Vidya Vikas Educational Trust (R),

Vidya Vikas Polytechnic

27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Department of Mechanical [General]

Laboratory Portfolio

Subject : Elements of Industrial Automation

Subject Code : 20ME44P

Semester : 4th Semester

Name of the Student: …………………………………………….

Register Number: …………………………………………….

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
APPENDIX 5 (Certificate issued by guide)
Name of the Institution: VIDYA VIKAS POLYTECHNIC
Address with pin code: 27-128, Mysore - Bannur Road Alanahally,Alanahally Post, Mysuru, Karnataka
570028

Department: MECHANICAL ENGINEERING (General)

CERTIFICATE

Certified that this Practical Record entitled “Elements of Industrial Automation 20ME44P” which is being

submitted by Mr.………………..…..…………..………bearing Register Number….....…………………, is a

bonafide student of Mechanical Engineering Department, studying in Fourth Semester in our Institution and

has fulfilment the Laboratory prescribed by Department of Technical Education, Bangalore during the year

2021-2021.

It is certified that all corrections/suggestions indicated for internal Assessment have been incorporated in the

Report.

Signature of the Staff In-charge

Signature of H.O.D

CIE (Internal Assessment Marks Obtained in Words):…………..……………………………………………

External Examiner 1:………………………………

Dept. …………………………College…….…………………

External Examiner 2:………………………………

Dept. …………………………College…….…………………

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Course Outcomes

Introduction to Elements of Industrial Automation

In present scenario, Manufacturing industries are moving towards complete automation. Small and medium
industries are in a phase of switching to PLC and SCADA technology for data acquisition and control.
Industrial automation systems are used to control and monitor a process, machine or device in a computerized
manner that usually fulfils repetitive functions or tasks. They are intended to operate automatically in order to
reduce and improve human work in the industry. Advantages of this technology is commonly attributed to
higher production rates and increased productivity, more efficient use of materials, better product quality,
improved safety, shorter workweeks for labor, and reduced factory lead times.

The Automation Engineer will design, program, simulate and commission automated machines and plant-
wide processes to perform many job functions. Depending on the size of the organization, the engineer will
perform some or all of these responsibilities. Therefore, it is necessary for diploma engineers to have
knowledge of both PLC and SCADA technology. This course attempts to provide basic theoretical and
practical aspects of automation technologies to develop operational competency. Hence this course is the
foundation for diploma engineers who want to further specialize in the field of industrial automation

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
CIE and SEE Assessment Methodologies

Format for CIE written Test

(a)For CIE Skill Test -4

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
(b) For CIE Skill Test -5

SEE Scheme of Evaluation

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Content
Staff
Sl No Experiment Date Sign /
Marks
Study of following Appliances / automation systems and
identify various elements used and their function
1. Air conditioning System
1 …../…../2024
2. Automatic water level control
3. Elevator (for Three Floor)
4. Washing Machine
Write the Block Diagram For each and explain
Execute / Simulate a PLC program to energized motor or bulb …../…../2024
2
using Switches in series or Parallel
Execute / Simulate a PLC program for logic gates. AND, OR, …../…../2024
3
NOT, NAND, NOR, XOR, XNOR
Execute / Simulate a PLC program to count the number of …../…../2024
4
Items moving
Execute / Simulate a PLC program for motor control …../…../2024
5 automation such that the motor reverses its direction when the
limit switches are activated
6 Execute / Simulate a PLC program for an alarm system …../…../2024
Execute / Simulate a PLC program for the Traffic light …../…../2024
7
controlling application
Execute / Simulate a PLC program for the Water level …../…../2024
8
controlling application
Execute / Simulate a PLC program automatic door system using …../…../2024
9
optical sensor and linear actuator
Execute / Simulate a PLC program for an Automatic Elevator …../…../2024
10
control
11 Execute / Simulate a PLC program for car parking. …../…../2024
There are 3 mixing devices on a processing line A, B, C. After …../…../2024
the process begin mixer-A is to start after 7 seconds elapse, next
12 mixer-B is to start 3.6 second after A. Mixer-C is to start 5
seconds after B. All of then remain ON until a master enable
switch is turned off. Develop PLC ladder diagram, timing
diagram and simulate the same
13 Logic Experiment: Develop a PLC ladder diagram to construct …../…../2024
an alarm system which operates with conditions
14 Multi media Exposure to SCADA system …../…../2024

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 01: Study of following Appliances / automation systems and identify various
elements used and their function with the Block Diagram For each.

1) Air conditioning automation systems

2) Automatic water level control automation systems

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
3) Elevator (for Three Floor) automation systems

4) Washing Machine automation systems

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 01: A

Students Sign Staff Sign

Experiment No 01: B

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 01: C

Students Sign Staff Sign

Experiment No 01: D

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Summary about PLC Programming (Ladder Dagram)

Quality Being Measured The input device (Sensors) Output device (Actuators)
Light Dependent Resistor (LDR)
Lights and Lamps
Photo Diode
Light LEDs and Displays
Phototransistor
Fibre Optics
Solar cell
Thermocouple
Thermistor Heater
Temperature
Thermostat Fan
Resistive Temperature Detectors (RTD)
Strain Gauge
Lifts and Jacks
Force or Pressure Pressure switch
Electromagnetic vibrations
Load cells
Potentiometer
Motor
Encoders
Position Solenoid
Reflective/slotted opto-switch
Panel Meters
LVDT
Tacho – generator AC and DC Motors
Speed Reflective/slotted optocoupler Stepper Motor
Doppler effect sensors Brake
Bell
Carbon microphone
Sound Buzzer
Piezoelectric crystal
Loudspeaker

Symbols used for I/O Devices in PLC Program

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Dear Students

There are many open-source simulation software’s available to execute PLC program Ladder Diagram mode.
Among these software LogixPro is one of the best platforms to learn the PLC Logic along with built in
simulations.
LogixPro is the ideal tool for learning the fundamentals of ladder logic programming. The look, feel and
operation of LogixPro's ladder rung editor so closely mimics Rockwell's world renown PLC editing software,
that many need a second look to be sure whose editor they're using. Of course, the give-away is the window
containing one of our ProSim-II Simulations. This is where LogixPro really out-shines typical PLC training
setups employing a PLC connected to a handful of switches and lights. By graphically simulating process
equipment such as conveyors, bottling plants, etc. in software, the synchronous and interactive nature of real
industrial processes, presents the student with a far more realistic and challenging programming experience.
Download site:
https://canadu.com/
https://canadu.com/lp/logixpro.html
I kindly request you to support TheLearningPit.com, and Canadu.com for their unique software for learning
PLC programming.
With regard
Author

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Introduction to LogixPro

Layout [Select Micrologix 1000] Input / Output Data [Create Ladder Logic]

Label the I/O Logics Select I/O Simulator

Go online to Run Program or offline mode to

Select RUN Mode to see simulation
stop

Toggle the Input Switches to see Output

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 02: Execute / Simulate a PLC program to energized motor or bulb using
Switches in series or Parallel

Problem Description
Implementation of Series and Parallel Switches to Energize Motor / Bulb

Problem Solution
• Assuming a Latching Circuit to develop constant voltage supply
• Connecting Series and Parallel Switches to Ladder Program
• Connect Motor Output or Bulb Output
• Simulate the Program and record the Input / Output Table

PLC Program

Truth Table

Input Details Value Output Details Value Remark

1 B:3.0 Charge Coil 1 Coil will be charged
I:1/15 ON Switch
0 B:3.0 Charge Coil 0 Coil will be reset
Switch 1 1 1
I:1/1 If both Switches is ON then only
and O:2.0 Motor / Bulb
I:1/2 0 0 we get Output
Switch 2
Switch 3 1 1
I:1/3 If any one of the Switch is ON
and O:2.1 Motor / Bulb
I:1/4 0 1 then we get Output
Switch 4
I:1/14 OFF Switch 1 B:3.0 Switch OFF 1 Resets all Value to zero

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 02

Students Sign Staff Sign

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 15
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 03: Execute / Simulate a PLC program for logic gates. AND, OR, NOT, NAND,
NOR, XOR, XNOR

Problem Description
Implementation of various Logic Gates AND, OR, NOT, NOR, NAND, EX-OR and EX-NOR in PLC using
Ladder Diagram programming language.
Symbol of Logic Gates

Problem Solution
PLC program to implement various logic gates, along with program explanation and run time test cases.
AND

• By connecting Normally Open / XIC contacts in series, AND gate can be implemented.
• When both inputs are set to 1, then and then only output goes high.
OR

• By connecting Normally Open / XIC contacts in parallel, OR Gate can be implemented.

• When either input is set to high, output goes high.
NOT

• By using just one Normally Closed / XIO contact, NOT Logic Gate can be implemented.
• Inverted state of input is obtained as an output.
NOR

• By connecting Normally Closed / XIO contacts in series, NOR Logic Gate can be implemented.
• If both inputs are Reset to 0, output goes High otherwise remains in Low state.
• Or by inverting output of a OR Gate, that is by using output of OR Gate as an input of NOT Gate,
NOR Gate can be implemented.
NAND

• By connecting Normally Closed contacts in parallel to each other, NAND Gate can be implemented.
• Or by simply inverting output of AND gate, NAND Gate can be implemented.
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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
EX-OR

• By connecting XIC and XIO in series with parallel to XIO and XIC in series as shown in diagram
above, EX-OR Gate can be implemented.
• When both inputs are identical, output is 0. Output is high when A ≠ B.
• Note here that XIC of first series contacts and XIO of second series contacts must be given same
address and similarly for the other two.
EX-NOR

• By connecting two XIO contacts in series with parallel to two XIC contacts in series, EX-NOR gate
can be implemented.
• When both inputs are identical A=B=O or A=B=1, output goes high.
• It implies same here as in EX-OR gate that address must be given same.
• By inverting output of EX-OR gate, implementation of EX-NOR can be accomplished.

Runtime Test Cases

Inputs Outputs
A B AND OR NOR NAND EX-OR EX-NOR
0 0 0 0 1 1 0 1
0 1 0 1 0 1 1 0
1 0 0 1 0 1 1 0
1 1 1 1 0 0 0 1

Inputs Output
A NOT
0 1
1 0

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 03

Students Sign Staff Sign

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 18
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 04: Write a Ladder Program to count the number of Items moving on a conveyor
Belt and Execute / Simulate the same

Problem Description:

Problem Solution: Ladder Diagram

Truth Table

Input Values Output Values Description

1 1 Charging of Coil ON /
I:1/0 B3:0
0 0 OFF
I:1/1 1 0 All Input OFF
1 1 Count 1
CTU
I:1/5 0 1 Count 1
C5:0
1 2 Count 2 and so on

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 04

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 05: Develop Ladder Program for relay-based motor control automation such that
the motor reverses its direction when the limit switches are activated

Problem Description
A motor is connected to PLC. Run this motor in the Forward and Reverse direction using Ladder Diagram
programming language.

Problem Solution
• For any three-phase AC motor, reversing can be accomplished by reversing any two leads. For single-
phase motor, reversing start lead with respect to the main leads. And for DC motor, reversing the field
leads with respect to the armature leads.
• There are certain ways to reverse the motor. One is to use DPDT (Double Poles, Double Throw) switch
and another one is by using Reversing Contactors.
• DPDT switch is best suitable for reversing a small DC motor while Reversing Contactor is used to reverse
Three-Phase AC motors.
• Single-phase motors are not widely used for reversing operation. In fact, these are not even available
widely with reversing capability.
• As here we have a three-phase AC motor, reversing any two leads will drive the motor in reverse direction.
• Contactor is an electrical switch used for switching an electrical power circuit.
• Two magnetic contactors are used, one for forward connections and the other for reverse connections.
• Only Push-Button switches are used to control the direction of this three-phase AC motor.
• We have the input commands to these Push Button switches which are then internally processed by PLC
and then there is the output terminal which activates the corresponding relay to energize the relevant
magnetic contactors.
• Configure forward and reverse wiring of the motor with contactors such that forward contactor is
connected directly in the normal direct phasing of the motor terminal and reverse contactor is connected
with two of the motor terminals in the opposite phase.
• When it is switched to reverse direction, forward rotation does not stop instantaneously hence we have to
determine what time it takes to completely stop one particular direction. Then provide time delay of a
second or two and activate the other contactor.

PLC Program
Here is PLC program to Drive Motor in Forward and Reverse Direction, along with program explanation and
run time test cases.

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
List of Inputs and Outputs

Ladder Diagram to solve this problem

Runtime Test Cases

• Simulation of this problem was successfully performed in software LogixPro of Allen Bradley and verified
using I/O Simulator.
• Instead of actual contactors or motor outputs, simple LED outputs were used to perform this in I/O
Simulator.

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 05

Students Sign Staff Sign

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 23
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 06: Simulate the PLC ladder diagram developed for an alarm system

Problem Description
Consider the design of a Burglar Alarm for a house. This alarm will be activated if an unauthorized person is
detected by a Window Sensor or a Motion Detector. Implement this Alarm System in PLC using Ladder
Diagram programming language.

Problem Solution
• Basically, two sensors are used, one is Motion Detector and other one Window Sensor.
Window sensor is nothing but a loop of wire that is a piece of thin metal foil which encircles the window.
• The motion detector is designed such that when a person is detected, the output of sensor goes true.
• Important thing to note here is that in Window Sensor, current is always passing until there is a breakage
in glass of a window. Hence output is always true. When alarm system is active and someone tries to
break the window, current does not flow through the metal foil causing output to go false.

PLC Program
Here is PLC program for Burglar Alarm Security System, along with program explanation and run time test
cases.
List of Inputs and Outputs
I:1/0 = Master Switch (Input)
I:1/1 = Deactivate system (Input)
I:1/2 = Motion Detector (Input)
I:1/3 = Window Sensor (Input)
I:1/4 = Button to Stop Alarm (not the system) (Input)
O:2/0 = Master Coil (Output)
O:2/1 = Alarm Coil (Output)
O:2/2 = Alarm (Output)

Ladder Diagram for Burglar Alarm Security System

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Problem Description
• RUNG000 simply shows a latching of a coil O:2/0 to activate the entire security system.
• When Activate button I:1/0 is pressed momentarily, the security system is activated.
• If the system is not activated, alarm does not indicate anything since sensors will have no effects on the
Alarm Coil O:2/1.
• When system is active and Motion detector detects a person, the alarm coil will momentarily go high
activating the Alarm O:2/2 which stays ON until I:1/4 is pressed manually.
• As we can see in RUNG001 that XIO (Normally Closed) contact is used for Window Sensor input I:1/3
because it is normally in true state when not activated. So when the breakage of a window is detected, it
goes false from its true condition allowing Alarm Coil O:2/1 to go high for a moment which in turn activates
Alarm O:2/2.
• In RUNG002, latching has to be provided in order to keep the alarm ringing even if the detection by the
sensors is momentary or to be accurate, pulsating.
Runtime Test Cases
Master Window Motion Alarm
Switch
0 x x 0
0 x x 0
0 x x 0
0 x x 0
1 0 0 1
1 0 1 1
1 1 0 0
1 1 1 1

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 06

Students Sign Staff Sign

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 26
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 07: Execute / Simulate a PLC program for the Traffic light controlling application

Problem Description: Implement controlling of Traffic Lights in PLC using Ladder Diagram programming
language.
Problem Solution
• There are two methods to solve this problem. One is by using stack operation and the other one is by
using sequencer output method.
• Sequencer output method is best suited for this problem since very less configuration is needed and
program length is also reduced.
• In this method, we need to assign SQO instruction by configuring all the parameters given in the
instruction.
• File, Mask, Dest, Control, Length and Positions are parameters which we need to configure.
• File: It is the starting address for the registers in the sequencer file.
• Mask: Mask is the bit pattern through which data flow happens from source to the destination address. If
there is 1 in the masking, it passes values and if 0, it blocks the data flow.
• Dest: It is the address of the input to which the Sequencer Output instruction moves the data.
• Control: Is the address that contains the parameters with control information for the instruction. EN, DN
and ER are bit which sets according to the status of sequencer output. EN and DN bits are set just as in
timers. ER bit stands for Error bit, it is set when a negative position/length value is detected by the
processor, or zero length value.
• Length: It is the number of steps of the sequencer file starting at position 1. Position 0 is the start-up
position.
• Position: It indicated the steps that is desired to start the sequencer instruction. The start position is all
zeros, this is represented as the neutral position; so no outputs will be turned ON in position 0.
• So, to start the actual function of output sequence, Position 1 is determined as starting sequence while
programming.
• Integers or Bit Registers are used as Destination Address.
PLC Program
Here is PLC program to Control Traffic Lights, along with program explanation and run time test cases.
List of Inputs and Outputs
I:1/0 = Start (Input)
I:1/1 = Stop (Input)
B3:0/0 = Latched Coil Bit (Bit)
T4:0 = Timer to update output sequence (Timer)
SQO = Sequencer output (Sequencer)
O:2/0 = North-South Green Light (Output)
O:2/1 = North-South Yellow Light (Output)
O:2/2 = North-South Red Light (Output)
O:2/3 = East-West Green Light (Output)
O:2/4 = East-West Yellow Light (Output)
O:2/5 = East-West Red Light (Output)

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Ladder Diagram to control Traffic Light

Program Description
• RUNG000 again here is for Master Start and Stop the process.
• File; #N7:0 and File length is 10, hence output sequence is varied from N7:0 to N7:10 with each input.
• Destination is set to O:2 hence with each transition, N7:0 to N7:10 are moved to O:2 with masking.
• O:2/0 to O:2/5 are used as the output address to Traffic Lights and hence Mask has value 003Fh which
means data flow of N7:0/0…N7:10/0 to N7:0/5…N7:10/5 is passed and the remaining N7:0/6…N7:10/6
to N7:0/15…N7:10/15 are blocked.
• Control parameters are assigned to register R6:0.
• Sequence of traffic lights to be operated are stored in the registers from N7:0 to N7:10 as following.
• Time base is set to 4secs, hence after every 4secs, output sequence is changed to its next register pattern
outputs which is then transferred to O:2 and O:2/0 to O:2/5 are energized accordingly.
• As we can see, from N7:1 to N7:4 have the same bit pattern. So, these bits are set to 1 for 4 cycles that is
16secs. These bits are used for South-North Green light and East-West Red light.
• Similarly, the entire sequence is followed.
• When Stop I:1/1 is pressed, Position is reset to 0 and all the outputs are de-energized.
Runtime Test Cases

Experiment: Develop PLC program for the following application

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 07

Students Sign Staff Sign

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 29
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 08: Execute / Simulate a PLC program for the Water level controlling application

Problem Description
One open tank is installed in the plant of which liquid level is to be controlled. When level reaches the Level
Low, Outlet flow is blocked and inlet flow is allowed until high level is achieved. And when Level High is
detected, outlet flow is allowed and inlet flow is blocked.
Problem Diagram

Problem Solution
• To detect high and low level of liquid in the tank, two level switches are used which gives output in digital
terms, that is when corresponding levels are detected, it gives output high otherwise remain low.
• To control level of this system, Single Acting piston valve can be used which has two states, either fully
open or fully close.
• Low Level Switch is mounted at the bottom of the tank and Level High switch mounted at the side upper
most position.
• When these inputs are detected, output to Control Valve has to be latched in order to continuously fill or
empty the system.
• Master start/stop is also provided to shut down or start the entire process.
PLC Program
Here is PLC program to Control Level of a Single Tank, along with program explanation and run time test
cases.
List of Inputs and Outputs
I:1/0 = Level High Switch (Input)
I:1/1 = Level Low Switch (Input)
O:2/0 = Inlet Valve (Output)
O:2/1 = Outlet Valve (Output)
I:1/14 = Start (Input)
I:1/15 = Stop (Input)

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 30
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Ladder Diagram to control this process

Program Description
• RUNG000 is simply for latching a coil and master start-stop buttons.
• RUNG001 is to control the outlet valve through O:2/1. This is done when Level High is detected.
• Latching of Output O:2/1 is done because when High Level is detected, input to RUNG001 is temporary,
like Push Button. So, in order to keep outlet valve open until the Level Low I:1/1 is detected, latching is
done. XIO of Level Low Switch is connected in series so that when Level Low is detected, it goes true
closing the outlet valve.
• Similarly, in RUNG002, it works exactly same. The only difference in RUNG002 is that extra I:1/14
contact in parallel with LLS.
• Suppose when the system is started and the tank is partially filled, neither LHS nor LLS is detected, in
this case, outlet and inlet valves remain closed while inlet valve should open to start filling the tank
because it’s partially filled.
• To eliminate this error, I:1/14 (Start) is connected in parallel to LLS I:1/1 contact. This checks if LHS
(I:1/0) is detected or not. If LHS is not detected, then it opens the inlet valve until LHS is detected.

Runtime Test Cases

Inputs Outputs Physical Elements
I:1/0 = 1, I:1/1 = 0 O:2/1 = 1, O:2/0 = 0 LHS Detected, Open Outlet Valve
I:1/0 = 0, I:1/1 = 1 O:2/0 = 1. O:2/1 = 0 LLS Detected, Inlet Valve
I:1/0 = 0, I:1/1 = 0 O:2/0 = 1. O:2/1 = 0 None detected, Open Inlet Valve

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 31
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 08

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 09: Execute / Simulate a PLC program automatic door system using optical
sensor and linear actuator

Problem Description
Implement logic for the automatic door open & close system in PLC using ladder diagram programming
language.
Problem Diagram

List of inputs
• Infrared sensor: I:1/0
• Closing limit switch: I:1/1
• Opening limit switch: I:1/2

List of outputs
• Opening motor: O: 2/0
• Closing motor: O: 2/1
Problem Solution
• In this system when someone enters the infrared sensing field, opening motor starts working to open
the door automatically till the door touches the door opening limit switch.
• If the door touches the opening limit switch for 8sec and no body enters the sensing field/area, then
closing motor starts to close the door automatically till the door touches the closing limit switch.
• Stop the closing action immediately if someone enters the sensing field during the door closing process.

PLC Ladder diagram for Automatic Door Control System

Program Description
Rung 1: When infrared sensor is detected (I:1/0), door opening motor (O:2/0) will start. The door will be
open. When it touches the close limit switch (I:1/1), opening motor will be stop.
Rung 2: When the door touches the opening limit switch (I:1/2), timer will be executed.
Rung 3: After 10 seconds time closing motor (O:2/1) will start. When it touches the closing limit switch,
closing motor will turn OFF.

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 33
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 09

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 10: Execute / Simulate a PLC program for an Automatic Elevator control

Problem Description
Design a PLC program to execute the elevator system Call buttons in a 4-floor apartment using Allen
Bradley PLC programming.
Problem Diagram

In the above picture, there are totally four floors. There are two user panels. One is inside the lift and other is
outside the lift. Limit switches are used to locate and stop the lift at each floor. Priority is given to the Outside
Call input.
Sl No I/O Value Used for
1 O:4/0 Motor Up movement control
2 O:4/1 Motor Down moment control
3 I:5 = 296 First / Ground Floor
4 I:5 = 212 Floor 2
5 I:5 = 128 Floor 3
6 I:5 = 46 Floor 4
7 I:1/11 Floor 4 Down Button
8 I:1/6 Floor 1 Up Button
9 I:1/8 Floor 3 Up Button
10 I:1/10 Floor 3 Down Button
11 I:1/7 Floor 2 Up Button
12 I:1/9 Floor 2 Down Button

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 35
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Problem Solution / PLC Ladder Diagram

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 36
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 10

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 11: Execute / Simulate a PLC program for car parking.

Problem Description
A parking plot has total capacity of Cars. Number of empty spots are displayed on the display outside the
Parking Plot and which spots are available is to be indicated by LEDs. Implement this in PLC using Ladder
Diagram programming language.
Problem Solution
• Counter is used to count the number of empty spots.
• Proximity Sensors or IR Sensors are used to detect the presence of car.
• Here in this system IR Sensor can be well installed to make this system
cost efficient since Proximity Sensors are costly than IR Sensors.
• Value of counter is displayed on the display which is mounted outside the parking plot.
• This counter value is converted into decimal.
PLC Program
Here is PLC program for a Car Parking System, along with program explanation and run time test cases.
List of Inputs and Outputs
I:1/0 to I:1/4 = IR Sensor to detect the presence of cars (Inputs)
O:2/0 to O:2/4 = LEDs to indicate presence of car spots (Outputs)
C5:0 = To increment when Car exits (Counter Up)
C5:0 = To decrement when Car enters (Counter Down)
O:6 = Display address (Output)

Runtime Test Cases

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 38
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Ladder Diagram for Car Parking System

Program Description
• Counter Up CTU and Counter Down CTD are used to determine the Exit and Entry of cars respectively.
• Value 5 is already stored in the accumulator since only 5 number of spots are there in this Parking Plot.
• So whenever car enters or exits from the Parking area, the value in the counter is incremented and
decremented accordingly.
• Accumulator holds decimal values, this value thus sent to the display through BCD converter which
converts Decimal digits into equivalent Binary Coded Decimal signals.
• Display receives whatever the value Accumulator holds, in terms of BCD.
• I:1/5 and I:1/6 are two inputs from other two IR Sensors to detect the exit and entry of cars accordingly.
• Here again, CTU and CTD both have the same address in order to vary accumulator value of both counters
according to Exit and Entry of cars.
• XIO (Normally Closed) contact is used here for IR Sensor outputs so that LED is ON when the spot is
empty.

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 39
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 11

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 12: There are 3 mixing devices on a processing line A, B, C. After the process begin
mixer-A is to start after 7 seconds elapse, next mixer-B is to start 3.6 second after A. Mixer-C is to start
5 seconds after B. All of then remain ON until a master enable switch is turned off. Develop PLC ladder
diagram, timing diagram and simulate the same

Problem Description:

Ladder Diagram

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 41
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 12

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Experiment Number 13: Logic Experiment: Develop a PLC ladder diagram to construct an alarm
system which operates as follows.

- If one input is ON nothing happens.

- If any two inputs are ON, a red light goes ON.
- If any three inputs are ON, an alarm sirens sound.
- If all are ON, the fire department is notified.
• Execute the Ladder

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 43
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 13

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Experiment Number 14: Lab Experiment: Execute a PLC program for the Traffic light controlling

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 45
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Work Sheet
Experiment No 14

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028

Logic Reasoning Exercise Problem

Execute a PLC program for Water level controlling

Answer this question: Does water level sensor send signal [0 or 1] when water is fill or empty?

Note:
a) Motor switch = O:2/0
b) Low level indicator I:1/4
c) High Level indicator I:1/5
c) Level indicator send signals like Push Button

Prepared by: Mr Thanmay J.S, H.O.D Mechanical Engineering, VVETP, Mysore Page | 47
 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Unit Test 01
Draw the Ladder Logic for the given Problem

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Unit Test 02
Draw the Ladder Logic for the given Problem

Students Sign Staff Sign

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 Vidya Vikas Educational Trust (R),
Vidya Vikas Polytechnic
27-128, Mysore - Bannur Road Alanahally, Alanahally Post, Mysuru, Karnataka 570028
Students Unit Test 03
Draw the Ladder Logic for the given Problem

Students Sign Staff Sign

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