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PLC Programming Tasks (in class or practice again at

home)

PLC Programming Tasks

Please work through the tasks here to practice the techniques of simple logic combinations in a PLC
ladder program. Make sure you add comments and tag names throughout your programs, so you
can understand them when you refer back later on. Make sure you save your programs with
understandable names.
These tasks are designed to give you a good foundation in PLC programming. You will need to
assess yourself against the requirements for each taks - are you sure that your program operates as
required? What if something unexpected happens? (eg. two pushbutton inputs at once)
The time required for each task may increase as you progress to more difficult problems.

Labelling formats for your ladder programs

Change the final digit to use new values:

Inputs %I0.0
Outputs %Q0.0
Internal memory %M0

Tasks
Use the switches & lights on PLC boards to test your programs for these requirements:
1) A PLC must turn on a fan when a temperature switch (PLC input) closes.
a) Now add a manual bypass run switch and a manual stop switch.
Write a logic expression using AND, OR, NOT etc for this new requirement. How does this relate to
the PLC ladder logic youve designed?
2) Repeat the task above, this time using SET and RESET type outputs.
What effect does the order of operations have? ie. which logic line comes first.
Which order would be safer? Why?
3) What happens if you create two ladder logic rungs with the same output label on each rung, but
with different inputs? Which input becomes more important?
4) The load on a distribution transformer is monitored by a PLC and sensors. There are two
switches which close at 95% and 105% respectively, of the transformers rated maximum load.
a) When the 95% switch closes, an output must be energised to begin load shedding phase 1 and
a cooling fan must be switched on.
b) When the 105% switch closes, another output must be energised to begin load shedding
phase 2 and a warning light must be energised.
5) A warning light must turn on if two temperature switches are in opposite states.
a) Sketch a truth table showing all combinations of the states of the switches and the
corresponding states of the warning light.
b) Now create the ladder program.
6) A motor starts when button 1 is pushed and keeps running until button 2 is pushed.
(Tip Latching the output as an input contact)
7) An old bridge is monitored by a PLC and two load cells (weight sensors). If either of the load
cells close the PLC must turn on red traffic lights to stop any more traffic. If neither of the load cells is
closed, the PLC should turn on the green traffic lights
8) Repeat the task above, this time using SET and RESET type outputs.
9) One part of the coca cola factory requires filling the bottles. Your PLC controls a valve to do the
filling operation (energised output = closed valve). There are PLC inputs to detect that a bottle is in
the correct position and to detect a full level (both are wired to open when the action is complete).
a) Sketch the physical configuration of the system
b) Create a program to meet the requirements above
c) Add master control buttons: ON and OFF, both wired NO.

10) A motor drives a conveyor, dropping gravel on to a truck. The truck weight is monitored by a
digital load cell (on/off). The motor is controlled by a PLC output. There are 3 PLC inputs:
%I0.0 = NO wired start button
%I0.1= NC wired stop button
%I0.2 = NC wired load cell
The motor must stop when either the stop button is pushed (becomes open) or the load cell
activates (becomes open).
The motor starts when the start button is pressed (becomes closed), provided theres no stop
command as above, and continues to run after the start button is released (latched).
11) A PLC controls a motor using two outputs: forward and reverse. There are three PLC inputs
from NO pushbuttons: stop, forward, reverse.
Common sense tells us that the PLC must not let the user activate the forward and reverse outputs
together. Interlocking is required.
a) Create a ladder program which uses the states of the PLC outputs as input contacts (similar to
the latching method used above), to prevent dangerous operation of both outputs.
b) Test it by activating both push-button inputs: forward and reverse. Is there a safe operation?
12) A PLC controls a pump for draining a storm-water tank.
The PLC inputs are one emergency stop button (NC) and two level switches high (80% full) and
low (10% full). Both level switches are wired to close when the water level is equal to or higher than
the switch location.
Steps:
a) Sketch the physical arrangement of the components described above.
b) Sketch a wiring diagram with all components, including a relay to drive the motor. Show the PLC
input/output terminals as numbered boxes. Use 24VDC for the PLC input and output circuits and
230VAC for the pump motor.
c) For each of the following water levels, determine the state of each level switch (open/closed)
i) Completely empty
ii) 25% full
iii) 75% full
iv) 100% full
This will help you to test the functioning of your program.
d) Create a program to use the above information, and the following logic:
The pump is required to switch on only when the water reaches the high-level float switch and run
until the water has dropped below the low-level switch.
13) Modify the above program to allow for the use of two pump motors for draining the tank of
storm-water. Each motor has a PLC output allocated. Only one pump should operate at once and
they must alternate. ie. After pump1 stops, pump2 will turn on next.

Challenge:
14) An elevator operates between two levels of a construction site and is controlled by a PLC.

One PLC output drives the elevator up, another output drives it down.
One output controls the doors, which close when the output is energised and spring open when
the output is de-energised.
Inside the elevator are two NO push-buttons: up and down when pressed, the doors will close
and the elevator will move in the appropriate direction.
There is a limit switch at each level which opens when the elevator is at that location. This will be
the signal to your program to stop the motor.

a) Sketch a flow-chart showing how this system should operate. Assume that the elevator starts
at the low level and show what must happen next. Specify the states of the PLC inputs and outputs
at each stage.
b) Now create your ladder logic program and test it against your flow-chart design
Last modified: Thursday, 5 March 2015, 1:08 PM