MT 451L: Manufacturing Automation Lab

Lab Report No. 5B

Name Muhammad Saud Dar

Reg. ID 211277

Section BEMTS-8B

Submitted To: Mam Mahnoor Zahid

Department of Mechatronics and

Biomedical Engineering
Air University

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 Lab No. 5b
Timer OFF and RTO

Objective

To understand the operation of Timer OFF and RTO and simulate the given tasks in Allen
Bradley PLC.
TOF Timer Off Delay
 Symbol

 Definition
 Counts time base intervals when the instruction is false.
 The Timer Off Delay instruction begins to count time base intervals when the
rung makes a true to false transition. As long as rung conditions remain false,
the timer increments its accumulated value (ACC each scan until it reaches
the preset value (PRE). The accumulated value is reset when rung conditions
go true regardless of whether the timer has timed out.
Each timer address is made of a 3-word element.
Word 1 is the control word
 Bit 0-12: Internal Use
 Bit 13: DN- Done
 Bit 14: TT - Timer Timing
 Bit 15: EN - Timer is enabled
Word 2 stores the preset value. (PRE)
 Specifies the value, which the timer must reach before the controller sets the done
bit. When the accumulated value becomes equal to or greater than the preset value,
the done bit is set.
 Preset value is from 0 - 32,767
 If a timer-preset value is negative an error will occur.
Word 3 stores the accumulated value. (ACC)
 This is the time elapsed since the timer was last reset. When enabled the timer
updates this continually.
 Time Base: is the timing update interval, this can vary from 0 - 1 second.

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RTO Retentive Timer
 Symbol

 Definition
 Counts time base intervals when the instruction is true and retains the
accumulated value when the instruction goes false or when power cycle occurs.
 The Retentive Timer instruction is a retentive instruction that begins to count
time base intervals when rung conditions become true.
 The Retentive Timer instruction retains its accumulated value when any of the
following occurs:
 Rung conditions become false.
 Changing Processor mode from REM run /Test / program mode.
 The processor loses power while battery back-up is still maintained and a fault
occurs.
Note: To reset the accumulated value in RTO, you must use a reset instruction (RES) with
the same address.
Each Retentive Timer is made of a 3-word element.
Word 1 is the control word
 Bit 0-12: Internal Use
 Bit 13: DN- Done
 Bit 14: TT - Timer Timing
 Bit 15: EN - Timer is enabled
Word 2 stores the preset value. (PRE)
 Specifies the value, which the timer must reach before the controller sets the done
bit. When the accumulated value becomes equal to or greater than the preset value,
the done bit is se.
 Preset value is from 0 - 32,767
 If a timer-preset value is negative an error will occur.
Word 3 stores the accumulated value. (ACC)
 This is the time elapsed since the timer was last reset. When enabled the timer
updates this continually.
 Time Base: is the timing update interval, this can vary from 0 - 1 second.

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 IN LAB TASKS:
Exercise 1:
Write ladder program for LED to glow for 10 secs when the High time of the pulse at the
input is equal to 10 sec (Hint: Use RTO)

Simulations

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Exercise 2:
Implement using Timer Off :
Let's say we have in the field an emergency stop. Once the E-Stop is pressed we want the
siren to go on for 5 seconds.

Simulations

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Exercise 3:
Write a program that will turn on a flashing light for the first 15 seconds after a Push
button is turned on. The light should flash for half a second on and half a second off.
a) Implement using Timer ON

Simulations

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 b) Implement using Timer Off

Simulations

Sources of Error

1. Incorrect Timer Configuration in Software

o Setting an incorrect Preset Value (PRE) in the simulation might result in
unexpected delays.
o Example: If the preset value for a TOF timer is mistakenly set to 15s
instead of 5s, the emergency siren will stay ON for too long.
2. Simulation Lag or Software Bugs
o Some PLC simulation software may have lags or glitches that cause
timers to behave inconsistently.
o Example: If the simulator does not properly update the Accumulated
Value (ACC) in an RTO timer, it may not retain the correct time after
stopping and restarting.
3. Logic Programming Errors
o Incorrect placement of TOF or RTO instructions may cause unintended
behavior.

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 o Example: If a TOF timer is placed before an output relay instead of
after it, the siren may turn OFF immediately instead of waiting for the
delay.
4. Improper Use of Reset (RES) Instruction for RTO
o If an RTO timer is not reset properly using a RES instruction, it may
keep accumulating time incorrectly.
o Example: In a flashing light system, if RTO is used without a reset, the
light might not restart flashing correctly when turned on again.
5. Mismatched Time Base in Simulation
o Different PLC software may use different time bases (e.g., 1ms vs.
100ms), which can affect the timing of the process.
o Example: If a 1s delay is mistakenly set as 100ms, the timer will
complete 10x faster than expected in the simulation.

Applications of Timer Off Delay (TOF) and Retentive Timer (RTO) in PLCs with
Industry Examples

1. Emergency Siren Systems (TOF)

o Used to keep an alarm active for a set period after an emergency stop is pressed.
o Example: In oil refineries (Shell, ExxonMobil), TOF ensures sirens stay active
for 5–10 seconds even after the button is released.
2. Machine Stopping Sequences (TOF)
o Ensures a smooth shutdown process by delaying machine stop.
o Example: In CNC machines (Siemens, Haas Automation), TOF is used to
delay spindle stops to prevent tool damage.
3. Flashing Light Indicators (TOF & RTO)
o Used to create blinking light signals for warnings and alerts.
o Example: In airport runway lighting (Boeing, Airbus operations), TOF
controls the blinking rate of caution lights for safe taxiing.
4. Conveyor System with Retentive Timer (RTO)
o Ensures conveyor resumes operation from the same point after a temporary stop.
o Example: In Amazon’s automated warehouses, RTO keeps track of conveyor
runtime even after a power outage.
5. Production Line Timers (RTO)
o Maintains accumulated time for processes that require continuous tracking.
o Example: In baking ovens (Nestlé, Mondelez), RTO keeps track of elapsed
baking time to prevent product defects in case of a temporary shutdown.

Conclusion

This software-based lab focused on implementing Timer Off Delay (TOF) and
Retentive Timer (RTO) in Allen Bradley PLC simulations. The TOF timer is used for
delayed turn-off operations, such as emergency sirens, while RTO retains timing
values even after stopping the simulation.

In simulation-based PLC programming, common sources of error include incorrect

timer settings, software lag, logic programming mistakes, missing reset instructions,
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and mismatched time bases. Understanding and resolving these issues ensures accurate
and reliable simulation results, helping to verify automation processes before
implementing them in real industrial systems.

By mastering these timers in software simulation, engineers can efficiently test

automation logic, reduce programming errors, and ensure a smooth transition from
virtual simulation to real-world PLC implementation.

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 ASSESSMENT RUBRIC AND GRADING OF LAB PERFORMANCE
PLO2(P1): Problem Analysis

Min.
No Progress Benchmark Basics Good Excellent Outstanding
Attributes
0 1 2 3 4 5
Can build circuit,
Can start
Cannot operate Doesn’t know Can build circuit Can built circuit, can can simulate it and
software but
Simulation simulation basics of but cannot simulate it but can analyze it using
cannot complete
software software simulated. cannot analyze it. different tools of
circuit
software.
Can provide
Can provide comprehensive
comprehensive Can provide conclusion, using
Can provide basic Can accurately
Critical analysis and comprehensive engineering
analysis and provide analysis
Analysis & No Progress conclusion with analysis, using terminologies while
conclusion of and conclusion of
Conclusion relevant engineering encompassing
task performed task performed
keywords / terminologies. objectives of the
technical terms task and future
applications

PLO 5(P3): Modern Tool Usage

No progress Min Benchmark Basics Good Excellent Outstanding
Attributes 0 1 2 3 4 5
Aware of the Aware of process
Aware of process Aware of process Aware of
Mostly unaware process but lacks but lack
and follow it and follow it. application
Apparatus of the process of competency in competency in
rightly with Setup apparatus process and can
setup setting up following setting up
error. rightly. implement it
apparatus procedure apparatus
Knows the basics
Implement IDE/ Can troubleshoot
IDE/ Logic of IDE/ Logic Cant trouble Can modify for
Does not Logic and get the right
Development Developmentand shoot the error new problem
comprehend Development result
can formulate

PLO 9(A4): Individual and Team Work

No progress Min Benchmark Basics Good Excellent Outstanding

Attributes 0 1 2 3 4 5
Does not performs Inconsistently Task performed Task performed Performs all duties
Fulfil Assigned No progress any duties performs duties that completely with accurately but assigned and
Duties assigned are assigned error not on time actively on time
Experiment
Experiments Experiment Report submitted is
Report submitted objective,
Individual Lab Report not results are accurate report is not on time and format
is not proper introduction and
Report submitted but conclusion is submitted on is perfect and
format procedure added but
not added. time. results are accurate.
results have error

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