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SIMAT-25 Control object simulator for PLCs

Andrzej_Tomaszewski 3645 17

TL;DR

  • SIMAT-25 is a compact PLC control-object simulator for 24V DC systems, built to test Siemens LOGO! programs on a workbench before final installation.
  • It combines DO and DI blocks, selectable 0-10V/0-20mA analog outputs, PT100 resistance simulators, voltmeter/ammeter inputs, and a pulse generator on one front panel.
  • The DO outputs use 1k/1W series resistors, while the AO ranges intentionally overdrive to 10.5V and 21mA to reduce damage from wiring mistakes.
  • The pulse generator spans roughly 0.3Hz to 5kHz, and the PT100 simulators cover 91Ω–191Ω or up to 291Ω with RTD1 and RTD2 bridged.
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  • SIMAT-25 signal simulator on a wooden table with displays and switches. .

    Welcome.

    Some time ago I started my adventure with PLC programming. To start with, I found that Siemens LOGO! was sufficient. Creating a program in FBD language is quite transparent but, as you know, the created program must somehow affect reality. It is a good idea to test the written programme on a workbench in order to identify and repair potential errors before the whole assembly is assembled in the final location. This involves simulating certain states to the controller at its inputs and visualising states at its outputs to determine if the application is functioning as expected. I found that combining with switches, lights, potentiometers, etc. was not very convenient. I found signal simulators dedicated to LOGO! on the web, but for various reasons I refrained from buying one. I decided that I would design and make my own simulator. It was to be a compact design providing all the basic signals for the PLC under test. And so the device I called SIMAT-25 was created, and many factors determined this name.

    The complete device is shown in the photograph below.
    SIMAT-25 simulator casing with diagram on top .

    The case is a Z33 model from a well-known company in the industry. Dimensions: height 46.0 mm, width 140.0 mm, length 190.0 mm. On the lid there is a plate showing in simplified form the idea of the construction of the individual signal tracks. For those in the trade, this information contains all the necessary data. The lid protects the panel components from mechanical damage. When the lid is removed, the panel is visible.

    SIMAT-25 signal simulator for PLC environment. .

    On the side of the case there is a DC 2.5/5.5 socket for connecting a 24VDC power supply ("plus" inside).

    SIMAT-25 controller with knobs and switches on a wooden table. .

    The simulator is designed for PLCs supplied with 24V DC. The power supply is connected to the ARK connectors with the description +24V DC and GND. The GND terminal is common to the power supply and the simulated signals. In this way, the power supply for the simulator can be taken from the system in which the PLC under test is running. It is also convenient to use an additional 24VDC power supply and connect it to the DC 2.5/5.5 connector on the side of the housing. In this way, the controller under test can be powered by wires plugged into the ARK +24VDC and GND connectors and in this way it is the simulator that powers the controller under test. This way of power supply suits me so far.
    The main electronics board of the simulator is also the front panel. All electronic components are smd type and are located on the underside of the board. The main board itself has protection against reverse connection of the supply voltage, while the corresponding pins of the DC supply connector and the ARK +24VDC and GND terminals are directly connected to each other.
    Correct connection of the power supply is indicated by the illumination of the red LED with the description PWR.
    Sets of potentiometers, switches, LEDs, displays are given names identifying the supported function/signal. The corresponding names are also found on the ARK screw terminals, so it is immediately clear which connector is the signal of interest.

    Signals and their characteristics:

    DO1-DO8: three-state digital output: logic 1 "High" state (short-circuits to plus supply), logic 0 "Low" state (short-circuits to GND) and high impedance state (output "hangs in the air"). There is a 1k/1W resistor in series at the output of each DO signal. This protects both the simulator and the PLC from connection errors (short circuit). A value of 1k is sufficient for a correct reading via the DI input of the PLC.

    DI1-DI8: digital input. LEDs with series resistors. The current drawn by one input for 24V DC is approximately 4.5 mA.

    AO1-AO4: analogue outputs 0-10V and 0-20mA selectable by switches. With the potentiometer position at 100%, the voltage is equal to 10.5V and the current 21mA. This slight overdrive has been implemented intentionally. The minimum load resistance of the 0-10V output is 2kOhm. Below this value, the output starts to limit the output current. This ensures that when the 0-10V output is mistakenly connected to the 0/4-20mA input of the controller under test, it will not damage this input. The maximum load resistance of the 0-20mA output is 500Ohm. The open loop voltage is 11.8V. Thus, mistakenly connecting the 0-20mA output to the 0-10V input of the controller under test will not damage this input.

    RTD1: PT100 sensor simulator. A 10-turn precision potentiometer with a value of 100Ohm. Connected in series internally with a 91Ohm precision resistor. The whole provides a resistance range of 91Ohm-191Ohm which corresponds to a temperature range of -23 to + 245 stC. Per revolution, there is a change in simulated temperature of approximately 26stC

    RTD2: same operation as RTD1 but in this block it is possible to eliminate an additional series resistor by using a switch. The Rs position indicates a 91Ohm resistor in series and the Rs crossed out position indicates the bypassing of this resistor. This option offers two advantages:
    (a) this allows very low negative temperatures to be simulated
    (b) it is possible to connect two RTD1 and RTD2 blocks in series using an external bridge and create a single circuit to simulate a PT100 sensor with a maximum resistance value of 291Ohm while maintaining continuous control with two potentiometers. This corresponds to a temperature of approximately 530stC.

    AI1, AI2: these are voltmeters/ammeters for visualising the status of the AO output of the controller under test. In the 0-10V position the circuit measures the voltage, the value is displayed in volts. The input resistance is several hundred kilohms. In the 0-20mA position, the circuit is an ammeter. The displayed value is in milliamps. The input resistance is then 100Ohm.

    PO: rectangular wave generator. It is useful for pulse counting circuits. The amplitude of the waveform is approximately 22Vp-p. An LED labelled "Output" is connected to the generator output and flashes in sync with the output signal. There is a 1k/1W resistor in series with the generator output. This protects both the simulator and the PLC from connection errors (short circuit). A value of 1k is sufficient for a correct reading by the PLC input. The operating modes are selected by a 5-position rotary switch. Positions FR1-FR4 are the ranges of the frequency of the generated signal fluently varied by a potentiometer within the range.

    OFF- generator turned off. Low state at the PO output.

    FR1- Potentiometer position 0%- frequency f= 0.3Hz, duration of high state TH= 100ms, duration of low state TL= 3200ms.
    Potentiometer position 100%- f= 5Hz, TH= 100ms, TL= 100ms.

    FR2- Potentiometer position 0%- frequency f= 3Hz, duration of high state TH= 10ms, duration of low state TL= 320ms.
    Potentiometer position 100%- f= 50Hz, TH= 10ms, TL= 10ms.

    FR3- Potentiometer position 0%- frequency f= 30Hz, high state duration TH= 1ms, low state duration TL= 32ms.
    Potentiometer position 100%- f= 500Hz, TH= 1ms, TL= 1ms.

    FR4- Potentiometer position 0%- frequency f= 300Hz, high state duration TH= 0.1ms, low state duration TL= 3.2ms.
    Potentiometer position 100%- f= 5kHz, TH= 0.1ms, TL= 0.1ms.

    The frequency ranges "overlap" providing access to any value in the range of approximately 0.3Hz to approximately 5kHz.

    I made the board design in OSHWLAB, manufacturing with component assembly in JLCPCB.

    This is what the TOP side of the board looks like
    Front panel of the SIMAT-25 simulator with printed descriptions of inputs and outputs. .

    And this is the BOTTOM side
    Top view of the PLC simulator main board.

    TOP side after installation of potentiometers, switches etc.
    SIMAT-25 PLC simulator with various knobs and displays on the control panel.

    And the BOTTOM side after making the connections. Spaghetti but unfortunately unavoidable.
    Signal simulator circuit board with numerous components and connections. .

    Greetings! :) .

    Cool? Ranking DIY
    About Author
    Andrzej_Tomaszewski
    Level 13  
    Offline 
    Andrzej_Tomaszewski wrote 270 posts with rating 335, helped 2 times. Been with us since 2005 year.
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  • #2 21451639
    TechEkspert
    Editor  
    Posts: 7047
    Help: 16
    Rate: 5457
    WOW! super for PLC testing. Such a little HIL ;) or at least a convenient hardware parameter setter.

    Maybe there would be a chance for an article on FBD, what are your impressions and how to get started.

    Ew. maybe you would like to record a podcast together about PLC/FBD :) .
    https://www.elektroda.pl/rtvforum/audio.php
  • #3 21451727
    Andrzej_Tomaszewski
    Level 13  
    Posts: 270
    Help: 2
    Rate: 335
    >>21451639 .
    Thank you.
    FBD reminds me very much of the time some 20 years back when I used to make schematics on a piece of paper, "on my knee" and FBD blocks were logic gates, flip-flops, timers, counters, registers based on the popular TTL 74 series. Only then it took a lot of time to make an uncomplicated circuit, not to mention the lack of flexibility in terms of modifications. Now it's a fairy tale. I draw the schematic, modify as I want and see how it works straight away. Thanks for the podcast/article suggestion. When I feel strong enough on the subject I'll get back to you:) .
    Regards
  • #4 21451791
    efi222
    Level 21  
    Posts: 655
    Help: 12
    Rate: 1057
    A beautifully crafted device.
    I was reminded of when I started working as an automation technician. Logic systems were built then in the German pneumatic system DRELOBA.
    Distributed logic in EX zones.
    Such a moment of nostalgia :) .
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  • #5 21451860
    elukam
    Level 16  
    Posts: 325
    Help: 7
    Rate: 118
    I make such a thing for each non-unit manufactured separately. It makes setup and basic testing very easy. However, even such a dedicated tester, even with dedicated logic and analysis of selected protocols sewn in, works only in a basic way. For example, if you need specific signal values, you still need to use a professional class referencing device or referencing devices. Usually, a simulated object to be controlled is also needed and, in this case, "potentiometer and LED" logic is no longer sufficient, the properties of the object need to be accurately calculated and reproduced in the circuit, and this must work without contact in real time.
    If the author is satisfied with such a helper, then ok, but I would like to point out that it is not worthwhile to solder the cheapest Chinese connectors, because at this stage you can already become disgusted with the use of the tool.
    I would also add at least a basic integration facility with inertia, so that the energy invested is not wasted too much.
  • #6 21451954
    Andrzej_Tomaszewski
    Level 13  
    Posts: 270
    Help: 2
    Rate: 335
    elukam wrote:
    I make such a thing for myself for each non-unit manufactured separately.
    .
    Then please insert a photo of your design, at least one of what I'm guessing are many different pieces. Just for comparison.

    Andrzej_Tomaszewski wrote:
    I decided that I would design and make my own simulator. It was to be a compact design providing all the basic signals for the PLC under test.
    .
    This was the intention of this circuit and will remain so. It was intended to provide basic I/O signals for the purpose of testing a utility program for a PLC, where potentiometers, LEDs and switches are quite sufficient. For simple applications we use simple tools, for complex ones we use complex tools.
  • #7 21451977
    gulson
    System Administrator  
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    Rate: 5984
    Amazingly this has come out. If I had seen it like that for the first time I would have thought it was factory equipment from some well known manufacturer ;) .
    Thanks for the presentations! I'll send something small to the Parcel Post.
  • #8 21452089
    Andrzej_Tomaszewski
    Level 13  
    Posts: 270
    Help: 2
    Rate: 335
    Thank you :) .
  • #9 21452656
    elukam
    Level 16  
    Posts: 325
    Help: 7
    Rate: 118
    Andrzej_Tomaszewski wrote:
    Yes for comparison.
    I don't photograph and by no means make my work public. But here I have an example of such a tester from 17 years ago, a photo taken as you might guess for a different reason :) I chose one on which you can see most of the panel surface.
    The tester is what is needed. Universal testers do not work in my opinion.
    Child in a green shirt operating a control panel with buttons and knobs. .
  • #10 21452694
    Andrzej_Tomaszewski
    Level 13  
    Posts: 270
    Help: 2
    Rate: 335
    >>21452656 .
    Thank you for the photo.

    elukam wrote:
    Test is what is needed.
    - exactly right.

    Greetings
  • #11 21452937
    pikarel
    Level 39  
    Posts: 4960
    Help: 407
    Rate: 1821
    Instead of buying a tester - you made your own. Already a huge plus for just making one, another for the design and implementation at a high level. Everything in a pile, in one place.
    From the description I deduce that you added your own improvements to what was available "for a piniondze" :) .

    If the simulator is used even once - it has already served its purpose, but it follows that you are "in the subject" and will use it more than once.
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  • #12 21452980
    Andrzej_Tomaszewski
    Level 13  
    Posts: 270
    Help: 2
    Rate: 335
    >>21452937 .
    You put it very aptly. It was just supposed to be everything in a pile and in one place. What was available for sale did not meet my expectations, besides the price was too high in relation to the possibilities of the offered product, I mean dedicated simulators for LOGO! and S7-1200. Thank you for appreciating my work. Best regards to you :) .
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  • #13 21457708
    electro
    Level 18  
    Posts: 487
    Help: 9
    Rate: 106
    It looks great! But when fully assembled, the inside becomes a visual mess; if the paths were routed so that there was no need for a spider web of wires, just the shortest possible wires, it would be even better.
  • #14 21457973
    Andrzej_Tomaszewski
    Level 13  
    Posts: 270
    Help: 2
    Rate: 335
    >>21457708 .
    Thank you:) Yes, it looks quite chaotic, but according to the design :) Your idea to locate the soldering points as close as possible to the switches which would allow the use of short wires I also analysed during the design. And unfortunately, because of the path-free area on the PCB that has to be provided for switches, potentiometers, displays etc. there is not enough space for routing further paths. Nevertheless, from the point of view of soldering the wires, it is the same job regardless of the length of the wires. Aesthetics suffer, of course, but ultimately the wires are well hidden. The most important thing is the solidity of the connections and the insulation of each other.
    Regards
  • #15 21460607
    goodbay
    Level 12  
    Posts: 28
    Rate: 3
    It looks great in person. Will definitely be useful for learning.
  • #16 21481660
    Andrzej_Tomaszewski
    Level 13  
    Posts: 270
    Help: 2
    Rate: 335
    Welcome,

    I have prepared a video presentation of my simulator. The first 10 minutes is a discussion of the features of the device which I have already presented in the first post. From 10:35 I present some simple practical examples using all the capabilities of the simulator. I encourage you to watch the material.

    Regards



    .
  • #17 21481784
    TechEkspert
    Editor  
    Posts: 7047
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    Rate: 5457
    The video looks professional as does the design.
    What microphone did you use?
    Sometimes it's useful to use additional stage lighting.
  • #18 21481797
    Andrzej_Tomaszewski
    Level 13  
    Posts: 270
    Help: 2
    Rate: 335
    Thank you, I recorded the whole thing with a Samsung Galaxy S23. Yes, the lighting is poor and for the future I will try to refine this. Regards
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Topic summary

✨ The discussion revolves around the design and implementation of a custom control object simulator for PLCs, specifically for Siemens LOGO! and S7-1200 models. The author shares their experience in PLC programming and the challenges faced when testing programs using physical components like switches and lights. They opted to create a compact simulator to facilitate input signal simulation and output state visualization, enhancing the testing process. Responses highlight the nostalgia of early automation work, the importance of quality in component selection, and the effectiveness of the simulator for educational purposes. A video presentation of the simulator was also shared, showcasing its features and practical applications.
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FAQ

TL;DR: With 8 DO, 8 DI and 4 AO, SIMAT-25 gives PLC learners and integrators a compact 24V DC bench tester before field installation. One reviewer called it "a little HIL" because it can inject, display and measure the basic signals needed to verify LOGO! or similar PLC logic safely on the bench. [#21451523]

Why it matters: It reduces wiring improvisation with loose switches, lamps and potentiometers, so you can find logic and I/O mistakes before commissioning.

Approach Best use Concrete scope from the thread
SIMAT-25 universal bench simulator Learning, utility programs, pre-install checks 24V DC, 8 three-state DO, 8 DI, 4 AO, 2 AI, 2 RTD, pulse output
Dedicated tester for one machine Commissioning one specific device Can include dedicated logic, protocol analysis and object-specific behavior
Commercial dedicated simulators Quick purchase option Author rejected them because price and features did not meet expectations

Key insight: SIMAT-25 is not a full physical plant model. It is a compact, practical signal source and indicator for fast bench testing of common PLC inputs and outputs.

Quick Facts

  • The simulator targets 24V DC PLCs and accepts power through a DC 2.5/5.5 jack or ARK +24VDC/GND terminals; the DC jack uses plus inside. [#21451523]
  • The front-panel PCB fits a Z33 enclosure with dimensions 46.0 × 140.0 × 190.0 mm, keeping switches, displays and terminals in one compact box. [#21451523]
  • AO1-AO4 switch between 0-10V and 0-20mA; at 100% setting they reach about 10.5V or 21mA to give slight intentional overrange. [#21451523]
  • RTD1 simulates 91-191Ω, which corresponds to about -23°C to +245°C for PT100 testing; one potentiometer turn changes temperature by about 26°C. [#21451523]
  • The PO pulse generator covers roughly 0.3Hz to 5kHz across ranges FR1-FR4, with overlapping bands for easier pulse-count input testing. [#21451523]

How does the SIMAT-25 simulator help with bench testing Siemens LOGO! and other 24V DC PLC programs before final installation?

It gives a compact bench tool that can both force input conditions and show output states before final assembly. The author built it after finding loose switches, lights and potentiometers inconvenient for testing LOGO! programs. SIMAT-25 lets you simulate digital, analog, RTD and pulse signals on the workbench, then verify whether the PLC application behaves as expected before installation in the real system. [#21451523]

What signals and functions are available in the SIMAT-25 PLC simulator, including DO, DI, AO, AI, RTD and pulse output blocks?

SIMAT-25 provides 8 digital outputs, 8 digital inputs, 4 analog outputs, 2 analog measurement inputs, 2 RTD simulators and 1 pulse generator. DO1-DO8 are three-state outputs, DI1-DI8 are LED-indicated inputs, AO1-AO4 switch between 0-10V and 0-20mA, AI1-AI2 read volts or milliamps, RTD1-RTD2 simulate PT100 resistance, and PO generates rectangular pulses from about 0.3Hz to 5kHz. [#21451523]

How do the three-state DO1-DO8 outputs work in SIMAT-25, and why is a 1k/1W series resistor used on each output?

Each DO output can force logic High, logic Low or high impedance. High shorts to the supply positive, Low shorts to GND, and high impedance leaves the line floating. A 1k/1W resistor sits in series with every output to limit fault current during wiring mistakes or short circuits. The author states that 1k still allows correct reading by a PLC digital input. [#21451523]

What is FBD in PLC programming, and why is it considered an easy way to start with Siemens LOGO! controllers?

"FBD is a PLC programming language that builds control logic from connected function blocks, making the signal flow visible and easy to modify." The author says Siemens LOGO! was enough to start with and that creating a program in FBD is transparent. He compares FBD to drawing old TTL 74 logic with gates, timers, counters and flip-flops, but with far faster changes and testing. [#21451727]

What is HIL testing, and in what sense can a compact PLC simulator like SIMAT-25 be treated as a small HIL tool?

"HIL is a hardware-in-the-loop test method that connects a real controller to simulated signals or object behavior, so the control program can be checked without the final machine." A forum reply called SIMAT-25 “a little HIL” because it can inject hardware-like input states and let users observe PLC reactions. It is a compact HIL-style helper for basic I/O verification, not a full real-time plant model. [#21451639]

How can I power a 24V DC PLC from the SIMAT-25 using the DC 2.5/5.5 jack and the ARK +24VDC/GND terminals?

You can feed 24V DC into the SIMAT-25 through the side DC 2.5/5.5 jack, then pass that supply to the tested PLC from the ARK +24VDC and GND terminals. The simulator shares GND between its own electronics and the simulated signals. 1. Connect a 24V DC supply to the side jack. 2. Confirm the red PWR LED turns on. 3. Wire the PLC power input to the ARK +24VDC/GND terminals. [#21451523]

Why were the 0-10V and 0-20mA analogue outputs in SIMAT-25 designed with slight overrange and current or voltage limiting protection?

They were designed to survive common miswiring and still test the edge of PLC analog input ranges. At full scale, the outputs reach about 10.5V or 21mA on purpose. The 0-10V output limits current below a 2kΩ load, which helps prevent damage if it is connected to a current input. The 0-20mA output allows up to 500Ω load and has 11.8V open-circuit voltage, so a mistaken connection to a 0-10V input should not damage it. [#21451523]

How do the AI1 and AI2 measurement inputs work in voltage mode and current mode, and what input resistance do they present to the tested PLC output?

AI1 and AI2 let the simulator visualize the tested PLC analog output as either volts or milliamps. In 0-10V mode, the circuit works as a voltmeter and shows the value in volts, with input resistance of several hundred kilohms. In 0-20mA mode, it works as an ammeter and shows milliamps, with input resistance of 100Ω. That makes them useful as built-in readback channels for AO testing. [#21451523]

What is a PT100 sensor simulator, and how do RTD1 and RTD2 in SIMAT-25 reproduce temperature using a potentiometer and precision resistor?

"A PT100 sensor simulator is a resistance source that imitates a platinum RTD, reproducing temperature by presenting the ohmic value a PLC analog input expects from a PT100 probe." RTD1 uses a 10-turn 100Ω precision potentiometer in series with a 91Ω precision resistor. That gives 91-191Ω, which the author maps to about -23°C to +245°C. RTD2 works the same way, but adds a switch to bypass the 91Ω series resistor. [#21451523]

How can RTD1 and RTD2 be combined to simulate a wider PT100 temperature range up to about 530°C?

You can connect RTD1 and RTD2 in series with an external bridge and disable the extra series resistor in RTD2 when needed. In that configuration, the combined simulator can reach about 291Ω maximum resistance. The author states that this corresponds to approximately 530°C for PT100 simulation, while still allowing continuous adjustment with two potentiometers instead of fixed resistor steps. [#21451523]

What frequency and pulse-width ranges does the PO rectangular wave generator cover, and how can it be used for PLC pulse counting tests?

The PO block generates rectangular pulses from about 0.3Hz to 5kHz across four overlapping ranges. FR1 spans about 0.3Hz to 5Hz with 100ms high pulses, FR2 spans 3Hz to 50Hz with 10ms highs, FR3 spans 30Hz to 500Hz with 1ms highs, and FR4 spans 300Hz to 5kHz with 0.1ms highs. That makes it useful for checking pulse counters, high-speed input behavior and timing thresholds in PLC programs. [#21451523]

Why does the inside of the assembled simulator use many wire connections instead of routing everything on the PCB, and what layout limitations caused that?

The wiring harness exists because the component-filled panel leaves too little routing space on the PCB. The author says switches, potentiometers, displays and other panel parts require track-free areas, which prevents full routing of all connections. He considered placing solder points closer to switches for shorter wires, but there still was not enough room for additional traces. The result looks chaotic, yet the wires remain hidden and the electrical goal stays intact. [#21457973]

Universal PLC tester vs dedicated tester for one machine: which approach is better for commissioning, setup and basic diagnostics?

Both approaches are useful, but they solve different problems. One commenter said a dedicated tester for each separately manufactured machine makes setup and basic testing easier and can include custom logic or protocol analysis. The author answered that SIMAT-25 was intentionally built as a compact universal source of basic I/O signals for utility PLC programs, where switches, LEDs and potentiometers are enough. For simple applications, the thread clearly favors simple tools. [#21451954]

How can I design and manufacture a custom PLC signal simulator using OSHWLAB for PCB design and JLCPCB for assembly?

You can follow the same workflow used for SIMAT-25: design the PCB in OSHWLAB, then order fabrication and component assembly from JLCPCB. The author made the main electronics board as both the control PCB and front panel, with all electronic parts in SMD form on the underside. He then added panel components such as potentiometers, switches and displays, and completed the remaining internal wire connections by hand. [#21451523]

What should I pay attention to when choosing connectors, load limits and protection features in a DIY PLC simulator for 24V automation systems?

Choose robust connectors and define electrical limits before you build. One commenter warned that using the cheapest connectors can make the tool unpleasant to use. The thread also shows why protection matters: SIMAT-25 includes reverse-polarity protection on the main board, 1k/1W series resistors on digital outputs and the pulse output, a 2kΩ minimum load guideline for 0-10V mode, and a 500Ω maximum load for 0-20mA mode. Those limits reduce damage from common wiring errors. [#21451860]
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