PROJECT SEMESTER REPORT

UNDERTAKEN AT

PROLIFIC SYSTEMS & TECHNOLOGIES PVT.ITD

NOIDA

ON

PLC (PROGRAMMABLE LOGIC CONTROLLER)

SUBMITTED BY:

DISHANT GOEL

UNDER THE GUIDANCE OF: MR ALOK KUMAR (MENTOR)

2023

ELECTRICAL ENGINEERING DEPARTMENT

SETH JAI PRAKASH POLYTECHNIC DAMLA, HARYANA

 ACKNOWLEDGEMENT

I would like to convey my sincere thanks to prof. Mr Rajeev Sharma (HOD) Electrical Department.
Seth jai Prakash polytechnic, for giving me such a wonderful opportunity to do enhance my skill
through this training.

I would like to express my deep sense of gratitude, indebtedness to Mr Rajeev Sharma (Lecturer)
Electrical department 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 ALOK 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

Training is a process where people acquire new/improved skills, concepts and attitudes helping them
in the achievement of specified goals- chief of these being the applications of the theoretical
knowledge to its practical form. This sentence seemed to me realistic when I finished my training at
PROLIFIC SYTEMS & TECHNOOGIES PVT.ITD. This report is result of my training at PROLIFIC SYSTEMS
most widely used electronic device in the control of production and assembly process is most
automated factories due to simplicity and versatility.

PROLOFIC INFOTEL PVT.ITD is a platform to learn your skills for improved employability in PROLIFIC
SYSTEMS industry. Conceptualized by team of qualified and experienced professionals, the school
imparts training in programmable logic controller (plc) is a user- friendly, microprocessor-based,
specialised computer, carrying out controller 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, in working, advantages, disadvantages & its applications. Various
software were used for programming the plc: RS LOXIX PRO 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 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.
• TLP Logix Pro Simulator
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.

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.
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.

PLC programming software Delta is written by Delta Electronics and used to create a program for
active Delta PLC, unlike other PLC firms, PLC Delta has copyright software provided free of charge,
creating economic benefits for users and giving customers good economic conditions easily
accessible.
WPLSoft V2.47 software is the latest version used to specialize in programming DVP-Series
OS : Windows XP , Windows Vista , Windows 7 , Windows 8 , Windows 10
• Installation video tutorial (Download link at the end of the article) :
• Installation instructions for images
 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.

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
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. X

NOT Logic

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

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
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, Present 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).

❖ Present 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
downcounter. 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 < 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.

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

About
Factory I/O is a 3D factory simulation for learning automation technologies. Designed to be easy to
use, it allows to quickly build a virtual factory using a selection of common industrial parts. Factory
I/O also includes many scenes inspired by typical industrial applications, ranging from beginner to
advanced difficulty levels.
The most common scenario is to use Factory I/O as a PLC training platform since PLC are the most
common controllers found in industrial applications. However, it can also be used with
microcontrollers, Soft PLC, Modbus, among many other technologies.
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