LAB 10

INTRODUCTION TO LADDER LOGIC PROGRAMMING

1 Lab Objective
In this lab you will be introduced to programmable logic controllers and the use of relay ladder
logic.

2 Lab Equipment
2.1. CLICK Series Micro Programmable Logic Controller (PLC)
For this lab we will be working with the CLICK Series Micro PLC (C0-01DD2-D). The main
module has 8 DC inputs and 6 source DC outputs (see Figure 1). Each PLC is accompanied by
an add-on output module (C0-08TD2) with 8 additional source DC outputs (see Figure 2).

Figure 1: CLICK Series PLC CPU Module Figure 2: CLICK Series PLC Output Module

The modules have been pre-wired to an input/output control panel to interact with the PLC for
each lab activity.

The PLC communicates with the PC using a standard serial communication port. The PLC
transfers data to and from the PC by sending 38,400 signals per second (38,400 baud). Data is
sent 8 bits at a time, with odd parity, and using a stop bit of 1. Once the PLC has been
programmed, it can be untethered from the PC. Additionally, since these PLCs have retentive
memory, after a power cycle the PLC will resume running the previously loaded program.

2.2. CLICK Software for Relay Ladder Logic (RLL) Programming

The CLICK Series PLCs are programed using CLICK Software. The software allows a user to
define ladder logic which can control the desired outputs. The logic can be a function of
 current inputs, outputs, and internal variables (coils). After the program has been completed,
the software will upload the PLC program to the CLICK PLC. While tethered to the PLC, the
software has tools with which a user can monitor the real-time value of both internal and
external variables (ie. logic states, timer/counter values).

If you’re interested, the CLICK Software has been made available for free download by the
distributor at http://support.automationdirect.com/products/clickplcs.html

Step-by-step instructions for starting a new PLC program, writing a program, and uploading a
program to a PLC using the CLICK Software can be found in the Appendix. Additionally, a
detailed help file for the PLC software can be found at
http://www.aboutplcs.com/click/click_help/click_help.htm

3 Ladder Logic Examples

3.1. Oscillating Lamp
Program a single output lamp to oscillate ON/OFF on 3 second intervals.

1a. Sequence of Events

1. After 3 seconds turn on Output Lamp and enable Timer 2
2. After 3 seconds turn off Output Lamp
3. Repeats Steps 1-2 indefinitely

1b. Relay Ladder Logic

Figure 3: Oscillator - Ladder Logic

 1c. Features
 Timers in RLL
 Discrete outputs (relay coils and contacts)
 Internal coils (used only for intermediate logic)

1d. Additional Information

No external inputs are required to initiate the oscillator as shown. However, one can add a
“START” switch to initiate the loop or stop it. The program as shown is self-starting.

The only physical output is Y1 (connected to a lamp). The control relay C1 is an internal coil in
the PLC.

3.2. Real-Time Clock

2a. Sequence of Events:
1. Turn on “Seconds” indicator every second
2. After 60 ticks of “Seconds” turn on “Minutes” indicator
3. After 60 ticks of “Minutes” reset Minutes Counter and turn on “Hours” indicator
4. After 24 ticks of “Hours” reset Hours and turn on “Days” indicator
5. Reset “Days” indicator
6. Repeat Steps 1-5 indefinitely
2b. Relay Ladder Logic

Figure 4: Real-Time Clock - Ladder Logic

2c. Features
 Counters, Timers, Relay coils and contacts.

2d. Additional Information

The current time on the real time clock is indicated by the output indicators Y2 (hours): Y3
(minutes): Y4 (seconds), and Y1 (days).
3.3. Alternating Red Lights
A controller is needed to simulate an intersection where both sides are flashing red lights (the
equivalent of a four-way stop). The timing diagram is as shown below.

3a. Timing Diagram

On
Red 1
Off
On
Red 2
Off

0 2 4 6 8 10
Time (s)

Figure 5: Alternating Red Lights - Timing Diagram

For this scenario, the red light on street 1 is one output and the red light on street 2 is the
second output. According to the timing diagram, the red lights should alternate on and off at
two-second intervals.

3b. Sequence of Events

1. Turn Red 1 on and Red 2 off for 2 seconds
2. Turn Red 1 off and Red 2 on for 2 seconds
3. Repeat steps 1 through 2 indefinitely.
3.4. Traffic Signal
A controller is needed to control the traffic lights of an intersection of two streets. Street #1
(Washington Avenue) is a main street whereas Street #2 (Union Street) is a side street (or
secondary street). Since Street #1 is a main street, it will be given a longer green light. The
timing diagram for each light is shown below.

4a. Timing Diagram

On
Green 1
Off

On
Yellow 1
Off

On
Red 1
Off

On
Green 2
Off

On
Yellow 2
Off

On
Red 2
Off

0 10 20 30 40 50 60
Time (s)

Figure 6: Traffic Signal - Timing Diagram

As seen in the timing diagram, this scenario requires six outputs: Red (2x), Yellow (2x), and
Green (2x). One direction of traffic at a time is given a long green light followed by a short
yellow light while the other direction maintains a constant red light. This sequence alternates
between each direction indefinitely.

Here, the cycle time for each light has been decreased for simplicity.

4b. Sequence of Events

1. Turn Green 1 on for 35 seconds and Red 2 on for 40 seconds.
2. Turn Green 1 off and turn Yellow 1 on for 5 seconds.
3. Turn Yellow 1 off, Red 2 off, Green 2 on for 15 seconds and Red 1 on for 20 seconds.
4. Turn Green 2 off and Yellow 2 on for 5 seconds.
5. Turn Red 1 and Yellow 2 off.
6. Repeat steps 1 through 6 indefinitely.
4 Prelab
4.1. Alternating Red Lights
Using the outputs given in Table 1, create a ladder logic diagram for the alternating red lights
described in Figure 5.

Table 1: Alternating Lights - Input/Output

Output Address Input Address

Red 1 Y001 None
Red 2 Y004

Use the appropriate ladder logic representation and naming convention (found in the
Appendix) for each element in the diagram.

For each timer, be sure to clearly indicate the set point and include the desired units (eg. 4 s).
For the CLICK Programming Software, keep in mind that timers are placed at the end of a rung
and have their own output memory address (eg. T1). A second rung is required to send this
output to a coil.

4.2. Traffic Signal

Using the outputs given in Table 2, create a ladder logic diagram for the traffic signal described
in Figure 6.

Table 2: Traffic Signal - Input/Output

Output Address Input Address

Red 1 Y001 None
Yellow 1 Y002
Green 1 Y003
Red 2 Y004
Yellow 2 Y005
Green 2 Y006

Once again, use the appropriate ladder logic representation and naming convention (found in
the Appendix) for each element in the diagram.
5 Lab Procedure
5.1. Alternating Red Lights
Implement the alternating red lights from Prelab Exercise 1. Show your working PLC program
to the TA. Save or print a copy of the ladder logic diagram for the postlab.

5.2. Traffic Signal

Implement the traffic signal from Prelab Exercise 2. Show your working PLC program to the
TA. Save or print a copy of the ladder logic diagram for the postlab.

6 Postlab
6.1. Ladder Logic Diagrams
Print out the Ladder Logic Diagrams for both exercises.

6.2. Comment Diagrams

On each diagram write comments for every rung explaining what is happening (logic, counter,
finish flag etc.)

6.3. Analyze Ladder Logic Diagram

The ladder diagram below uses 1 timer with a time delay of 2 seconds. Analyze the diagram
and predict what the signals Y1 and Y2 will look like from 0 to 10 seconds. Assume that the
initial values of Y1 and Y2 are zero.
 Appendix
1. Start New Project
1. Open CLICK Programming Software
 Start → All Programs → Local →AutomationDirect →Click_Programming_Software
2. Select “Start a new project”

2. Write to PLC
1. Write Project
 PLC → Write Project into PLC
 Click “OK” to begin read/write program
 If PLC is in RUN Mode, click “YES” to change to STOP Mode
 Click “OK” to acknowledge transfer complete
 Click “OK” to set PLC mode to RUN
2. Connect to PLC (Only if Write Project fails)
 PLC → Connect
 Verify settings
 PC COM Port No.: COM1
 Baud Rate: 38400
 Address: 1
 Parity Bit: Odd
 Stop Bit: 1
 Click “OK” to connect to PLC

3. Address Naming Convention

Each element has an independent name. The following address naming convention is used by
the CLICK Software.

 X001-X008: Input
 Y001-Y006: Output
 C1-C2000: Coil
 T1-T500: Timer
 CT1-CT250: Counter
4. Ladder Logic Elements
The following standard ladder logic elements are available in the CLICK Software.

Element Description Ladder Logic Representation

Normally Open Contact Is ON when the
defined address (eg.
X001, Y001, C1, or
T1) is ON
Normally Closed Contact Is ON when the
defined address (eg.
X001, Y001, C1, or
T1) is OFF
Out Coil Turns ON/OFF a
given address (eg.
Y001 or C1) when
the rung is
true/false.
Timer When enabled,
measures the
elapsed time. Turns
on output address
once it reaches the
set point.

Counter When enabled,

counts up or down
until it reaches the
set point

End Instruction Marks the

termination point of
a program