Experiment 7 Student Manual

American International University- Bangladesh

Department of Electrical and Electronic Engineering
EEE 4101: Control Systems Laboratory

Title: An Introduction to Industrial Programmable Controllers Using PC45/ML (Part II)

Abstract:

PLC: A Programmable Logic Controller (PLC) is an industrial computer control system that
continuously monitors the state of input devices and makes decisions based upon a custom
program to control the state of output devices. In this experiment, a complete program will be
designed using relay, timer and counters.

Introduction:

The main objectives of this experiment are -

1. learning the use of timers and counters.

2. designing a complete program using switch, timer and counters.

In this experiment, students will learn how to program using switch, timer, and counters
using PC45/ML.

Theory and Methodology:

The PLC must be able to perform counting and timing operations. Most PLCs have timers
and counters that can be programmed into a ladder diagram. The timer is essentially an
internal clock that can be set to count in set intervals of seconds or parts of seconds. The
number of intervals counted is called the accumulated value (AC). For example, if each
interval is 0.1 seconds and the AC value is 10, then the time elapsed is 1 second.

Timers are used to insert a delay. Timers are enabled so that an output can be activated after a
certain time. During the time the timer is enabled, it continuously increments its accumulator
value by the timing step, until it reaches the preset value. Counters count events. Every time
it is activated, it increments or decrements the accumulator value by one, unless it reaches the
preset value. When a timer or a counter reaches the preset value a DONE (denoted as DN in
the ladder logic diagrams) signal becomes active. To restart timing or counting, the reset
signals have to be active (denoted as RES in the ladder logic diagrams).

A timer is activated by a latched input. That is why it cannot be simply activated by a switch
or an active sensor. However, a counter is generally activated by a switch or an active sensor.
The following figure illustrates this. Note that the input and output addresses are not the real
addresses of the PLC-they are just used to illustrate the above point.

Timer in Allen Bradley PLC (TON Delay)

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 Timers Counters

I8
I8 O12 CU/CD
L

O12
RTO END

END
I9
CU/CD

END

Pre-Lab Homework:

You must solve the following questions and make a short report on that before the start of the
lab-

1. Get all the theoretical basics on timers and counters that will be helpful to
implement the experiment.

Apparatus:

The PC45/ML module contains following items:

1. Allen-Bradley MicroLogix 1500 Programmable Controller.
2. PC45 Programmable Controller Trainer.
3. PC45 Accessory kit.
4. PC49 Hand held compressor pump.

Precautions:

Students should take the following precautions while conducting the experiment –
1. Check the computer if it is working; otherwise inform lab instructor,
2. Be careful while handling the power supply buttons of computers and to keep them
off when they are not needed,
3. Check if PLC is working correctly and beware of typing mistakes.

Experimental Procedure:

Be familiar with the RSLogix software. All programming will be done using RSLogix
programming software.
StartProgramsRockwell Software RSLogix 500 Starter.

© Dept. of EEE, Faculty of Engineering, American International University-Bangladesh (AIUB) 2

Timer:

In following exercise, you will use the Timer ON instruction in order to see how each of its
instruction bits operate in a real-life system.

• Turn on your PC and ensure that Windows is running

• Click the Start button and choose Programs. The main Programs menu appears.
Choose the Rockwell Software folder, then choose the RSLogix 500 Starter folder,
and click on the RSLogix 500 starter program.
• When RSLogix has started, press the New icon in the standard icon bar in order to
begin a new project.
• Start a new project. Below a ladder logic diagram for the program that you will be
developing in this exercise.
• Enter the instructions shown in the Figure into the ladder diagram. The timer ON
(TON) instruction can be found in the Timer\Counter category of the instruction
toolbar.
• The timer ON instruction should appear in rung 0000 as shown in figure
• Enter addresses I:0. 0/0 and O:0. 0/7 as shown in the figure. You will be told how to
enter the Timer ON instruction parameters and Examine ON address next.
• Double-click your left mouse button on the question mark (?) to the right of Timer
and enter the address T4:0 into the box that appears. Press the Enter key on your
keyboard. A drop-down list will now appear to the right of Time Base
• Select the value 0.01 from the list and press the Enter key
• Type 250 into the box that has now appeared next to Preset, then press Enter.
• Press Enter to clear the box that appears next to Accum in order to allow the timed
count to start from 0.
• You have set up the parameters for the Timer ON instruction and should now appear
as shown in figure below.
• Click on the Examine ON instruction in rung 0001 in order to highlight it, type
T4:0/EN, then press the Enter Key
• This examine ON instruct will become true when the Enable (EN) bit of timer T4:0 is
active

The following programming exercises primarily require that either a tall or short object is
detected and then thrown off the conveyor. You should note that Sensor 1 can detect only tall
object, while Sensor 2 can detect both short and tall object. Therefore, detecting tall objects
are straightforward; however, detecting short objects are not. If the total number of objects is
known, then it is easier to detect short objects.

Also require timers and counters. Note that the timers should be named as T4:0, T4:1 etc. and
counters should be named as C5:0, C5:1 etc. The timers that should be used here is the Timer
ON (TON) or Retentive Timer ON (RTO). The counters that should be used are Up Counter
(CU) and Down Counter (CD).

© Dept. of EEE, Faculty of Engineering, American International University-Bangladesh (AIUB) 3

Programming Exercise 1:
Design a ladder logic program where pressing of green push button will start the conveyor in
forward direction and pressing of red push button will stop the conveyor.

Programming Exercise 2:
Design a ladder logic program where pressing of green push button will start the conveyor in
forward direction and after 45 second conveyor will stop automatically.

Programming Exercise 3:
Some objects including both tall and short objects-are passing through the conveyor. Develop
a program that starts the conveyor when green switch is turned on and stops the conveyor
after detecting 5 tall objects.

Programming Exercise 4:
Two objects-one tall and one short-are passing through the conveyor. It is not known which
object comes first. Develop a program to detect the tall object and throw it off the conveyor
through cylinder 1. Use timers.

Programming Exercise 5:
Two objects-one tall and one short-are passing through the conveyor. The tall object should
follow the short object. Develop a program to detect the short object and throw it off the
conveyor through cylinder 2. Use timers.

Programming Exercise 6:
Two objects-one tall and one short-are passing through the conveyor. The short object should
follow the tall object. Develop a program to detect the short object and throw it off the
conveyor through cylinder 2. Use 2 timers or 1 timer and 1 counter.

Programming Exercise 7:
You have to develop a program to perform the following:
(i) Use Sensor 1 on the conveyor to determine if a component is tall or short (Should
be set to detect a tall component only)
(ii) Sensor 2 on the conveyor is used to start timing for either a tall or short
component. (Should be set to detect all components)
(iii) Cylinder 1 (cylinder furthest from the sensors) is operated when a tall component
reaches it.
(iv) Cylinder 2 (middle cylinder) is operated when a short component reaches it.
(v) If the red push button is pressed, the conveyor stops, any timing taking place
should be stopped and the content of Accum held at its last value.
(vi) Pressing the green push button should re-start the conveyor and timing if
previously stopped.

Programming Exercise 8:
1. A press of green push button starts the conveyor in forward direction (using a self-
latch operation) and a press of red push button stops the conveyor. Green lamp comes
on when conveyor starts and red lamp comes on when conveyor stops.
2. If MCR zone is activated, taller objects (detected by both sensor 1 and sensor 2) will
be detected and cylinder 1 is activated to hit the object. For short object (detected by
both sensor 2) cylinder 3 is activated to hit the object.
3. Use two counters. First counter counts no. of short objects and second counters counts
no. of tall objects. Conveyor belt stops when total 5 tall objects and 5 shorts object is
detected.

© Dept. of EEE, Faculty of Engineering, American International University-Bangladesh (AIUB) 4

 Example:

© Dept. of EEE, Faculty of Engineering, American International University-Bangladesh (AIUB) 5

Questions for report writing:

Explain how each program works.

Discussion and Conclusion:

Interpret the data/findings and determine the extent to which the experiment was successful
in complying with the goal that was initially set. Discuss any mistake you might have made
while conducting the investigation and describe ways the study could have been improved.

Reference(s):

[1] Norman S. Nise, “Control Systems Engineering”, available Edition, John Wiley & Sons
Inc.
[2] An Introduction to Industrial Programmable Controllers, PC45/ML Curriculum Manual,
LJ Technical Systems
[3] Control System Laboratory Manual, American International University-Bangladesh
(AIUB), 2013

Appendix

PLC Input Terminal Description

I/0 Green Push Button
I/1 Red Push Button
I/2 Sensor 1
I/3 Sensor 2
I/4 Microswitch 1
I/5 Microswitch 2
I/6 Microswitch 3

PLC Output Terminal Description

O/4 Conveyor (Forwards)
O/5 Conveyor (Reverse)
O/6 Green Lamp
O/7 Red Lamp
O/8 Cylinder 1
O/9 Cylinder 2
O/10 Cylinder 3

© Dept. of EEE, Faculty of Engineering, American International University-Bangladesh (AIUB) 6

How to setup and run RSLogix Emulation (SLC 500, Micrologix 1000)
Monday, April 07, 2014
11:12 AM

SOFTWARE Download Link

http://jjackson.eng.ua.edu/courses/ece485/lectures/

Download only the following files:

Allen Bradley RSLogix Lite Software

Allen Bradley RSLinx classic Lite Software
Allen Bradley RSLogix Emulate 500 Software

Setup RSLinks: (Taken from original instructions)

1. Under the Communications menu select Configure Drivers.

2. Under the Available Drivers Types select the SLC 500 (DH485) Emulator driver and click the Add New button.
3. You can give the driver a name but I just leave it at the default of EMU500-1.
4. Leave the configuration options as Station Number 00 and click OK.

Your driver should now be running and look like the picture below.

Close the Configure Drivers dialog box and close RSLinx. Actually RSLinx is now running in the background and you'll probably see its little icon in
the system tray.

Setup RSLogix Micro Starter Lite:

Create a new program.

RSLogix Emulation Page 1

The next very important step is to verify the project with the Edit > Verify Project menu item. This will compile
the project and get it ready for the emulator.

Save the project as something like Test.RSS in an easy place to find like My Documents.

RSEmulator 500
The emulator lets us test our work by running a virtual PLC. We'll be able to download our program to it and run it in a very similar fashion to a
real PLC. Start the emulator with the START > All Programs > Rockwell Software > RSLogix Emulate 500 > RSLogix Emulate 500 shortcut. The
emulator is pictured below. I know. It doesn't look like much but it gets the job done.

RSLogix Emulation Page 2

Select File > Open and open the RSLogix project you created earlier (I named mine TEST.RSS). In the dialog box that pops up put the Station # as 1
and click Ok.

Believe it or not but the emulator is now ready. Leave it running and go back to your project in RSLogix Micro.

Testing the Ladder Logic:

In RSLogix Micro Starter select the Comms > System Comms menu item. The following dialog box will pop up.

In the left hand pane, drill down and select the 01, MicroLogix 1000, TEST processor. Yours might look a little different if you selected different

RSLogix Emulation Page 3

In the left hand pane, drill down and select the 01, MicroLogix 1000, TEST processor. Yours might look a little different if you selected different
hardware or gave the processor a different name. For good measure make sure Apply to Project is checked and then click on Download. When
prompted to go Online click on Yes.

If successful you'll see the ladder picture spinning round on the online toolbar. To scan the ladder logic put the processor into Run mode by
clicking on the arrow to the right of mode status (REMOTE PROGRAM).

To test the ladder logic, change the input state by right clicking on the address and selecting toggle bit.

You will see the instruction go green indicating it is true and it will make the output instruction turn green also indicating the output is turned on.
That's it! You get all that for the cost of a download. Now break out the manuals and start learning about all the different instructions.

RSLogix Emulation Page 4