Ladder Logic Programming

Examples
Latching in a PLC
Latching is one of the most important pieces of ladder logic programming that
you’ll ever use.

Latching in a PLC refers to ladder logic code that simulates the operation
of a latching relay. It requires two inputs and an output. The output is
latched (set TRUE) with one of the inputs. The output is unlatched (reset
to FALSE) with the other input. A momentary pulse can be used for the
inputs.
This can be achieved with two methods….

1. Set and Reset instructions: called Latch and Unlatch

instructions. These instructions simulate the function of an
electro-mechanical latching relay. Advantages include flexibility in
programming because the Set (Latch) and Reset (Unlatch)
symbols do not need to be in the same rung. The disadvantage is
that debugging can become more difficult because the Set (Latch)
and Reset (Unlatch) symbols may be scattered throughout the
program.
2. Latching logic: Quite often “latching logic” is referred to as “hold
in logic”. It’s ok to interchange the terms. The advantage of
latching logic is that troubleshooting is easier because the
symbols used are all in the same rung. The disadvantage is that
there is some inflexibility in programming because latching logic
requires all the symbols to be on the same rung and may even
overflow to the next rung. This can be restrictive in some cases.
Simple applications requiring a latch are well suited to use latching logic.

But when it comes to more complex applications the use of Set (Latch) and
Reset (Unlatch) symbols may be required.

Sometimes it just comes to personal preference.

Latching in a PLC requires at least one input to set the latch (Input A), one
input to reset the latch (Input B) and one output to store the latch state
(Output Y).

The inputs that set and reset the latch are usually momentary pulses. A great
example of a device that can provide a momentary pulse to a PLC input is a
push button.

Ladder Logic Latch with SET & RESET

Symbols
Let’s start with the Set (Latch) and Reset (Unlatch) logic. Remember Allen
Bradley PLC’s use Latch and Unlatch symbols.

The rungs below show the basic code.

When both Input A and Input B are FALSE then the state of Output Y does not
change. If Output Y is FALSE then it stays FALSE….

Ladder Logic Programming Examples – Ladder Latch

If Input A goes TRUE momentarily then the SET symbol changes the state of
Output Y to TRUE.

Then, after subsequent scans, if Input A changes state to FALSE it does not
affect the state of Output Y. In other words, Output Y is latched TRUE…
Ladder Logic Programming Examples – Ladder Latch (Set or Latch)
Only when Input B changes state to TRUE will the RESET symbol change the
state of Output Y back to FALSE. In other words, Output Y is now unlatched….

Ladder Logic Programming Examples – Ladder Latch (Reset or Unlatch)

Remember the PLC scan runs from left to right and from top to bottom.

So if both Input A and Input B are TRUE at the same time, then in the ladder
diagram above the first rung is evaluated and Output Y is set TRUE.

But, then the second rung is evaluated and Output Y is set FALSE.
Once the scan reaches the end of the entire program it will execute the state
of Output Y as FALSE.

Ladder Logic Latch with Hold In Logic

Using hold in logic to achieve latching has a similar outcome to using Set
(Latch) and Reset (Unlatch) symbols.
But with hold in logic both Input A and Input B are on the same rung as
Output Y. Also, the way in which the latch is SET and RESET is done differently.

Notice that Input B is a normally closed (NC) contact symbol and Output Y is
used twice and branched (or in parallel with Input A).

Ponder that thought for a second, let’s continue….

Ladder Logic Programming Examples – Ladder logic latch with hold in

logic
Remember the scan goes from left to right and top to bottom.

So the scan starts from the left hand side of the rung and moves right to Input
A.

If Input A goes TRUE and Input B is FALSE then Output Y goes TRUE….
The scan continues on with the rest of the program and it cycles back to the
rung.

Previously Output Y had changed state to TRUE, so now Output Y that is in a

branch across Output A, also goes TRUE and there is no other change….

When the scan cycles back again from the top, if Input A goes FALSE, with
Input B still FALSE, then Output Y stays TRUE.

This is because Output Y is held in by itself using the branch across Input A.

Notice that the logic flows from the left hand side rail through the Output Y
branch and then through Input B to Output Y at the right hand side rail. Pretty
cool…..
Ladder Logic Programming Examples – Ladder hold in logic (Latched)
Once we have triggered the hold in logic using Input A, Output Y will remain
latched even if Input A goes FALSE.

Output Y will remain latched TRUE until Input B goes TRUE. Because Input B is
a normally closed (NC) contact symbol, when it goes TRUE, the logic flow is
blocked and Output Y goes FALSE. Thus releasing the latch.

Remember the NC contact symbol works like a NOT statement, it’s reverse
logic….

So, when the scan cycles back again from the top then Output Y, branched
across Input A, also goes FALSE….
Ladder Logic Programming Examples – Ladder hold in logic (Unlatched)
Once Input B returns to the FALSE state we are back at the start, ready to
initiate the latch again.

We can write out the logic expression above as…

IF (INPUT A OR OUTPUT Y) AND NOT (INPUT B) THEN OUTPUT Y.

Hold in logic is great to use because it simplifies your code. It enables us to
place all the conditions that initiate and release latch in the same rung. This
makes it easier to read and troubleshoot.

PLC Motor Control

Ladder logic for motor control can be accomplished using hold in logic.
Remember it’s ok to also call it latching logic.

Simple ladder logic for motor control using push button start stop logic
includes a start button, stop button, motor thermal overload and motor run
contactor.
When we wire up the inputs to the PLC the start push button input is wired
normally open (NO). So when the start button is pushed the PLC input
changes state from FALSE to TRUE…
PLC Wiring Basics – Start button
But the stop push button and thermal overload are always wired normally
closed (NC). So when the stop button is pushed it changes from CLOSED to
OPEN. In turn the PLC input changes state from TRUE to FALSE….

PLC Wiring Basics – Stop Button

In fact the rule of thumb is that any device that is required to stop the motor
should be wired normally closed (NC), to make it “fail safe”.

The most common failures are wire break, device failure or PLC input failure.

Wiring the stop push button normally closed (NC) is done because when a
failure occurs in the PLC input circuit it will, more often than not, lead to an
open circuit which changes the state of the PLC input from TRUE to FALSE.

However, if we wire the stop PLC inputs as normally open (NO) and a failure
occurs then the state of the PLC input does not change. It stays FALSE, even if
the stop button is pressed, because there is an open circuit in the connection
to the PLC input.
So if there is no change in state, we cannot tell the motor to stop in our ladder
logic program. This is really bad!!!

So for any PLC input that is intended to stop the motor we need to..…

WIRE THE MOTOR STOP SIGNALS NORMALLY CLOSED AND USE A NORMALLY
OPEN SYMBOLS IN THE PLC.
Now that we’ve grasped the concept of the fail safe stop input let’s move on
to the motor control ladder logic programming example.

Motor Control Ladder Diagram

First up let’s list the required inputs and outputs for our motor control ladder
diagram.

PLC manufacturers use different memory address allocation so the input

output allocations used here are arbitrary address.

Below is the list of required inputs …..

Next let’s list the required outputs…..

The ladder logic programming example uses the M1 START push button input
to activate the M1 RUN output.

The M1 RUN output is used a second time to latch the M1 RUN output.

Both M1 STOP and M1 TOL are wired normally closed (NC) to the PLC inputs
and thus need to be configured as normally open (NO) symbols in the logic.

So when either stop is activated the logic flow is broken and the latch is
reset….
Ladder Logic Programming Examples – Motor Control Ladder Diagram
Remember, we must wire M1 Stop and M1 TOL using normally closed (NC)
contacts to the PLC inputs to make it “fail safe” and for this motor control
ladder diagram to work.

PLC Wiring Basics

If you are still a little confused about the different PLC wiring and ladder
diagram symbol combinations and their different logic states then….DON’T
PANIC!

To help out we’ve developed a nifty table which displays the different
combinations of PLC digital input wiring and ladder logic symbols that can be
used.

Further more, it outlines the logic state each of the ladder logic symbols
depending on whether the PLC input is activated or de-activated. When the
symbol is BLACK it’s state is FALSE and when the symbol is GREEN it’s state is
TRUE.
PLC Wiring Basics and Ladder Logic Symbols
A PLC timer is an instruction used in ladder logic programing. When
added to a ladder diagram it introduces a time delay when a specific
event occurs. In its most basic form a PLC timer has a start input, a preset
time input and a done output.
It is important to understand that a PLC timer instruction introduces a time
delay which only affects the execution of the timers outputs. The PLC scan is
not directly delayed, it still scans through all the ladder logic rungs as per
normal.

How does a PLC timer work? A PLC timer continually monitors its start input
for a change in its logic state. When the logic state of the start input changes
the timer starts running. After the timer reaches the preset time setting, the
done output is triggered.
How is a PLC timer reset? Depending on its type, a PLC timer can be reset in
one of three ways. ON-delay timers can be reset by removing the start input.
OFF-delay timers and Pulse timers are reset after the preset time expires.
Other timers, in fact any timer with a reset input, can be reset at any time by
triggering the reset input.
Types of PLC Timers
Different types of PLC timers exist based on how they implement the time
delay within the timing instruction. The 3 types of PLC timers, as defined in IEC
61131-3 International PLC Programming Standard, are:

1. ON-Delay Timer (TON)

2. OFF-Delay Timer (TOF)
3. Pulse Timer (TP)
In my experience with ladder logic programming I have actually come across
11 different types of PLC timers from various PLC brands, they are:

1. ON Delay Timer
2. OFF Delay Timer
3. Retentive (Accumulating) Timer
4. Retentive ON Delay Timer (Siemens PLC)
5. Pulse Timer
6. Extended Pulse Timer
7. Frequency Timer
8. Teaching Timer
9. Dual Timer
 10. Multi Output Timer
11. Special Timer
However, not all PLC brands have every timer available for use in their ladder
logic programming software. For example some Mitsubishi and Omron PLCs
do not have OFF-delay timers. And, as far as I know, the dual timer is unique
to Idec PLCs.

Check out the table below which is a comparison of PLC timer

instructions that are available in some of the most common PLCs brands….

Comparison of PLC Timer Instructions

Fun Fact… In the table above you’ll notice that there are 2 types of Siemens
timers, Simatic and IEC. The Siemens Step7 programming software uses
Simatic PLC timers, but the new Siemens TIA Portal programming software has
access to both the Simatic timers and the IEC timers.
Application of PLC Timer Types
The most common application of PLC timer types are the ON Delay PLC
timer, OFF Delay PLC timer, Retentive PLC timer and Pulse PLC timer. Each
type uses its time delay and triggers its output in a specific way.
The application of a PLC timer depends on when the time delay is
required. If a delay is required after an event changes state to ON, then
application of an ON-Delay timer is required. However, if a delay is
required after an event changes state to OFF, then application of an OFF-
delay timer is required.
Use the chart below to help decide what type of PLC timer to use for your
specific application…

PLC Timer Types

PLC Timer Instructions
Timer instructions in a PLC have a number of elements which must be defined
and/or assigned to an address in order for them to operate correctly. The
most common elements that I have come across are shown below….

 PLC Timer Type

 Tag / Address
 Start / Enable (Input)
 Preset Time Value (Input)
 Time Base (Input)
 Reset Input (Input)
 Enabled (Output)
 Done (Output)
 Elapsed / Accumulated Time (Output)
 Remaining Time (Output)
The PLC CPU usually has a memory area assigned specifically for PLC timer
instructions. Within the PLC ladder logic instruction set, there’s typically
support for a limited number of PLC timers. Generally, the larger the PLC CPU
memory, the greater the number of available PLC timers.

Timer instructions in a PLC can vary from one PLC brand to another.
Things like the PLC timer symbols, tag, addressing, inputs, outputs, count
direction (increment/decrement) and time base (usually 1ms, 10ms, 100ms or
1s) can all be different.
the generic layout of a PLC timer symbol, from IEC 61131-3 International PLC
Programming Standard, that is used in ladder logic programming….

PLC Timer Ladder Logic Symbol

Let’s have a look at the different types of PLC timers in a little more detail.
We’ll examine all the different PLC timer instructions, their symbols, timing
diagrams and operational description from various manufactures and brands.
Lets read on….

1) PLC ON Delay Timer

Out of all the different types of PLC timers, the ON delay timer is the one I
most commonly use in ladder logic programming. In fact, most of the other
timers can be created in ladder logic by using the ON delay timer as the base
building block. Luckily most PLCs have created other timing instructions to
save us the hassle.

In a PLC the ON delay timer is commonly known as a TON timer. The

operation of the ON delay timer is a reflection of its name. You see, the
ON Delay Timer (TON Timer) only turns its output ON after a preset time
DELAY. In other words, the output is DELAYED before it turns ON.
The ON delay timers instruction name, symbol and input/output variables can
be expressed in different ways in a ladder logic program depending on which
PLC brand you’re using.

For example the TON instruction in a PLC is used in Allen Bradley, Siemens,
ABB and Unitronics PLCs. Whereas, the Omron, Mitsubishi, Automation Direct,
Delta and Idec PLCs do not use the TON notation for their ON delay timer
instruction.
Some examples of ON delay timer instructions, used in different PLC brands,
are shown below.…
PLC ON Delay Timer (TON)
How the ON Delay Timer Works

The function of an ON delay timer in a PLC is to monitor the occurrence of a

certain event (input), add a time delay and then trigger an action (output) after
the time delay expires. The time delay is adjustable (preset time input) and the
output is reset when the input turns OFF.
The best way to describe the operation of an ON delay timer is by using
a timing diagram like the one below…

PLC ON Delay Timer (TON) – Timing Diagram

Below is the description of how an ON Delay Timer operates in a PLC. The
numbers correspond to the PLC ON Delay Timer – timing diagram above…
1. When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output
remains FALSE while the timer is running.
2. After the timer has expired, if the START input is still TRUE, the
DONE output is set TRUE.
3. The DONE output is reset back to FALSE when the START input
goes FALSE.
4. If the START input changes from FALSE to TRUE and then back to
FALSE before the timer has expired, the DONE output stays FALSE.

2) PLC OFF Delay Timer

The PLC OFF delay timer is the second most commonly used PLC timer that I
use in ladder logic programming, only after the PLC ON delay timer.

In a PLC the OFF delay timer is commonly known as a TOF timer. The
operation of the OFF delay timer is a reflection of its name. You see, the
OFF Delay Timer (TOF Timer) only turns its output OFF after a preset time
DELAY. In other words the output is DELAYED before it turns OFF.
In a ladder logic programming the OFF delay timers instruction name, symbol
and input/output variables can actually differ depending on the brand of PLC
you’re working with.

For example the TOF instruction in a PLC is used in Allen Bradley, Siemens,
ABB, Unitronics, Schneider and Emerson PLCs. Whereas the Automation Direct
and Idec PLCs do not use the TOF notation for their OFF delay timer
instruction. In fact, the Omron, Mitsubishi and Delta PLCs do not have an OFF
delay timer instruction at all.
Some examples of OFF delay timer instructions, used in different PLC brands,
are shown below.…
PLC OFF Delay Timer (TOF)
How the OFF Delay Timer Works

The function of an OFF delay timer in a PLC is to monitor the occurrence of

a certain event (input) and immediately trigger an action (output). Then, wait
for the input to turn OFF, add a time delay and then reset the output. The
delay time is adjustable via the preset time input.
What is the basic difference between a TOF and TON delay timer? The
TON timer delays the output from turning ON after the input turns ON.
Whereas the TOF timer turns the output ON immediately after the input turns
ON and delays the output from turning OFF after the input turns OFF.
A great way to describe the operation of an OFF delay timer is by using
a timing diagram like the one below…

PLC OFF Delay Timer (TOF) – Timing Diagram

Below is the description of how an OFF Delay Timer operates in a PLC. The
numbers correspond to the PLC OFF Delay Timer – timing diagram above…
1. When the START input changes state from FALSE to TRUE the
DONE output is immediately set TRUE.
2. If the START input changes state from TRUE to FALSE, the PRESET
TIME is loaded and the timer begins running.
3. After the timer expires, the DONE output is reset to FALSE.
4. If the START input changes state from TRUE and FALSE multiple
times, before the timer has expired, the DONE output remains
TRUE and the PRESET TIME is re-loaded each time.
5. After the timer expires, the DONE output is reset to FALSE.

3) PLC Retentive (Accumulating) Timer

The Retentive Timer in a PLC works in a similar fashion to the ON Delay Timer
because it delays the output from turning ON. But it has some extra features
and subtle differences.

In a PLC the Retentive Timer is commonly known as a RTO timer

(Retentive Timer ON). The operation of the Retentive Timer is a reflection
of its name. You see, it RETAINS the amount of time that the input is
active for and only turns the output ON once the total retained time is
equal to the preset time value.
A retentive timer is used to record the amount of time that the input is
active for and trigger an output after a preset period of time has been
reached. A great example is monitoring the accumulated run time hours of a
piece of equipment then triggering an alarm when it is time to be serviced.
What happens when the input of a RTO timer becomes false? When the
input of a RTO timer becomes false the timer is paused and the current time
value is retained. When the input goes true again, the timer resumes from
where it left off. Unlike the ON delay timer, the output is not reset when input
of an RTO timer becomes false.
How do you reset RTO timer? After the RTO timer is done the output stays
ON and can only be reset by triggering the reset input. The reset input has
priority and will reset the timer accumulated value back to 0 and the output to
OFF. The RTO timer will restart when the start input is ON and the reset input
is OFF.
The name, symbols, and input/output variables for Retentive timers can vary
within a ladder logic program based on the specific brand of PLC that you’re
utilizing. For example the RTO instruction in a PLC is used in Allen Bradley
PLCs. However, Siemens (IEC) use TONR, Mitsubishi use T and GE Fanuc
(Emerson) use ONDTR.
The PLC Retentive Timer is also known as an Accumulating Timer in some
PLC brands. Some examples of PLCs with accumulating timer instructions are
Omron with TTIM, Unitronics with TA, Automation Direct
with TMRA instruction. Whether the terminology used is retentive timer or
accumulating timer their operation is essentially the same.
Some examples of Retentive timer instructions, used in different PLC brands,
are shown below.…

PLC Retentive (Accumulating) Timer

How the Retentive Timer Works

The function of a Retentive timer in a PLC is to monitor the occurrence of a

certain event (input), record the amount of time that the input is ON and turn
the output ON after the accumulated time reaches the preset time value. The
retentive timer can only be restarted by triggering the reset input.
An awesome way to describe the operation of a Retentive timer is by using
a timing diagram like the one below…
PLC Retentive Timer – Timing Diagram
Below is the description of how a Retentive Timer operates in a PLC. The
numbers correspond to the PLC Retentive Timer – timing diagram above…
1. When the START input changes from FALSE to TRUE and the
RESET input is FALSE, the timer PRESET VALUE is loaded and the
timer starts running. The DONE output is FALSE at this stage.
2. When the START input goes FALSE the timer is stopped, but the
accumulated time is retained. When the START input is set TRUE
again, the timer resumes running from its last accumulated value,
but the DONE output does not change state.
3. After the PRESET TIME expires, the DONE output is then set TRUE.
Under this condition, if the START input changes state, the DONE
output is unaffected.
4. When the RESET input goes TRUE, the DONE output is reset to
FALSE.
5. If the START input and RESET input are TRUE at the same time,
the RESET input has priority. Therefore, the DONE output is reset
to FALSE and the timer is stopped.
6. If the START output is TRUE and the RESET input is FALSE, the
PRESET TIME is loaded and the timer begins running.
7. If the RESET input is set TRUE, regardless of the state of the START
input or timer status, the DONE output is reset to FALSE and the
timer is stopped.
4) Retentive ON Delay Timer (Siemens PLC)
The Retentive ON Delay Timer is unique to the Siemens PLC. In the Siemens
PLC the Retentive ON Delay Timer is known as S_ONDTS timer (Retentive ON
Delay S5 Timer).
The operation of the Retentive ON Delay Timer (S_ONDTS) is similar to
the ON Delay Timer because it only turns its output ON after a preset
time DELAY. However, the output can only be reset by triggering the
reset input and if the start input is re-triggered, while the timer is
running, the timer restarts.
It’s kinda like blending the ON delay and Retentive timers together.

The S_ONDTS timer delays the output from turning ON, but unlike the
Retentive timer, does not retain (accumulate) the timer value. Instead it
restarts the timer. And unlike the ON delay timer it does not reset when the
start input turns OFF. Instead the reset input must be triggered.

In my opinion it should have been called an “ON Delay Extended Timer”.

The Retentive ON Delay Timer instruction is expressed in the Siemens PLC as
per below….

Siemens PLC Retentive ON

Delay Timer (S_ODTS)
How the Retentive ON Delay Works

The function of a Retentive ON Delay Timer in a Siemens PLC is to monitor

the occurrence of a certain event (input), add a time delay to it, trigger an
action (output) and keep the output ON even if the input turns OFF (aha – the
output is “retentive”). The output is only reset by triggering the reset input.
A fantastic way to describe the operation of a Retentive ON Delay Timer in a
Siemens PLC is by using a timing diagram like the one below…
Siemens Retentive ON Delay Timer (S_ODTS) – Timing Diagram
Below is the description of how a Retentive ON Delay Timer operates in a
Siemens PLC. The numbers correspond to the PLC Retentive ON Delay Timer
(S_ODTS) – timing diagram above…
1. When the START input changes from FALSE to TRUE and the
RESET input is FALSE, the PRESET TIME is loaded and the timer
begins running. The DONE output remains FALSE while the timer
is running.
2. After the timer has expired, the DONE output is set to TRUE,
regardless of the state of the START input.
3. When the RESET input goes TRUE, the DONE output is reset to
FALSE. If the START input and RESET input are TRUE at the same
time, the RESET input has priority. Therefore, the DONE output is
reset to FALSE.
4. When the START input is TRUE and the RESET input is FALSE, the
PRESET TIME is loaded and the timer begins running.
5. If the START input transitions from TRUE to FALSE, while the timer
is running, the timer is unaffected and keeps running. But if the
START input transitions from FALSE to TRUE, while the timer is
running, the PRESET TIME is re-loaded and the timer re-starts.
6. After the timer has expired, the DONE output is set to TRUE,
regardless of the state of the START input.
7. The DONE output is reset back to FALSE by setting the RESET
input to TRUE.
5) PLC Pulse Timer
The PLC Pulse Timer is another common timer found in PLC programming. It is
one of the three PLC timers defined in IEC 61131-3 International PLC
Programming Standard.

In a PLC the Pulse Timer is commonly known as a PT timer. The Pulse

Timer creates an output PULSE with a pulse duration equal to that of the
preset time value. In simple terms, the TP timer output is ON when the
timer is running and is OFF all other times.
In a ladder logic programming the Pulse timers instruction name, symbol, and
input/output variables can differ based on the brand of PLC you’re using.

For example the TP timer instruction in a PLC is used in Siemens (IEC),

Unitronics, Schneider, ABB and Emerson PLCs. However, Siemens PLCs
(Simatic) use the S_PULSE instruction instead. Some PLC brands such as Allen
Bradley, Automation Direct,
Mitsubishi, Omron (CX Programmer) and Idec do not have a pulse timer
instruction at all.

Some examples of Pulse timer instructions, used in different PLC brands, are
shown below.…

PLC Pulse Timer

How the Pulse Timer Works
How does a pulse timer work? A PLC pulse timer begins to work when its
input changes state from FALSE to TRUE. The output is turned ON and the
timer starts counting. When the preset time expires the output is turned OFF.
Thus, a pulse is created which has a duration equal to that of the timers preset
time value.
What is the output of a PLC TP timer? The PLC TP timer output generates a
pulse that has a specific time duration. The TP timer output is usually
expressed as the letter “Q”. The output of the TP timer is set TRUE when its
input changes state to TRUE and its output will stay TRUE until the preset time
expires, regardless of the state its input.
A magnificent way to describe the operation of a TP Pulse timer is by using
a timing diagram like the one below…

PLC Pulse Timer (TP) – Timing Diagram

Below is the description of how a TP Pulse Timer operates in a PLC. The
numbers correspond to the PLC Pulse Timer (TP) – timing diagram above…
1. When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output is
set to TRUE.
2. If the timer expires while the START input is TRUE then the DONE
output is reset to FALSE.
3. When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output is
set to TRUE.
4. If the START input is reset to FALSE the timer keeps running.
When the timer expires the DONE output is reset to FALSE.
5. When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output is
set to TRUE.
 6. If the START input transitions from TRUE to FALSE, while the timer
is running, the timer is unaffected and keeps running. When the
timer expires the DONE output is reset to FALSE.
How the Siemens SIMATIC Pulse Timer Works

The Siemens Simatic Pulse timer (S_PULSE) operates slightly differently

compared to the TP pulse timer. You see, the Siemens Simatic Pulse timer
resets the DONE output when the START input transitions from TRUE to FALSE.
Whereas, the TP Pulse timer reset the DONE output after the preset time
expires.
Check out the operation of a S_PULSE timer in a Siemens Simatic PLC using
the timing diagram below…

Siemens (S_PULSE) Timer – Timing Diagram

Below is the description of how a S_PULSE Timer operates in a Siemens
Simatic PLC. The numbers correspond to the PLC Pulse Timer – timing
diagram above…
1. When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output is
set to TRUE.
2. If the timer expires while the START input is TRUE then the DONE
output is reset to FALSE.
3. When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output is
set to TRUE.
 4. If the START input is reset to FALSE then the DONE output is also
reset to FALSE.
5. When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output is
set to TRUE.
6. If the RESET input changes from FALSE to TRUE, the timer is
stopped and the DONE output is reset to FALSE. After the RESET
input has been triggered the timer can only be restarted if the
RESET input is FALSE and the START input changes from FALSE to
TRUE (Section 1).

6) PLC Extended Pulse Timer

The PLC Extended Pulse Timer operates in a very similar way to the Pulse
Timer. However, as its name suggests, the Extended Pulse timer has
an extended feature.
The Extended Pulse Timer (TE timer) creates an output PULSE with a
pulse duration equal to that of the preset time value, just like the Pulse
Timer. Additionally, the output pulse is EXTENDED if the input is re-
triggered before the timer expires.
What is the difference between a Pulse Timer and Extended Pulse timer
in a PLC? The PLC Pulse timer, once triggered, has a pulse duration equal to
the preset time regardless of the input state. Whereas, the Extended Pulse
timer restarts its timer every time the input is re-triggered, thus extending the
pulse duration.
In my experience I’ve only come across Extended Pulse timers in Siemens PLCs
and Unitronics PLCs. The Siemens SIMATIC PLC Extended Pulse timer
instruction is known as a S_PEXT timer. While the Unitronics PLC Extended
Pulse timer is known as a TE timer.
The Siemens SIMATIC PLC Extended Pulse timer (S_PEXT) and Unitronics PLC
Extended Pulse timer (TE) instructions are shown below.…

PLC Extended Pulse Timer

How the Extended Pulse Timer Works
The Siemens PLC extended pulse timer uses the instruction name S_PEXT.
While the Unitronics PLC extended pulse timer uses the instruction name TE.
Even though these extended pulse timer have different instruction names their
operation is essential the same.

A spectacular way to describe the operation of an Extended Pulse timer is by

using a timing diagram like the one below…

PLC Extended Pulse Timing Diagram

Below is the description of how an Extended Pulse Timer operates in a PLC.
The numbers correspond to the PLC Extended Pulse Timer – timing
diagram above…
 When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output is
set to TRUE.
 If the timer expires while the START input is TRUE then the DONE
output is reset to FALSE.
 When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output is
set to TRUE.
 If the START input is reset to FALSE the timer keeps running.
When the timer expires the DONE output is reset to FALSE.
 When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running. The DONE output is
set to TRUE.
 If the START input transitions from TRUE to FALSE, while the timer
is running, the timer is restarted. When the timer expires the
DONE output is reset to FALSE.
7) PLC Frequency Timer
As far as I know, the Frequency timer is unique to the Automation Direct PLC.
It works differently to other timers because it doesn’t introduce a time delay.
In fact, I think it’s more like a frequency counter as opposed to a PLC timer.

In an Automation Direct PLC the Frequency timer is referred to as the

FREQTMR instruction. The operation of the Frequency timer is a
reflection of its name. Simply put, it measures the time between input
pulses and converts it to a frequency value.
The frequency timer has a number of settings that enable it to be
implemented to convert a pulsed input into the desired engineering units like
speed or flow rate. These settings are:

 Frequency Time base in seconds, minutes or hours

 Filter for data smoothing
 Scaling factor
 Output as a REAL (floating point) variable
An example of a Frequency timer (FREQTMR) instruction used in an
Automation Direct PLC is shown below.…

Automation Direct Frequency

Timer (FREQTMR)
How the Frequency Timer Works

The function of a Frequency timer in an Automation Direct PLC is to monitor

the occurrence of a certain event (input), measure the time between successive
events and then convert the value to engineering units based on the time
base, filter and scaling settings.
The Frequency timer output value can be reset in one of 2 ways:
  The reset input is set ON.
 The time between input pulses is longer than the Timeout setting.
An outstanding way to describe the operation of a Frequency timer in an
Automation Direct PLC is by using a timing diagram like the one below…

Automation Direct Frequency Timer (FREQTMR) – Timing Diagram

Below is the description of how a Frequency timer operates in an
Automation Direct PLC. The numbers correspond to the Automation Direct
PLC Frequency Timer (FREQTMR) – Timing Diagram above…
1. When the PULSE input changes from FALSE to TRUE (positive
edge signal) the TIMEOUT preset time is loaded and the TIMEOUT
timer starts running.
2. Initially, after two consecutive positive edge signals at the PULSE
input the FREQUENCY output is calculated and its value set. The
TIMEOUT preset time is reloaded each time there is a positive
edge signal at the PULSE input.
3. If the TIMEOUT timer expires before a positive edge signal at the
PULSE input, the FREQUENCY output value is set to zero.
4. When the PULSE input changes from FALSE to TRUE (positive
edge signal) the TIMEOUT preset time is loaded and the TIMEOUT
timer starts running.
5. Initially, after two consecutive positive edge signals at the PULSE
input the FREQUENCY output is calculated and its value set. The
TIMEOUT preset time is reloaded each time there is a positive
edge signal at the PULSE input.
 6. If the RESET input is set to TRUE the FREQUENCY output value is
reset to zero.

8) PLC Teaching Timer

The Teaching timer is not a very common timer at all. In fact, I’ve only seen it
in used in Mitsubishi PLCs and Idec PLCs. The Teaching timer doesn’t actually
apply a time delay, but rather measures the time. Let’s check it out…

The Teaching timer is referred to as the TTMR instruction in

the Mitsubishi PLC, while in the Idec PLC, the Teaching timer is referred
to as the TTIM instruction. The Teaching timer works by monitoring the
status of its input and storing the input ON duration time value in the
allocated PLC data register.
A teaching timer is used to record the amount of time that the timers input
is active for and store the recorded time in the PLC memory. The stored time
value, recorded by the Teaching timer, can be scaled and used in other parts
of the ladder logic program, like the preset time of a time instruction.
The difference between the Mitsubishi PLC and Idec PLC Teaching
timers is one minor detail. The Mitsubishi PLC has an additional scaling factor
that is applied as part of its teaching timer instruction. After the input ON
duration has been measured the scaling factor is applied and then the result is
stored.
The Mitsubishi PLC Teaching timer (TTMR) and Idec PLC Teaching timer
(TTIM) instructions are shown below.…

PLC Teaching Timer

How the Teaching Timer Works

The function of a Teaching timer in a PLC is to monitor the occurrence of an

event (input), record the time that the input is ON and store the value in the
PLC memory. The teaching timer is restarted when the input transitions from
OFF to ON and the value is stored when the input transitions from ON to OFF.
A phenomenal way to describe the operation of a Teaching timer is by using
a timing diagram like the one below….
PLC Teaching Timer – Timing Diagram
Below is the description of how a Teaching Timer operates in a PLC. The
numbers correspond to the PLC Teaching Timer – timing diagram above…
1. When the START input changes from FALSE to TRUE, the timer
starts running and the last stored measured time value (output) is
reset.
2. When the START input changes from TRUE to FALSE the timer is
stopped and the measured time value (output) is stored in the
PLC memory.
3. While the START input is FALSE, the measured time value (output)
is retained in the PLC memory.
4. Same as 1), 2) &3). Please note: the measured time value (output)
increases in proportion to the time the start input is TRUE.

9) PLC Dual Timer

The Dual timer is another timer that is not commonly found in PLCs. In fact,
I’ve only seen it used in Idec PLCs. The Dual timer has two timers built into the
one instruction. These timers work together to create a pulsed output. Let’s
take a closer look.…

The Dual timer is commonly referred to as the DTIM instruction in

the Idec PLC. It has two built in timers which are used to generate a
pulsed output whenever the status of its input is ON. The ON and OFF
duration of the output pulse is set using the preset time inputs.
The Dual timer has a number of settings that enable it to be create a pulsed
output. These settings are:
  S1 – Preset Time Input 1
 S2 – Preset Time Input 2
 D1 – Timer Done Output
 D2 – System Work Area (2x Data Registers)
As with other Idec PLC timers, there are multiple instruction names for the
Dual timer depending on the time base value. So if the preset time value is 10
and the time base is 100ms, then the actual timer value is 10 x 100ms =
1000ms, or 1sec. Here are the Dual timer instructions and their respective time
base values….

 DTML = 1 s time base

 DTIM = 100 ms time base
 DTMH = 10 ms time base
 DTMS = 1 ms time base
An example of an Idec PLC Dual timer (DTIM timer) instruction is shown
below. It has a time base of 100ms with both S1 and S2 preset time values
equal to 10. So it has a 1 second ON and 1 second OFF pulse output.…

IDEC Dual Timer

How the Dual Timer Works

The function of a Dual timer in an Idec PLC is to monitor the status of the
timer input and generate a pulsed output according to the preset time values.
The output pulse generated by the Dual timer is active as long as the status of
the timer input is ON.
A splendid way to describe the operation of a Dual timer in an Idec PLC is by
using a timing diagram like the one below….
IDEC Dual Timer – Timing Diagram
Below is the description of how a Dual Timer operates in a PLC. The
numbers correspond to the IDEC Dual Timer – timing diagram above….
1. When the START input changes from FALSE to TRUE the S1
PRESET TIME is loaded and the S1 timer begins running. The
DONE output is set to TRUE.
2. After the S1 timer expires, the DONE output is reset to FALSE. The
S2 PRESET TIME is loaded and the S2 timer begins running.
3. After the S2 timer expires, the DONE output is set to TRUE. The S1
PRESET TIME is loaded and the S1 timer begins running.
4. After the S1 timer expires, the DONE output is reset to FALSE. The
S2 PRESET TIME is loaded and the S2 timer begins running.
5. If the START input transitions from TRUE to FALSE, while the
timers are running, the timers are stopped and the DONE output
is reset to FALSE.
6. When the START input changes from FALSE to TRUE the S1
PRESET TIME is loaded and the S1 timer begins running. The
DONE output is set to TRUE.
7. If the START input transitions from TRUE to FALSE, while the
timers are running, the timers are stopped and the DONE output
is reset to FALSE.
The Dual timer in an Idec PLC creates a pulsed output with a single instruction.
However, in other PLCs a timed pulsing output must be created with ladder
logic using 2x ON delay timer instruction. The functionality of 2 timers is built
into the Dual timer instruction.

10) PLC Multi Output Timer

The Multi Output timer is yet another not-so-common timer. It uses a single
timer, with multiple preset time values and multiple outputs. This “beast of a
timer” is only found in some Omron PLCs.

In an Omron PLC the Multi Output timer is referred to as the MTIM

instruction. It has eight independent done outputs each with their own
preset time input. The Multi Output timer works just like an ON Delay
timer (TON Timer). Each output is delayed from turning on by its
corresponding preset time value.
Multi Output timer has a number of settings that enable it produce multiple
done outputs. These settings are:

 D1 – Timer Done Outputs.

 D2 – Elapsed Time Output.
 S – Preset Time Inputs.
D1 contains the 8 Timer Done Output bits. It uses bit 0-7 for the Timer Done
Outputs, bit 8 for Reset and bit 9 for Pause. Bits 10-15 are not used.

1. D1 – Bit0: Timer Done Output 1.

2. D1 – Bit1: Timer Done Output 2.
3. D1 – Bit2: Timer Done Output 3.
4. D1 – Bit3: Timer Done Output 4.
5. D1 – Bit4: Timer Done Output 5.
6. D1 – Bit5: Timer Done Output 6.
7. D1 – Bit6: Timer Done Output 7.
8. D1 – Bit7: Timer Done Output 8.
9. D1 – Bit8: Reset Input.
10. D1 – Bit9: Pause Input.
D2 contains the elapsed timer value.

S1 is assigned to the Preset Time Input 1, which acts as an address pointer. An

address offset is used to allocate a separate Preset Time Input for each timer
output. See below:
 1. S1+0: Preset Time Input 1.
2. S1+1: Preset Time Input 2.
3. S1+2: Preset Time Input 3.
4. S1+3: Preset Time Input 4.
5. S1+4: Preset Time Input 5.
6. S1+5: Preset Time Input 6.
7. S1+6: Preset Time Input 7.
8. S1+7: Preset Time Input 8.
An example of an Omron PLC Multi Output timer (MTIM) instruction is shown
below….

Omron PLC Multi Output

Timer
How the Multi Output Timer Works

The function of a Multi Output timer in an Omron PLC is to monitor the

status of the timer input and generates eight done output bits according to
the preset time values. All eight timer done outputs are generated
independently and are based their own separate preset time values.
The MTIM instruction has a time base of 100ms with a max preset time value
of 999.9 seconds. If a preset time value is set to 0 then all subsequent preset
time values are ignored. The reset bit sets the elapsed timer value back to zero
and the timer done output bits to FALSE.

An amazing way to describe the operation of a Multi Output timer in an

Omron PLC is by using a timing diagram like the one below….
 Omron
Multi Output Timer – Timing Diagram
Below is the description of how a Multi Output Timer operates in an Omron
PLC. The numbers correspond to the Omron PLC Multi Output Timer – timing
diagram above…
1. When the START input changes from FALSE to TRUE and the
RESET input is triggered all the DONE output bits are reset to
FALSE and the timer is restarted.
2. The timer counts up and when PRESET TIME 1 value is reached
the DONE 1 output is set TRUE.
 3. The timer continues to count up and when PRESET TIME 2 value is
reached the DONE 2 output is set TRUE.
4. The timer continues to count up and as each PRESET TIME value is
reached the corresponding DONE output is set true up to PRESTE
TIME 8 where DONE 8 output is set TRUE.
5. Once the timer reaches the max value of 9999 the timer restarts
and all DONE outputs are reset to FALSE.
6. The timer continues to count up and when PRESET TIME 1 & 2
values are reached the corresponding DONE outputs are set
TRUE.
7. When the PAUSE input changes from FALSE to TRUE the timer
stops counting up and the DONE outputs do not change state.
After the PAUSE input resets back to FALSE the timer continues to
count up.
8. If the RESET input is triggered and the START input is reset to
FALSE, all the DONE outputs are also reset to FALSE and the timer
is reset and stopped

11) PLC Special Timer

I’ve saved “the best” PLC timer instruction for last. It’s called the Special timer.
It certainly is “special”. I’ve only ever seen the Special timer used in Mitsubishi
and Delta PLCs. This sucker has four separate timer functions built into the one
PLC instruction. What a monster! Let’s take a closer look.…

The Special timer is commonly referred to as the STMR instruction in

the Mitsubishi and Delta PLCs. The Special timer uses only one timer and
one PRESET TIME input. But has four separate timer instructions built
into it, each with their own DONE output.
The four types of timer functions contained in the Special timer are the OFF
delay timer, Pulse timer (OFF), Pulse timer (ON) and a combined ON delay +
OFF delay timer.
The four timer functions of the Special timer are assigned to the DONE output
(D) which acts as an address pointer. An address offset is used to allocate a
separate DONE output bits for each timer output. See below….

1. D+0: OFF delay timer.

2. D+1: Pulse timer (OFF).
3. D+2: Pulse timer (ON).
 4. D+3: Combined ON delay timer + OFF delay timer.
Examples of the Mitsubishi PLC and Delta PLC Special timer (STMR timer)
instructions are shown below….

Mitsubishi & Delta PLC Special Timer

How the Special Timer Works

The function of a Special timer in the Mitsubishi and Delta PLCs is to

monitor the status of the timer input and generate the four types of timer
done outputs according to the preset time values. All four timer done outputs
are based on a single preset time value and are generated separately.
An awe-inspiring way to describe the operation of a Special timer in a
Mitsubishi and Delta PLC is by using a timing diagram like the one below….

Mitsubishi & Delta PLC Special Timer – Timing Diagram

Below is the description of how a Special Timer operates in a PLC. The
numbers correspond to the Mitsubishi & Delta PLC Special Timer – timing
diagram above…
1. When the START input changes from FALSE to TRUE the PRESET
TIME is loaded, the timer begins running and :
 D+0 output (TOFF) is set to TRUE.
 D+1 output (Pulse-OFF) is reset to FALSE.
 D+2 output (Pulse-ON) is set to TRUE.
 D+3 output (TON+TOFF) is reset to FALSE.
2. If the timer expires, while the START input is TRUE, then :
 D+0 output (TOFF) remains TRUE.
 D+1 output (Pulse-OFF) remains FALSE.
 D+2 output (Pulse-ON) is reset to FALSE.
 D+3 output (TON+TOFF) is set to TRUE.
3. After the preset time has expired and the START input is reset to
FALSE, the PRESET TIME is loaded, the timer begins running and :
 D+0 output (TOFF) remains TRUE.
 D+1 output (Pulse-OFF) is set to TRUE.
 D+2 output (Pulse-ON) remains FALSE.
 D+3 output (TON+TOFF) is remains TRUE.
4. If the timer expires, while the START input is FALSE, then :
 D+0 output (TOFF) is reset to FALSE.
 D+1 output (Pulse-OFF) is reset to FALSE.
 D+2 output (Pulse-ON) remains FALSE.
 D+3 output (TON+TOFF) is reset to FALSE.
5. When the START input changes from FALSE to TRUE the PRESET
TIME is loaded and the timer begins running :
 D+0 output (TOFF) is set to TRUE.
 D+1 output (Pulse-OFF) is reset to FALSE.
 D+2 output (Pulse-ON) is set TRUE.
 D+3 output (TON+TOFF) is reset to FALSE.
6. If the START input changes from TRUE back to FALSE, before the
timer gets a chance to expire, then the PRESET TIME is loaded and
the timer restarts :
 D+0 output (TOFF) remains TRUE.
 D+1 output (Pulse-OFF) is set to TRUE.
 D+2 output (Pulse-ON) is reset to FALSE.
 D+3 output (TON+TOFF) remains FALSE.
7. If the START input remains FALSE and the timer expires, then :
 D+0 output (TOFF) is reset to FALSE.
  D+1 output (Pulse-OFF) is reset to FALSE.
 D+2 output (Pulse-ON) remains FALSE.
 D+3 output (TON+TOFF) remains FALSE.

PLC Timer Examples :

PLC timers are frequently used in ladder logic programming. There are many
different types of PLC timers, each with their own unique operation and
application. Here we will explore some real world PLC timer examples, draw
out the ladder diagrams and explain their operation.
A common real world example of using an ON delay timer would be
introducing a delayed start to a conveyor and sounding a warning siren
before it starts rotating. Another example, using an OFF delay timer,
would be to delay a conveyor from stopping allowing it to empty so it is
ready for a re-start.
Some ladder logic timer examples that are commonly use while PLC
programming are….
1. ON Delay Timer Example: Delay Start with Warning Siren
2. ON Delay & OFF Delay Timer Example: Flasher Timer
3. OFF Delay Timer Example: Delay Stop
Let’s have a look at each one of these examples in a little more detail…

1) ON Delay Timer : Delay Start with

Warning Siren
Nowadays most conveyors in factories and mine sites sound a warning siren
before they start rotating as a safety precaution for operators and
maintenance staff. The siren warns anyone near the conveyor of an imminent
start and the delay allows them to get clear of the conveyor as to avoid injury.

A common real world example of using an ON delay timer is to delay the

start of a conveyor while sounding a warning siren. The conveyor start
command activates the ON delay timer and siren at the same time. After
the time delay expires, the siren turns OFF and the conveyor starts
running.
With conveyor start warning siren examples we use the ON delay PLC
timer to both delay the start of the conveyor and also turn the siren OFF after
the delay time expires. We can build on the previous motor control ladder
diagram latching example and introduce an ON delay timer to trigger the
delayed start and sound the warning siren.
Because we are trying to accomplish two actions (warning siren and motor
run) we’ll need to add an intermediate internal variable to replace the M1 RUN
output. It’s not essential, it’s just good practice. Maintaining a neat and
simple programming structure is important. Otherwise you’ll find your code
will become messy, cluttered and hard to follow.
Let’s call the internal variable START COMMAND with address M1.0
(remember, PLC manufacturers use different memory address allocation so
M1.0 is an arbitrary address).

Below is the list of inputs required, no change to the previous ladder logic
example…..
NAME ADDRESS TYPE COMMENT PLC WIRING

M1 START I:1.0 BOOL Motor No.1 Start Push Button Normally Open

M1 STOP I:1.1 BOOL Motor No.1 Stop Push Button Normally Closed

M1 TOL I:1.2 BOOL Motor No.1 Thermal Overload Normally Closed

Next let’s add the extra siren output, M1 SIREN…..

NAME ADDRESS TYPE COMMENT PLC WIRING

M1 RUN O:1.0 BOOL Motor No.1 Run Normally Open

M1 SIREN O:1.1 BOOL Motor No.1 Siren Normally Open

We also need to add an extra internal variable, M1 START COMMAND….

NAME ADDRESS TYPE COMMENT

M1 START COMMAND M:1.0 BOOL Motor No.1 Start Command

Finally let’s add the ON delay timer, T1….

NAME ADDRESS TYPE COMMENT

T1 T1 TIMER Motor No.1 Start Delay Timer

Now we can add the required control logic by using the M1 START
COMMAND to trigger each action on a different rung.
Remember…..Both M1 STOP and M1 TOL are wired normally closed (NC) to
the PLC inputs to make them “fail safe” and thus need to be configured as
normally open (NO) symbols in the ladder diagram.
Check out the motor control ladder diagram with delay start warning siren
below…

ON Delay PLC Timer Example – Delay Start Warning Siren

The first rung works the same as the standard motor control latching logic
previous example. The only difference is we replace the M1 RUN output with
an internal variable called M1 START COMMAND. This enables us to use the
M1 START COMMAND latch to trigger multiple actions.
After the first rung is scanned it moves to the second rung. If the M1 START
COMMAND is TRUE on the first rung and the M1 RUN output is FALSE (motor
is not running) then M1 SIREN output is activated.

Please Note – The M1 RUN output symbol is triggered from the third rung.
The scan then jumps to the third rung and if the M1 START COMMAND
symbol is TRUE then T1 TON delay timer is activated. After the M1 START
COMMAND is TRUE for 5 seconds (preset time) the T1 TON delay timer will
activate the M1 RUN output and then Motor No.1 will start running.

That’s not the end of the story, because the siren is still activated. So, when the
PLC scan cycles back to the top and moves through the rungs, if the stop
inputs have NOT been triggered, the M1 START COMMAND latch will still be
active.

So, when the scan gets to the second rung the M1 START COMMAND symbol
is still TRUE and the M1 RUN output is also TRUE (the motor is now running).
However, the M1 RUN symbol is normally closed (NC), so when it is TRUE, no
logic flows and the M1 SIREN output goes FALSE and switches off.

In the first rung, if either the M1 STOP or M1 TOL (thermal overload) inputs
are activated, then logic flow is broken in the latching logic and the M1 START
COMMAND goes FALSE. This also breaks the logic flow in the second and
third rungs resulting in the motor stopping.

If either the M1 STOP or M1 TOL inputs are activated during the five second
starting time, while the siren is activated, then the logic flow to the M1 SIREN
output is also broken and the siren de-activates.

2) OFF Delay PLC Timer : Delay Stop

The term OFF delay timer naturally implies that there is a delay before
something turns off. You know those sensor lights that turn on when you walk
into the room and then after you leave they wait awhile before turning off.
Right there is one of many everyday examples of an OFF delay PLC timer.

A popular OFF delay timer example using PLC ladder logic is the “delay
stop”. My favorite application example is to delay stop a conveyor belt
leaving it empty for a no load, trouble free re-start. Another example is
to delay stop an electric motor cooling fan to help cool down the motor
quicker.
To delay stop an electric motor cooling fan we need to implement an OFF
delay timer to start timing after receiving the motor stop signal. To delay stop
a conveyor belt and empty it we need to implement the OFF delay timer after
the conveyor belt material feeder stops running.
For our OFF delay timer ladder logic example let us build on the previous
motor control ladder diagram examples and add an OFF delay PLC timer to
create a delay stop using the M1 RUN output. In this example the OFF delay
timer is set to 10 seconds.
In this case we would add an OFF delay timer just after the T1 (motor start On
delay timer) and before the M1 RUN output. That way the M1 RUN output will
activate as soon as the warning siren has finished sounding. And when M1
START COMMAND turns OFF, the Off delay timer will initiate a delay stop with
the M1 RUN output.

However, a delay stop is not desired when the motor thermal overload input is
triggered. So, in the ladder diagram we must also add the M1 TOL symbol
along with the T2 OFF delay timer.

We need to add an extra internal variable and an OFF delay timer to our
variable declarations.

Below is the list of required inputs, no change ….

NAME ADDRESS TYPE COMMENT PLC WIRING

M1 START I:1.0 BOOL Motor No.1 Start Push Button Normally Open

M1 STOP I:1.1 BOOL Motor No.1 Stop Push Button Normally Closed

M1 TOL I:1.2 BOOL Motor No.1 Thermal Overload Normally Closed

Below is the list of required outputs, no change ….

NAME ADDRESS TYPE COMMENT PLC WIRING

M1 RUN O:1.0 BOOL Motor No.1 Run Normally Open

M1 SIREN O:1.1 BOOL Motor No.1 Siren Normally Open

We need to add an extra internal variable, M1 DELAY RUN, for the delay
stop….

NAME ADDRESS TYPE COMMENT

M1 START COMMAND M:1.0 BOOL Motor No.1 Start Command

M1 DELAY RUN M:1.1 BOOL Motor No.1 Delay Run

Finally let’s add the extra OFF delay timer T2….

NAME ADDRESS TYPE COMMENT

T1 T1 TIMER Motor No.1 Start Delay Timer

T2 T2 TIMER Motor No.1 Stop Delay Timer

Check out the PLC Delay Stop timer ladder diagram where we modify the third
rung of the previous ladder diagram and then tack on a fourth rung with a
TOFF timer to create the delay stop function….

OFF Delay Timer PLC Example: Delay Stop

The third rung works the same as the delay ON timer example above, except
we replace the M1 RUN output with internal variable M1 DELAY RUN. This
enables us to create a fourth rung and trigger a delay OFF timer in order to
create the delay stop.

When the PLC scan hits the third rung it comes across the symbol, M1 START
COMMAND . If the motor is running this symbol will be TRUE and the logic
will flow to the next symbol, T1 (TON timer for the start siren). Timer T1 starts
timing and after 5 second timer T1 DONE output goes TRUE. The logic then
flows to M1 DELAY RUN output and it too goes TRUE.

The scan then jumps to the fourth rung where the M1 DELAY RUN symbol is
TRUE allowing logic flow to timer T2 (delay OFF timer). When the TOFF timer
T2 START input is TRUE its done output also goes TRUE.
The logic then flows to the next symbol M1 TOL input which is TRUE, if the
thermal overload input is healthy, and in turn to the M1 RUN output which
also goes TRUE. Motor No.1 will start running.

From here the scan will happily cycle through the logic and the motor will
continue running until the stop button is pressed. If the M1 STOP input is
triggered the logic flow in the first rung will be broken causing M1 START
COMMAND output to go FALSE and unlatch.

The scan then moves to the second rung. If the M1 START COMMAND symbol
is FALSE it will again break the logic flow, which is of no consequence because
the siren is already OFF.

Then the scan will move to the third rung where the M1 START COMMAND
symbol is FALSE. This breaks logic flow to both the T1 TON delay timer and
M1 DELAY RUN output and they change state to FALSE.

As the scan moves to the fourth rung, M1 DELAY RUN symbol is now FALSE
which will break logic flow to T2 timer. When the T2 timer START input
changes state to FALSE the timer starts timing.

After 10 seconds has lapsed the timer DONE output changes state from TRUE
to FALSE and logic flow is broken to M1 RUN output which also changes to
FALSE. Hence, the motor experiences a 10 second delay stop.
Now, if the thermal overload trips, then the motor is overheating and we need
an immediate stop. In this case the M1 TOL input, in the first rung, will go
FALSE and unlatch the M1 START COMMAND.

When the scan reaches the fourth rung the M1 TOL input will be FALSE which
will break the logic flow to M1 RUN output, disabling the delay stop function
and causing an immediate motor stop.

3) ON & OFF PLC Timer : Light Flasher.

On and OFF timer logic is often referred to as flasher ladder logic. Why?
Because, among other things, we can use it to make a light flash on and off
and blink at different rates.

The ON and OFF ladder logic timer is basically a two-step cyclic sequence
based on time. Both the ON and OFF times are adjustable. The preset
time of the first timer dictates the OFF time and the preset time of the
second timer dictates the ON time.
The flashing light PLC timer with two adjustable ON delay timers can be set
with an uneven blinking cycle if required. Another timer example with two
different cycle times is a plastic shredder that runs cyclically to reduce
jamming by going forward for 60 seconds and then reversing for 5 seconds.

A PLC flasher timer utilizes a timer loop in the ladder logic program.
Two ON delay timers are programmed in the ladder diagram on consecutive
rungs, one after the other. The output of the first timer triggers the second
timer, the output of the second timer resets both timers, and the cycle repeats.
For our flashing light ladder logic example let us build on the previous
motor control ladder diagram example and add a flashing warning light that
activates after the siren has finished and the motor starts running. In this
example the light blinking rate is set to 1 second ON and 1 second OFF.
In this case we would use the M1 RUN output (from the example above) to
trigger our timing circuit.

We need to add an extra output, internal variable and two ON delay timers to
our variable declarations.

Below is the list of required inputs, no change ….

 NAME ADDRESS TYPE COMMENT PLC WIRING

M1 START I:1.0 BOOL Motor No.1 Start Push Button Normally Open

M1 STOP I:1.1 BOOL Motor No.1 Stop Push Button Normally Closed

M1 TOL I:1.2 BOOL Motor No.1 Thermal Overload Normally Closed

Next let’s add the extra light output, M1 LIGHT….

NAME ADDRESS TYPE COMMENT PLC WIRING

M1 RUN O:1.0 BOOL Motor No.1 Run Normally Open

M1 SIREN O:1.1 BOOL Motor No.1 Siren Normally Open

M1 LIGHT O:1.2 BOOL Motor No.1 Warning Light Normally Open

We need an extra internal variable for the timers, M1 LIGHT TIMER….

NAME ADDRESS TYPE COMMENT

M1 START COMMAND M:1.0 BOOL Motor No.1 Start Command

M1 DELAY RUN M:1.1 BOOL Motor No.1 Delay Run

M1 LIGHT TIMER M:1.2 BOOL Motor No.1 Warning Light Timer

Finally let’s add the two extra ON delay timers, T3 and T4….

NAME ADDRESS TYPE COMMENT

T1 T1 TIMER Motor No.1 Start Delay Timer

T2 T2 TIMER Motor No.1 Stop Delay Timer

T3 T3 TIMER Motor No.1 Light Flasher Off Timer

T4 T4 TIMER Motor No.1 Light Flasher On Timer

Check out the PLC ON & OFF timer ladder diagram which we can tack onto
the bottom of the previous ladder diagram….
ON & OFF PLC timer examples – Flashing Warning Light
When the PLC scan hits the fifth rung it comes across the M1 RUN output
symbol. If the motor is running this symbol will be TRUE and the logic will flow
to the next symbol, M1 LIGHT TIMER.

The M1 LIGHT TIMER symbol is normally closed (NC) and will be FALSE
because timer T4 (on the sixth rung) is not active and done. This means the
M1 LIGHT TIMER symbol allows logic flow to timer T3.

Timer T3 starts timing and after 1 second timer T3 DONE output goes TRUE
and the logic flows to M1 LIGHT output and it too goes TRUE.

Then the PLC scan moves to the sixth rung where M1 LIGHT symbol is now
TRUE allowing timer T4 to start timing. While timer T4 is timing it’s DONE
output is FALSE, therefore the logic flow is broken and M1 LIGHT output is
also FALSE.

The scan keeps cycling through the rungs until the 1 second preset time for
timer T4 has expired and then timer T4 DONE output on rung six goes TRUE.
Then logic flows to M1 LIGHT TIMER output and it too goes TRUE.
When the scan cycles back to the top and moves through to the fifth rung
again we notice that M1 LIGHT TIMER symbol has changed state from FALSE
to TRUE thus breaking the logic flow and resetting timer T3 and M1 LIGHT
output back to FALSE.

As the scan progresses from the fifth to the sixth rung timer the M1 LIGHT
symbol at the start of the rung is now FALSE thus breaking the logic flow to
the rest of the rung and resetting T4 and M1 LIGHT TIMER output back to a
FALSE state as well. Effectively resetting the timer sequence. So when the scan
cycles back to the top it starts the timing cycle once again.

The timing cycle will continue until the motor stops running, when the M1
RUN symbol changes state to FALSE.

M1 LIGHT output is used to wire to the flashing light. It will be OFF for T3 time
preset (1 second) and ON for T4 timer preset (1 second). The timing cycle will
continue until the motor stops running, when the M1 RUN symbol changes
state to FALSE.

PLC Timer Examples : Complete Ladder

Diagram
The Delay Start Warning with Siren, Flasher Timer and Delay Stop timer
are my 3 favorite timer examples. I frequently use these example in my
day to day ladder logic programming. The complete ladder diagram
including all three examples for motor start application is below….
PLC Timer Examples – Complete Ladder Diagram
PLC Sequencer Logic
PLC sequencer logic is an essential component to have in your quiver of ladder
logic sample code.It forms the backbone to the majority of processes for
industrial automation. Applications that require sequencer logic
include conveyor systems, palletizing machines, batching plants, packaging
machines, storage and retrieval systems and the list goes on and on.
A sequence in industrial automation is merely a series of actions required to
be taken to achieve a specific outcome arranged in an orderly fashion.

The basis to develop a sequence in ladder logic is to use sequence steps.

It’s a good idea to declare the sequence steps as internal variables, which in
turn can be used multiple times in the program if required.

PLC Sequence Steps

To illustrate how sequence steps are derived for PLC Sequencer Logic let’s
look at the sequence of events required for a common household task,
brushing your teeth….

1. Grab your toothbrush.

2. Grab your toothpaste.
3. Put some toothpaste on the toothbrush.
4. Put the toothbrush in your mouth.
5. Brush your teeth with the toothbrush for two minutes.
6. Remove the toothbrush from your mouth.
7. Rinse your mouth out with water.
8. Rinse your toothbrush with water.
9. Put your toothbrush away.
To automate an industrial process with a sequence we use the same concept.
The complexity of the sequence ladder logic program will depend on the
specific process outcomes required.

Even with the tooth brushing example above some of the steps can be broken
down even further.

For example step 3 can be broken down into three steps with significantly
more detail….
3a) Position the toothpaste nozzle at the far end of the toothbrush head.

3b) Squeeze the toothpaste while moving it lengthwise along the toothbrush
head until it reaches the end of the toothbrush head.

3c) Stop squeezing the toothpaste and place it in the toothpaste holder.

Types of PLC Sequencer Logic

A sequence can either be cyclic or linear.

A cyclic sequence moves through the sequence steps and when the final step
is completed the sequence automatically restarts from the beginning and
keeps repeating the sequence until a stop command is initiated.

A linear sequence moves through the sequence steps and when the final step
is completed stops and sits idle until a start command is re-issued manually by
the operator.

The 4 Essential Elements of PLC Sequencer

Logic
There are various ways to structure the sequence ladder logic but as a
minimum it must contain four essential items of code…..

1. Sequence start and stop.

2. The Sequence steps.
3. Sequence step transition conditions.
4. The outputs that initiate actions.
Once we know the basic sequence ladder logic structure we can modify it to
suit the process requirements. We can create multiple sequences, parallel
sequence branches and add logical expressions and timers to help control it.

The sequence start, stop and steps require latching logic using either hold in
logic or Set (latch) Reset (Unlatch) symbols.

If you don’t know what hold in logic and Set/Reset symbols are then click
here.
PLC Sequencer Logic Example
Let’s follow on from our motor control example used earlier and define a
sequence utilizing a motorized trolley.
The trolley runs forward to a certain position. Accepts a pallet of produce from
an automated crane. Then reverses back to it’s starting position ready to be
unloaded by a forklift operator and put into the back of a truck for
transportation.

The motorized trolley has a limit switch for the unloading and loading
positions so it can stop in the correct place.

It has a sensor to detect if there is a pallet on the trolley.

It also has a sensor to detect if the loading area is clear and is safe for the
motorized trolley to start moving.

To activate the sequence the operator decides if the trolley is unloaded and
safe to run, then pushes the start push button.

When the sequence completes a cycle it stops and waits for the operator to
push the start button again. This is a linear sequence with a start and end
point.

After the sequence is complete it must be re-initiated manually by an operator

in order for the sequence to restart.

Having said that, we just as well could have chosen to do an automatic cyclic
sequence. This is easily done at the last step by re-activating the first sequence
step instead of ending the sequence. We will also need to add some extra
conditional logic to replace the operators manual start operation.

Below is the list of required inputs that need to be declared …..

Next let’s declare the outputs…..

We also need to declare the following internal variables…..

The sequence logic diagram below is a basic linear sequence with three steps
that ends after the third step transition conditions are met….
The transition conditions that enable the steps to progress to the next step
and the actual sequence steps are all declared as internal variables.

In this way we can take the conditional logic out of the sequence logic rungs
to de-clutter it and make it easily readable.

We should place the transition conditional logic before the sequence logic to
allow for the PLC scan going from top to bottom….

Lastly we need some logic to trigger the PLC outputs to make the trolley
move.
There’s no need to use additional latching logic for the motor start because
we are utilizing the sequence step latching logic.

We should place logic that triggers the outputs after the sequence logic to
allow for the PLC scan going from top to bottom.

Advanced Sequence Ladder Logic

Programming
Even though this example is a simple control sequence it provides the
backbone for more complex additions.

Some examples of additional features include….

 Auto and manual modes so that individual components can be

operated in case of failures and maintenance.
 Sequence status and indication lights and sirens.
 A stopping sequence and/or emergency stop function can also be
added if required.
 Conditional logic that needs to be met before the sequence can
be started.
  Sequence pause logic to remember the last step before the
sequence was stopped, so that the sequence can resume from
where it left off.
 Conditional start logic that decides the step that must be
triggered to resume operation.
 Alarm and fault logic to capture failure of equipment.
It’s great using hold in logic to latch the sequence steps because all the
transition and stopping conditional logic is located in the same area.

When we encounter more complex processes then using hold in logic for our
sequence steps can become difficult because we are limited to using only one
output.

Using multiple output symbols with the same variable declaration is a recipe
for disaster.

We don’t want to do this because the output symbol may be overwritten

inadvertently during the PLC scan causing haphazard like behavior.

If the ladder diagram complexity is high then we can latch and unlatch
sequence steps using the Set (Latch) and Reset (Unlatch) symbols.

These symbols provide a lot more flexibility with the sequence programming,
but require extra caution and expertise.

In the next section we’ll provide you with a comprehensive guide to

programming ladder logic flip flop’s and toggle logic.
CHAPTER 5

PLC Toggle Logic & Flip Flops

PLC toggle logic emulates the function of flip flop circuits that are
commonly used in electronics and computer systems.
What is a Flip Flop in a PLC?
You may have heard of a flip flop in electronics and computer systems, but
what is a flip flop in a PLC?

A flip flop in PLC programming is created using toggle logic. Whenever

the state of the PLC input changes momentarily, the state of the PLC
output will be latched to the opposite of it’s current state. There can be
either 1 or 2 inputs and outputs depending on the type of PLC flip flop
function required.
Understanding the flip flip function is the key to developing PLC toggle logic.
So let’s take a closer look at the different types of flip flops used in a PLC, how
they work, how to program them and what they can be used for.

The 3 Most Useful Types of Flip Flops in a

PLC
There are several types of flip flops used in electronics and computer systems,
but which types are the most useful in a PLC?

The 3 most useful types of flip flops that can be emulated using PLC
toggle logic are:
 T Flip Flop
 SR Flip Flop
 JK Flip Flop
The type of flip flop that is chosen will mainly depend on how many inputs are
required to trigger the output to toggle it’s state. If one input is required then
then T flip flop type is suited. But if 2 inputs are required then the SR flip flop
or JK flip flop types are required.
Let’s look at how the electronic flip flops translate into PLC flip flops:

The T flip flop has a T input, a CLOCK input, a Q output and a NOT Q output.
This type of flip flop toggles the state of the output whenever the state of the
input is TRUE and the CLOCK input is triggered.
When the T flip flop is implemented using PLC toggle logic we use one input
and generally only one output. There is no need for a CLOCK input and a
second output can be added if a NOT output is required.

The SR flip flop has a S input, a R input, a Q output and a NOT Q output. This
type of flip flop toggles the output depending on the state of the S and R
inputs.
When the SR flip flop is implemented using PLC toggle logic we use two
inputs and one output. The two inputs are called Set and Reset. A second
output can be added if a NOT output is required.
The JK flip flop has the same inputs and outputs as a SR flip flop except it has
an extra CLOCK input.
The JK flip flop operates the same way as a SR flip flop except it has bit stable
operation when both inputs are in the same state. The CLOCK input in the JK
flip flop facilitates bit stable operation by only initiating an output toggle
when the CLOCK input is triggered.
When we talk about JK and SR flip flops in a PLC we refer to both of them as
ladder logic SR flip flops. The differentiation in functionality isn’t made
because bit stable operation can be achieved for the SR flip flop in a PLC
without the need for the third clock input.

In fact, by virtue of our ladder logic code and the nature of the PLC scan cycle,
we can choose the state of the PLC output when both PLC inputs are the same
state. In this scenario, if we require that the output state be FALSE then we use
SR flip flop toggle logic. However, if we require that the output state be TRUE
then we use a RS flip flop toggle logic.

How Does a PLC Flip Flop Work?

A handy piece of ladder logic programming to have in your kit is the flip flop,
but do you know how it works in a PLC?

The operation of a flip flop function in a PLC utilizes both PLC inputs and
PLC outputs. The PLC output is fed back to the input logic so that the
state of the flip flop output is dependent on both the state of the input
and the current state of the output.
So when the input is triggered and the state of the output is FALSE then the
output will toggle from FALSE to TRUE. And vice versa, when the input is
triggered and the state of the output is TRUE then the output will toggle from
TRUE to FALSE. Hence the use of the term flip flop.
Let’s look at the most common types of flip flops and how they work in a PLC
in a little more detail….

How Ladder Logic T Flip Flop Works in a PLC

The ladder logic T flip flop is probably the mostly used flip flop when it comes
to PLC programming.

When used in a PLC the ladder logic T flip flop has 1 input that is used to
toggle the flip flop output every time the input changes state from FALSE
to TRUE.
The operation of a ladder logic T flip flop is summarized in the truth table
below:

Ladder
Logic T Flip Flop Truth Table
When the state of the PLC output is TRUE and the state of the PLC input
changes from FALSE to TRUE, the state of the PLC output will change to FALSE
and be maintained. Even if the state of the PLC input changes back to FALSE.

When the state of the PLC output is FALSE and the state of the PLC input
changes from FALSE to TRUE, the state of the PLC output will change to TRUE
and be maintained. Even if the state of the PLC input changes back to FALSE.

When the PLC input is FALSE, there is no change to the state of the PLC output
and it maintained at it’s present state.

How Ladder Logic RS and SR Flip Flop Works in a PLC

The RS and SR flip flops operate a little differently to the T flip flop. So how
exactly do the RS and SR flip flops work in a PLC?
The ladder logic RS and SR flip flop in a PLC have SET and RESET inputs
that are used to toggle the state of the flip flop output. When the SET
input is TRUE, the state of the flip flop output is maintained TRUE, even if
the SET input changes state back to FALSE. The state of the flip flop
output will only revert back to FALSE if the RESET input is TRUE.
If both the SET and RESET inputs are FALSE then there is no change in the
state of the flip flop output.

The difference in the operation of a ladder logic RS and SR flip flop is the way
they handle the situation where both SET and RESET inputs are TRUE at the
same time. When both SET and RESET inputs are TRUE at the same time the
ladder logic SR flip flop unlatches the output to FALSE. Whereas, the ladder
logic RS flip flop latches the output to TRUE.

The operation of a ladder logic SR flip flop is summarized in the truth table
below:

Ladder Logic SR Flip Flop Truth Table

The operation of a ladder logic RS flip flop is summarized in the truth table
below:
 Ladder
Logic RS Flip Flop Truth Table

How to Program a Toggle Logic in a

PLC Using Ladder Logic
Now that we know the most useful types of flip flops and understand their
operation, let’s see how to program them in a PLC using ladder logic.

The main PLC programming component for developing toggle logic is a

PLC output latch. Equally important is PLC output feedback logic so that
the state of the flip flop output is dependent on both the state of the
input and the current state of the output. The most popular way to
program toggle logic for a flip flop in a PLC is by using ladder logic.
The three main methods of programming PLC toggle logic using ladder logic
are latching logic, SET and RESET instructions and flip flop function blocks.

In order for an electronic T flip flop to have bit stable operation we need to
use a clock input. However, with a ladder logic flip flop the PLC scan acts as a
kind of clocked input providing a cyclic update of the program state. We can
use this to our advantage in our ladder diagram to program in bit stable
operation.

To implement a ladder logic flip flop in a PLC let’s firstly list the required
inputs, outputs and internal variables.

PLC manufacturers use different memory address allocation so the input,

output and internal variable allocations used here are arbitrary address. Below
is the list of required inputs, outputs and internal variables that need to be
declared:
PLC Toggle Logic Variable Table

T Flip Flop Ladder Logic Examples

The 3 most common ways to program toggle logic for a T Flip flop in any PLC
using ladder logic are:

1. Positive edge one shot instructions and latching logic.

2. Latching logic.
3. SET and RESET instructions.
The 1st T flip flop ladder diagram example uses positive edge one shot
instructions and latching logic:
PLC Toggle Logic – T Flip Flop Ladder Diagram Example 1
The 2nd T flip flop ladder diagram example uses latching logic. But, if you’re
working with a super basic mega cheap PLC it may not have one shot
instructions and you may be forced to use this method.….
PLC Toggle Logic – T Flip Flop Ladder Diagram Example 2
The 3rd T flip flop ladder diagram example uses SET and RESET instructions,
which tends to simplify the ladder diagram a little….

PLC Toggle Logic – T Flip Flop Ladder Diagram Example 3

SR Flip Flop Ladder Logic Examples

The 2 most common ways to program toggle logic for a SR Flip flop in any
PLC using ladder logic are:
 1. Latching logic.
2. SET and RESET instructions.
The 1st SR Flip Flop ladder diagram example using latching logic is shown

below…. SR
Flip Flop Ladder Diagram Example 1
The 2nd SR Flip Flop ladder diagram example using SET and RESET
instructions is shown below….

SR Flip Flop Ladder Diagram Example 2

RS Flip Flop Ladder Logic Examples

Remember, compared to the ladder logic SR flip flop, the ladder logic RS flip
flop is the same except it has a different result when both SET and RESET
inputs are TRUE. We can achieve this by using the PLC scan to our advantage
and rearranging the code a little.

The 2 most common ways to program toggle logic for a RS Flip flop in any
PLC using ladder logic are:

1. Latching logic.
2. SET and RESET instructions.
The 1st RS Flip Flop ladder diagram example using latching logic is shown
below….

RS Flip Flop Ladder Diagram Example 1

The 2nd RS Flip Flop ladder diagram example using SET and RESET
instructions is shown below….
RS Flip Flop Ladder Diagram Examples 2

Ladder Logic RS and SR Flip Flop in a

Siemens PLC
The Siemens PLC has dedicated ladder logic RS and SR flip flop function
blocks as part of their standard instruction library.

These function blocks operate exactly the same way as the other ladder logic
RS and SR flip flop examples, but requires an internal variable to be assigned
to the function block.

The memory address allocation for a Siemens PLC is I=Inputs, Q=outputs and
M=Internal Variables. Below is the list of required inputs, outputs and internal
variables that need to be declared for a Siemens PLC…..
Siemens PLC SR Flip Flop Variable Table
Siemens PLC SR Flip Flop Ladder Logic Example
The Siemens PLC SR flip flop function block has been implemented in the
ladder diagram example below…

SR Flip Flop in a Siemens PLC

Siemens PLC RS Flip Flop Ladder Logic Examples
The Siemens PLC RS flip flop function block is programmed in a similar
fashion to the SR flip flop function bock as per the ladder diagram example
below…
RS Flip Flop in a Siemens PLC

How Can a Flip Flop Be Used in a PLC?

Now that you’re full bottle on PLC flip flops and PLC toggle logic you might be
wondering how they can be used in a PLC ladder logic program?

Using a ladder logic flip flop in a PLC is simple. If there is a situation

where 1 input must toggle an output, then use a ladder logic T flip flop. If
there is a situation where 2 inputs are required to toggle an output then
use a ladder logic RS or SR flip flop.

A Ladder logic flip flop application example could be a silo fill control
sequence.

We could utilize north and south selection push button inputs and implement
a ladder logic SR flip flop to control which silo gets filled. Also, a pause toggle
switch input could be implemented using a ladder logic T flip flop in order to
pause and resume the sequence to allow for foreign debris to be removed
from the inspection conveyor.
So when the operator pushes the north or south selection buttons the silo
feed diverter changes position from north to south and vice versa.
And when the operator pushes the pause toggle switch the filling sequence
stops, the foreign debris is removed, then the pause toggle switch is pressed
again and the sequence resumes from where it left off.

Now that you know enough to be dangerous it’s time to get your hands dirty
on a PLC Programming Simulator.
Chapter 6 -simulators

Ladder Logic Simulator

A ladder logic simulator is a software application that lets you simulate the
operation of a PLC ladder diagram with a personal computer, mobile phone or
tablet. It allows you to test your PLC ladder diagram without the need to
purchase any PLC hardware.

A ladder logic simulator also has the ability to control the state of the inputs,
outputs and internal variables. This means that input and output devices do
not need to be purchased or connected to the PLC.

You can save time and money by using a ladder logic simulator to test your
ladder diagram.

Saving 100’s, even 1000’s of dollars on purchasing a PLC sounds like a good
idea. Especially if you are just starting out on the journey to learn ladder logic
programming.

Ladder Logic Simulator Free Download

The Do-more Designer PLC Programming Simulator is by far the easiest, most
flexible, feature packed ladder logic simulator that’s out there at the moment
for a PC.

It’s free to download with no registration required and genuinely no strings

attached.

The Do-more Designer is actually the PLC programming software used for the
Do-more PLC by Automation Direct.

The actual PLC Programming Simulator is built into the Do-more Designer
software and is a full-featured programming tool, not just a demo version.

The beauty of using actual PLC programming software with a built in PLC
simulator is that it allows you to get a feel for what real PLC programming
software is like.

So when you transition to using real life PLC hardware the learning curve is
much easier. Even if you are using different PLC hardware.

The Do-more Designer Software is compatible with Windows Vista, Windows

7, Windows 8 and Windows 10 operating systems.

The minimum system requirements are a 1GHz single core CPU with 1GB RAM
and 330Mb of storage.

To get the Do-more Designer PLC Ladder Logic Simulator Free Download from
Automation Direct click here.
Ladder Logic Simulator Example
Once you’ve installed the software it’s time to get stuck into a PLC ladder logic
simulator example.

Let’s do a ladder logic latch example with the PLC simulator.

For an explanation on ladder logic latch programming click here.

Create a New Project To Use With the PLC Simulator
Run the application and choose New Offline Project….
If the “Select Project” dialog box does not automatically pop up then go to
File, New Project and select Offline…

In the “New Offline Project” dialogue box select “Do-more Simulator” in the
Do-more Hardware Class. Then name the project, select the directory location
and click OK….
Well done. We have just created a new project file for the PLC simulator.

PLC Simulator Layout

When your newly created project first fires up the layout should be similar to
below….

The Main Toolbar is at the top, the Project Browser is on the left, the
Instruction Toolbox is on the right and the Status Bar is down the bottom.

The Main Toolbar and Project Browser can be hidden or made visible by
selecting the View menu in the Main Toolbar. And the Instruction Toolbox can
be hidden or made visible by selecting the Edit menu in the Main Toolbar.
We should have the Main program displayed. It will have a bunch of rungs
connected to NOP (no operation) outputs.

We can close the Dashboard and Start Page tabs (next to the Main tab) to
simplify things.

If you accidentally close the Main program just double click on “Main” in the
Project Browser on the left hand side…

The Do-more Designer is fully functional PLC programming software. There is

an awful lot that we can do with this kind of software with regards to
structuring and organizing our program.

Because we are using the PLC programming simulator we will be limited to the
amount of ladder logic programming that we can simulate at any one time. So
we don’t need to fully utilize all of the software’s features.

We will only need to do our ladder logic programming in the Main program.
There is no need to create extra programs or sub routines at this stage. We’ll
stick to the essentials for now.

Using the Ladder Diagram Editor

So let’s get started with our first piece of ladder logic programming.
If Edit Mode is not highlighted in the Main Toolbar then click on it to enable
program editing….

This will also pop up the Instruction Toolbox on the right hand side.

Please note that the Do-more PLC simulator calls a symbol an instruction. Don’t
worry, the two terms, instructions and symbols, are readily interchangeable.
Grab a Normally Open contact symbol (or instruction) from the Instruction
Tool bar and drag and drop it into the start of the first rung….

If we drop the instruction in the wrong spot or have accidentally dropped the
wrong instruction then we can cancel it by hitting the ESC key.

If we have already declared the symbol and want to delete it then select the
symbol and hit the Delete key.

A dialogue box will popup so we can declare the symbol.

PLC Simulator Input Symbol Declaration
The Do-more PLC programming simulator allocates symbol addressing the
same as the actual real life PLC.

In this example we will be declaring digital inputs and digital outputs as per
below….

X0-2047 (Digital Inputs)

Y0-2047 (Digital Outputs)

Because this PLC simulator is fully featured there are other symbol
declarations possible, but we will not be using them for this example….

C0-2047 (Digital Internal Variables)

RX0-255 (Real Analog Inputs)

WX0-255 (Signed Word Analog Inputs )

RY0-255 (Real Analog Outputs )

WY0-255 (Signed Word Analog Outputs

R0-2047 (Real Internal Analog Variables)

V0-2047 (Unsigned Word Internal Analog Variables)

N0-2047 (Signed Word Internal Analog Variables )

D0-2047 (Signed Double Word Internal Analog Variables)

T0-255 (Timers )

CT0-255 (Counters)

ST0-1023 (System Variables)

To declare the instruction as a digital input type X0 into the text field and click
on the magnifying glass icon. Don’t worry about the yellow popup box for
now, you can close it if you want….

After the magnifying glass icon is selected the Element Browser table will
popup. Fill it in as per below….

And then click Select.…

Save the changes when prompted.

Then click on the tick icon to accept the instruction declaration…

Now, the first rung of the ladder diagram should have the normally open
contact with all the declared information displayed above it, as per below…..
PLC Simulator Output Symbol Declaration
So let’s add an output to the first rung.

Double click on the NOP output on the right hand side of the first rung. The
instruction declaration pop up box appears.

This time we need to declare an output address, so type Y0 into the text field.
Then click the magnifying glass….
After the magnifying glass icon is selected the Element Browser table will
popup. Fill it in as per below….

And then click Select.…

Save the changes when prompted.

Then click on the tick icon to accept the instruction declaration…

The first rung of the ladder diagram should now have the normally open
contact in series with the output. All the declaration information should be
displayed above each ladder logic symbol….

Adding More Symbols Using the Ladder Diagram Editor

Let’s continue with adding the rest of the ladder diagram symbols for the
Latching logic.

This time we need to drag and drop a normally closed contact into the
position next to INPUT A.

Use the same procedure as above to declare the instruction. This time declare
it as input X1 as per the information below…
Remember to click Select, Save the changes if prompted and then click on the
tick icon to accept the instruction declaration.

Now we’re cooking. The Main program should look like this….
Adding a Symbol Branch Using the Ladder Diagram Editor
Time to add the last ladder diagram symbol to complete our ladder logic latch
PLC simulator example.

Grab a normally open contact and drag and drop it into the area just below
the INPUT A symbol.

This symbol has already been declare so we do not need to declare it again.
Just enter Y0 in the instruction declaration text box and hit the tick icon or
press enter.

The Main program should look like this….

Notice there is a connection missing between the new symbol just added and
rung 1.

We can add that connection by clicking on INPUT B symbol to select it. Then
going to the main toolbar and selecting Edit, Wire and the Down.

This will create a connection from rung 1 down to the end of Output Y
normally open contact. Thus creating a branch (or parallel) connection across
INPUT A normally open contact….
The final result should look like this….

Compile the Changes Made to the Ladder Diagram

Before we can proceed we need to compile any changes that have been made
to the ladder diagram.

The yellow bar on the left hand side of the first rung on the ladder diagram
prompts you to compile the programming changes by clicking the Accept
button in the Main Toolbar….
After the Accept button is clicked a green bar appears prompting you to save
the ladder diagram project.

Click the Save button in the Main Toolbar and if the properties pop up box
appears click ok. Once the project is saved the green bar disappears….

Connect to the PLC Simulator

We are now ready to connect to the PLC programming simulator.

The PLC programming simulator behaves just like a PLC. You need to connect
to it, download your program and place it in RUN mode.
First we need to fire up the PLC simulator by clicking on the Do-more/Sim
button on the Main Toolbar….

Click OK when the “Launch and Connect to Do-more PLC Simulator?” pop up
appears. The Do-more PLC Simulator will then launch….

PLC Simulator

You may have some communication errors pop up. This is because we haven’t
connected to the PLC simulator yet.

Please Note….The error popup box may be behind the PLC simulator window.
This took a bit to figure out, very sneaky. Hope that saves you some pain!

If you get an error pop up box appear displaying “Comm Link not responding”
then click Cancel….
If you get an error pop up box appear “Unable to establish a link to the PLC.”
then click OK….

Now, let’s connect to the PLC simulator. Go to the PLC tab in the Main Toolbar
and click on Connect….

The “Select Link…” pop up box appears with “MySim: on Local Port”
highlighted. Make sure to select the “Link Enabled” check box in the bottom
left hand corner and then click the Select button….
The “Resolve Online/Offline Differences” pop up box appears because we have
not downloaded the ladder diagram to the PLC simulator yet. Click on “Go
Online and view the DISK project” button….
Then click the Continue Online button when the “Online/Offline
Incompatibility” pop up box appears….
Click the Next button when the “Set PLC Clock” pop up box appears….

Click the Finish button when the “Setup System Configuration” pop up box
appears….
We should now be connected to the PLC simulator. The Status Bar at the
bottom of the ladder diagram editor should read Online….

Also, the PLC simulator EthRX and EthTX indication boxes should be green to
indicate simulated Ethernet transmit and receive signals between the software
and PLC simulator.

If they are flashing then the Status function is turned off, we’ll take care of that
a bit later….
Download and Run the PLC Simulator
The light blue bar on the left hand side of the first rung on the ladder diagram
indicate that there are differences between the offline ladder diagram and
online PLC programming simulator.

Also, the S, P and D boxes in the bottom Status Bar are also highlighted light
blue to indicate that there are program differences between the offline ladder
diagram and online PLC programming simulator.

Lastly, there should be warning message appear just below the rung editing
area which is triggered because of the differences between the offline ladder
diagram and online PLC simulator …..
All we need to do to now is download the offline ladder diagram to the PLC
programming simulator.

Click on “Write PLC” in Main Toolbar to download the ladder diagram to the
PLC simulator….

When the “Download Project to PLC” pop up box appears select the check box
to “Switch to RUN mode after download completes” and then click OK….
Click Yes to turn ALL STATUS ON….

Now we are connected to the PLC programming simulator, have downloaded

the ladder diagram and have turned the Status indication ON.
We should have the status bar at the bottom of the ladder diagram editor
window displaying Online and Run….

The PLC simulator EthRX and EthTX indication boxes should change to be
steady green when the Status indication ON.

We have already put the PLC simulator into RUN mode when we did the
download, but while we are here we can drag and drop the PLC Mode Switch
from TERM to RUN….

Now we’re ready to put the PLC simulator through its paces!
Using the PLC Simulator
To use the PLC Simulator we just need to click on the input address buttons
X0-X15 to change the state of the inputs. When the button is the depressed
position the input is ON and when the button is in the released position the
input is OFF.

In the ladder diagram the status of the logic symbols highlights in light blue
when the ladder symbol logic flow is TRUE.

If the ladder diagram symbols are not highlighting then click on “Status” in
Main Toolbar to enable it….

PLC Programming Simulator

When Inputs X0 and X1 are both de-activated then the logic flow is blocked
and Output Y0 is OFF….
To activate and de-activate inputs we simply click on the X0-15 buttons in the
PLC simulator. One click turns the input ON another click turns it OFF….

To SET the latch we must activate Input X0 and de-activated Input X1.

So, Click on the X0 button in the PLC simulator to activate Input X0. Input X1 is
already de-activated so we don’t need do anything with it at this stage….

Ladder Logic Simulator – Latching Logic

Ladder Logic Simulator – X0 Sets the Latch

Notice that logic flows through X0 and X1 to output Y0 and they are all
highlighted….
Once the latch is SET we can de-activate Input X0 by clicking on the X0 button
in the PLC simulator. Notice that Output Y0 is ON and is held in….

Ladder Logic Simulator – Latching Logic Set

To RESET the latch activate Input X1 by clicking on the X1 button in the PLC
simulator.

Because Input X1 is assigned to a normally closed contact symbol logic flow is

blocked when the input is activated. That’s opposite to how a normally open
contact symbol works and it’s called reverse logic….

Ladder Logic Simulator – X1 Resets the Latch

To once again SET the latch from this point, Input X1 must be de-activated
and then input X0 can be activated.

Adding a Rung Comment Using the Ladder Diagram Editor

To really start program like a pro let’s add a comment to the rung. First click
on rung 1 and in the top toolbar click on Tools and then Comment Editor….
Enter the comments in the dialog box that pops up and hit OK….

Now our ladder diagram should have the comment displayed at the very top
of the rung as shown below….
Congratulations…. you have just simulated a PLC latching logic using ladder
logic simulator software.

Ladder Logic Simulator Tips

Here are some handy tips to remember…

 Turn Edit Mode on in the Main Toolbar to start programming

changes.
 After changing the program click Accept in the Main Toolbar to
compile the program.
 Remember to save any programming changes.
 Start the PLC programming simulator before connecting to it.
 When connecting to the PLC make sure to tick the “link Enable”
box.
 Put the PLC programming simulator to Terminal mode before
downloading.
 To download to your ladder logic to the PLC programming
simulator click on the “Write PLC” button in the Main Toolbar.
 Flick the PLC programming simulator to RUN mode to enable
logic processing.
 Make sure Status is turned on in the Main Toolbar to see the logic
flow indication.