automatic memory allocation
and management. Students then easily monitors the state of the input and output devices in
the computer to check whether the output produced is correct. TIMER (count-down) and
COUNTER (count-up) symbols allows easy track of timer and access the value and students
can modify it by accessing it according to their specific names such as TIM 0001. That means
zero maintenance to resolve addresses when a program is very complex and just a single data
is needed to be modified.

2.0 Experimental Design

Figure 2.1: OMRON Programmable Logic Controller (PLC)

2.1 Materials and Apparatus

1. OMRON SYSMAC CS1G-CPU42H (Programmable Controller)
2. CX- Programmer
3. Computer

2.2 Methodology
For every experiment, students are required to draw the input and output devices in the CX
program based on the lab sheet provided. The next step is to set value and names for the
devices drawn in the CX program. After troubleshooting and confirmed that the circuit is
functioning, it is sent to the PLC OMRON SYSMAC CS1G-CPU42H and executed. The
switch on the PLC is switched on and off depending on the experiment procedure. The result
for each action taken is recorded and screenshotted for report writing purposes.

2.3 Experimental Procedure

Experiment 1
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Figure4:Conventional Circuit for Experiment 1

1. An input and output table together with a ladder logic diagram was drawn as shown
respectively for the conventional circuit as shown in Figure4 above.
2. Ladder logic diagram was developed in the CX programmer and transferred to the
PLC.
3. Program was run and executed and hence observations and explanations were made.

Experiment 2

Figure5: Conventional Circuit for Experiment 2

1.

An input output table together with a ladder logic diagram was drawn as shown in

Figure 5.
2. The timer was set to 5 seconds.
3. The ladder logic diagram was developed in the CX-Programmer and the program was
transferred to the PLC trainer.

4. The program was run and executed and hence observations and explanations were
made about the application.

Experiment 3

Figure6: Conventional Circuit for Experiment 3

1.

An input output table together with a ladder logic diagram was drawn as shown in

Figure 6.
2. The timer was set to 8 seconds.
3. The ladder logic diagram was developed in the CX-Programmer and the program was
transferred to the PLC trainer.
4. The program was run and executed and hence observations and explanations were
made about the application.

Experiment 4

Figure7: Conventional Circuit for Experiment 4

1. An input and output table together with a ladder logic diagram was drawn as shown for
the conventional circuit as shown in Figure7 above.
2. Timer was set to 5 seconds.
3. Ladder logic diagram was developed in the CX programmer and transferred to the PLC.
4. Program was run and executed and hence observations and explanations were made.

3.0 Results and Discussion

Experiment 1
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Table 3.1: Input output table for experiment 1

INPUT DEVICE
PB Start

COMMAND
0.01

OUTPUT DEVICE
Relay Coil

COMMAND
1.01

PB Stop

0.02

Lamp 1

1.02

Figure 3.2: Ladder logic diagram Experiment 1

PB Start button is Normally Open, which means when the button at the PLC trainer is

activated, the circuit will be complete and allow current to flow through it.
PB Stop button is Normally Closed, which means when the button is activated, the

circuit will be cut and stop the current to flow through it.
Relay Coil will be activated when there is a current flowing through it. The parallel
circuit of relay coil will support the current flow even the PB Start is switched off

later after it is being activated.

Lamp will be activated when there is current flowing through it.

Figure 3.3: Circuit of PB start activated and PB stop deactivated.

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It is clear that when current is allowed to flow and PB start is activated and pass through PB
Stop which is normally closed and it activates the relay coil and parallel current flow through
it and activates the lamp.

Figure 3.4: Circuit of PB start deactivated and PB stop deactivated.

Even that when the PB Start is deactivated again, the parallel relay coil has already been
activated and supports the current flow through PB Stop and continue relaying itself and
activates the lamp.

Figure 3.5: Circuit of PB Stop activated.

The circuit path for the current to flow has been cut. There is no way for the relay to continue
function as the activator for the relay cannot be reach by current. This causes the circuit to be
incomplete and the lamp is deactivated.

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Figure 3.6: Circuit of PB Start activated and PB Stop activated

Even PB start is activated, there is no way to activate the relay coil and lamp as PB Stop is
the only path that allow the circuit to be completed. Nothing will be activated if PB stop is
activated.

Experiment 2
Table 3.7 Input and Output table Experiment 2
INPUT DEVICE
Latching Switch

COMMAND
0.01

OUTPUT DEVICE
Timer 1

COMMAND
TIM 1 #0050

Lamp 1

1.01

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Figure 3.8: Ladder Logic Diagram for Experiment 2

Switch 0.01 is a Normally Open switch. It will allow current to pass through if it is

activated.
Timer switch is coded as TIM 0001 and preset a timer of 50 milliseconds. It will
count for 50 milliseconds before it turns on the circuit and allow the circuit to be

closed for T0001 switch.

Lamp will be activated if current flows through it.

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Figure 3.9: Switch 0.01 is activated

When the normally open switch 0.01 is activated, the currents flows through the timer switch
which starts to count for 50 milliseconds. Note that the circuit is not complete when it havent
finished counting.

Figure 3.10: Complete circuit after timer switch finishes counting

After counting for 50 milliseconds, the normally open timer switch is now closed. Current
flows through the circuit and completes it while activating the output, which is the lamp.

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Experiment 3
Table 3.11 Input and Output Table For Experiment 3
INPUT DEVICE
PB Start

COMMAND
0.01

OUTPUT DEVICE
Relay Coil

COMMAND
1.01

Timer 1

TIM 1 #0080

Lamp

1.02

Figure 3.12: Ladder Logic Diagram Experiment 3

Switch 0.01 which is normally open

Timer contact is Normally Closed this time. Means after the counting of the timer the

circuit will open and stops the current flow

Relay switch allow parallel current flow through the relay coil when current is

supplied to the switch.

Lamp activates when current flows through it.

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Figure 3.13 PB start activated

When PB Start is activated, it activates the relay coil and timer contact. Parallel current flows
through the relay switch which is now closed. The lamp is activated as current flows through
parallel circuits.

Figure 3.14 PB start deactivated

When PB start is closed, current is still flowing through the relay, timer switch, and lamp
because the relay coil is still supplied with current. The timer switch is still counting for 80
milliseconds.

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Figure 3.15: Timer switch finishes counting

When timer switch finished counting for 80 milliseconds, the timer contact switch is now
open as it is Normally Closed before. This shuts down the current that flow through it. Now,
the relay coil is not supplied with current, therefore, the relay switch is now open again. The
lamp does not receive current and therefore is not activated.

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Experiment 4

Figure 3.16 When LS1 and PB start is activated

When LS1 and PB Start are activated, it passes through PB Stop and LS2 which are Normally
Closed and activates Motor Right switch which is normally opened. The car will move to the
right. Even when the PB start is deactivated now, the motor will still be moving right.

Figure 3.17 When LS2 activated

When the motor reaches the end, LS2 sensor sense the car and open the Normally Closed
LS2 switch which stops the Motor Right from moving. It also activates the Timer switch
which counts for 50 milliseconds.

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Figure 3.18 When Timer switch finishes counting and motor Left activated
After counting for 50 milliseconds, timer switch is closed and LS1 switch which is normally
closed allow currents to flow through and activates Motor Left. The car moves left. And after
the car reaches the Left end, LS1 sensor will sense the car and open the Normally Closed LS1
switch which cuts off the current and motor left stops. The car is back to original position.

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4.0 Error Analysis

For experiment 1, Relay coil is the risk that will cause error to the PLC system. This is due to
the electromagnetic force generated is not strong enough to allow the switch to contact with
it. Causing no current to flow through it after PB Start is switched off.
For experiment 2, malfunction of timer switch will cause the timer to be looping forever
without activating its timer switch. This will shut down the current that should be passing
through the lamp.
For experiment 3, risk and error caused will be similar to experiment 1 and experiment 2 as
the components used in experiment 3 consists of components that being used previously such
as relay and timer switch.
For experiment 4, the sensor will probably causes error as student might accidentally put their
hands along the path of the sensor which sends a signal to the PLC to stops the motor before
it is supposed to be stopped. This will greatly affect the outcome of the result that students
wanted to obtain.

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5.0 Conclusion
After completing the experiment, students are able to understand the functions of the
components that is used to draw the ladder logic using CX programmer software. A relay coil
will allow current to flow through the switch when the current is supplied to it. A timer switch
will allow switches to turn on and off based on the delay time set by the user. Sensors
instantly changes the related switch when it is blocked by an object such as the car that
blocking its sensing path.
For experiment 1, the key learning is to understand that the circuit will continue to flow when
the relay coil is supplied with current. Even after the PB start is deactivated, the parallel
circuit still loaded with current will continue to supply current to the lamp. It can only be
turned off by activating the PB stop button which is Normally Closed because it is located at
the only path the current move across. This will shut down the relay coil and shutdown the
lamp.
For experiment 2, key learning is to manipulated variable such as time. A delay can be set by
students to demand a presence of current after certain amount of time. When the timer
finishes counting, the current starts flowing through the parallel current path and supply
energy to the lamp.
For experiment 3, key learning is to combine several components to produce a new and more
complex function based on experiment 1 and 2. This helps students to design complex system
that not just uses one components but more than one components to produce complex
function.
Experiment 4 teaches students to convert electrical signals into mechanical movement by
adding actuators such as electric motors in this experiment. The car is actuated to move left
and right when the motors is activated by sensors when the car move pass through it,
blocking its receiver. The setting is a good practice and students can draw a more complex
ladder logic that move in a more complex direction.
Lastly, the experiments carried out had help students understand more about PLC and help
student to prepare for the industrial environment when they starts to work in industry where
PLC is often used by companies in assembly lines. It is very beneficial to have knowledge on
PLC to alter the assembly plan to produce more value to the company by modifying the robot
movement for better production cycle time.
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References
[1] E. A. Parr, Industrial Control Handbook, Industrial Press Inc., 1999 ISBN 08311-3085-7
[2] M. A. Laughton, D. J. Warne (ed), Electrical Engineer's Reference book, 16th
edition,Newnes, 2003 Chapter 16 Programmable Controller
[3] "The father of invention: Dick Morley looks back on the 40th anniversary of the
PLC". Manufacturing Automation. 12 September 2008.
[4] Harms, Toni M. &Kinner, Russell H. P.E., Enhancing PLC Performance with
Vision Systems. 18th Annual ESD/HMI International Programmable Controllers
Conference Proceedings, 1989, p. 387-399.`
[5] CX Programmer 9.1, undated, Omron , [online], Viewed: 14/6/2016, Available at:
https://industrial.omron.eu/en/products/cx-programmer

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