PROJECT SEMESTER REPORT

Undertaken at
ThinkNEXT Technologies Pvt. Ltd.
Mohali, Punjab

on

PLC(PROGRAMMABLE LOGIC CONTROLLER)

Submitted by
Abhishek Kumar

Under the Guidance of

Mr. Deepak Kumar

2018
Electrical Engineering Department
RIMT-INSTITUTE OF ENGG. & TECHNOLOGY
MANDI-GOBINDGARH, PUNJAB.
 ACKNOWLEDGEMENT

I would like to convey my sincere thanks to Prof. MS Gill (HOD) Electrical Dept.
RIMT IET, Mandi Gobindgarh, for giving me such a wonderful opportunity to do
enhance my skills through this training.

I would like to express my deep sense of gratitude, indebtedness to Mr. Manjit Verma
(Lecturer) Electrical Dept. and all the faculty members for their guidance, ever inspiring
help, affectionate encouragement & motivation. They have been a great source of
inspiration for me. I’ve been receiving valuable suggestions from them.

I would like to express my deep sense of gratitude, indebtedness to Mr. Deepak Kumar
for his guidance, ever inspiring help, affectionate encouragement & motivation during
my training. I had been receiving valuable suggestions from him.

No words are sufficient to express my gratitude to colleagues for their exemplary

patience, understanding, co-operation & for creating congenial environment to carry out
this work.
 ABSTRACT

Programmable logic controllers are the most widely used electronic devices in the
control of production and assembly process in most automated factories due to its
simplicity and versatility.
A programmable logic controller (PLC) is a user-friendly, microprocessor-based,
specialized computer, carrying out control functions of many types and levels of
complexity in industrial applications.
I got to know about the various components like Relay, Contactor, Various types of
switches & power supply.
I got to know about the PLC, its working, advantages, disadvantages & its Applications.
Various softwares were used for programming the PLC ie. WPLSoft, LADSIM &
LogixPro that are listed in the report.
 1) INTRODUCTION

The development of microprocessors brought a great revolution in the field of computing.

Microprocessors form the Central Processing Unit (CPU) of a computer that is capable of
performing arithmetic and logical functions defined by a given program. The CPU receives
the data from the input devices like the keyboard and the mouse, in the form of binary signals
and stores the data for further processing. It performs the arithmetic and logical operations on
the input data in accordance with the previously stored instructions (programs), and delivers
the results to the user via the output devices like the monitor and the printer.

Along with the development of the microprocessors, Control Engineering has also evolved
with time. In the past humans was the principle method of controlling a system. Later
electrical control was introduced where it was mainly based on relays. These relays allow
power to be switched on and off without a mechanical switch. They were used to make the
simplest Logical and Control Decisions. The recent development of the low cost computer
has brought forth the recent technological miracle the Programmable Logic Controllers
(PLC).

The advent of the PLC began in the 1970’s and since then has begun the most common
choice for the control operations.

Early machines were mainly controlled by mechanical means such as cams, levers, gears and
other basic mechanical devices. As complexity grew so did the need for a sophisticated
control system. So the electrical relays came into play. These elements were wired as
required to provide control logic necessary for the particular type of machine operation. This
was an acceptable system for a machine which did not required to be changed or modified.
But as the manufacturing techniques improved the plant changeover to new products became
more desirable and necessary.

A constant demand for better and more efficient manufacturing and process machinery has
led to the requirement for higher quality and reliability in control techniques. With the
availability of intelligent, compact solid state electronic devices, it has been possible to
provide control systems that can reduce maintenance, down time and improve productivity to
a great extend. By installing efficient and user friendly industrial electronics systems for
manufacturing machinery or processors, one can obtain a precise, reliable and prolific means
for generating quality products.

Considering the varied demand and increasing competition, one has to provide for flexible
manufacturing process. One of the latest techniques in solid state controls that offers flexible
and efficient operation to the user is “PROGRAMMABLE CONTROLLERS”. The basic
idea behind these programmable controllers was to provide means to eliminate high cost
associated with inflexible, conventional relay controlled systems. Programmable controllers
offer a system with computer flexibility.

The PLC that was developed during this time was not very easy to program. The language
was cumbersome to write, requiring highly skilled programmers. These early PLCs were
merely relay replacements and could do very less. The at first gradually and then rapidly
developed into a sophisticated and highly versatile control system components. Units today
are capable of performing complex mathematical functions and are capable of the performing
complex mathematical functions like numerical integration and differentiations and operate
at a fast microprocessor speeds that are available.

Older PLCs were capable of handling discrete inputs and outputs (i.e. ON-OFF type signals),
while today’s system can accept analog voltages and current and as well as a wide range of
voltage levels and pulsed signals. PLCs are also designed to be rugged. Unlike their personal
computers they can typically withstand vibration, shock, elevated temperatures and electrical
noise to which the manufacturing equipment is exposed.

1.1) Benefits of Programmable Logic Controllers

 Programmable controllers are made of solid state components and hence provide high
reliability.

 They are flexible and changes in sequence of operation can easily be incorporated due to
programmability. They may be modular in nature and thus expandability and easy
installation is possible.

 Use of PLC results in appreciable savings in Hardware and wiring cost.

 They are compact and occupy less space.

 Eliminate hardware items like Timers, counters and Auxiliary relays. The presence for
timers and counters has easy accessibility.

 PLC can control a variety of devices and eliminates the need for customized controls.
As more manufacturers become involved in the PLC production and development, and PLC
capabilities expand, the programming language is also expending.

Also manufacturers also tend to develop their own versions of the ladder logic. Then the
system designers settle on a particular PLC, which is personally comfortable to program.
 2) ARCHITECTURE OF PLC

What is a PLC?

A Programmable controller is a solid state user programmable control system with functions
to control logic, sequencing, timing, arithmetic data manipulation and counting capabilities.
It can be viewed as an industrial computer that has a central processor unit, memory, input
output interface and a programming device. The central processing unit provides the
intelligence of the controller. It accepts data, status information from various sensing devices
like limit switches, proximity switches, executes the user control program store in the
memory and gives appropriate output commands to devices like solenoid valves, switches
etc.
Input output interface is the communication link between field devices and the controllers;
field devices are wired to the I/O interfaces. Through these interfaces the processor can
sense and measure physical quantities regarding a machine or process, such as, proximity,
position, motion, level, temperature, pressure, etc. Based on status sensed, the CPU issues
command to output devices such as valves, motors, alarms, etc.
Programmer unit provides the man machine interface. It is used to enter the application
program, which often uses a simple user-friendly logic.

According to NEMA (National Electrical Manufacturers’ Association, USA), the definition

of PLCs is “A Digital Electronic device that uses a programmable memory to store
instructions and to implement specific functions such as logic, sequencing, timing, counting
and arithmetic to control machines and process.”
A Programmable Logic Controller by any company has all of the following functional units:

 Processor (Logic Server)

 Memory Unit

 Input / Output (I/O)

 Program Loader

 Power Supply

1) Processor

The subsection of the processor that actually performs the program execution will be called
the central processing unit (CPU) with reference to input and output vector table CPU
executes the user program and continuously updates the output vector table.

The output vector table has a dual nature; its first function is to receive immediate
information from the CPU and pass if on to the output modules of the I/O section; but
secondly, it also must be capable of passing output information “backward” to the CPU,
when the user program instruction that the CPU is working on calls for an item of output
information. The input image table does not have its dual nature. Its single mission is to
acquire information from the input modules and pass that information “forward” to the CPU
when the instruction that the CPU is working on calls for an item of input information.

2) Input/Output Modules

Inputs are defined as real-world signals giving the controller real- time status of the process
variables. These signals can be analog or digital, low or high frequency, maintained or
momentary. Typically, they are presented to the Programmable Controller as a varying
voltage, current and resistance value.
Signals from thermocouples and RTD are some common examples of analog signals. Some
flow meters and strain gauges provide variable frequency signals, while push buttons, limit
switches and the electromechanical relay are some examples of digital closure type signals.
The register input is another type of input signal that reflects the computer nature of the
programmable controller.
There are three common categories of output: discrete, register and analog. Discrete outputs
can be pilot lights, solenoid valves, or annunciator windows. Register outputs can drive panel
meters or displays. Analog signals can drive signals to variable speed drives or to current ot
pressure converters and thus to control valves.

The I/O section contains input modules and output modules. Functionally, the input modules
are equivalent to the signal converters (i.e. Analog to Digital or high power to low power).
All modern PLC input modules use optical devices to accomplish electrically isolated
coupling between the input circuit and the processor electronics.
Each input device is wired to a particular input terminal on the I/O section. Thus if the
switch is closed, 5v dc appears on input terminal, converts this dc voltage to a digital 1 and
sends it to the processor via programmable peripheral interface (PPI). Conversely, if the
switch is open, no dc voltage appears on input terminal. Input section will respond to this
condition by sending a digital 0 to the processor. The other input terminals behave
identically.

3) Memory Unit

The memory unit of PLC serves several functions. It is the library where the application
program is stored. It is also where the PLCs executable program is stored. An executable
program serves as the operating system of the PLC. It is the program that interprets, manages
the user’s application program. Finally the memory unit is the part of the programmable
controller, where the process data from the input modules and the control data from the
output modules are temporarily stored as data tables. Typically, an image of this data tables
is used by the processor and, when appropriate sent to the data tables.

4) Program Loader

The program loader allows the engineer or technician to enter and edit the program to be
executed. In its simplest form it can be a hand held device with keypad for program entry and
a display device (LED or LCD) for viewing the program steps or functions. PLC
manufacturers are now providing a separate personal computer which allows the programmer
to write, view and edit the program and download it into the PLC. This is accomplished by
proprietary software available from the PLC manufacturer. This software also allows the
programmer or the engineer to monitor the PLC when it is running a program. With this
monitoring system, such things as internal coils, registers, timers, and other items which are
not visible externally can be monitored to determine proper operation. This feature of the
program loader is to debug the existing program of errors. Communication is done via a
cable connected to a special programming port on the controller. Connection to the personal
computer is mainly through the serial port or through a dedicated card installed in the
computers.

Here in Ardent PLC manufacturer is Honeywell. Here this company provided a personal
computer in order to load the program to the PLC. A software named “Soft Master” is mainly
used for the interfacing the PLC with the computer. The PLC kit is connected to the serial
port.

The steps of executing a program is given below:-

 Online  Connection Setting  Select RS232C

 Online  Connect

 After that we get a pop up window showing whether the connection has been
established.

 Online  Write  Ok (Program is written in the PLC memory)

 Online  Change Mode (From Stop to Run Mode)

 Monitor  Start Monitoring (For viewing the outputs and the status of the
various limit switches and the output ports)

5) Power Supply

The power supply unit drives the I/O logic signals, the central processing units, the memory
unit and some peripheral devices. The power supply unit converts power line voltage to those
required by the solid state components. The power supply unit is 24V

Scan Time of PLC

As long as the PLC is left in the RUN mode, the processor executes the user program over
and over again. Figure depicts the entire repetitive series of events. Beginning at the top of
the circle representing the scan cycle, the first operation is the input scan. During the input
scan, the current status of every input module is stored in the input image table, bringing it up
to date.
Following the input scan, the processor enters its user program execution. Sometimes called
“program scan”. The program executes with reference to input and output image tables and
updates output image table.
Throughout the user program execution, the processor continuously keeps its output image
table up to date, as stated earlier. However, the output modules themselves are not kept
continuously up to date. Instead, the entire output image table is transferred to the output
module during the output scan following the program execution.

The scan time of the PLC is the sum of the time taken for input to enter the input vector
table, time taken for program execution and output being sent to the output vector table and
finally to the output contacts. The schematic is shown below.

Input Input Vector Program Output Vector Output

Table Table

Operation of the PLC

The function of the operating system is to present the user with the equivalent of an extended
machine or virtual machine that is easier to program than the underlying hardware.
Due to this operating system, PLC is very easy to program. It can be programmed using
electrical schemes with familiar relay symbols so that a plant electrician can easily access the
PLC. Even though he does not know the assembly language or even if he may not have any
familiarity with computers and electronics, he will be able to program the PLC.
The function of PLC Operating system is:

1. Loads the user program from programming device to program memory.

2. To read status of input devices.

3. To execute user program.

4. To form and update input image table.

5. As per the status of output image table controls the output devices.

6. To provide user-friendly functions.

When the user completely enters his program in user memory, he transfers control from
STOP mode to RUN mode. In RUN mode the control of the whole system is transferred to
operating system. Now operating system takes care of the whole system such that the whole
system becomes automatic and appears as magic to users.

Types of PLC

There are two types of PLC. The modular PLC and the rack type PLC. There are given in
detail below:

1) Modular Type PLC:

In the modular type of PLC all the parts i.e. Processor, memory, input/output modules are
accommodated in the singular module. Input and output terminals are limited in modular type
PLC and there is no provision to increase the input, output terminals. For example, the PLC
used by had only eight inputs and one common terminal. This arrangement is also the same
for the output terminals.

The modular type PLC is much smaller and cheaper than the rack type PLC.
2) Rack Type PLC:

Rack type PLC consists of separate processing module, Input and output Modules. These
modules are mounted on a motherboard like board, on which separate slots are allotted for the
processor, input modules and output modules as shown. The number of terminals for an I/O
module is fixed but one can mount multiple I/O card in the I/O slots to increase the terminal
numbers. A rack type PLC is often large and can hold multiple cards.

When necessary multiple numbers of racks can be connected together. For example, we can
add a certain number of I/O terminals in addition to the given terminals. The rack type PLC is
of higher cost and it is also the most flexible and easy to maintain.
 3) PROGRAMMING WITH PLC
USER SOFTWARE

This is the software that the control engineer writes and stores the program in the user
memory in order to perform the required control over the machine process. This user
software can contain both configuration data and language program.

 LADSIM

 DELTA WPLSoft
  TLP LogixPro Simulator

Configuration Data

The configuration data contains information that tells the processor what its environment is
and how it should execute the language program. The configuration process typically
consists of

 Assigning I/O points to particular I/O racks,

 Telling the processor how much memory and I/O it has,
 Assigning specific memory for tasks,
 Assigning many other items for the program loader.

Language Program

The modern PLC is required to do more in terms operator interfacing, communications, data
accusation and supervisory control. There are different types of languages used for PLC
programming, such as LADDER Language, Boolean Language, High-Level Language, State
language, etc. Among these the Ladder Language is still the primary language of the PLC.
This is because the Ladder Language has the following advantages:

 It is readily understood and maintained by skilled workers who are familiar with
relay logic.
  It provides graphic display of the program execution by showing the power flow
through the ladder diagram, thereby providing a higher debugging facility.
 Program is sufficiently fast.
 It generates more readable program for sequence control.

Program Loader

The primary importance to programming goes to the program loader. It provides an

environment for entering the program. Actually the major portion of the time spent in
programming and debugging a PLC is spent to interact with the program loader. A program
loader has the following features.

 It provides an environment for entering programs.

 It contains sophisticated debugging tools that will reduce the time taken for
eliminating errors from the program.
 It provides an environment for monitoring program execution in real time.
 It generally provides displays that show power low through the relay ladder diagram.
 It allows the user to obtain hard copies of the program.
 It allows the user to get cross references of variable usage, enter comments on the
program and defines name for all variables.

There are usually two types of the program loaders, namely the hand held program loader
and the computer based program loaders. The hand held loaders are small but cheap that
typically use keyboards and LED displays. While on the other hand in the computer based
program loaders use a personal computer running in MS-DOS or Windows operating system
as a means to upload the program in the PLC memory. In this type of loaders the
manufacturers provide loader software that enables the communications between the user and
the PLC.

3.1) Structure of the Ladder Diagram

The first PLCs were programmed with a technique that was based on relay logic wiring
schematics. This eliminated the need to teach the electricians, technicians and the engineers
to how to program a computer. But now a days the ladder logic is preferred than the relay
logic because it is more flexible and cheap. An example of ladder logic is given below.
 SIMPLE LADDER LOGIC DIAGRAM

Now in order to interpret this diagram we have to imagine say that the power is on vertical
line on the left hand side called the left bus rail. On the other side the vertical line is called
the right bus rail.

In this given figure the left bus rail and the right bus rail are clearly depicted. The line
connecting the left bus rail and the right bus rail is called the rung. On the rung we have an
input contact and an output contact. If the input contact is made the power will flow from the
left bus rail to the right bus rail. An input may automatically come from a sensor or from any
switching device. The output of this device mainly depends in the input signal. If there is an
input signal output will be obtained.There are two types of input contact namely the normally
closed and the normally open contact. Their related diagrams are shown below.

All the possible logics of the Programmable Logic Controller are formulated using the ladder
logic owing to its convenience and simplicity.
This diagram shows the output contact that is mainly used in the ladder logic. These contacts
in case of modular PLC are connected either to the LEDs for output indications or connected
to the various operating devices which controls the operations.

3.2) Comparison between Relay Logic and Ladder Logic

Control engineering has evolved over time. In the past humans was the main method of
controlling a system. More recently electricity has been use for control and early electrical
controls were based on relays. Theses relays allow power to be switched on and off without a
mechanical switch. It is common to use relays to make simple logic control decisions. The
development of the low cost computers has brought the most recent evolution in the field
control and automation, Programmable Logic Controllers (PLC). The PLC was introduced in
the 1970s and since then is being widely used as the main device for automation and control.

The main advantages of PLC are:

 Cost effective for controlling complex systems.

 Flexible and can be reapplied to control other systems quickly and easily.
 Computational abilities allow more sophisticated control.
 Trouble shooting aids make programming easier and reduce downtime.
 Reliable components make this likely to operate for years before failure.

Ladder logic is the main programming method for programming the PLC. The main
advantage of the ladder logic over the relay logic is that it can be reprogrammed in case of
the change of logic or due to change of the operational procedures.

But in case of relay logic in order to change the control procedures we have to rewire the
relays in order to implement the new logic.
3.3) Implementation of Boolean Expressions Using Ladder Logic

The process of converting control objectives into a ladder logic program requires structured
thought. Boolean algebra provides the tools needed to analyze and design these systems.
Boolean algebra was developed in 1880s by James Bool. It was found extremely useful for
designing digital circuits and is still heavily used by electrical engineers and computer
scientists. The techniques can model a logical system with a single equation.

Boolean equations consist of variables and operations and look very similar to normal
algebraic equations. Three basic operators are AND, OR, and NOT. However, there are more
complex operators like XOR (Exclusive OR), NAND (Not AND), NOT (Not OR). The
Boolean equation form can be simplified or rearranged to form ladder logic, or a circuit.
They are explained in detail below.

AND Logic

The Boolean Expression for AND logic is Y0=X0.X1. This logic can be implemented using
ladder diagram as given below.

Y0=X0.X1

Here X0 and X1 are two normally open input contacts and Y0 is an output contact. Its
corresponding truth table is given below.

X0 X1 Y0
0 0 0
0 1 0
1 0 0
1 1 1
OR logic

The Boolean expression for OR logic is Y0= X0+X1. The implementation of this logic using
ladder diagram is given below.

Y0= X0+X1

Here Xo and X1 are normally open input contacts and Y0 is the output contact. The
corresponding truth table of the OR logic is shown below.

Xo X1 Y0
0 0 0
0 1 1
1 0 1
1 1 1
NOT Logic

The Boolean expression for NOT Logic is given by Y0=X0. The implementation of this logic
using ladder diagram is shown below.

Y0=X0

Here Io is a normally closed contact and Y0 is generally an input contact. Its corresponding
truth table is shown below.

X0 Y0
0 1
1 0
Exclusive OR(X-OR) Logic

X-OR means exclusive OR. The Boolean expression of X-OR is given by Y0= X0.X1+
X1.X0. The implementation of this logic using Ladder diagram is given below.

Here two inputs X0 and X1 are used as both normally open and normally closed contact. Y0
is output contact. Its truth table is given below.

X0 X1 Y0
0 0 0
0 1 1
1 0 1
1 1 0
3.4) Programmable Logic Controllers Timers

Introduction

More complex systems cannot be controlled with combinational logic alone. The main
reason for this is that we cannot, or choose not to add sensors to detect all conditions. In these
cases we can use events used by PLC include first scan of the PLC.

Classification of PLC Timers

Normal PLC timers are of mainly two types they are on-delay timers and of-delay timers. An
on-delay timer will wait for a set time after a ladder logic have been true before turning on,
but will turn off immediately. In case of the off delay timer will turn on immediately but will
delay before turning off.

Another classification of the timer is retentive type and non retentive type timer. A retentive
type timer will remember the count value even if the timer is turned off, and it will start
counting from that previous stop point. A non-retentive type of timer will start timing the
delay from zero every time it is switched off.

These timers are represented as TON (On-Delay Timer), TOFF (Off-Delay timer) and
retentive type timer known as TMR.

Parameters of a Timer

Timers have three parameters Time base, Preset Value and Accumulated Value

 Time Base: It is base time of a timer. It is mainly the time after which the timer value
will increase by one. It is mainly denoted by (T.B).

 Preset Value: It is the total number of cycles the timer will undergo before it finally
turns off or turns on. It is mainly denoted by (P.V).

 Accumulated Value: It stores the current time value of the timer. It shows us how
time is covered by the timer.
3.5) Programmable Logic Controllers Counters

Introduction

The counter counts the rising edges of the pulses, driving its input signal and counts once
only when the input signal is switched from off to on. There are two basic counter types they
are up-counter ad down-counter. When the input to the up-counter goes true the accumulator
value will increase by 1. If the accumulator value reaches the pre-set value the counter DN
bit will be set. The down counter will gradually decrease the accumulator value until the pre-
set value is reached.

Types of Counters

There are 4 counter instructions such as CTU, CTD, CTDU and CTR. Some brief
information about these counter operations are given below:

 Up Counter (CTU) increases the current value.

 Down Counter (CTD) decreases the current value.
 Up/Down Counter (CTUD) compares the input value from both counters input.
 Ring Counter Increases the current value and the current value is cleared as 0 when
the current value reaches the pre-set value.

UP Counter (CTU)

The up counter increases the current value at the rising edges of the input. The controller
output contact is turned on when the current value reaches the pre-set value. When the reset
input is turned on, the counter output contact is turned off.

Down Counter (CTD)

The down counter decreases the current value at the rising edges of the input. The output
contact is turned on when the current value reaches the pre-set value. When the reset input is
turned on, the counter output contact is turned off.

Up/Down Counter (CTUD)

The current value is increased with the rising-edge of the up-count input signal, and
decreased with the rising edge of the down-count input signal. The counter output contact is
turned on when the current value is same or more than the pre-set value. The counter output
contact is turned off when the current value is same or less than the pre-set value.
 4) CASE STUDIES

Various automatic processes were studied using PLC. Various problems were worked out
and debugged and was applied. Various experiments were also conducted on the modular
PLC training kit. The PLC we used for conducting our experiments were manufactured by
Honeywell and its model number is RC232C. This PLC kit was used in combination with a
personal computer and the PLC kit was connected to the serial port or the com port of the
computer. The software was used as an operating interface of the PLC which was provided
by the company itself. This software known as “Soft Master” was used to write the ladder
logic oriented programs in the PLC memory and to monitor the mode of operations of the
PLC. Some of the case studies that were discussed are shown below.

4.1) Automatic Pump ON/Off

Let us consider a tank which has two sensors connected in their upper level and lower
level. Let Ls1 and Ls2 be two such sensors. This tank has an inlet flow of water which is
connected to a pump and also an outlet flow. Pump will start when the water level falls
below the Ls1 and will stop when the water level exceeds Ls2.

Solution

Let us consider Ls1 and Ls2 which are two level switches as Xo and X1 which are two input
contacts of the PLC.

Now for this problem the following observations are made:

1) Level < L1 PUMP is ON

2) L1 < Level < L2 PUMP is ON
3) Level <=L2 PUMP is OFF
4) L1 < Level <L2 PUMP is OFF
5) Level < L1 PUMP is ON

These above observations occur sequentially and they are responsible for automatic operation
of the PUMP. The logical ladder diagram is shown below.
Here X1 and X0 are normally closed contacts and P20 is the PUMP output. Now in this
problem we are assuming that

Ls1 = X0 and Ls2 = X1

Pump output is assumed to be Y0. The following steps will explain the working of the PLC
in detail:

1) (Level < L1), X0 = 0, X1 = 0 and hence Y0 = 1. So the PUMP is ON.

2) (L1 < Level < L2), X0 = 1, X1 = 0 and hence Y0 = 1. So the PUMP is ON.
3) (Level <= L2), X0 = 0, X1 = 0 and hence Y0 = 0. So the PUMP is OFF.
4) (L1< Level < L2), X0 = 1, X1 = 0 and hence Y0 = 0. The PUMP remains OFF.

After the water Level Falls below L1 again this cycle repeats.

4.2) Sequential Motor Operations by Using Timers

Draw the ladder diagram to fulfill the following sequences. Motor 1 (Y0) starts as soon
as start switch is on, where start switch is X0. After 50 seconds, Motor 1 stops and
Motor 2 (Y1) starts. After 50 seconds Motor 2 stops and Motor 3 (Y3) starts. Again
after 50 seconds Motor 3 stops and again Motor 1 starts.

Solution:

In this problem we provide timed sequential operation of the three motors.

Let us consider, System Start be X0.

The outputs are operations of motors 1, 2, 3 for contacts Y0, Y1, Y2 respectively.

MOTOR 1 = Y0

MOTOR 2 = Y1

MOTOR 3 = Y2

The following steps are followed during the time of sequential motor on and off. They are
given below:

1) When X0=1 the Motor 1 readily starts (Y0).

2) After 50 seconds the Motor 1 (Y0) stops and Motor 2 starts (Y1).
3) After 50 seconds Motor 2 (Y1) stops and Motor 3 starts (Y2).
4) Again after 50 seconds Motor 3 (Y2) stops and gain Motor 1 starts (Y0).

The corresponding Ladder Diagram is given below:

Here X0 is the start switch which starts the Motor 1 (Y0). It is a normally open contact which
when zero is off and when one the Motor is on.

Here P1 is a normally closed contact which acts as a stops switch. Its main operation is to
stop the sequential operation. When this contact P1=0 then the contact is made and operation
occurs. But when this input turns to on the normally closed contact will be open and the
operation will stop.
So when the input contact P0 switched on the Motor 1 (P20) readily starts its operation. Now
using the status of the Motor 1 output P20 we use a retentive type timer with tag name T0 to
count 10 seconds. After 10 seconds the Motor 2 is switched on by the timer T0 and at the
same time T0 switches off the Motor 1. Similarly, after 5 seconds Motor 2 is switched off by
another retentive timer T1 and Motor 3 is switched on. And after 10 seconds a on delay timer
resets the retentive type timer. If one needs to stop the operation the stop button should be
pressed.

4.3) Sequential Motor Operation by Using Compare Instructions

Draw the ladder diagram to fulfill the following sequences. Motor 1 (Y0) starts as soon
as start switch is on, where start switch is X0. After 10 sec, Motor 1 stops and Motor 2
(Y1) starts. After 5 seconds Motor 2 stops and Motor 3 (Y2) starts. Again after 10
seconds Motor 3 stops and again Motor 2 starts. Then after 5 seconds Motor 2 stops
and Motor 1 starts.

Solution:

In this problem we provide timed sequential operation of the three motors.

Let us consider, System Start be X0

The outputs are operations of motors 1, 2, 3 for contacts Y0, Y1, Y2 respectively.

MOTOR 1 = Y0

MOTOR 2 = Y1

MOTOR 3 = Y2

The following steps are followed during the time of sequential motor on and off. They are
given below:

1) When X0=1 the Motor 1 readily starts (Y0).

2) After 10 seconds the Motor 1 (Y0) stops and Motor 2 starts (Y1).

3) After 5 seconds Motor 2 (Y1) stops and Motor 3 starts (Y2).

4) Again after 10 seconds Motor 3 (Y2) stops and gain Motor 2 starts (Y1).
 5) After 5 seconds Motor 2 stops (Y1) and Motor 1(Y0) starts.

The corresponding Ladder Diagram is given below:

In this problem X0 is the start switch. If it is switched on then the on delay timer starts with
the tag name T0.

Here in this problem we have made use of the compare instruction. In this problem if the
present time is less than 10 sec then we switch on the Motor 1(Y0). Now when the present
time becomes more than 10 seconds then Motor 1(Y0) stops and Motor 2 (Y1) starts. When
the present time exceeds 15 seconds, Motor 2 (Y1) stops and Motor 3 (Y2) starts and
continues to run until it reaches 25 seconds. Now when the present time exceeds 25 seconds
again Motor 2 (Y1) starts and Motor 2 stops.
4.4) Silo Simulation

Completely design and de-bug a ladder control circuit which will automatically position and
fill the boxes which are continuously sequenced along the conveyer

Solution:

The following steps are to be followed to design a service in logical order in an industry:

1. Let the System Start be i:1/0. The indicator of the run(O:2/2) glows after the input in
ON.
2. The run(O:2/2) output becomes the input to motor(O:2/0) which moves the conveyer
belt.
3. When the container placed on the conveyer belt reaches the Proximity sensor(i:1/3) it
stops.
4. Now the solenoid valve(O:2/1) get opened when the container reaches the proximity
sensor(i:1/3).
5. Now the container started filling till it reaches the level sensor(i:1/4) which inturn
closes the solenoid valve(O:2/1) which further turns off the Proximity Sensor(i:1/3) &
Starts the conveyer belt again.

The corresponding Ladder Diagram is given below:

The corresponding simulation is shown below:
REFERENCES:

1. "PLC Security Risk: Controller Operating Systems - Tofino Industrial

Security Solution". www.tofinosecurity.com
2. Erickson, Kelvin T. (1996). "Programmable logic controllers". Institute of
Electrical and Electronics Engineers.
3. Wedd Reis, “programmable logic controller”, Pearson education, 2nd
edition
4. http://en.wikipedia.org/wiki/programmable logic controller