Control and Automation Laboratory

Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS

Sepuluh Nopember Institute of Technology, Surabaya

EXPERIMENT 3
PROGRAMMABLE LOGIC CONTROLLER (PLC) - LG

OBJECTIVE
Understanding the automation process in the industrial field is essential for an engineer.
Engineering students have to be used to work and practice in an industrial environment.
Therefore, they are ready with the real system. In this experiment, we will use PLC LG
Chungpa and GMWIN software that shows basic automation commands clearly and easy to
understand. We would have introduced basic instruction, counter, and timer.

REFERENCE
Anonymous, User’s Manual LG Programmable Logic Controller: Instruction and Programming,
LG Industrial Systems.
David W. Pessen, Industrial Automation: Circuit Design and Components, 2008.

EQUIPMENTS REQUIRED
PLC LG Chungpa 1 piece
Red Short Cable (40 cm) 10 piece
Red Long Cable (110 cm) 10 piece
Black Short Cable (40 cm) 10 piece
Black Long Cable (110 cm) 10 piece
Power Cable 2 piece
RS-232 and USB to Serial cable 1 piece

PRE-EXPERIMENT TASK
1. What kind of industries use or apply PLC to their system? Why do industries use them?
2. What is the difference between PLC and microcontroller?
3. What is the company that produces the PLC?

INTRODUCTION
Automation System is a system that makes human life easier. It has so many advantages,
because it can work effectively and efficiently in case of time, energy, and cost needed. So that
we can achieve it all, many industries use PLC. A PLC is an industrial computer control system
that continuously monitors the state of input devices and makes decisions based upona custom
program to control the state of output devices. Almost any production line, machine function,
or process can be greatly enhanced using this type of control system. However, the biggest
benefit in using a PLC is the ability to change and replicate the operation or process while
collecting and communicating vital information.
There is two type of PLC, that is Compact and Modular PLC. Compact PLCs are used in
automation as replacements of relays. A PLC does not cost more than a handful of relays and
the programming is as flexible as wiring. The weak points of this type PLC are low memory
for the program and data, low processor performance, low number of PLC timers andcounters,
and missing data types (like floating point, string). On the other hand, today’s more expensive
compact PLCs have the same functionalities as other PLC types, the only flaw is the fixed
number of I/Os. Examples of compact PLC are Festo FEC PLC, Siemens Logo and S7-200
PLC.
A modular PLC contains several different modules that can be coupled together to build a

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

customized controller. Typically, a base module contains core functions such as

electricalpower regulation, the computer processor, and input connections. Additional
modules, including analog to digital signal converters or additional outputs, can be added to
this core unit as needed. This modular design allows a PLC to be customized and changed
easily. The Allen Bradley Micrologix 1200 is a commonly used example of the modular PLC
type. This unit is able to handle between 23 and 40 inputs and outputs. The actual number of
connections can be expanded easily by adding modules. This provides a wide range of
flexibility and is typical of a modular PLC. While Ladder Logic is the most commonly used
PLC programming language, it is not the only one. There are five programming language used
to put in use :
• Ladder Diagram (LD)
Traditional ladder logic is graphical programming language. Initially programmed with
simple contacts that simulated the opening and closing of relays, Ladder Logic
programming has been expanded to include such functions as counters, timers, shift
registers, and math operations.
• Function Block Diagram (FBD)
A graphical language for depicting signal and data flows through re-usable function
blocks. FBD is very useful for expressing the interconnection of control system
algorithms and logic.
• Structured Text (ST)
A high level text language that encourages structured programming. It has a language
structure (syntax) that strongly resembles PASCAL and supports a wide range of
standard functions and operators.
• Instruction List (IL)
A low level “assembler like” language that is based on similar instructions list
languages found in a wide range of today’s PLCs.
• Sequential Function Chart (SFC)
A method of programming complex control systems at a more highly structured level.
A SFC program is an overview of the control system, in which the basic building blocks
are entire program files. Each program file is created using one of the other types of
programming languages. The SFC approach coordinates large, complicated
programming tasks into smaller, more manageable tasks.

We will use PLC LG and GMWIN 4.0 for its software. PLC LG has many types that were
GLOFA GM1, GM2, GM3, GM4, GM5, GM6, and GM7. In this experiment, we will use
GLOFA GM4 that is shown in Figure 1.

Figure 1. PLC LG GLOFA GM4

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

In this experiment we will use software for PLC LG named GMWIN 4.0. There are two ways
to Addressing in GMWIN : one is to give a name to a data element using an identifier(Variable
by Identifier) and the other is to directly assign a memory address (DirecVariable).
• Variable by Identifier
A variable by identifier should be unique within its program area where the variable
was declared in order to distinguish it from other variables. Example of addressing by
Variable Identifier is shown in Figure 2 :

Figure 2. Variable by Identifier Method

• Direct Variable
A direct variable is expressed as one, which starts with the percent sign (%) followed
by a prefix of the data size and more than one unsigned integer numbers divided by a
period(.). Example of addressing by Direct Variable is shown in Figure 3:

Figure 3. Direct Variable Method

The prefix that used to addressing are shown in Table 1:

Symbol Description
X Bits
B Byte
W Word
D Double Word
L Long Word
M Memory
I Input
Q Output
Table 1. Symbol those were used in order to addressing

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

Every PLC have their way to addressing. In PLC LG, there were some functions and symbol
of basic instruction.
1. Contacts and Coils
‘Contact’ transmits a value to the right horizontal line, which is the result of logical AND
operation of these: the state of left horizontal connection line. Coil stores the state of the left
connection line or the processing result of state transition in the associated BOOL variable.

a. Normally Open Contact

Normally Open is a condition when the contact need to energize to execute an action.

Description : The value of NO Instruction will be “1” when it active and will be “0”
when it does not.

b. Normally Close Contact

Normally Close is condition when the contact need not to energize to execute an action.

Description : The value of NC Instruction will be “0” when it active and will be “1”
when it does not.

c. Normally Open Coil

Normally Open is a condition when the coil need to energize by the contact to activate.

Description : When the value of RLO is “1” then NO coil will be “1” and when RLO
“0” then NO coil will be “0”.

d. Normally Close Coil

Normally Open is a condition when the coil need to energize by the contact to activate.

Description : When the value of RLO is “1” then NO coil will be “0” and when RLO
“0” then NO coil will be “1”.

2. Timer
a. TOF (Timer-Off Delay)
Time off delay is a condition when the coil active if the contact have been pressed and
inactive after the period time.

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

Description : When input value of IN is “1” then output Q is “1” and when IN is “0” then
timer will count until PT value. After the count end then output Q will be “0”. Remember
to write the time, fill in the ‘PT’ by click once and write T#. S.

b. TON(Timer-On Delay)
Time on delay is a condition when the coil active if the contact have been pressed for a
period of time.

Description : When input value of IN is “0” then output Q is “0” and when IN is “1” then
timer will count until PT value. After the count end then output Q will be “1”.
Remember to write the time, fill in the ‘PT’ by click once and write T#. S

3. Counter
a. Counter Up
Counter Up is a function that could counting from zero to a value that have assigned.

Description : When input CU changed from “0” to “1” then CV will increased by 1.
Output of Q will be “1” when CV=PV. Value of Q is “1” until input R is “1”. When Ris
“1” then CV is reset to “0”. Remember to count, fill in the ‘PV’ by click once and write
(Numerical Value).

b. Counter Down
Counter Down is a function that could counting from value that have assigned to zero.

Description : When input LD is “1” then CV will be the same with PV. When CD changed
from “0” to “1” then CV decreased by 1. Output Q will be “1” when CV=0. Value of Q

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

will be ”1” until LD is “1” again. Remember to count, fill in the ‘PV’ by click once and
write (Numerical Value).
Electrical module is provided to make an electrical circuit, activate contact and coil, timer,
counter and many function which needed an electrical supply.
1. Power Supply Module
Electric module that have function as voltage supplier. Red Port (Top) as +24 volt supply
and Black Port (Bottom) as ground (0 V). It is shown in Figure 4.

Figure 4. Power Supply module

2. Switch Module
Electric module that have function as manual input. Red Port (Top) as + 24 volt supply,
Black Port (Bottom) as Ground (0 V), Yellow Port as Com (Reference), Blue Port as
Normally Close Contact, Green Port as Normally Open Contact. It is shown in Figure 5.

Figure 5. Switch module

3. Buzzer and Lamp Module

Electric module that have function as indicator. Red Port (Top) as +24 volt supply, Black
Port (Bottom) as ground (0 V). It is shown in Figure 6.

Figure 6. Buzzer and Lamp module

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

It is necessary to connecting the port module-module and module-PLC safely. Because if there
is a mistake in connecting the port, it may cause damage to equipment and danger safety, an
example of connecting port module-module and module-PLC shown in Figure 7.

Figure 7. Simple Connection of PLC and Electric Module

EXPERIMENT

Configuration of PLC LG with GMWIN 4.0

1. Turn on the Computer and PLC, ensure USB to Serial cable has connected from
computer with PLC LG.
2. Check connection USB to Serial on the computer. Then right click My Computer →
Manage → Device Manager → Ports. It is shown in Figure 8.

Figure 8. Windows display shown how to check USB to Serial connection.

3. Open GMWIN 4.0, choose menu Project → Option → Connection Option. Set RS.232C
on method connection, (com 1 ~ 10) on communication port, and local on depth of
connection. They are shown in Figure 9.

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

Figure 9. Option display to check connection setting.

4. Make a new project. In the Project → New project then rename. In the Select PLC type,
choose GM4 shown in Figure 10.

Figure 10. Menu display to give project name and choosing PLC type

5. In the final step, choose programming language LD (ladder) then click Finish. It is
shown in Figure 11.

Figure 11. Menu display to choose programming language.

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

6. After make the program, choose Online → Connect+Write+Run. If offline word in the
status bar changed to GM4 stop, so the PLC have connected with PC.

EXPERIMENT 1 : Basic Instructions and Logic Circuit

A.Operational Procedure
1. Configure Ladder Diagram for Contacts and Coils as shown in Figure 12. Do not forget
to make the circuit in electrical module.
2. Place each contact (Normally Open and and Normally Close) for NO coil.
3. Write condition of lamp/buzzer when it is depressed and released.

Figure 12. Ladder Diagram of Contacts and Coils Circuit Experiment(NO and NC Coil)

5. Configure Ladder Diagram for AND circuit as shown in Figure 13. Do not forget to
make the circuit in electrical module.
6. Place two NO contact consecutively with a NO coil. Place both of them in same row with
NO coil.
7. Write condition of lamp/buzzer when it is depressed and released.

Figure 13. Ladder Diagram of AND Circuit

8. Configure Ladder Diagram for OR circuit as shown in Figure 14. Do not forget to
make the circuit in electrical module.
9. Place two NO contact consecutively with a NO coil. Place one of them in same row with
NO coil and the other one in second row, connected vertically with first row.
10. Write condition of lamp/buzzer when it’s depressed and released

Figure 14. Ladder Diagram of OR Circuit

B. Experimental Data
All of condition, experience and image that you observe after Contacts and Coils experiment

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

can be written in Table A. Hence, for AND & OR circuit experiment can be written in Table
B.
Lamp Condition
Normally Open Normally Close
Condition Depress
Contact

Release
Table A. Contact and Coils Experimental Data

Contact State
Lamp Condition
Normally Open Normally Open 2
0 0
0 1
AND
1 0
1 1
0 0
0 1
OR
1 0
1 1
Table B. AND & OR circuit experiment

Information : 0 = Released;1 = Depressed

C. Analysis and Experiment Task

1. What is the difference between contacts and coils? How about Normally Open and
Normally Close?
2. Why should we connect COM port with ground? Could we connect with +24 V supply?
3. Explain the functions of each parts of the switch module!

EXPERIMENT 2 : Self Holding Circuit

A. Operational Procedure
1. Configure Ladder Diagram for Self Holding Circuit as shown in Figure 15. Do not forget to
make the circuit in electrical module.
2. Place two NO contact, and one NC contact with a NO coil. Place NO contact in same row
with NC contact, and connect with NO coil. The other NO contact in second row,connected
vertically with first row. Address for this contact is same with NO coil.
3. Write condition of lamp/buzzer when it is depressed and released.

Figure 15. Ladder Diagram of Self Holding Circuit

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

B. Experimental Data
All of condition, experience and image that you observe after Self Holding circuit
experiment, can be written in Table C.

Contact Condition Coil Condition

Normally Open Normally Closed
0 0
1 0
0 0
0 1

Table C. Self Holding circuit experiment

C.Analysis and Experiment Task

1. Why should we put an NC contact in the Self Holding circuit?
2. Make a ladder design of blinking lamp with Self Holding circuit. Explain your design!

EXPERIMENT 3 : Timer and Counter

A. Operational Procedure
1. Configure Ladder Diagram for Timer On Delay as shown in Figure 16. Do not forget
to make the circuit in electrical module.
2. Write condition of lamp/buzzer when the contact is depressed and released!
3. Configure Ladder Diagram for Timer Off Delay as shown in Figure 17. Do not forget
to make the circuit in electrical module.
4. Write condition of lamp/buzzer when the contact is depressed and released!

Figure 16. Ladder Diagram of Timer On Delay

Figure 17. Ladder Diagram of Timer Off Delay

5. Configure Ladder Diagram for Counter Up as shown in Figure 18. Do not forget to
make the circuit in electrical module.
6. Write condition of lamp/buzzer in table!
7. Configure Ladder Diagram for Counter Down as shown in Figure 19. Do not forget

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

to make the circuit in electrical module.

8. Write condition of lamp/buzzer in table!

Figure 18. Ladder Diagram of Counter Up

Figure 19. Ladder Diagram of Counter Down

B. Experimental Data
All of condition, experience and image that you observe after Timer On Delay experiment
can be written in Table D and Timer Off-Delay experiment in Table E. Hence for Counter
Up experiment can be written in Table F and Counter Down experiment in Table G.

Time[Second(s)] Lamp Condition

0
Contact
5

Table D. Timer On Delay Experimental Data

Time[Second(s)] Lamp Condition

0
Contact
5

Table E. Timer Off Delay Experimental Data

Count(s) Lamp Condition

0
Contact
5

Table F. Counter Up Experimental Data

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 Control and Automation Laboratory
Lab AJ 104 & B 105, Electrical Engineering Department, ELECTICS
Sepuluh Nopember Institute of Technology, Surabaya

Count(s) Lamp Condition

0
Contact
5

Table G. Counter Down Experimental Data

C. Analysis and Experiment Task

1. How many variable in the Timer and Counter function? Explain!
2. Could we make two Timer function in a rung? Explain!

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