UNIVERSITY OF NAIROBI

DEPARTMENT OF ELECTRICAL AND INFORMATION

ENGINEERING

FOURTH YEAR CONTROL LAB MANUAL

INTRODUCTION TO PLCs

May, 2021

1 / 11
Contents
OBJECTIVES 3
BACKGROUND READING 3
BASIC LOGIC FUNCTIONS 4
INTRODUCTION USING A CONTROL UNIT 5
TRAFFIC LIGHT CONTROL 7
Objective 7
Equipment Description 7
Work Schedule 7
Functional description and problem definition 8
Assignment list 9
APPENDIX A: USE OF TIMERS 11
APPENDIX B: SOFTWARE AND SIMULATOR DOWNLOAD 11

2 / 11
 1 OBJECTIVES
1. To acquire an overview of PLCs and the Basic PLC architecture.
2. To appreciate the differences between PLC, relay and PC-based control.
3. To understand basic ladder logic symbols.
4. To write PLC ladder logic for simple applications.
5. To download and run PLC programs.
6. To design and implement a PLC control program in Ladder Logic to control traffic lights at a
cross junction.

The objectives are to be met through the actual lab work as well as through the pre-lab
preparation and reading of the recommended and other material.

2 BACKGROUND READING
Ensure you go through the following material. The first two can be found on the eLearning
platform and the last one on the internet (Google “S7-200 manual”):
● Chapter 1: Introduction to PLCs
● Chapter 2: Basic Ladder Logic Programming (NB: the PLCs in this document are based
on Allen-Bradley PLCs but the concepts are also applicable to Siemens PLCs, which we
use in the lab).
● S7-200 Manual. Specifically, go through the following sections:
o Creating a Simple Program (Pg. 10 – 14).
o Understanding how the S7-200 executes your control logic (Pg. 24).
o Accessing the data of the S7-200 (Pg. 27 – 28).
o Bit Logic Instructions (Pg. 70 & 72 – 74).
o Compare Instructions (Pg. 96 – 97).
o Timer Instructions (Pg. 196 – 200).

Answer the following basic questions:

i. What is the scan cycle?
ii. Why should two output coils in a ladder diagram never be given the same label (or memory
address)?
iii. How many kinds of timers are there in the S7-200 PLC? Name them.
iv. What are the different timing resolutions available in the S7-200?
v. What are the different kinds of memory areas available in the S7-200?
vi. Analyze the following addresses and explain what each part means: Q0.5, VW101
vii. In no. vi) above, how do we refer to the two different kinds of addressing used?

3 / 11
3 BASIC LOGIC FUNCTIONS
The diagrams below show some logic functions that can be achieved using ladder diagrams.

4 / 11
4 INTRODUCTION USING A CONTROL UNIT
NB: for the exercises below, follow the simple steps outlined below:

1. Based on the Functional Description (design requirement) given, identify all the inputs and
outputs needed and write up an assignment list (illustrated in Appendix A) that specifies the
memory addresses for each of those inputs and outputs.
2. Design the control task using LADDER diagrams. This should be done using pen and paper
and discussed in the group.
3. In the STEP 7-Micro/WIN, populate the symbol table using the assignment list you came up
with in no. 1 above. In the symbol table ensure you include meaningful comments for all the
memory addresses you are using.
4. Enter the control program in the Program Block editor of the STEP 7-Micro/WIN.
5. Download and run the program entered and correct existing errors. For troubleshooting, the
Program Status view is useful for seeing the status of various elements in the ladder diagram.
6. If your program is running satisfactorily, export/print the program to a pdf. Ensure you select
the check boxes for Program Block and Symbol Table as you are printing to pdf. This pdf
will be required in the final report.

The diagram below shows a typical control unit.

5 / 11
1. Based on an understanding of the basic logic functions and in conjunction with the Control
Unit of the TSM-700/EV implement and test ladder logic to achieve the following:

i. When S1 is pressed once, the lamp for S1 comes on and stays on until S2 is pressed once.
ii. When S1 and S3 are pressed simultaneously they both come on and stay on until S2 and
S4 are both pressed simultaneously i.e. for S1 and S3 to come on, they both have to be
pressed; similarly, for S1 and S3 to go off once turned on, both S2 and S4 have to be
pressed.
In both cases, pressing the emergency stop (S0) should turn of any lamp that is on.

2. Design and implement a ladder diagrams that result in the following operations:
i. The lamps for S1 and S3 flash on and off (simultaneously) at a frequency of 0.5 Hz.
ii. The lamps for S2 and S4 flash on and off (simultaneously) at frequency 0.5 Hz. This
should be at the same time as S1 and S3 are flashing on and off; the operation should be
such that when the green lamps (S1 and S3) are on, the red lamps (S2 and S4) are off, and
vice versa.
iii. A running light. The lamps turn and off in the following infinite sequence:
S1-S2-S3-S4-S1-S2-S3-S4-…
There should only be one lamp on at a time and each lamp comes on for 0.5s.
Hint: for no. 2 above, you will need to use Timer and Compare Instructions (see Appendix
B). See also the simple example given in the S7-200 Manual, pg. 12. Note that Compare
Instructions can be connected in series, if necessary, to achieve different results.

6 / 11
5 TRAFFIC LIGHT CONTROL

5.1 Objective
To design and implement a PLC control program in Ladder Logic to control traffic lights at a
cross junction.

5.2 Equipment Description

The equipment simulates the traffic signal operation in a 4-roads crossing. The different
components of the electrical circuit to be controlled by PLC are mounted on a Bakelite
silk-screen-printed panel, with the relative signaling and commands.

Fig. 1: Didactic Panel for Traffic Control

All the signaling lamps are connected in an independent way to a terminal box composed of
safety terminals with 4 mm diameter, so that the user can choose the type of connections
between the different components and the PLC, depending on the management operation mode.

5.3 Work Schedule

1. Based on the Functional Description given below, complete the assignment list by specifying
appropriate memory addresses. NB: other symbols in addition to the ones specified in the
assignment list on page 4 may be used if necessary.
2. Design and Implement the control task in LAD/FBD/STL.
3. Clearly arrange the programming device, the programmable controller and the required
simulators at the training setup.
4. Enter the control program.

7 / 11
5. Read the program entered and correct existing errors.
6. Function-test the control with the simulators.
7. Save the function-tested control program on the programming device
8. Document the function-tested control program.

5.4 Functional description and problem definition

The control of the traffic light system for a pedestrian crossing is performed in two operating
modes: day operation and night operation.
A start-up button allows initialization of the system at ignition, and a switch allows activation of
the “Day” and “Night” operation modes. These modes operate as follows:
● Operation mode “Night”: The yellow lamps flash on and off continuously.
● Operation mode “Day”: The red, yellow and green lights of traffic lights 1 and 2 work in a
pre-specified sequence to control the traffic of the crossing.
When a change is made from one operating mode to the other (Night/Day) a confirmation has to
be made by pushing the start-up button.
The flowchart in Fig. 2 illustrates the day and night operation.

8 / 11
5.5 Assignment list
OPERAND
(MEMORY SYMBOL COMMENT
ADDRESS)
To initialize the system; to confirm a change
I_RESET_TRAFFIC_LIGHT
from day to night and vice versa
I_DAY_NIGHT day/night switch
Q_RED1 Output for red light of Traffic Light 1
Q_YELLOW1 Output for yellow light of Traffic Light 1
Q_GREEN1 Output for green light of Traffic Light 1
Q_RED2 Output of red light of Traffic Light 2
Q_YELLOW2 Output of yellow light of Traffic Light 2
Q_GREEN2 Output of green light of Traffic Light 2

9 / 11
Fig. 2: Day and Night operation

10 / 11
APPENDIX A: USE OF TIMERS
To learn more about timers and compare instructions read the following material
● Timers (especially TON): pg. 196 – 200 of S7-200 Manual
● Compare Instructions: pg 96-97 of S7-200 Manual

These are the Instruction Sets for those commands. The manual can be found on the elearning
portal or easily be downloaded from the internet. If you search for “S7-200 manual” the first
result is a pdf of the manual. Be sure to read through those pages, including the given examples
and timing diagrams of the timers.
Feel free to read other parts of the Instruction Set (chapter 6) or of the manual. It is always a
good point of reference whenever in doubt.

APPENDIX B: SOFTWARE AND SIMULATOR DOWNLOAD

To get additional practice outside the lab, you can install the S7-200 Microwin program on your
computer and write your own ladder diagrams. You can also install a simulator that you can use
to test to some extent the functionality of your programs.
As of the writing of this lab manual, S7-200 Microwin and the simulator could be downloaded
using the following links:
● S7-200 Microwin software

● S7-200 simulator

11 / 11