PROGRAMMABLE LOGIC CONTROLLER 2023-2024

CHAPTER 01

COMPANY PROFILE
1.1 Profile

Welcome to Government Tool Room & Training Centre (GTTC) a globally acclaimed Tool
Room and Training Centre. This is a joint venture of the Government of Karnataka and DANIDA,
Government of Denmark, established in the year 1972. The Government of Karnataka has
established 28 GTTC Centre’s all over Karnataka and a skill development centre. The main
objective is to provide skilled manpower and technical services to the existing and emerging
Industries all over the world.

GTTC has trained more than 50,000 candidates in various Diploma and Short-Term Skill
Development Training Program.

GTTC graduates have underlined their presence around the world in various domains like Tool
& Die maker, Tool Designers, CNC programmers and Mechatronics and Electronics technicians
Diploma graduates of GTTC due to their excellence in skill are most sought after in countries
such as Australia, Canada, Singapore, Malaysia etc.

Alumni of graduates GTTC have been entrepreneurs in the Precision manufacturing area, setting
up cutting edge companies and providing employment to youngsters.

GTTC has many firsts to its credit in precision manufacturing. It was the first to establish
production of Heart valves, manufacture of an import substitute, SUNSHIELD for ISRO, dies
for COCO COLA Bottles, Fire Extinguisher Bottle for ADA and HAL, and complicated castings
for Automotive sector. GTTC aims to excel in its chosen fields and serve the Nation and the
World.

1.2 Introduction

GTTC was established in 1972 at Bangalore with the participation of the Karnataka State
Government, in collaboration with the Government of Denmark under the Bilateral Development
Co-operation Agreement. The excellent performance of GTTC Bangalore, proactive Government
of Karnataka which saw the need for expansion, got second unit of GTTC started in 1992 with
DANIDA assistance.

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Proliferation of technology for development of the industries with supply of skilled manpower is
the key to meet the needs of the global requirement. With this Government of Karnataka
encouraged GTTC to start 10 more sub-centres to train in the area of tool and die making in
various parts of Karnataka.

GTTC is an autonomous society, and a recognised Scientific and Research Organisation by the
Government of India. Govt. Tool Room and Training Centre (GTTC), is serving industry by way
of precision tooling and providing in well trained craftsmen the area of tool and die making.

Today, the GTTC has acquired mastery in Mould and Die making technology and have
blossomed into an epitome of precision and quality in the development and manufacture of
sophisticated moulds, dies and tools.

Fully aware of the rapid advancement in technology the world over, the GTTC is periodically
adding new technologies to the existing set of advanced equipment like CAD / CAM, CNC
machines for tooling, Precision Components, Laser for Industries, Rapid prototyping, vacuum
casting etc.

GTTC is concentrating on the Integrated Development of the related segments of industries by

way of providing international quality tools, trained personnel and consultancy in tooling and
related areas. In future, the focus would be more on turnkey projects in Tooling, Aerospace
components & their assemblies, and also to support the development of small and medium scale
enterprises.

1.3 Vision

To emerge as an International Centre of Excellence in Training production, R & D and

Consultancy Services related to Manufacturing Technology – from Concept to End Product

1.4 Mission

To continuously improve the skills in Training, Develop Innovative Process to Optimise Product
ionisation using Latest Facilities / Methodologies, Trends, Techniques to Meet all Stake Holder
Needs and be the Leader.

1.5 Objectives

To conduct Industry Oriented Technical Training Programs to youth with Employable skills.

To assist MSME units in Technological upgrading by providing quality tools.

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CHAPTER 02
AUTOMATION
2.1 Overview on Automation
Automation or industrial automation is the use of control system such as computers, controllers
to control industrial machinery and processes, to optimize productivity in production of goods
and delivery of services. Automation is a step beyond mechanization.

Fig. 2.2 Automation

2.2 Automation Impacts

It increases productivity and reduce the cost. It gives emphasis on flexibility and convertibility
of manufacturing process. Hence give manufacturers the ability to easily switch from
manufacturing product A to manufacturing product B without completely rebuilt the existing
system or product lines. Automation is now often applied primarily to increase quality in the
manufacturing process, where automation can increase quality sustainability.

Fig. 2.2 Complete Automation System Components

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AUTOMATION
2.3 SIMATIC S7-1200

Fig. SIMATIC STEP7 1200

Fig.2.3 SIMATIC STEP7 1200

SIMATIC S7-1200 controllers by Siemens are the intelligent choice for compact
automation solutions with extended communication options and integrated technology functions.
They are available in standard and fail-safe versions.

SIMATIC STEP 7 integrated to TIA Portal offers transparency, intelligent user

navigation, and straightforward workflows in every work and programming step. Functions such
as drag and drop, copy and paste and AUTO Complete make work much quicker and easier.

The S7-1200 controller is designed as a compact CPU, which means that IOs are already
integrated. Yet the S7-1200 station can be equipped with additional IO modules to enlarge the
capabilities of the PLC.

SIMATIC S7-1200 Communications modules increase the communication capabilities of

the SIMATIC S7-1200 PLC through additional functions and interfaces. S7-1200 communication
modules support serial communication, PROFIBUS, IO-LINK, AS interface and several mobile
standards.

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CHAPTER 03

Introduction to Programmable Logic Controller

A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control
systems that continuously monitors the state of input devices and make decisions based upon a
custom program to control the state of output devices
It is designed for multiple inputs and outputs arrangements, extended temperature Ranges,
immunity to electrical noise, and resistance to vibration and impact.
Almost any production process can greatly enhance this type of control systems, the biggest
benefit in using a PLC is the ability to change and replicate the operation or process while
collecting and communicating vital information.
Another advantage of a PLC is that it is modular. i.e., you can mix and match the types of input
and output to best suit your application.

3.1 History of PLC

The first Programmable Logic Controllers were designed and developed by Modicon as a
relay replacer for GM and Landis.

The primary reason for designing such a device was eliminating the large cost involved in
replacing the complicated relay-based machine control systems for major U.S. car manufacturers.

These controllers eliminated the need of rewiring and adding additional hardware for every new
configuration of logic. The first PLC, model08, was invented by Dick Morley in 1969.

The first commercial successful PLC, the 184, was introduced in 1973 and was designed by
Michel Greenberg. Communications abilities began to appear in approximately 1973. The first
such system was Modicin’s Modbus. The PLC could now talk to other PLCs and they could be
far away from the actual machine they were controlling

3.2 What is inside PLC

The PLC being a microprocessor device, has a similar internal structure to many embedded
controllers and computers.

They consist of the CPU, Memory and I/O device. These components are integral to the PLC
controller. Additionally, the PLC has a connection for the programming and monitoring Unit or
to connect PLCs in another field.

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Fig. 3.2 Block Diagram of PLC

The CPU is the brain of a PLC system. It consists of the microprocessor, memory integrated
circuits necessary to store and retrieve information from memory.

PLC’s or programming terminals. The job of the processor is to monitor status of input devices,
scan and solve the logic of a user program, and control on or off state of output devices.

Random Access Memory is a non-volatile memory that would lose its information if power were
removed, hence some processor units are provided with battery backup. Normally CMOS
(Complementary Metal Oxide Semiconductor) type RAM is used.

ROM is a non-volatile type of memory. This means it stores its data even if no power is available.
This type of memory information can only be read, it is placed there for the internal use and
operation of processor units.

EEPROME or Electrically Erasable Programmable Read Only Memory is usually an add on

memory module that is used to back up the main programme in CMOS RAM of the processor.
In many cases, the processor can be programmed to load the EEPROM’S program to RAM, if
RAM is lost or corrupted.

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3.3 INPUT MODULE

Input Module interface directly to devices such as switches and temperature sensors. Input
modules convert many different types of electrical signals such as 120V AC, 24V DC, or 420mA,
to signals which the controller can understand. Since all electrical systems are inherently noisy,
electrical isolation is provided between input and processor. The component most often used for
this purpose is optocoupler. Input signal from the field devices is usually 4 to 2 ma or 0-10 V.

Fig. 3.3 Input Module of PLC

3.4 OUTPUT MODULE

Output module interface directly to devices such as motor starters and lights output modules take
digital signals from the PLC and convert them to electrical signals such as 24VDC and 4 mA that
field devices can understand. D to A conversion is carried out in their modules. Usually Silicon
Controlled Rectifier (SCR), trial, or dry contact relays are used for this purpose. Normally the
output signal is 0-10V or 4-20 mA.

Fig. 3.4 Output Module

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CHAPTER 04

PROGRAMMING LANGUAGES
4.1 Programming Languages used to Program a PLC

While ladder logic is the most commonly used LC programming languages, but it is not
only one. Following table lists some of the languages that are used to program a PLC.

• Ladder Diagram (LD)

• Functional Block Diagram (FBD)
• Structured Text (ST)
• Instruction List (IL)
• Sequential Functional Chart (SFC)

4.2 LADDER LOGIC

Ladder diagrams are advanced schematics widely used to record logic structures for industrial
controls. These are called ladder diagrams because they mimic a ladder, with two vertical rails
(supply power) and as many "rungs" (horizontal lines) as there are to represent control circuits.

The load device (lamp, relay coil, solenoid coil, etc.) is drawn almost always on the right-hand
side of the rung in ladder diagrams. Although it doesn't matter electrically where the relay coil is
within the rung, it does matter that the end of the power supply of the ladder is grounded, for
stable operation.

4.3 Why Is a Ladder Diagram Used for PLC Programming?

Ladder logic is a programming language used for PLC (Programmable Logic Controller)
programming. It is a graphical PLC programming language which uses ladder diagrams to
express logic operations with symbolic notation, much like the rails and rungs of a typical relay
logic circuit.

In order to bring industrial automation applications, it is used by engineers and electricians to

execute mathematical, linear, measuring, pacing, and arithmetic functions. It is a common
process from which to program a PLC. Ladder logic programming is still used now since the
basic concepts of system and process control are still the same.

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Chapter 05

Creating a new project in TIA Portal

5.1 Steps to create a new project

We can start writing our PLC program.

Start by launching TIA Portal. Then, on the first screen, click on “Create a new project”, give it
a name (“Box sorting machine” in this instance), and click on “Create”.

Fig. 5.1 Creating a new project in TIA portal

Then on the next view click on “Configure a device”.

Fig. 5.1(a) Selecting “ Configure a device”

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Once on the device configuration, click on “Add a new device”, open the folders “Controllers >
SIMATIC S7-1500 -> CPU -> CPU 1511-1 PN”, and select the 6ES7 511-1AK02-0AB0 CPU.
Choosing this CPU specifically is not mandatory, you are free to choose the CPU you want. We
simply selected the latest version of the simplest S7-1500 CP

Fig. 5.1(b) Selecting an S7-1200 CPU

Let the software initiate the project until the project’s interface appears.

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Open the “Program blocks” folder on the Project tree then double click on “Main [OB1]”

Fig. 5.1(c) Opening MAIN OB1

This is the main block of the project (OB1 for Organization Block 1). This is a cyclic block which
means that all instructions that are programmed inside will be executed repetitively as long as
the CPU is in RUN mode. We will program using only this block for more simplicity. On the
right side of the screen, you can find the instructions list. This can be accessed any time by
clicking on the “Instructions” side tab.

Fig. 5.1(d) Basic Instruction

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CHAPTER 06
PLC Ladder logic For BASIC logic Gates
As we all know, logic gate is a building block for the digital circuit. It takes binary input
(0, 1) and gives binary output based on the input provided
Logic gates using the programmable logic controller (PLC) is the basic thing we must learn.

6.1 Basic Logic Gates in PLC

6.1.1 AND GATE
Only when A and B are both on is there an output. Thus, if we use 1 to indicate an on signal and
0 to represent an off signal, then for there to be a 1 output we must have A and B both 1.

Fig. 6.1.1 AND Logic gate

6.1.2 OR GATE

This describes an OR logic gate in that input A or input B must be on for there to be an output.
Either input A or input B have to be closed for the output to be energized

The line then terminates with O to represent the output.

Alternative paths provided by vertical paths from the main rung of a ladder diagram, i.e., paths
in parallel represent logical OR operations.

Fig. 6.1.2 OR Logic gate

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6.1.3 NOT LOGIC

The input A contacts are shown as being normally closed.

This is in series with the output ( ). With no input-to-input A, the contacts are closed and so there
is an output. When there is an input-to-input A, it opens and there is then no output.

Fig. 6.1.3 NOT Logic gate

6.1.4 NAND GATE

Both the inputs A and B have to be 0 for there to be a 1 output.
There is an output when input A and input B are not 1.

Fig. 6.1.4 NAND Logic gate

6.1.5 NOR GATE

The combination of OR and NOT gates is termed a NOR gate. There is an output when neither
input A or input B is 1.

Fig. 6.1.5 NOR Logic gate

When input A and input B are both not activated, there is a 1 output. When either X400 or X401
are 1 there is a 0 output.

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6.1.6 XOR LOGIC

Such a gate is called an Exclusive OR or XOR gate.

One way of obtaining such a gate is by using NOT, AND and OR gate.

When just input A is activated, then the upper branch results in the output being 1. When just
input B is activated, then the lower branch results in the output being 1.

Fig. 6.1.6 XOR Logic gate

When both input A and input B are activated, there is no output.

In this example of a logic gate, input A and input B have two sets of contacts in the circuits, one
set being normally open and the other normally closed.

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CHAPTER 07

Timers in PLC Programming

Timers are very important instructions in any PLC logic; you can hardly find any automation
code that doesn’t include a timer inside. There are many types of timers you can use but, in this
article, we will talk about the most commonly used timers in Siemens PLC.

Contents:

What are timers in PLCs?

ON-Delay timers TON.

OFF-Delay timers TOF.

Retentive on delay timer TONR.

7.1 What are Timers in PLC?

Timers in PLCs are built-in function blocks FBs that are used to provide the same timing
instructions as a mechanical timing relay would do.

Timers are function blocks in the sense that they will need a data instance associated with them
each time you use a timer. This data instance will include all data related to the operation of the
timing instruction.

PLC timers are instructions that provide the same functions as on-delay and off-delay mechanical
and electronic timing relays. A PLC timer provides a pre-set delay to the control actions.

In general, there are three types of PLC timer delays, ON-delay timer, OFF-delay timer and
retentive timer on.

The terms represented in the timer block in the PLC are a Pre-set value which means the delay
period of the timer, an Accumulated value which is the current delay of the timer.

A timer begins the counting on time-based intervals and continues until the accumulated value
equals the pre-set value. When the accumulated value equals the pre-set time, the output will be
energized. Then the timer sets the output.

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7.2 TON timer or ON delay timer

An ON-delay timer is used where we need a time delay before the time delay before an instruction
becomes true.

Fig. 7.2 A Representation TON timer

A representation TON timer is shown above, which contains,

Timer number: The timer file name Time base: which is shown in seconds, Pre-set value:
Numeric valve set as the delay required to the timer. Accumulated value: The values are counting
is displayed from zero. Value becomes zero whenever the timer is reset

Fig. 7.2(a) Execution of TON timer

• The timer starts operating when the rung condition becomes true. The timer delay starts counting
when the rung condition starts to accumulate.
• When the Pre-set value becomes equal to the accumulated value, the output is made true.
• The timed output becomes true sometime after the timer rung becomes true; hence, the timer is
said to have an on-delay.
• The length of the delay can be adjusted by setting the pre-set value.

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7.3 TOFF timer or OFF delay timer:

A TOFF timer will keep the output energized for a pre-set time after the rung signal has gone
false.

Fig. 7.3 A Representation TON timer

The TOFF timer will have all the contents as in the TON timer, with the similar function.

Fig. 7.3(a) Execution of TON timer

• When the rung timer is true, the output will be true without any delay. When the rung signal
becomes false the timer starts operating.
• The timer starts accumulating times when the rung condition becomes true, until the accumulated
value becomes equal to the Pre-set value.
• The output turns off when the output will turn false when the accumulated value equals the pre-
set value.

7.4 Retentive timer:

A retentive timer is used when you want to retain accumulated time value through the power
loss or the change in the rung state.

A retentive timer accumulates time whenever the device receives power, and it maintains the
current time should power be removed from the device.

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Chapter 08
PLC Counter
8.1 What is a counter in PLC?

A PLC Counter is a function in PLC programming that is used to measure things like how many

times an event has happened in a process or how many times a product has been produced. In

Siemens PLC we have three types of counter functions,

• Up Counter
• Down Counter
• Up and Down Counter

Fig. 8.1 Blocks of Counter in PLC

These are the blocks that are used as a counter in PLC ladder logic. All counter blocks have some
inputs and some outputs.

Inputs,

• CU – Count Up Input
• CD – Count Down Input
• S – Set Input for pre-setting counter
• PV – Value for pre-setting counter
• R – Reset Input

Outputs,

• Q – Status of Counter
• CV – Current counter value
• CV_BCD – Current counter value in BCD coded
• Up Counter(S_CU)
• PLC Counter

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8.2 Up Counter (S_CU)

Fig. 8.2 Block of Up Counter

For each pulse at Count up (CU) bit, the current Counter Value (CV) will be increased by 1.
When there is a pulse at Set input(S), it will set Pre-setting Value (PV) at the current Counter
Value (CV).

When there is a pulse at Reset input(R), the counter block will get reset and the current counter
value is set at 0 again.

8.3 Down Counter (S_CD)

Fig. 8.3 Block of Down Counter

PLC Counter for each pulse at Count Down (CD) bit, the current Counter Value (CV) will be
decreased by 1. When there is a pulse at Set input(S), it will set Pre-setting Value (PV) at the
current Counter Value (CV).

When there is a pulse at Reset input(R), the counter block will get reset and the current counter
value is set at 0 again.

8.4 Up Down Counter (S_CUD)

This block has both the count up and count down functions.

Fig. 8.4 Block of Up Down Counter

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TASK PERFORMED
9.1 Task 1 Problem statement
Draw a ladder logic diagram to control the following output as per the given logic. Make use of
start and stop pushbuttons, 4 switches to turn on and off 3 Pumps, and a lamp (L).

1.Take a start and stop push button to turn on and off the system from two different positions.

Pressing Switch 1 results in turning ON of Lamp L1 and Pressing Switch 2 results in turning
OFF of Lamp L1.

2. Take a start (switch 1) and stop (switch 2) push button to turn on and off the motor M1 and
the motor remains ON even after the Switch 1 is released and turned OFF only if switch 2 is
pushed.

3. Network 2 when PB1, PB 2 & PB 3 are on the pump 1, pump 2 & pump 3 must be on
even when the PB1’, PB 2’ & PB 3’ switch is off respective motors are turned OFF; when
PB 4 is on PUMP 2 & 3 are off.
Write down a ladder logic diagram for the above problem statement.

Network 1
It is the two way network. Two different switches are used to turn the lamp ON from two different
positions and turned OFF from the same.

A Normally Open (NO) input is taken for turning the lamp ON from position 1 similarly, A
Normally Open (NO) input is taken for turning the lamp ON from position 2. A Normally Closed
(NC) input is inter connected with the Normally Open (NO) switch in such a way that one NO
switch is turned ON the linked NC get Opened and vice versa.

The cycle is ON by pressing START PB (I0.2) and turned OFF by pressing START PB (I0.3)
and the lamp can be turned ON by START PB (I0.3) and turned OFF by pressing START PB
(I0.2).

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Network 2
It is the cycle Start and Stop network of the motor. Push Button (PB) is used for starting and
stopping purposes.

A Normally Closed (NC) input is taken for stopping the cycle. A Normally Open (NO) input is
taken to start the cycle. A memory (M0.0) is taken that will be used in further networks. This
memory is latched to the Start PB.

The cycle is started by pressing START PB (I0.0) and is stopped by pressing STOP PB(I0.1).

Network 3
Network 2 when PB1,2 &3 are on the pump 1,2 & 3 must be on even when the PB switch is off;
when PB 4 is on PUMP 2 & 3 are off.

Here there are three different pumps set for different tanks. Each pump is turned on using push
buttons respectively, when PB 1’ is ‘ON’ the pump I will turn ‘OFF’, when PB 2’ is ‘ON’ the
pump 2 will turn ‘OFF’, and when PB 3’ is ‘ON’ the pump 3 will turn ‘OFF’, or if PB 4’ is
‘ON’ the pump 2 & 3 will turn ‘OFF’ at a same time.

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9.2 Task 2 Problem statement

Draw a ladder logic diagram to produce the following output as per the given logic. Make
use of Timers for this problem.

1. Draw a ladder logic diagram by taking timers. when SW1 is turned ON, lamp 1 must turn
ON & off with a gap of 5 sec one after the other
2. Draw a ladder logic diagram by taking timers when SW1 is turned ON, lamp 1 must turn
ON & off with a gap of 5 sec one after the other.

Network 1
when SW1 is turned ON, lamp 1 must turn ON & off with a gap of 5 sec one after the other.

It is the main program network that contains 4 timers among which 2 are T-ON and 2 are T-OFF
timers. The start PB (I0.0) is ON then using T-ON timer lamp 1 and lamp 2 are turned ON with
the time delay of 5 seconds. And turned OFF the same with the help of T-OFF timer with the
same time difference of 5 seconds.

The cycle is started by pressing START PB (I0.0).

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Network 2
when SW1 is turned ON, lamp 1 must turn ON & OFF with a gap of 5 sec one after the other.

It is the main program network that contains 2 Time Pulse (TP) timers. The start PB (I0.2) is
ON then using TP timer lamp is turned ON with the time delay of 5 seconds and turned OFF.
At the same time the NC contactor is open till the lamp 1 is ON, once the lamp 1 is turned OFF
the lamp 2 is turned ON for the time of 5 seconds and turned OFF automatically.

The cycle is started by pressing START PB (I0.2).

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9.3 Task 3 Problem statement

Draw a ladder logic diagram to control the traffic light output as per the given logic. Make
use of Time Pulse timers for this problem.
Start with Push Button
Make use of timers (TP)
Start the system using the start push button.
Lamp ‘R’ turns ON and after 5 seconds it will turn off. Then the Lamp ‘O’ turns ON and
after 5 seconds it will turn off. And similarly, Lamp ‘G’ turns ON and after 5 seconds it will
turn off.

It should continue the cycle till the system is turned off.

1. Draw a ladder logic diagram by taking timers in parallel to control the one-way traffic light that
receive an impulse from the push button to turn ON.
2. Draw a ladder logic diagram by taking timers in parallel to control the two-way traffic light that
receive an impulse from the push button to turn ON.

Network 1
It is a two-way traffic light control using the timers.

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It is the main program network that contains 3 timers and 3 output lamps. All the timers are
connected in parallel to each other. All the timers receive an impulse from the start push button
at the same time.

A Normally Open (NO) input is taken for Starting the cycle. A Normally Open (NO) input is
taken to start the cycle. A timer (TP) is used with each network. This timers are linked together
in such a way that one timer turns on other timers are set off using a NC switch in order to control
two way traffic.

The cycle is started by pressing START PB (I0.1).

Network 2
It is a two-way traffic light control using the timers.

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It is the main program network that contains 6 timers and 6 output lamps. All the timers are
connected in parallel to each other. All the timers receive an impulse from the start push button
at the same time.

A Normally Open (NO) input is taken for Starting the cycle. A Normally Open (NO) input is
taken to start the cycle. A timer (TP) is used with each network. These timers are linked together
in such a way that one timer turns on other timers are set off using a NC switch in order to control
two-way traffic.

It is designed in such a way that when RED light is turned ON in one way ORANGE light is
turned in other way mean while the same sequence is repeated with the time difference of 5
seconds.

The cycle is started by pressing START PB (I0.0).

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