Unit 22: Programmable Logic controllers Lab workbook

LABORATORY WORK BOOK

HND Unit -22

PROGRAMMABLE LOGIC CONTROLLERS

Name:
Student Number:
Date:
Year:

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 Unit 22: Programmable Logic controllers Lab workbook

Table of Contents

1. Operating a simple loads using relays, switches and pushbuttons

2. Realization of logic gates using ladder logic

3. Programming Techniques

4. Ladder logic from process control descriptions

5. Mini project

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Unit 22: Programmable Logic controllers Lab workbook

LAB SESSION 01: OPERATING A SIMPLE LOADS USING RELAYS, SWITCHES

AND PUSHBUTTONS
Objectives:-
After successfully completing this laboratory, you should be able to:
 Identify the basic components of the control board.
 Assemble and arrange a simple control board.
 Explain the operation of electromagnetically controlled circuits.
 Operate a simple loads using relays, switches and pushbuttons.

Equipments:-
 3x10A mcb.
 230V(coil), 50Hz, 10A Relay
 Green and red indicator lamp.
 NO and NC pushbuttons.
 ON-OFF switch.
 Toggle switch (1-0-2)
 Flexible wires.
 Single phase power source

Procedure:-

1. Assemble the components of the circuit shown in figure 1 on the control board and
make the required wiring and connections.

2. Once you are finished with the connections, call the instructor to check it for you and
make sure that it is correct.

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Unit 22: Programmable Logic controllers Lab workbook

3. Connect the circuit to the power source and try to change the position of the switch
SW1. What is your observation?

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Unit 22: Programmable Logic controllers Lab workbook

LAB SESSION 02: REALISATION OF LOGIC GATES USING LADDER LOGIC

OBJECTIVE: Familiarize basic logic gates used in Digital Electronics

AIM: Using PLC ladder logic, verify the truth table for the logic gates given below.

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Unit 22: Programmable Logic controllers Lab workbook

LAB SESSION 03: PROGRAMMING TECHNIQUES

OBJECTIVE: Familiarize Programmable logic programming techniques

AIM: Apply programming techniques to different applications given.

Scenario: Julphar Pharmaceutical Company uses Transistor-Transistor- Logic system to

automate their production. The entire system uses hardwired logic and obsolete HNL
semiconductor ICs to implement the logic. Recently company decided to replace the
existing logic system with modern modular PLCs. Your company, LAC has taken the
contract of this outsourced work. You are provided with the following tasks to prove your
knowledge.

Convert the word description to

1. Gate logic 3. PLC ladder logic

2. Functional block diagram 4. Statement list

You may also use an appropriate software to support your results.

Task 1:

The bottles to which tablets are to be filled are kept on a conveyor belt. You are asked to
program the PLC control of conveyor belt in such a way that the Conveyor C is to run
when any one of the four inputs is ON. It is to stop when any one of the other four inputs
is ON.

Task 2:

A motor control circuit has two start and two stop buttons. When a start button is
depressed, the motor runs. By sealing it, it continues to run even when the start button is
released. Either stop buttons stop the motor when pressed.

Task 3:

A process fan is to run only when all the below conditions are met.

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Unit 22: Programmable Logic controllers Lab workbook

 Input 1 is OFF
 Input 2 is ON or input 3 is ON or both are ON
 Input 5 and 6, both are ON
 One or more of the inputs 7, 8 or 9 is ON.

Task 4:

Assume PLC is monitoring five tanks of liquid and must give a warning to the operator
when any three of them are empty.

Task 5:
Make a ladder diagram for 4 bit Binary to BCD conversion. This will be useful to display
the number of bottles dispensed in a box as the maximum number of bottles allowed per
box is 16.

Task 6:

A feeder drops material on the conveyor which sends material for further process through
one more conveyor. Conveyor must start automatically when material is dropped on it.
Feeder has a motor mounted to feed material on conveyor belts. Load cells are installed
at the bottom of conveyor belts to detect if material is present on the conveyor belt. When
material falls on conveyor belt 1, motor 1 should start, and when material in present on
conveyor belt 2, motor 2 remain ON.

Fig: Load cells and conveyor belts

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Unit 22: Programmable Logic controllers Lab workbook

LAB SESSION 04: LADDER LOGIC FROM PROCESS CONTROL DESCRIPTIONS

AIM: To develop ladder logic from given process control descriptions

SCENARIO: You got selected as Automation Engineer in a company that takes

outsourcing tasks from different industries. Before finalizing your appointment the process
control team wants to assess your level of knowledge and understanding in PLC systems.
You are given the following tasks and asked to convert the word descriptions to
appropriate ladder logic. You may use an appropriate software package to support your
results.

Task 1: Automation of heating and transferring

When the START button is pressed and released, the valve 1 (V1) opens for 5 seconds,
so the water pass through the valve to the heating tank. And when the water level reaches
the float switch (FS), the valve should close and heating must begin and continue for 10
seconds. When the temperature reach the required level the thermostat disconnects the
heater and opens valve 2 (V2) for 5 seconds then the alarm bell is activated for 3 seconds.
You may use three timers for Valve1, Valve 2 and Alarm. Refer the figure shown below.

Fig: Heating of water from one tank and filling it in another tank

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TASK 2: Drive two motors with interlocking

Two Motors are running in a sequence one by one for a particular time. If the start button
is pressed Motors run in sequence such that 1st Motor stays ON for 5secs and then 2nd
Motor is turned ON and stays ON for 5secs. And the cycle is repeated until it is interrupted.
While motors are running in the sequence, if one motor is running and the button of other
motor is pressed, then the running Motor should stop and the other motor should run.
Implement this logic in PLC using Ladder Diagram programming language.

TASK 3: Objects moving on a conveyor belt

Objects are on conveyor belt 1. When an empty box is detected, conveyor belt-1 starts
and 5pcs are packed in a box. When box is filled, it is carried to the storage area via
conveyor belt 2. Implement automation of this process in PLC using Ladder Diagram
programming language.

Fig: conveyor belts

TASK 4: Water Level Controller

Liquid level control is a basic and necessary process for all the process industry. Here
the level of liquid is to be maintained inside the tank to a specific height. Here there is a

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water reservoir from which the water needs to be pumped out to the process tank. In the
process tank there are two sensors connected around the edges of the tank according to
the required heights i.e., one sensor is connected at the near bottom end of the tank
called as lower level sensor and another one on the near top edge of the tank called as
higher level tank. To let the water out of the tank there is a pipe connected at the bottom
of the tank with a valve. This valve is to be used by user for the process application. The
level sensor is a magnetic sensor and when the liquid level is above the high level sensor
a HL (high level) signal is send to the PLC. When the liquid level goes down the low level
sensor LL (low level) signal is send to the PLC. The PLC checks the signals send by
these sensors through its input port and give the proper signals through its output port as
per the ladder logic program. Sequence of process control actions done by the PLC:

1. When the water level in the tank is less than the lower level then the sensor senses
and turns the motor on to fill the tank.

2. Then the tank is filled up until it reaches the higher level where the higher level
sensor senses and makes the motor off and filling of water stops.

Figure: Block level of Water level set up

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Unit 22: Programmable Logic controllers Lab workbook

LAB SESSION 05: MINI PROJECT

A project topic will be agreed between student and tutor, requiring a PLC automation.
Students will design, build and demonstrate a PLC ladder logic to satisfy the project need.
Example topics are traffic control system, elevator logic control etc. It will be important to
avoid both the trivial and the over-complex project topic.

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Unit 22: Programmable Logic controllers Lab workbook

TRAFFIC LIGHT CONTROL USING PLC

Scenario: In Sharjah Al Khan area there exists a four-way traffic round-about. Last year
study by the traffic control departments shows that the number of accidents in this round-
about is increasing every year by 30%. Recently the volume of pedestrians also increased
substantially due to a hypermarket opened nearby. In order to reduce traffic congestion
and fatal accidents, Sharjah Traffic Control department decided to implement a Traffic
Signal Control System using relay logic. You have been assigned with the task of
programming the system using logic functions based on relay ladder logic making use of
sequencer and timers.

Process description

In the four way round-about:

 Illumination of the green light for 10 sec allows traffic to proceed in the direction
denoted.
 Illumination of yellow light for 5 sec denoting, if safe to do so, prepare to stop short
of the intersection and
 Illumination of red signal for 10 sec prohibits any traffic from proceeding.

Discuss the enhancements that can be made to the proposed model so as to make the
traffic control system better and useful.

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Unit 22: Programmable Logic controllers Lab workbook

LIFT CONTROL SYSTEM

Scenario:
You have been appointed as an automation engineer in a branded elevator company in
Ajman. Recently the company won a contract to install an elevator (lift) for a two storeyed
(Ground, First and Second Floors) building in Sharjah. You have been assigned the task
of writing the program for the PLC to control the elevator.
Process description:
I1, I2, I3 - Requisition switch.
I4, I5, I6 - Sensor Inputs.
Q2, Q3, Q4, Q5 - Output for stepper motor.
1. I1, I2, I3 are requisition switches I4, I5, I6 are the sensor placed in each floor. The other
coils used in the program are the set coil, reset coil, positive transition coil, negative
transition coil are in memory location.
2. The timer functions are used to produce the required time delay.
3. Bit sequence functions used to drive the stepper motor.
4. Whenever the requirement switch I1, is pressed the set coil M1 is energized and bit
sequence outputs are enabled then the stepper motor rotates.
5. When the motor reaches the respective floor, the switch I4 gets closed and energizes
both positive transition coil & negative transition coil.
6. The positive transition coil energizes one more set coil, which is used to enable the
timer.
7. This is used to give time delay for the lift in each floor.
8. The negative transition coil, which was energized, is used to reset the requisition.
9. The above functions are repeated in each floor.

Conditions for rotation of Motor:

1. Consider the lift is in ground floor, when the requisition is given from first floor or second
floor the motor has to move forward.
2. If the lift is in top floor then it has to move in the reverse direction.
3. If the lift is in middle floor then according to the requisition, lift will move in forward or
reverse direction.

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Unit 22: Programmable Logic controllers Lab workbook

OPERATE CONVEYOR BELTS AND SEVEN SEGMENT DISPLAY

Scenario: Julphar Pharmaceutical Company uses Transistor-Transistor- Logic system

to automate their production. The entire system uses hardwired logic and obsolete HNL
semiconductor ICs to implement the logic. Recently company decided to replace the
existing logic system with modern modular PLCs.

Problem description:
Filled bottles are on conveyor belt 1. When an empty box is detected, conveyor belt-1
starts and 15 bottles are packed in a box. A counter is used to count the number of bottles
falling into the box and the count is displayed using two seven segment displays. The
counter is automatically reset after filling 15 bottles in a box. When box is filled, it is carried
to the storage area via conveyor belt 2. The whole process is repeated when another
empty box is detected.

Table: Truth table of seven segment display

Implement automation of this process in PLC using Ladder Diagram programming

language

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Unit 22: Programmable Logic controllers Lab workbook

Reference

Functional Block Diagram for logic gates:

1. & --- AND GATE

2. >=1 --- OR GATE
3. 1 --- NOT GATE
4. & and “not at output” --- NAND GATE
5. >=1 and “not at output” ---- NOR GATE
6. =1 --- XOR GATE

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