TABLE OF CONTENTS

About the Machine ...................................................................................................... 1

Components and functions ...................................................................................... 2

Circuit Diagram ...................................................................................................... 4

Technical Specifications ............................................................................................. 5

Other Apparatus Required .......................................................................................... 6

List of Accessories ...................................................................................................... 6

Application ................................................................................................................... 7

Before the Experiment ................................................................................................ 17

A Comprehensive Guide for GX Works2................................................................... 21

A Comprehensive Guide for Kinco Dtools V4.4.0 Configuration............................. 33

Laboratory Experiment No. 1.................................................................................................. 43

Laboratory Experiment No. 2.................................................................................................. 55

Laboratory Experiment No. 3.................................................................................................. 69

Laboratory Experiment No. 4.................................................................................................. 88

Laboratory Experiment No. 5.................................................................................................. 102

Laboratory Experiment No. 6.................................................................................................. 115

Laboratory Experiment No. 7.................................................................................................. 133

Laboratory Experiment No. 8.................................................................................................. 154

 ABOUT THE MACHINE

The Basic Programmable Logic Controller

(PLC) Trainer is an interactive, hands-on tool
designed to teach electrical engineering students the
fundamentals of automation and industrial control
systems. It allows students to apply theoretical
concepts to real-world scenarios, such as motor
control and process automation, using components
like indicator lights, switches, and relays. With its
user-friendly interface and versatile programming
options, the PLC Trainer provides an engaging
learning experience that enhances troubleshooting
and programming skills, preparing students for future
careers in automation engineering.

FEATURES
Comprehensive platform for teaching PLC
concepts and application
Stand-alone operation
User-friendly interface
Incorporates safety features
Graphical representation of the circuit for
convenient connection purposes.

Page |1
 COMPONENTS AND FUNCTIONS

PLC. The PLC serves as the core component for managing various control operations,

including motor control, sensor input processing, and output management, through ladder logic

programming.

Circuit Breaker. It acts as a safety device that automatically interrupts the electrical

circuit when the current exceeds a predetermined threshold, preventing damage to the PLC,

motors, sensors, and other connected components.

Pushbutton. The pushbuttons serve as input devices that allow users to interact with

and control the system.

Emergency Stop Switch. The emergency stop pushbutton in the Basic PLC Trainer is

a crucial safety feature designed to immediately halt all operations in the system in the event

of an emergency or hazardous situation.

Page |2
 Magnetic Contactor. It acts as an electrically controlled switch that opens and closes
the power circuit, allowing the PLC to remotely control the start and stop functions of the motor
or other connected devices.

Relays. The relay in the Basic PLC Trainer functions as an electrically operated switch,
allowing the PLC to control multiple circuits with different voltage levels.

Timers. In the Basic PLC Trainer, their function is to introduce controlled time delays
into processes.

Indicator Lamps. The indicator lamps in the PLC trainer provide essential visual
feedback to users, indicating the operational status of various laboratory experiments.

Limit Switch. In a pressurized water tank laboratory, the limit switches act as binary
input devices for the PLC to manage water levels.

Linear Actuator. The actuator moves in a straight line, opening or closing the valve
based on signals from the PLC.

Color Sensor. In a basic PLC trainer, a color sensor is typically used to detect the
color of an object and provide this data as an input to the PLC.

Terminal Block. In a PLC trainer, its main purpose is to organize and facilitate safe,
reliable wiring by providing a secure and easy-to-manage interface for connecting wires.

Human Machine Interface. In a PLC trainer, its main purpose is to provide real-time
monitoring and control of the process being simulated or controlled by the PLC.

Motor Starter. The motor starter in the Basic PLC Trainer is essential for safely
starting and stopping the electric motor while controlling its power supply according to the
PLC's programmed logic.

Power Supply Switch. To control the power supply to the PLC trainer, allowing users
to easily turn it on or off as needed.

Single Phase Induction Motor. The function of the single-phase motor in the Basic
PLC Trainer is to serve as the output for various laboratory experiments.

Page |3
 CIRCUIT DIAGRAM

The diagram shows the detailed circuit structure of a Basic Programmable Logic Controller

(PLC) Trainer, demonstrating how each component is represented by different variables that

relate to their functions inside the system. The PLC is key to this system, serving as the

principal command source for the complete trainer configuration. Furthermore, the figure

highlights the integration of a reliable power supply system that powers all components, with

particular consideration given to those that require variable voltage levels. For example,

converters are used to accept components with lower voltage ratings, such as the 24V DC

power supply required for various sensors and actuators, as well as to supply the appropriate

voltage to the PLC itself. This thorough arrangement not only improves the PLC Trainer's

value, but also ensures its safety and efficiency.

Page |4
 TECHNICAL SPECIFICATIONS

These specifications are designed to meet the needs of educational institutions and
training programs that focus on electrical engineering and automation. They provide a thorough
insight into the trainer's design, components, performance characteristics, and the types of
exercises and experiments it supports. The machine consists of:

1. Programmable Logic Controller

● Supply: 220VAC

● Power Consumption: 37W

● Inputs: 27 pts

● Outputs: 17 pts

● Output type: Relay

2. Circuit Breaker

● Rating: 15 A, 2 Poles

3. Terminal Block Fuses

● Rating: Common Terminals: 2 A, I/O Terminals: 500 mA

4. Push Button

● 22mm, NO-NC, Momentary, 10A, (2 green, 2 red, 2 yellow)

● 22mm, NO-NC, Pushlock, 10A, (1 yellow)

5. Emergency Stop Switch

● 22mm, NC 10A

6. Magnetic Contactor

● 3P 25A, 18A, 9A 220V Coil

7. Thermal Overload Relays

Page |5
 ● 3P Setting: 4-6A

8. Indicator Lights

● 22mm, 220V (3 red, 2 green, 2 blue, 2 yellow)

9. Linear Actuator

● 24V, 100mm, 100N

10. Color Sensor

● 24V, Photoelectric switch type

11. Human Machine Interface (HMI)

● Supply: 24VDC

● Power Consumption: 17W

12. Power Supply

● 220V Input, 24V 5A Output

13. Single Phase Motor

● 0.37kW (0.5HP) Cap Start 4P 71F Flange

14. Dimensions

● Size: Compact and portable design suitable for classroom or laboratory use.

● Weight: Construction is easy for transport and handling

OTHER APPARATUS REQUIRED (NOT INCLUDED)

● Multimeter (for checking of connections)

LIST OF ACCESSORIES

● Wires (For User Wiring: 18AWG Stranded, For Motor Wiring: 14 AWG Stranded)

● Terminal Lugs, DIN Rails, Plug, Cable Rails, and other accessories.

Page |6
 APPLICATION

This section covers the download and usage of GX Works 2 and Kinco Dtools V4.4.0,

essential software for the PLC Trainer's control system. GX Works 2, a tool from Mitsubishi

Electric, supports programming and maintenance, while Kinco Dtools V4.4.0 is used for

designing interfaces and programming HMI controls. These programs allow students to

simulate motor control processes and PLC applications, providing a hands-on learning

experience that bridges theoretical knowledge with practical skills.

PROCEDURE TO INSTALL GX WORKS 2:

1. Disable any antivirus software on your computer and turn off Windows Defender

Firewall in the Control Panel before installing the applications.

2. Download GX Works 2 software and extract it with password “plc247.com”

Page |7
3. Click the file “GX Works 2 Version 1.560j” folder.

4. Click the file “setup.exe” and select “OK”.

Page |8
5. Click “Next” to continue the software installation.

6. Click the “Key-Install file and copy the provided key.

Page |9
7. You can choose whether to install extra GX-Developer applications.

P a g e | 10
8. Choose Destination Location.

9. Allow a few minutes for the installation process.

P a g e | 11
10. Select Install to install Device.

11. After the installation procedure is completed, select Finish

P a g e | 12
PROCEDURE TO INSTALL KINCO DTOOLS V4.4.0:

1. Disable any antivirus software on your computer and turn off Windows Defender

Firewall in the Control Panel before installing the applications.

2. Copy the software from the USB and proceed to extract the software.

3. Select Install language and click next

P a g e | 13
4. Accept the license agreement and choose next

5. Choose Next

P a g e | 14
6. Select the software installation directory

7. Click “Install” to start installing software

P a g e | 15
8. Wait for the installation process to take place in a few minutes until the installation

process is completed.

P a g e | 16
 BEFORE THE EXPERIMENT

While students are capable of independently conducting laboratory experiments, it is

essential for an instructor to supervise and guide them, particularly during the setup of the
laboratory trainer. Moreover, instructors can choose to accompany students throughout the
experiments to ensure safety, enhance understanding, and improve the overall learning
experience.

Prior to beginning the laboratory experiments, several preparatory tasks must be

completed. These tasks include:

1. Assembly of the modules:

The Basic PLC Trainer is designed with modular components, including relays, timers,
and contactors, which can be easily detached from the DIN rails to accommodate various
configurations based on the user’s preferences. This flexibility allows users to customize
the setup according to specific learning objectives or experimental requirements. To
remove a module, grasp the handle located at the back of the component, ensuring a secure
grip to prevent any accidental drops or damage.

2. Energizing and de-energizing of the machine:

To safely operate the Basic PLC Trainer, plug it into a suitable power source and turn
on the power supply switch on the panel to start the system. After the experiment, press the
emergency button to stop activities, then switch off the power supply and disconnect the
machine. Moreover, it is crucial to know the supply specifications of each component.
Components requiring DC power must be connected to the 24V DC supply, while those
needing AC power should be connected to the 220V AC supply. Mixing these connections
can cause damage and unsafe operation.

3. Circuit Checking and Parameters Reading:

Electrical Engineering has a rule to always check your connections first before
energizing. In this laboratory trainer, a multimeter will be used to verify the connections made
in this machine. The below discussions show the guideline on how to use the aforementioned
electrical devices.

P a g e | 17
CONTINUITY TESTING

Turn on the clamp meter with the mode of Ω and set to Continuity test or Buzzer mode
with a symbol of using SEL/NCV button. Then use the prongs to plug in the L1 and L2
terminals and test the circuit. When there is a buzzer sound meaning the circuit is shorted or
there is a wrong connection. The circuit is correct when there is no buzzing sound.

3. Ladder Diagram Familiarization:

Understanding ladder diagrams for PLC applications is essential for effective

troubleshooting, accurate design and modification, ensuring safety, and maintaining
standardization in industrial control systems. Ladder diagrams provide a clear visual
representation of the control logic, making it easier for engineers and technicians to
interpret the functioning of the system. The discussions outlined below will guide students
in comprehensively grasping a specific circuit by familiarizing them with the various
devices used within the Mitsubishi GX Works software, which serves as an excellent
educational tool for mastering PLC-based ladder diagrams.

P a g e | 18
 Device Name Type Function

X Input Input terminal on the PLC (e.g. pushbuttons)

Y Output Output terminal on the PLC (e.g. contactor or lamp)

A buffer memory in the PLC that can have two states, ON or

M Relay
OFF

T Timer A “time relay” that can be used to program timed functions

C Counter A counter

Data storage in the PLC in which you can store things like
D Data Register
measured values and the results of calculations.

Ladder Symbols and its Function

The Rails represent the start and end of each

line of symbolic code, running vertically
along the edges of the diagram.

Rungs are horizontal lines that represent the

logic flow through the symbolic code. They
connect the vertical rails to the logic
expressions, similar to how wires connect
components in a relay logic circuit.

P a g e | 19
The Normally Open (NO) contact symbol
represents a contact that is open when the
condition is false and closed when the
condition is true.
The Normally Closed (NC) contact symbol
represents a contact that is closed when the
condition is false and open when the
condition is true.
An OR operation is logically the same as
the parallel connection of multiple switches
in an electrical circuit.
The Output Coil symbol activates the
output when the input condition is true and
deactivates it when the condition is false.
SET instructions can be used to use a brief
switching pulse to switch an output or relay
on (set) and leave them on.

The device will then remain on until you

switch it off (reset) with a RST instruction.

A Rising pulse indicates a switch of the

device value from “0” to “1”

A Falling pulse indicates a switch of the

device value from “1” to “0”

P a g e | 20
CREATING LADDER DIAGRAM: A COMPREHENSIVE GUIDE FOR GX WORKS2

1. Launch GX Works 2 by double-clicking the application icon. Go to Project > New.

 In the prompt window select “FXCPU” for PLC series and

“FX3G/FX3GC” for CPU Type, then click OK to create the project.

P a g e | 21
2. Open Ladder Editor

 Once the project is created, the main screen will open, a blank ladder
editor window will open.

 The image below is the zoomed toolbar where the contacts, output coil,
and line icons are placed.

3. Insert a Contact (X Element):

 Click on the Contact icon in the toolbar (symbolized by normally open or

normally closed contacts).

 Click in the ladder editor where you want to place the contact.

 A prompt will appear to address the contact. Input the contact address

(e.g., X000 for input 0 or X001 for input 1).

 Click OK to place the contact.

P a g e | 22
 

Here is the Open Contact icon:

The prompt window

4. Insert an Output Coil (Y Element):

 Click on the Output Coil icon in the toolbar (symbolized by open and

close parenthesis)

 Click to place the output coil at the right side of the rung.

 A prompt will appear to address the output coil. Input the output address

(e.g., Y000 for output 0 or Y001 for output 1).

 Click OK to place the contact.

Here is the Output Coil icon:

The prompt window

P a g e | 23
5. Insert an Brach Contact Element:

 Click on the Branch Contact icon in the toolbar (symbolized by open

contact with a branch)

 In the ladder editor window, click under the contact element that requires a

latch to place the branch contact making a latching circuit.

 A prompt will appear to address the branch contact. Address it as either an

input or output address depends on the ladder logic.

 Click OK to place the contact.

Here is the Branch Contact icon:

Place the cursor under the contact

The prompt window

6. Insert a Timer Element:

 To insert a timer, click on the Output Coil icon in the toolbar (symbolized

by open and close parenthesis)

 Click to place the output coil at the right side of the rung.

P a g e | 24
  A prompt will appear to address the output coil. Type T (for Timer),

address the timer with a unique address (e.g., T1 for Timer 1 and K50 for

the 5 second timing cycle). Note: Timing cycle is in milliseconds so a

value of 10 is equivalent to 1 second

 Click OK to place the contact.

Here is the Output Coil icon:

The prompt window

7. Insert a Counter Element:

 Similar to inserting a counter, click on the Output Coil button in the

toolbar (symbolized by open and close parenthesis)

 Click to place the output coil at the right side of the rung.

 A prompt will appear to address the output coil. Type C (for Counter),

address the timer with a unique address (e.g., C1 for Counter 1 and K10

for the 10 counting cycle).

 Click OK to place the contact.

P a g e | 25
 Here is the Output Coil icon:

The prompt window

8. Addressing Ladder Elements:

 Input Contacts (X): Inputs such as switches, push buttons, and sensors are

addressed as X0, X1, X2, etc.

 Output Coils (Y): Outputs such as relays, motors, or actuators are addressed as

Y0, Y1, Y2, etc.

 Timers (T): Timers used for delays are addressed as T0, T1, T2, etc.

 Counters (C): Counters are addressed as C0, C1, C2, etc.

9. Adding Comments to Ladder Elements:

 From inserting the element (contact, coil, timer, or counter), select comment

icon at the left side of the prompt window. Then click OK.

 In the comment box, write a description or label for the element (e.g., "Start

Button" for X0 or "Motor Output" for Y0).

 Click OK to save the comment.

P a g e | 26
 Here is the Device comment icon:

 To view comment, select View, from the dropdown click the Comment.

 The comment will now appear next to the addressed element, helping you or

others understand its function at a glance.

P a g e | 27
 Comments can be viewed

10. Compiling the Ladder Diagram

 Click on Compile in the toolbar to check for any errors and select Build to

successfully create the ladder diagram.

P a g e | 28
 After successfully compiling, go to Project and select the Save button icon to

save the ladder diagram program.

 Rename the file and choose your desired location of the file.

P a g e | 29
11. Simulate and Download to PLC
 Click on Debug or the simulation icon in the toolbar and run the simulation

to verify the logic.

 If the indicator becomes green, the simulation is already running.

P a g e | 30
12. Uploading to PLC

 Connect your computer to the PLC using the appropriate communication cable.
 Click on Online > Write to PLC to download the ladder program to the PLC
and follow the prompts to complete the download process.

 Check only the applicable including the Program up to the Parameter.

P a g e | 31
 Click Execute to completely upload the ladder diagram into PLC.

P a g e | 32
A COMPREHENSIVE GUIDE FOR KINCO DTOOLS V4.4.0 CONFIGURATION

1. Install Kinco DTools and Necessary Software:

● Download and install Kinco DTools

● Make sure you have the Mitsubishi GX Works or any other Mitsubishi PLC

programming software installed.

2. Create a New Project in Kinco DTools:

● Open Kinco DTools.

● Go to File > New Project. Create a project name and select the HMI model

“GL070” you are using from the list. Then, click OK to create the new

project.

P a g e | 33
3. Configure Communication Settings Between HMI and PLC:

● Edit the Communication Parameters Set from the System Parameters Set

Window. Make sure that it resembles the image below.

● Then click the Advanced Settings. Edit the values similar to the input values

from the image below.

P a g e | 34
4. Selecting the PLC Model:
● From the graph element window, go to PLC select Mitsubishi Series, then
Mitsubishi FX3G. DRAG the device into the screen.

● From the connector list, get a serial port then connect the Com0 of the HMI
with the PLC, as shown in the image below.

P a g e | 35
 ● After completing the procedure, the PLC and HMI are now connected.
Proceed with the creation of the HMI interface. Go to Window > HMI Edit
window.

5. Configure Bitstate Switch:

● A Bitstate Switch allows you to toggle between two states (ON/OFF,

TRUE/FALSE).

This is where the bit state

switch located

P a g e | 36
● In the Component Library, select the Bitstate Switch and DRAG it onto the
HMI screen and arrange it in your preferred location.

● Double-click the Bitstate Switch to open the properties window as shown

below.

● In the Bit Address section, set the address of the bit you want to control in the
PLC (for example, X for Mitsubishi PLC).

● In the Bit State Switch section, set the switch type to Set 1 Pulse, and the
pulse width to 1 as shown below.

P a g e | 37
● You can also customize the appearance through the Graphics section.

v
1

● After configuring the bit state switch, click OK.

P a g e | 38
6. Configure Lamp Component:

● A Lamp component displays the status of a specific bit in the PLC.

This is where the bit state switch

located

● In the Component Library, select the Lamp and DRAG it onto the HMI
screen. Arrange it in your preferred location.

● Double-click the Lamp to open the properties window as shown below.

P a g e | 39
● In the Bit Address section, enter the address of the bit you want to monitor
(for example, Y for Mitsubishi PLC).

● You can also customize the appearance of the lamps in Graphics section.

v
1

● After configuring lamp, click OK.

P a g e | 40
7. Configure Number Display:

● A Number Display component shows numerical data (e.g., register values)

from the PLC.

● In the Component Library, select the Number Display and drag it onto the
HMI screen.

● Double-click the Number Display to open the properties window as shown

below.

● In the Register Address section, input the address of the register you want to

display (for example, D100 for Mitsubishi PLC).

● Set the Data Type (e.g., 16-bit integer, 32-bit integer, or floating-point)

● Customize the number format (decimal, integer, etc.).

● Then, click OK.

P a g e | 41
8. Download the Project to HMI:

● Connect the Kinco HMI to your PC via USB.

● Click Download in Kinco DTools or go to Tools > Download.

● Select the correct port (USB) and download the project to the HMI.

9. Test the HMI with Mitsubishi PLC:

● After downloading the project, test the HMI in conjunction with the

Mitsubishi PLC.

● Check if the Bitstate Switch properly toggles the corresponding bit in the

PLC.

● Ensure that the Lamp displays the correct status of the bit.

● Verify that the Number Display shows the correct values from the PLC

registers.

P a g e | 42
 LABORATORY EXPERIMENTS

LABORATORY ACITVITY 1: START-STOP MOTOR CONTROL OPERATION

(SINGLE PHASE)

DISCUSSION

In this experiment, students will learn how to use a Basic Programmable Logic

Controller (PLC) Trainer to implement a start-stop motor control operation. This fundamental

control operation is essential for understanding how industrial motors are managed and

controlled in various applications. The experiment highlights the activation and deactivation of

the motor. Once the push button for starting is pressed, the motor should start and run.

Conversely, the motor should stop working as soon as the stop push button is pressed.

OBJECTIVES

This activity aims to:

 Develop a start stop motor control ladder diagrams and enhance understanding of
wiring and programming in motor control systems.
 Operate the motor using pushbuttons, an HMI interface, and a Programmable Logic
Controller (PLC) to control its activation and deactivation.
 Verify the motor's response to start and stop commands to ensure proper operation
according to the programmed logic.

MATERIALS
 Terminal  Motor Starter  Pushbutton  Single Phase
Block Motor

 Programmable  Screwdrivers  Gloves  Multimeter

Logic
Controller
 I/O: 2/2

P a g e | 43
PROCEDURE: Ladder Diagram for Start-Stop Motor Control Operation

1. Insert the Start Button:

 Click the "open contact" icon, which will represent the start button, and place

this icon in the first rung and set the address to X0.

2. Insert the Stop Button:

 Click the "close contact" icon and place it beside the open contact icon in the

first rung. and set the address to X1.

3. Insert the Contactor Output:

 Click the "application instruction" icon at the end of the first rung and set the

address to Y0, which represents the contactor.

P a g e | 44
4. Add Latching Mechanism:

 Below the open contact icon in the first rung, add an "open branch" icon and set

the address to Y0.

5. The ladder diagram of the Start-Stop Motor Control Operation was shown below.

PROCEDURE: Actual Wiring for Start-Stop Motor Control Operation

1. PLC and Power Supply Wiring:

 Connect the 220V (black) supply to the AC (red) terminal block. Connect the

220V (red) supply to the AC (blue) terminal block. Connect the 0V PLC supply

DC (blue) terminal block. Connect the 24V PLC supply to Sink/Source (S/S) of

the PLC.

2. Start Push Button Wiring:

 Connect the Green Normally Open Push Button (black) to DC (blue) terminal

block. Connect the Green Normally Open PB (red) to X0 of the PLC.

P a g e | 45
3. Stop Push Button Wiring:

 Connect the Red Normally Open PB (black) to DC (blue) terminal block. X1 of

the PLC. Connect the Red Normally Open PB (red) to X1 of the PLC.

4. Motor Wiring:

 Connect the 220V (black) supply to the 1/L1 of the contactor and (red) supply

to the 3/L2 of the contactor. Connect the A1 to Com0, A2 to the AC (blue)

terminal block. Connect the AC (red) terminal block to Y0. T1 contact to the

U1 red terminal of the motor. T2 of the overload relay to 5/L3. T3 contact of

the U2 red, U2 terminal to Z2 and U1 terminal to Z1 terminal of the motor.

Note: The motor connections will use the terminals Z1, U1, Z2, and U2.

P a g e | 46
5. The wiring diagram of the Start-Stop Motor Control Operation was shown below

P a g e | 47
PROCEDURES: Operating the HMI

1. Connect the HMI to the PLC:

 Use cable to connect the HMI to the PLC.

 Use a USB cable to connect the HMI to the laptop.

 Edit the created ladder diagram, insert a new rung to the top, with an open

contact address as M8002, and an instruction output icon [ MOV K0 D8120]

 Use the Kinco software to control the components.

OVERALL EXPERIMENTAL PROCEDURES:

1. Launch GX Works on the Laptop

● Open the GX Works software to begin programming the PLC ladder diagram.

Go to File > New Project.

Note: Select FXCPU for PLC series and FX3G/FX3GC for CPU Type, then click OK to

create the project.

P a g e | 48
2. Create the Ladder Diagram

● Design the ladder diagram for the start-stop motor control operation. Once the

pushbutton for starting was pressed, the motor should start and run. On the other

hand, the motor should stop working as soon as the stop push button was

pressed.

● Compile the program to check for errors.

● The ladder diagram for this experiment is shown in the ladder diagram

procedure.

3. Wiring the Components

● Ensure the trainer is powered off before starting any wiring.

● Connect the components according to the actual wiring diagram of the

experiment, including pushbuttons, motor starter, and the motor.

4. Perform a Continuity Test

● Use a multimeter to verify all connections are correct.

● Check for any loose connections or short circuits to ensure safe operation.

5. Power On the Trainer

● After completing the continuity test and confirming all connections, turn on the

trainer.

6. Upload the Ladder Diagram to the PLC

● Connect the PLC to the laptop via the USB port. Check the connection

destination of the Serial Port in GX Works. Make sure that it is on USB.

● Confirm that the PLC is not in running mode before proceeding to the next step.

● Go to Online > Write to PLC in GX Works.

● Check only the applicable data (PLC Data Parameter) before proceeding.

P a g e | 49
 ● Execute the upload to transfer the ladder diagram to the PLC.

7. Create the HMI Display Using Kinco DTools

● Open Kinco DTools and follow the configuration procedure to connect the HMI

with the PLC.

● Create the HMI interface, adding all the inputs and outputs from the ladder

diagram to the HMI window, addressing them accordingly.

8. Download the HMI Program

● Connect the PLC to the HMI

● After completing the HMI display, go to Tools > Downloads

● Set the port to USB and download the HMI program to the HMI device.

● Wait for the download to complete successfully.

9. Operational Testing

 After wiring and programming, test the system using manual pushbuttons first.

 Press the start button to initiate the first operation, and press the stop button to

initiate the second operation. Examine the experiment’s operation outcome and

record your observation in the data and results table.

 Then test motor control via the HMI interface to ensure proper operation.

 Press the start button on the HMI display to initiate the first operation, and press

the stop button to initiate the second operation. Observe the operation of the

experiment and write your findings in the data and results table.

P a g e | 50
Notes:

● Double-check all wiring connections before powering the system to prevent damage.

In an emergency, immediately press the Emergency stop located at the left side of the

trainer to stop the trainer's operation.

● Always verify that the PLC is in the correct mode (Stop/Run) before uploading or

downloading programs.

DATA AND RESULTS

Manual Operation

Output Components Type of Operation Result (Run/Stop)

Single Phase Motor Start (Press) RUN

Start (Latch) RUN

Stop (Press) STOP

Stop (Release) STOP

Integrating HMI Operation

Output Components Type of Operation Result (Run/Stop)

Single Phase Motor Start (Press) RUN

Start (Latch) RUN

Stop (Press) STOP

Stop (Release) STOP

P a g e | 51
ANALYSIS

1. What happened when you pressed the start push button? What was the response of the

motor when the stop push button was pressed?

 When the start push button was pressed, the motor immediately began to

operate, indicating that the PLC successfully executed the command as per the

ladder logic program. This action showed that the electrical connections

between the push button, PLC inputs, and the motor were correctly configured,

allowing the motor to receive power and start running. On the other hand, when

the stop push button was pressed, the motor halted its operation without any

delay. This response confirmed that the stop command was correctly processed

by the PLC and that the output controlling the motor was deactivated as intended

2. What steps did you take to troubleshoot if the motor did not stop after pressing the stop

button?

● If the motor did not stop upon pressing the stop button, several systematic

troubleshooting steps were followed to identify and resolve the issue. First, the

wiring connections were thoroughly inspected to ensure that the stop button was

properly connected to the designated PLC input terminal (X1) and that there

were no loose or disconnected wires that could interrupt the signal transmission.

Next, the ladder diagram was reviewed to verify that the stop button was

represented correctly as a normally closed (NC) contact, which is essential for

the stop function to work correctly. Additionally, the functionality of the stop

button itself was tested using a multimeter to check for continuity and confirm

that it was operating as expected. These steps helped to systematically eliminate

P a g e | 52
 potential causes and identify the issue, allowing for effective resolution and

restoring proper motor control.

3. How effective is the manual push button in comparison to utilizing the HMI interface?

What are the differences in user preference and ease of operation between controlling

the system via HMI and manual push buttons?

 The manual push button is highly effective for basic operations such as starting

and stopping the motor, offering a direct and immediate means of control. It

provides tactile feedback, which many users find easy to use, particularly for

straightforward tasks. However, when compared to an HMI interface, the

manual push button is limited in its functionality. The HMI interface allows for

more advanced control, such as real-time monitoring of the motor’s operational

status, adjusting parameters, and executing multiple commands from a single

screen. This makes the HMI particularly useful for complex systems where

multiple inputs and outputs need to be managed simultaneously. In terms of user

preference, manual push buttons are often favored for their simplicity and

reliability, while the HMI is preferred for its flexibility and ability to provide

comprehensive control and feedback

4. Why is understanding the start-stop motor control operation important in industrial

settings?

● Understanding the start-stop motor control function is important in industrial

settings because it serves as the foundation for controlling and monitoring

numerous motor-driven systems, including conveyors, pumps, and machines.

Understanding this fundamental action allows operators to successfully operate

equipment, resulting in safe and efficient processes. For students, learning this

P a g e | 53
 information is essential for troubleshooting and optimizing motor control

systems in real-world industrial settings. It also provides a solid foundation for

more advanced motor control and automation tasks, which are critical to

maintaining operational efficiency and safety standards in manufacturing and

industrial settings.

5. How can the knowledge gained from this experiment be applied in real-world

scenarios?

● The knowledge gained through this experiment can be directly applied in a

variety of real-life situations in which motor control systems are essential to

operations. For example, in the manufacturing industry, the ability to develop

and execute start-stop control systems enables engineers to automate operations,

improve safety, and increase operational efficiency. Students can use this

information to design and troubleshoot motor control circuits, ensuring that

systems run smoothly and accurately in response to user inputs. Furthermore,

understanding these control mechanisms is critical for implementing emergency

stop functions, which are essential for protecting both personnel and equipment

in dangerous situations. This practical experience equips students with the skills

needed to design, maintain, and optimize motor control systems in a range of

industrial and commercial applications, preparing them for future roles in

electrical engineering and automation.

P a g e | 54
SUPPLEMENTAL ACTIVITY: ENHANCING START-STOP MOTOR CONTROL

WITH INDICATOR LIGHTS

In this supplemental activity, students will design and implement a start-stop motor

control system that incorporates indicator lights to enhance the user experience and provide

visual feedback about the motor's operational status. This scenario simulates a simple

manufacturing process where a motor-driven machine operates intermittently, allowing

students to explore the integration of control systems and visual indicators. The objective is to

create a control system where the motor starts when the start button is pressed and stops when

the stop button is pressed. To improve the functionality of the system, students will integrate

two indicator lights into their circuit. A green light will illuminate when the motor is running,

signaling that the machine is operational, while a red light will turn on when the motor is

stopped, indicating that the machine is not in operation.

OBSERVATION

During the start-stop motor control experiment, the effective interaction between the

PLC, motor, and manual control mechanisms was observed. The components were carefully

wired according to the schematic diagram, ensuring all connections were secure. When the start

button was pressed, the motor responded promptly, demonstrating that the PLC correctly

processed the input command. The immediate response of the motor validated the functionality

of both the programming and wiring. Activating the stop button halted the motor without delay,

confirming the accuracy of the control logic implemented in the PLC. It was noted that both

the manual push buttons and the Human-Machine Interface (HMI) allowed for effective motor

control, but the HMI provided enhanced user feedback, displaying real-time status and

P a g e | 55
facilitating easier monitoring of motor operations. Overall, this experience emphasized the

importance of precision in both wiring and programming within motor control applications.

CONCLUSION

The experiment successfully met its objective of demonstrating and verifying the proper

activation and deactivation of a motor through a start-stop control operation. The students were

able to check that the PLC correctly responded to user inputs, as evidenced by the immediate

motor activation upon pushing the start button and the quick interruption of activity when the

stop button was pressed. This clear illustration of the start-stop motor control operation gave

the students significant insights into the practical use of PLC systems in industrial settings.

Furthermore, the experiment's troubleshooting tasks provided students with important

problem-solving abilities, allowing them to detect and resolve potential difficulties in motor

control circuits. Additionally, the knowledge obtained from this experiment not only

established their theoretical understanding from class, but it also gave real experience that will

be useful in future careers in electrical engineering and automation.

P a g e | 56
LABORATORY ACTIVITY 2: BASIC PLC OPERATION: FORWARD-REVERSE

MOTOR CONTROL OPERATION

DISCUSSION

The forward-reverse motor control experiment aimed to evaluate the operational

capabilities of a motor system in both forward and reverse directions. This assessment focused

on verifying whether the motor could effectively start and change its rotational direction upon

command. During the experiment, the forward command initiated the motor's rotation in the

forward direction, demonstrating its ability to perform this function promptly. Subsequently,

activating the reverse command caused the motor to cease forward rotation swiftly and

transition smoothly into reverse rotation. By mastering the concepts of forward and reverse

motor control through hands-on experimentation, students gained valuable skills essential for

future applications in industrial automation and control systems.

OBJECTIVES

This activity aims to:

 Design and create a ladder diagram for managing motor operation in both forward and

reverse directions.

 Familiarize students with the principles and implementation of forward-reverse motor

control using a Basic Programmable Logic Controller (PLC) Trainer.

 Test the control system for consistent motor performance in both directions.

P a g e | 57
MATERIALS

 Terminal  Motor Starter  Pushbutton  Single Phase

Block Motor

 Wires  Screwdrivers  Gloves  Multimeter

 Programmable
Logic
Controller
 I/O: 3/4

PROCEDURE: Simulation for Forward-Reverse Motor Control Operation

1. Design First Rung:

 Click the "open contact" icon and set the address to M8002. Add a "coil" icon

at the end of the first rung and set the address to [MOV K0 D8120]

2. Design Second Rung for Forward Operation:

 Click the "open contact" icon and place it in the second rung. Add another "close

contact" icon beside the reverse contactor in the second rung. Create a rung

based on the image below, incorporating an open contact and an output coil.

Address each element accordingly.

P a g e | 58
3. Design Third Rung for Reverse Operation:

 Create a new rung for the reverse operation based on the image below,

incorporating an open contact and an output coil. Address each element

accordingly.

4. Design Third Rung for Reverse Operation:

 Create a new rung for the main contactor based on the image below,

incorporating an open contact and an output coil. Address each element

accordingly.

P a g e | 59
 5. The ladder diagram of the Forward-Reverse Motor Control Operation was shown

below.

PROCEDURE: Actual Wiring of Forward-Reverse Motor Control Operation

1. PLC and Power Supply Wiring:

 Connect the 220V (black) supply to the AC (red) terminal block. Connect the

220V (red) supply to the AC (blue) terminal block. Connect the 0V PLC supply

to the DC (blue) terminal block. Connect the 24V PLC supply to the ink/source

(S/S) of the PLC.

2. Forward Push Button Wiring:

 Connect the Green Normally Open (red) push button to X0 of the PLC. Connect

the Green Normally Open (black) push button to the DC (blue) terminal block.

P a g e | 60
3. Reverse Push Button Wiring:

 Connect the Red Normally Open (red) push button to X1 of the PLC. Connect

the Red Normally Open (black) push button to the DC (blue) terminal block

4. Stop Push Button Wiring:

 Connect the E-Stop Normally Open (NO) push button to X2 of the PLC.

Connect the E-Stop Normally Open (NO) push button to the DC (blue) terminal

block.

5. Motor Wiring for Forward-Reverse Operation:

 Connect Com3 of the PLC to the AC (red) terminal block; connect A1 to Y6

and A2 to the AC (blue) terminal block. Connect 220V positive supply to 1/L1

and 220V negative supply to 3/L2 of the main contactor.

 Wire the overload relay: T2 to 5/L3, T1 to U1, T3 to U2. Connect U1 to 1/L1

and U2 to 3/L2 of the second contactor (forward), with A1 to Y5 and A2 to AC

(blue).

 Wire T1 to Z1 and T2 to Z2 of the second contactor (forward); connect 3/L2 to

1/L1 and 1/L1 of the second contactor (forward) to 3/L2 of the third contactor

(reverse). Finally, connect A1 of the third contactor to Y4, A2 to AC (blue), and

T1 to Z1, with T2 of the second contactor to Z2.

P a g e | 61
6. The wiring diagram of the Forward-Reverse Motor Control Operation was shown

below

P a g e | 62
PROCEDURES: Operating the HMI

1. Connect the HMI to the PLC:

 Use cable to connect the HMI to the PLC.

 Use a USB cable to connect the HMI to the laptop.

 Edit the created ladder diagram, insert a new rung to the top, with an open

contact address as M8002, and an instruction output icon [ MOV K0 D8120]

 Use the Kinco software to control the components

OVERALL EXPERIMENTAL PROCEDURES

1. Launch GX Works on the Laptop

● Open the GX Works software to begin programming the PLC ladder diagram. Go

to File > New Project.

Note: Select FXCPU for PLC series and FX3G/FX3GC for CPU Type, then click OK to

create the project.

P a g e | 63
2. Create the Ladder Diagram

● Design the ladder diagram for the forward-reverse motor control operation. Once

the push button for forward operation is pressed, the motor should start and run in

a clockwise direction. To change to reverse operation, the current operation must

first be stopped. Then, when the push button for reverse is pressed, the motor should

start and run in a counter-clockwise direction. Additionally, the motor should stop

immediately when the emergency stop (e-stop) push button is pressed.

● Compile the program to check for errors.

● The ladder diagram for this experiment is shown in the ladder diagram procedure.

3. Wiring the Components

● Ensure the trainer is powered off before starting any wiring.

● Wire the components according to the schematic diagram, including pushbuttons,

motor starter, and the motor.

4. Perform a Continuity Test

● Use a multimeter to verify all connections are correct.

● Check for any loose connections or short circuits to ensure safe operation.

5. Power On the Trainer

● Once the continuity test is complete and all connections are verified, power on the

trainer.

P a g e | 64
6. Upload the Ladder Diagram to the PLC

● Connect the PLC to the laptop via the USB port. Check the connection destination

of the Serial Port in GX Works. Make sure that it is on USB.

● Confirm that the PLC is not in running mode before proceeding to the next step.

● Go to Online > Write to PLC in GX Works.

● Check only the applicable data (PLC Data Parameter) before proceeding.

● Execute the upload to transfer the ladder diagram to the PLC.

7. Create the HMI Display Using Kinco DTools

● Open Kinco DTools and follow the configuration procedure to connect the HMI

with the PLC.

● Create the HMI interface, adding all the inputs and outputs from the ladder diagram

to the HMI window, addressing them accordingly.

8. Download the HMI Program

 Connect the PLC to the HMI

 After completing the HMI display, go to Tools > Download.

 Set the port to USB and download the HMI program to the HMI device.

 Wait for the download to complete successfully.

P a g e | 65
 9. Operational Testing

 After wiring and programming, test the system using manual pushbuttons first.

 Press the forward button to initiate the first operation. Press the reverse button to

initiate the second operation. Examine the experiment's operation outcome and

record your observations in the data and results table.

 Then test motor control via the HMI interface to ensure proper operation.

 Press the forward button on the HMI display to initiate the first operation. Then

press the reverse button to initiate the second operation.

 Observe the operation of the experiment and write your findings in the data and

results table.

Notes:

● Double-check all wiring connections before powering the system to prevent damage.

In an emergency, immediately press the Emergency stop located at the left side of the

trainer to stop the trainer's operation.

● Always verify that the PLC is in the correct mode (Stop/Run) before uploading or

downloading programs.

P a g e | 66
DATA AND RESULTS

Manual Operation

Output Components Type of Operation Result (Run/Stop)

Single Phase Motor Start Forward (Press) RUN

Start Forward (Latch) RUN

Stop Forward (Press) STOP

Stop Forward (Release) STOP

Start Reverse (Press) RUN

Start Reverse (Latch) RUN

Stop Reverse (Press) STOP

Stop Reverse (Release) STOP

Integrating HMI Operation

Output Components Type of Operation Result (Run/Stop)

Single Phase Motor Start Forward (Press) RUN

Start Forward (Latch) RUN

Stop Forward (Press) STOP

Stop Forward (Release) STOP

Start Reverse (Press) RUN

Start Reverse (Latch) RUN

Stop Reverse (Press) STOP

Stop Reverse (Release) STOP

P a g e | 67
ANALYSYS

1. When switching from forward to reverse motor operation (using push button X1), what

observations did you make regarding the motor's response? Was there any noticeable delay

or smooth transition?

 When the students switched from forward to reverse motor operation using push

buttons, they noticed that the motor responded immediately to the input. There was

no obvious delay in the transition, which highlighted the efficiency of the control

system implemented. When the forward button was pressed, the motor smoothly

run in a clockwise direction. To change to reverse operation, the current operation

must first be stopped.

2. Explain the role of Y0 and Y1 in the ladder logic program for forward and reverse

motor control. How did these outputs affect the operation of the motor?

 In the ladder logic program, Y0 and Y1 serve essential functions in controlling the

direction of the motor's operation. The students noted that Y0 is dedicated to

forward motor operation, while Y1 is designated for reverse operation. When the

forward push button (X0) is pressed, it activates Y0, which initiates the motor to

run in the forward direction. Moreover, pressing the reverse push button (X1)

activates Y1, commanding the motor to rotate in the opposite direction.

3. Compare and contrast the reliability of motor operation between forward and reverse

commands. Were there any instances where the motor did not respond as expected?

● Throughout the experiment, the students evaluated the reliability of motor

performance when executing both forward and reverse commands. They

P a g e | 68
 discovered that the motor consistently responded to both orders as expected,

indicating a high level of reliability. However, they did notice that the motor

had a little delay during directional shifts due to the mechanical inertia that

comes with its operation. This small delay had no major impact on overall

functionality, as the motor completed both actions successfully. The students

determined that the system was reliable, with few discrepancies discovered

during testing, indicating that the control logic was effective in managing the

motor's operational states.

4. Compare the ease of operation between using the HMI (Human Machine Interface)

control and manual pushbutton control for initiating forward and reverse motor operations.

● The students discovered that operating the motor through the HMI (Human

Machine Interface) was significantly easier than using manual pushbuttons

control. The HMI interface provided a user-friendly graphical display, making

it easy for users to engage with the motor controls. Initiating forward and

reverse commands through the HMI required less effort, resulting in faster and

more efficient operations. In contrast, manual pushbutton control required

physical interaction with the buttons, which might be inconvenient, especially

when frequent direction changes were required. The visual input supplied by

the HMI regarding the motor's status improved the user experience by allowing

students to observe operations in real time.

5. What improvements or modifications would you suggest for optimizing the

performance of the forward-reverse motor control system?

P a g e | 69
  To increase the performance of the forward-reverse motor control system, the

students proposed several improvements. First, they proposed implementing soft

start and stop features to reduce mechanical stress on the motor during operation,

thereby improving its lifespan. Furthermore, updating the HMI interface to

incorporate more comprehensive control choices that, would increase users' greater

operational flexibility. Finally, the students highlighted the significance of

implementing a routine maintenance program to ensure the system's long-term

efficiency and to address any possible difficulties early on.

SUPPLEMENTAL ACTIVITY: OPTIMIZING FORWARD-REVERSE CONTROL

USING AN ACTUATOR OUTPUT

In this supplemental activity, students will enhance their understanding of forward-

reverse control by focusing on an actuator output within a practical scenario involving a robotic

arm. The activity simulates the arm’s movement to deliver materials forward to a specific

location and retrieve them back in reverse. Students will first assemble the basic forward-

reverse control circuit to operate the actuator. By pressing the forward button, the actuator will

extend to move materials, and pressing the reverse button will retract the actuator, bringing the

materials back to the starting point.

P a g e | 70
OBSERVATION

During the forward-reverse motor control operation experiment, students observed the

motor's immediate response to the ladder logic program and HMI interface, confirming

successful command execution. The motor transitioned smoothly to reverse after using the

emergency stop button, demonstrating consistent operation without delays. The HMI interface

enhanced monitoring and control by providing clear visual feedback on the motor's status,

while the emergency stop button ensured safety throughout the experiment.

CONCLUSION

Based on the results of the forward-reverse motor control operation experiment,

students concluded they achieved the primary objectives of designing, programming, and

testing a control system for motor operations in both directions. The experiment demonstrated

the effectiveness of using a Programmable Logic Controller (PLC) and Human-Machine

Interface (HMI) for motor control, with the motor responding accurately to both manual

pushbutton and HMI commands. This enhanced their understanding of the relationship

between programming logic and hardware components. Additionally, the importance of safety

measures, such as the emergency stop button, was emphasized for safe operation in industrial

settings. Overall, the experiment reinforced their knowledge and provided practical skills

valuable for their future engineering careers.

P a g e | 71
LABORATORY ACTIVITY 3: TIMER APPLICATION IN PLC FOR STOPPING A

MOTOR

DISCUSSION

Timers are vital in automation systems for facilitating delays and timed operations

essential for coordinating industrial tasks. Internal PLC timers are programmed within the PLC,

using the system clock and scan cycles for precise control of operations like setting time delays

and managing motor activity duration. In contrast, external timers are independent devices that

connect to the PLC or motor control circuits, offering timing capabilities without burdening

the PLC's processing power. In this laboratory activity, students will gain hands-on experience

in controlling a motor's running time using both internal and external timers, allowing them to

explore the different functionalities and applications of each type.

OBJECTIVES

This activity aims to:

 Control a motor by implementing both an external and internal PLC timer.

 Design and construct a functional PLC-based program that integrates a timer, both an

internal PLC timer and an external timer device, for stopping a motor at a predetermined

time.

 Compare and contrast the distinct characteristics of an external and internal PLC timers.

P a g e | 72
PART 1: INTERNAL PLC TIMER APPROACH

MATERIALS:

 Terminal  Motor Starter  Pushbutton  Single Phase

Block Motor

 Wires  Screwdrivers  Gloves  Multimeter

 Programmable
Logic
Controller
 I/O: 2/2

PROCEDURES: Ladder Diagram Simulation of the Internal PLC Timer Approach

1. Create and insert the first rung:

 Create a rung based on the image below, incorporating an open contact and an

output coil. Address each element accordingly.

2. Create and insert the second rung:

 Create a rung based on the image below, incorporating a falling pulse contact

and an instruction output coil. Address each element accordingly.

P a g e | 73
3. Create and insert the third rung:

 Create a rung based on the image below, incorporating an open contact and

timer output coil with a data register. Address each element accordingly.

4. Create and insert the fourth rung:

 Create a rung based on the image below, incorporating a timer open contact and

an instruction output coils for resetting the output. Address each element

accordingly.

5. Create and insert the fifth rung:

 Create a rung based on the image below, incorporating an open contact and an

instruction output coil representing the present value for the timer. Address each

element accordingly.

P a g e | 74
 6. The image below shows the whole ladder diagram of the Internal Timer Application in

PLC for Stopping a Motor.

PROCEDURES: Actual Wiring of the Internal PLC Timer Approach

1. PLC and Power Supply Wiring:

 Connect the 220V black supply to the AC (red) terminal block, the 220V red
supply to the AC (blue) terminal block, the 0V PLC supply to the DC (blue)
terminal block, and the 24V PLC supply to the Sink/Source (S/S) of the PLC.
2. Start Push Button Wiring:
 Connect the Green Normally Open Push Button (black) to the DC (blue)
terminal block and the Green Normally Open PB (red) to X0 of the PLC.
3. Stop Push Button Wiring:
 Connect the Red Normally Open Push Button (black) to the DC (blue) terminal
block and the Red Normally Open PB (red) to X1 of the PLC.
4. Motor Wiring:
 Connect the 220V (black) supply to 1/L1 and the 220V (red) supply to 3/L2 of
the contactor; connect A1 to Com0 of the PLC, A2 to the AC (blue) terminal
block, and Y0 to the AC (red) terminal block; wire the contactors T1 to U1, T2
to 5/L3 of the overload relay, T3 to U2, U2 to Z2, and U1 to Z1 of the motor.

Note: The motor connections will use the terminals Z1, U1, Z2, and U2.

P a g e | 75
5. The image below depicts the wiring diagram of the Internal Timer Application in PLC

for Stopping a Motor.

P a g e | 76
PROCEDURES: Operating the HMI

1. Connect the HMI to the PLC:

 Use cable to connect the HMI to the PLC.

 Use a USB cable to connect the HMI to the laptop.

 Edit the created ladder diagram, insert a new rung to the top, with an open

contact address as M8002, and an instruction output icon [ MOV K0 D8120]

 Use the Kinco software to control the components.

OVERALL EXPERIMENTAL PROCEDURES:

1. Launch GX Works on the Laptop

● Open the GX Works software to begin programming the PLC ladder diagram.

Go to File > New Project.

P a g e | 77
 Note: Select FXCPU for PLC series and FX3G/FX3GC for CPU Type, then click OK

to create the project.

2. Create the Ladder Diagram

● Design the ladder diagram for motor control using an internal timer in the PLC

to stop motor operation after a preset time.

● Compile the program to check for errors.

● The ladder diagram used in this experiment was shown in the ladder diagram

procedure.

3. Wiring of Components

● Make sure the trainer is turned off before beginning any wiring.

● Connect the components as shown in the actual wiring diagram, including the

pushbuttons, contactor, and motor.

4. Perform a Continuity Test

● Utilize a multimeter to check that all connections are accurate.

● Look for any loose connections or short circuits to ensure safe operation.

5. Power On the Trainer

● After completing the continuity test and confirming all connections, turn on the

trainer.

6. Upload the Ladder Diagram to the PLC

● Connect the PLC to the laptop via USB port. Check the connection destination

of the Serial Port in GX Works. Make sure that it is on USB.

● Confirm that the PLC is not in running mode before proceeding to the next step.

● Go to Online > Write to PLC in GX Works.

P a g e | 78
 ● Check only the applicable data (PLC Data and Parameter) before proceeding.

● Execute the upload to transfer the ladder diagram to the PLC.

7. Create the HMI Display Using Kinco DTools

● Open Kinco DTools and follow the configuration procedure to connect the HMI

with the PLC.

● Create the HMI interface, adding all the inputs and outputs from the ladder

diagram to the HMI window, addressing them accordingly.

8. Download the HMI Program

● Connect the HMI to the PLC

● After completing the HMI display, go to Tools > Download.

● Set the port to USB and download the HMI program to the HMI device.

● Wait for the download to complete successfully.

9. Operational Testing

● After completing the wiring and programming, test the experiment by first using

the manual pushbuttons.

● Press the start push button to initiate the first operation. After then, examine the

● experiment's operation outcome and record your observations in the data and

results table.

● Then test the motor control using the HMI interface to ensure proper operation.

● Press the start push button on the HMI display to initiate the first operation.

After observing the result of the experiment, note your findings in the data and

results table.

P a g e | 79
Notes:

● Double-check all wiring connections before powering the system to prevent damage.

In case of an emergency, immediately press the Emergency stop located at the left side

of the trainer to stop the trainer's operation.

● Always verify that the PLC is in the correct mode (Stop/Run) before uploading or

downloading programs.

DATA AND RESULTS

Manual Operation

Output Components Type of Operation Result (Run/Stop)

Single Phase Motor Start (Press) RUN

Timer (Timing Start) RUN

Timer (Timing Stop) STOP

Integrating HMI Operation

Output Components Type of Operation Result (Run/Stop)

Single Phase Motor Start (Press) RUN

Timer (Timing Start) RUN

Timer (Timing Stop) STOP

P a g e | 80
ANALYSIS

1. How does the internal timer's preset value affect the duration for which the motor

operates before stopping?

● The internal timer's preset value determines how long the motor runs before

stopping. A higher preset value extends the motor's operating time, while a

lower value shortens it.

2. What role does the HMI play in the timer-based motor control system, and how does it

differ from utilizing a manual push button?

● The HMI (Human-Machine Interface) allows for more flexible, real-time

control and monitoring of the timer and motor settings. Unlike a manual push

button, which only provides simple on/off control, the HMI can adjust timer

values, start/stop operations, and display system statuses.

3. In what ways do internal timers contribute to reducing manual intervention and

improving the reliability of automated operations?

● Internal timers automate motor operations by reducing the need for manual

input, enhancing precision in timing, and improving reliability by consistently

adhering to preset conditions, reducing human error.

P a g e | 81
SUPPLEMENTAL ACTIVITY: IMPLEMENTING INTERNAL PLC TIMER

APPLICATION FOR STARTING A MOTOR

In this supplemental activity, students will focus on implementing an internal PLC timer

application to control the starting of a motor, incorporating indicator lights for visual feedback.

The scenario simulates an industrial setup where a motor operates a conveyor system that needs

to start automatically after a predetermined delay, allowing for precise control over production

processes. Students will begin by wiring a basic motor control circuit that includes a start button

to manually initiate the motor and a timer that will activate the motor after a set duration (e.g.,

10 seconds). Once the timer is started, it will count down the specified time, and when it reaches

zero, it will automatically trigger the motor to start, engaging the conveyor system.

OBSERVATION

The internal PLC timer approach offers a highly efficient method for automating time-

based operations, such as motor control. By setting a precise preset value, the timer ensures

consistent operation durations without the need for manual intervention. This not only enhances

system accuracy but also improves reliability by reducing human error. Additionally,

integrating the timer with an HMI allows for real-time adjustments and monitoring, providing

greater control and flexibility over the system's operation. Overall, the use of internal PLC

timer streamlines processes, contributing to more efficient and automated industrial

environments

P a g e | 82
PART 2: EXTERNAL TIMER APPROACH

MATERIALS

 Terminal  Motor Starter  Pushbutton  Single Phase

Block Motor

 External  Screwdrivers  Gloves  Multimeter

Timer

 Programmable  Wires
Logic
Controller
 I/O: 3/6

PROCEDURES: Simulation of the External Timer Approach

1. Create and insert the first rung:

● Create a rung based on the image below, incorporating an open contact and an

output coil. Address each element accordingly.

2. Create and insert the second rung:

● Create a rung based on the image below, incorporating a falling pulse contact

and an instruction output coil. Addressed each element accordingly.

P a g e | 83
3. Create and insert the third rung:

● Create a rung based on the image below, incorporating an open contact and an

output coil represents the external timer. Address each element accordingly.

4. Create and insert the fourth rung:

● Create a rung based on the image below, incorporating a timer open contact and

an instruction output coils for resetting the output. Address each element

accordingly.

5. The image below presents the ladder diagram of the External Timer Application in PLC

for Stopping a Motor.

P a g e | 84
PROCEDURES: Actual Wiring of the External Timer Approach

1. PLC and Power Supply Wiring:

 Connect the 220V black supply to the AC (red) terminal block, the 220V red

supply to the AC (blue) terminal block, the 0V PLC supply to the DC (blue)

terminal block, and the 24V PLC supply to the Sink/Source (S/S) of the PLC.

2. Start Push Button Wiring:

 Connect the Green Normally Open Push Button (black) to the DC (blue)

terminal block and the Green Normally Open PB (red) to X0 of the PLC.

3. Stop Push Button Wiring:

 Connect the Red Normally Open Push Button (black) to the DC (blue) terminal

block and the Red Normally Open PB (red) to X1 of the PLC.

4. Motor Wiring:

 Connect the 220V (black) supply to 1/L1 and the 220V (red) supply to 3/L2 of

the contactor; connect A1 to Com0 of the PLC, A2 to the AC (blue) terminal

block, and Y0 to the AC (red) terminal block; wire the contactors T1 to U1, T2

to 5/L3 of the overload relay, T3 to U2, U2 to Z2, and U1 to Z1 of the motor.

Note: The motor connections will use the terminals Z1, U1, Z2, and U2.

5. Timer Connections:

● Connect the 24V (black) supply to terminal 13 of the timer, 24V (red) to Com1

of the PLC, terminal 14 to Y1, terminal 9 to X2, and terminal 5 to the PLC 0V

(DC negative blue terminal block)

P a g e | 85
6. The image below shows the wiring diagram of the External Timer Application in PLC

for Stopping a Motor.

P a g e | 86
PROCEDURES: Operating the HMI

1. Connect the HMI to the PLC:

 Use cable to connect the HMI to the PLC.

 Use a USB cable to connect the HMI to the laptop.

 Edit the created ladder diagram, insert a new rung to the top, with an open

contact address as M8002, and an instruction output icon [ MOV K0 D8120]

 Use the Kinco software to control the components

OVERALL EXPERIMENTAL PROCEDURES:

1. Launch GX Works on the Laptop

● Open the GX Works software to begin programming the PLC ladder diagram.

Go to File > New Project.

P a g e | 87
 Note: Select FXCPU for PLC series and FX3G/FX3GC for CPU Type, then click OK

to create the project.

2. Create the Ladder Diagram

● Create a ladder diagram to control the motor, incorporating an external timer

to stop the motor after a set duration.

● Compile the diagram to check for any errors.

● The ladder diagram for this experiment is shown in the ladder diagram

procedure.

3. Wiring of Components

● Make sure the trainer is turned off before beginning any wiring.

● Connect the components as shown in the actual wiring diagram, including the

pushbuttons, contactor, and motor.

4. Perform a Continuity Test

● Utilize a multimeter to check that all connections are accurate.

● Look for any loose connections or short circuits to ensure safe operation.

5. Power On the Trainer

● After completing the continuity test and confirming all connections, turn on the

trainer.

6. Upload the Ladder Diagram to the PLC

● Connect the PLC to the laptop via USB port. Check the connection destination

of the Serial Port in GX Works. Make sure that it is on USB.

● Confirm that the PLC is not in running mode before proceeding to the next step.

● Go to Online > Write to PLC in GX Works.

P a g e | 88
 ● Check only the applicable data (PLC Data and Parameter) before proceeding.

● Execute the upload to transfer the ladder diagram to the PLC.

7. Create the HMI Display Using Kinco DTools

● Open Kinco DTools and follow the configuration procedure to connect the HMI

with the PLC.

● Create the HMI interface, adding all the inputs and outputs from the ladder

diagram to the HMI window, addressing them accordingly.

8. Download the HMI Program

● Connect the HMI to the PLC

● After completing the HMI display, go to Tools > Download.

● Set the port to USB and download the HMI program to the HMI device.

● Wait for the download to complete successfully.

9. Operational Testing

● After completing the wiring and programming, test the experiment by first using

the manual pushbuttons.

● To begin the first operation, press the start push button. Next, review the

operation outcome of the experiment and note your findings in the data and

results table.

● Then test the motor control using the HMI interface to ensure proper operation.

● To begin the first operation, press the start push button located on the HMI

display. Make a note of your observations in the data and results table after

analyzing the experiment's operation outcome.

P a g e | 89
Notes:

● Double-check all wiring connections before powering the system to prevent damage.

In case of an emergency, immediately press the Emergency stop located at the left side

of the trainer to stop the trainer's operation.

● Always verify that the PLC is in the correct mode (Stop/Run) before uploading or

downloading programs.

DATA AND RESULTS

Manual Operation

Output Components Type of Operation Result (Run/Stop)

Single Phase Motor Start (Press) RUN

Timer (Timing Start) RUN

Timer (Timing Stop) STOP

Integrating HMI Operation

Output Components Type of Operation Result (Run/Stop)

Single Phase Motor Start (Press) RUN

Timer (Timing Start) RUN

Timer (Timing Stop) STOP

P a g e | 90
ANALYSIS

1. How does the external timer interact with the PLC input/output system?

● The external timer signals the PLC by activating an input when its countdown

ends, triggering an output, like stopping the motor.

2. What is the role of the HMI in controlling the motor with an external timer, and how

does this differ from using a manual push button for timer-based control?

● The HMI offers advanced control and monitoring of the external timer and

motor, allowing real-time adjustments to timer settings, unlike a manual push

button, which only starts or stops the motor.

3. What are the advantages and limitations of using an internal PLC timer compared to an

external hardware timer in controlling the motor?

● Internal PLC timers simplify integration and system design with greater

programmability and flexibility, while external hardware timers offer higher

precision and operate independently of the PLC, making them useful in certain

specialized applications.

4. In what situations would you prefer an external timer over an internal PLC timer?

● An external timer is preferred for precise, independent timing control or in

systems with minimal PLC reliance, like standalone mechanical processes.

P a g e | 91
SUPPLEMENTAL ACTIVITY: CONTROLLING MOTOR START-UP WITH AN

EXTERNAL TIMER DEVICE

In this supplemental activity, students will focus on utilizing an external timer device

to control the starting of a motor, incorporating indicator lights for visual feedback. The

scenario simulates an industrial setup where a motor operates a conveyor system that needs to

start automatically after a predetermined delay, allowing for precise control over production

processes. Students will begin by wiring a basic motor control circuit that includes a start button

to manually initiate the motor and an external timer device that will activate the motor after a

set duration (e.g., 10 seconds). Once the start button is pressed, the external timer will begin

counting down the specified time. When the timer reaches zero, it will send a signal to the

motor control circuit, automatically triggering the motor to start and engaging the conveyor

system.

CONCLUSION

The experiment comparing internal PLC timers and external hardware timers for

stopping a motor demonstrates that internal timers offer streamlined integration, enhanced

flexibility, and reduced hardware complexity, making them ideal for most automated control

systems. However, external timers provide higher precision and operate independently of the

PLC's processing cycles, which can be advantageous in specialized applications. Both

approaches effectively automate motor control, with the choice between them depending on

system requirements for precision and integration complexity.

P a g e | 92
LABORATORY ACTIVITY 4: SEQUENTIAL LIGHT CONTROL APPLICATION

DISCUSSION

The experiment conducted on the Basic Programmable Logic Controller (PLC) Trainer

focused on showcasing the capability of a PLC to manage the sequential operation of multiple

lights according to predefined timing criteria. This practical exercise utilized ladder diagram

programming, integrating timers and conditional logic to control the sequence of lighting.

Through this experiment, students gained valuable hands-on experience in PLC programming,

logical sequencing, and troubleshooting methodologies.

OBJECTIVES

This activity aims to:

 Familiarize students with the principles of sequential light control application using

a Basic Programmable Logic Controller (PLC) Trainer

 Design and create a ladder diagram for the sequential light control application.

 Demonstrate how a Programmable Logic Controller (PLC) can control the

activation and deactivation of lights in a specific sequence as programmed.

MATERIALS

 Terminal  Wires  Pushbutton  Indicator

Block Lamps

 Programmable  Screwdrivers  Gloves  Multimeter

Logic
Controller
 I/O: 2/4

P a g e | 93
PROCEDURES: Simulation for Sequential Light Control Application

1. Design First Rung:

 Add the "open contact" icon, and a "coil" icon at the end of the first rung and

set the address to [MOV K0 D8120] just like the figure below.

2. Design Second Rung for Start and Stop Buttons:

 Add the "open contact" icon and place it in the second rung. Place a "close

contact" icon beside the open contact icon in the second rung. Add the "coil"

icon at the end of the second rung. Address all the contacts according to the

image below.

3. Design Third Rung for Timer and Light Control Logic:

 Add the "open contact" icon for internal relay, a “coil" icon for timer, an “open

contact” for timer contacts and a “coil” icon for lamps. Create a rung based on

the image below, incorporating the said elements, and address them

accordingly.

P a g e | 94
4. Design Fourth Rung to operate Timer for present value (PV):

 Add the "open contact" icon and add an " instruction coil" icon at the end of the

rung. Place a parallel rung based on the image below, incorporating other

instruction coil. Address each element accordingly.

5. The ladder Diagram of the Sequential Light Control Application was shown below.

P a g e | 95
PROCEDURE: Actual Wiring of Components for Sequential Light Control Application

1. PLC and Power Supply Wiring:

 Connect the 24V supply of the PLC to the Sink/source (S/S), 0V supply of the

PLC to the DC terminal block (blue), 220V (black) supply to the AC (red)

terminal block, Connect the 220V (red) supply to the AC (blue) terminal block.

2. Lamp Wiring:

 Connect the red terminal to the corresponding output terminal (Y0 for red, Y1

for green, Y2 for yellow, Y3 for blue). Connect the black terminal to the AC

blue terminal block.

3. PLC Common Connections:

 Connect Com0 of the PLC to the AC (red) terminal block, Com1 of the PLC to

the AC (red) terminal block, and Com2 of the PLC to the AC (red) terminal

block.

4. Start Push Button Wiring:

 Connect the Green Normally Open (NO) push button to X0 of the PLC, and the

Green Normally Open (NO) push button to the DC (blue) terminal block.

5. Stop Push Button Wiring:

 Connect the Red Normally Open (NO) push button to X1 of the PLC and the

Red Normally Open (NO) push button to the DC (blue) terminal block

P a g e | 96
6. The wiring diagram of the Sequential Light Control Application was shown below.

P a g e | 97
PROCEDURES: Operating the HMI

1. Connect the HMI to the PLC:

 Use cable to connect the HMI to the PLC.

 Use a USB cable to connect the HMI to the laptop.

 Edit the created ladder diagram, insert a new rung to the top, with an open

contact address as M8002, and an instruction output icon [ MOV K0 D8120]

 Use the Kinco software to control the components

OVERALL EXPERIMENTAL PROCEDURES:

1. Launch GX Works on the Laptop

 Open the GX Works software to begin programming the PLC ladder diagram.

Go to File > New Project.

P a g e | 98
Note: Select FXCPU for PLC series and FX3G/FX3GC for CPU Type, then click OK to

create the project.

2. Create the Ladder Diagram

 Design the ladder diagram for the sequential light control application. Once the

start pushbutton is pressed, it activates the corresponding lights which are red,

green, yellow, and blue in a sequence manner as specified by the program where

it followed a specific order and timing dictated by the logic programmed into

the ladder diagram.

 Compile the program to check for errors.

 The ladder diagram for this experiment is shown in the ladder diagram

procedure.

3. Wiring the Components

 Ensure the trainer is powered off before starting any wiring.

 Wire the components according to the actual wiring diagram, including

pushbuttons, and lamps (red, green, yellow and blue).

4. Perform a Continuity Test

 Use a multimeter to verify all connections are correct.

 Check for any loose connections or short circuits to ensure safe operation.

P a g e | 99
5. Power On the Trainer

 Once the continuity test is complete and all connections are verified, power on

the trainer.

6. Upload the Ladder Diagram to the PLC

 Connect the PLC to the laptop via the USB port. Check the connection

destination of the Serial Port in GX Works. Make sure that it is on USB.

 Confirm that the PLC is not in running mode before proceeding to the next step.

 ·Go to Online > Write to PLC in GX Works.

 Check only the applicable data (PLC Data Parameter) before proceeding.

 Execute the upload to transfer the ladder diagram to the PLC.

7. Create the HMI Display Using Kinco DTools

 Open Kinco DTools and follow the configuration procedure to connect the HMI

with the PLC.

 Create the HMI interface, adding all the inputs and outputs from the ladder

diagram to the HMI window, addressing them accordingly.

8. Download the HMI Program

 Connect the PLC to the HMI

 After completing the HMI display, go to Tools > Download.

 Set the port to USB and download the HMI program to the HMI device.

 Wait for the download to complete successfully.

P a g e | 100
9. Operational Testing

 After wiring and programming, test the system using manual pushbuttons first.

 Press the start pushbutton to initiate the first operation, and press the stop

pushbutton to initiate the second operation. Examine the experiment's operation

outcome and record your observations in the data and results table.

 Then test sequential light operation via the HMI interface to ensure proper

operation.

 Press the start button on the HMI display to initiate the first operation, and press

the stop button to initiate the second operation. Observe the operation of the

experiment and write your findings in the data and results table.

Notes:

● Double-check all wiring connections before powering the system to prevent

damage. In an emergency, immediately press the Emergency stop located at the left

side of the trainer to stop the trainer's operation.

● Always verify that the PLC is in the correct mode (Stop/Run) before uploading or

downloading programs.

P a g e | 101
DATA AND RESULTS

Manual Operation

Output Components Type of Operation Result (Run/Stop)

Red Indicator Lamp 1 Start (Press) RUN

RL Timer (Timing Start) RUN

RL Timer (Timing Stop) STOP

Green Indicator Lamp 2 GL Timer (Timing Start) RUN

GL Timer (Timing Stop) STOP

Yellow Indicator Lamp 3 YL Timer (Timing Start) RUN

YL Timer (Timing Stop) STOP

Blue Indicator Lamp 4 BL Timer (Timing Start) RUN

BL Timer (Timing Stop) STOP

Emergency Stop (Press) STOP

Integrationg HMI Operation

Output Components Type of Operation Result (Run/Stop)

Red Indicator Lamp 1 Start (Press) RUN

RL Timer (Timing Start) RUN

RL Timer (Timing Stop) STOP

Green Indicator Lamp 2 GL Timer (Timing Start) RUN

GL Timer (Timing Stop) STOP

P a g e | 102
 Yellow Indicator Lamp 3 YL Timer (Timing Start) RUN

YL Timer (Timing Stop) STOP

Blue Indicator Lamp 4 BL Timer (Timing Start) RUN

BL Timer (Timing Stop) STOP

Emergency Stop (Press) STOP

ANALYSIS

1. Describe the sequence in which the lights were activated and deactivated during the

experiment. How did the timing intervals between each light change affect the overall

sequence?

 During the experiment, the light sequence of light activation began with the first

lamp (red lamp), which illuminated for the internal timer's preset period. Lamp 1

was turned off after the timer ended, and Lamp 2 was activated, following a similar

pattern for Lamps 3 and 4. This sequential process was executed at preset intervals

determined by the timers, ensuring that each lamp was illuminated in order for

specific time frames before moving on to the next lamp. The timing intervals were

critical in determining the smoothness and effectiveness of the transition between

lights. A well-defined interval allowed for a visually consistent sequence, which

improved the overall design and practical appeal of the light control system. If the

timing intervals were too short, it could create confusion, resulting in light overlap

or an unexpected visual appearance. On the other hand, long gaps can cause

P a g e | 103
 sequence delays, reducing the lighting system's desired dynamic flow. Overall, the

timing significantly impacted the sequence's clarity and effectiveness.

2. Compare the operation of the PLC-controlled sequential light system to manually

controlling each light individually. What are the advantages of using PLC automation in

this context?

 The operation of the PLC-controlled sequential light system markedly differs from

manually controlling each light individually. In a manual setup, an operator would

have to physically turn on and off each light, which can be inconvenient and prone

to human error, especially when multiple lights need to be operated in quick

succession. However, PLC automation enables exact timing and control over the

light sequence without the need for direct interaction, lowering the possibility of

errors and increasing operating efficiency. Furthermore, the PLC may be set up to

follow complex sequences and respond to changing situations. This level of control

not only improves system reliability but also allows the operator to focus on other

activities rather than manually controlling each light, demonstrating the major

benefits of employing PLC technology.

3. How did the use of timers (T0, T1, T2, T3) influence the timing of light activation and

deactivation? Were these timers effective in achieving the desired sequence?

 Throughout the experiment, the use of internal timers (T0, T1, T2, T3) was critical

in determining when light was activated and deactivated. Every timer was

programmed to control how long a given light remained illuminated, resulting in a

clear sequence of actions. For example, T10 was in charge of Lamp 1, while

P a g e | 104
 subsequent timers controlled the activation of Lamps 2, 3, and 4. T The

effectiveness of these timers in achieving the desired sequence was evident in the

seamless transitions between lamps, as each timer ensured that a light was

deactivated before the next was activated, adhering to the programmed intervals.

The reliability of the timers not only facilitated the intended lighting sequence but

also demonstrated how timers can be integrated into PLC programming to manage

complex operational tasks efficiently.

4. When using the HMI interface against the manual push button, which is more efficient?

What are the differences between using a manual push button system controller and an

HMI in terms of user preference and operational ease of use?

 When comparing the efficiency of the Human-Machine Interface (HMI) to the

manual push button system, it was obvious that the HMI provides more operational

ease and user preference. The HMI provides a visual display that allows users to

monitor and manage the lighting system more easily. Users may quickly check the

condition of each lamp and start the sequence with a single tap of the screen.

However, the manual push button system needs the operator to press each button,

which can be less efficient, particularly in situations requiring quick responses.

Furthermore, the HMI can include capabilities like as adjustable timers or custom

sequences that are not available with a basic manual setup. As a result, the HMI

interface not only improves the user experience but also simplifies operations,

making it the preferred choice in modern automated systems.

P a g e | 105
 5. What is the significance of understanding PLC programming and ladder logic in the

context of industrial automation? How does this experiment contribute to your

understanding of automation principles?

 Understanding PLC programming and ladder logic is essential in the field of

automation, as these skills are the foundation for modern automated systems. This

experiment offered useful information on how PLCs work and how ladder logic can

be used to effectively create complicated control systems. Students were able to

apply theoretical information to real-world situations through this hands-on

experience, which enhanced their understanding of automation principles. The

ability to program and troubleshoot PLC systems is essential for future

professionals in this field, since these abilities are becoming more important in

organizations that rely on automation for operational efficiency

P a g e | 106
SUPPLEMENTAL ACTIVITY: DESIGNING A LOOPING SEQUENCE FOR

SEQUENTIAL LIGHTS CONTROL

In this supplemental activity, students will design and implement a looping sequence

for controlling a series of indicator lights in a simulated assembly line production process. The

objective of this scenario is to teach students about sequential logic, timing, and automation in

an industrial setting. Students will set up a circuit that includes multiple LED lights, each

representing a different stage in the assembly process, such as "Assembly," "Quality Check,"

and "Packaging." The task is to create a programmable sequence where the lights turn on and

off in a specific order, reflecting the progress of items along the production line, and repeat the

sequence continuously. For example, the "Assembly" light will stay on for 4 seconds,

indicating that items are being assembled. After this, the "Quality Check" light will turn on for

3 seconds, signaling that products are undergoing inspection. Finally, the "Packaging" light

will illuminate for 5 seconds, showing that items are being packaged. Once the packaging is

complete, the sequence will loop back to the "Assembly" light, creating a continuous cycle that

mimics real-life production

OBSERVATION

The Sequential Light Control Application experiment successfully showed the use of a

Basic Programmable Logic Controller (PLC) to manage the sequential operation of multiple

indicator lamps. During the experiment, students noticed that the lights illuminated in a

predetermined order, first red, then green, yellow, and blue. Each lamp remained illuminated

for a set amount of time, which was programmed into the PLC using timers. The timing

intervals were important for ensuring that each light moved smoothly and without overlap,

P a g e | 107
providing a clear visual sequence. The Human-Machine Interface (HMI) allowed students to

easily start and stop the sequence, showing the practical benefits of automation.

CONCLUSION

The experiment achieved its primary objective of illustrating how a PLC can control

the sequential activation and deactivation of lights using preset timing. The results confirmed

that each lamp illuminated in the proper order, following the logic defined in the ladder

diagram. Timers were useful in maintaining exact control over the timing of each light,

ensuring that transitions went smoothly. Furthermore, the experiment showed the advantages

of using PLC automation over manual control, as it improved reliability and efficiency in

managing complicated sequences. The HMI integration improved user engagement by making

the lighting sequence easier and straightforward. Overall, this experiment not only provided

students with practical experience in programming and troubleshooting PLC systems but also

deepened their understanding of automation principles.

P a g e | 108
LABORATORY ACTVITY 5: COLOR SENSOR APPLICATION

DISCUSSION

Color sensors are versatile devices capable of detecting both the intensity and specific

color of light reflected from a surface. They find extensive applications in robotics, particularly

in line-following scenarios, where robots navigate along predefined paths. In this lab setup, we

utilize a color sensor to create a paper color detection system integrated with indicator lights

and motor control. The system is initiated by pressing a start button and can be manually halted

using a stop button. Upon detecting different paper colors, the color sensor activates

corresponding indicator lamps, with specific motor control triggered by the detection of a green

paper.

OBJECTIVES

This activity aims to:

 Demonstrate the application of a color sensor in detecting various paper colors.

 Create a ladder diagram that implement the detection of color sensor into different

colored object activating equivalent lamps and motor.

 Control a motor based on the detected color using the color sensor.

MATERIALS

 Color Sensor  Wires  Pushbutton  Indicator

Lamps

 Programmable  Screwdrivers  Gloves  Multimeter

Logic
Controller
 I/O: 2/7

P a g e | 109
PROCEDURES: Simulation for Color Sensor Application

1. Set Up Initial Conditions

● Add a normally open (NO) contact for M8002, typically used to reset or

initialize values when the PLC starts. Use the MOV instruction to move a

constant value of K0 to the memory address D8120 (or similar registers, as

shown).

2. Color Sensor Logic

● Create a rung based on the image below, incorporating open contacts for the

start buttons, internal relay, and the color sensor contacts for detecting colors as

well as output coil for color sensor output contact. Then address each element

accordingly.

P a g e | 110
3. Input and Timer Logic

● In the next rung, start with the coil M0 that you added previously. Add NO

contacts X001 and X002. Use a timer instruction T10 in the next rung. This

timer will count down and then activate its assigned output.

4. Control Outputs

● Use RST and SET commands to reset and set specific outputs like Y004. Create

a rung based on the image below, incorporating an open contact and an

instruction output coils for resetting the output. Address each element

accordingly.

5. Final Reset and Start Rungs

● The final rung includes an M8000 and adds a MOV command at the end of the

ladder logic to move the timer value (like T10) to a register such as D200.

P a g e | 111
6. The ladder diagram of the Color Sensor Application was show below:

P a g e | 112
PROCEDURE: Actual Wiring of Components for Color Sensor Application

1. Color Sensor and Power Supply Wiring:

● Connect the second-to-last terminal of the color sensor to the X1 input on the
PLC and the last terminal of the color sensor to the X2 input on the PLC;
Connect the red terminal of the color sensor to the y10 output on the PLC and
the blue terminal of the color sensor to the 24 VDC black terminal of the power
supply.

2. Push button Wiring:

● Connect the NO black terminal of the green pushbutton to the DC blue terminal
block and the NO red terminal of the green pushbutton to the X0. Connect the
NO black terminal of the red pushbutton to the DC blue terminal block and the
NO red terminal of the red pushbutton to the X3.

3. Indicator Lamp Wiring:

● Connect the red terminal to the corresponding output terminal (Y0 for red, Y1
for green, Y2 for yellow, Y3 for blue). Connect the black terminal to the AC
blue terminal block.

4. PLC Common Connections:

● Connect Com0, Com1, Com2, Com3 and Com4 of the PLC to the AC (red)
terminal block.

5. Motor Wiring:

● Connect the 220V (black) supply to the 1/L1 of the contactor and (red) supply
to the 3/L2 of the contactor. Connect the A1 wire terminal of the contactor to
Y4 of the PLC. A2 wire terminal of the contactor to the AC (blue) terminal
block; Connect the T1 contact of the contactor to the U1 red terminal of the
motor, T2 of the overload relay to 5/L3 of the main contactor, T3 contact of the
contactor to the U2 red terminal of the motor. Connect U2 terminal to Z2
terminal and U1 terminal to Z1 terminal of the motor.

P a g e | 113
6. The wiring diagram of the Color Sensor Application was shown below

P a g e | 114
PROCEDURES: Operating the HMI

1. Connect the HMI to the PLC:

 Use cable to connect the HMI to the PLC.

 Use a USB cable to connect the HMI to the laptop.

 Edit the created ladder diagram, insert a new rung to the top, with an open

contact address as M8002, and an instruction output icon [ MOV K0 D8120]

 Use the Kinco software to control the components

OVERALL EXPERIMENTAL PROCEDURES:

1. Launch GX Works on the Laptop

● Open the GX Works software to begin programming the PLC ladder diagram.

Go to File > New Project.

Note: Select FXCPU for PLC series and FX3G/FX3GC for CPU Type, then click OK

to create the project.

P a g e | 115
2. Create the Ladder Diagram

● Design the ladder diagram for the color sensor application, where lamps and

motor turn on corresponding to the detected color when it senses paper.

● Compile the program to check for errors.

● The ladder diagram for this experiment is shown in the ladder diagram

procedure.

3. Wiring of Components

● Make sure the trainer is turned off before beginning any wiring.

● Connect the components as shown in the actual wiring diagram, including the

pushbuttons, contactor, indicator lamps and motor.

4. Perform a Continuity Test

● Utilize a multimeter to check that all connections are accurate.

● Look for any loose connections or short circuits to ensure safe operation.

5. Power On the Trainer

● After completing the continuity test and confirming all connections, turn on the

trainer.

6. Upload the Ladder Diagram to the PLC

● Connect the PLC to the laptop via USB port. Check the connection destination

of the Serial Port in GX Works. Make sure that it is on USB.

● Confirm that the PLC is not in running mode before proceeding to the next step.

● Go to Online > Write to PLC in GX Works.

● Check only the applicable data (PLC Data and Parameter) before proceeding.

● Execute the upload to transfer the ladder diagram to the PLC.

P a g e | 116
7. Create the HMI Display Using Kinco DTools

● Open Kinco DTools and follow the configuration procedure to connect the HMI

with the PLC.

● Create the HMI interface, adding all the inputs and outputs from the ladder

diagram to the HMI window, addressing them accordingly.

8. Download the HMI Program

● Connect the HMI to the PLC

● After completing the HMI display, go to Tools > Download.

● Set the port to USB and download the HMI program to the HMI device.

● Wait for the download to complete successfully.

9. Operational Testing

● After completing the wiring and programming, test the experiment by first using

the manual pushbuttons.

● Press the manual start button and detect a specific color. Observe the operation

of the experiment, and write the findings in the table under data and results.

● Then test using the HMI interface to ensure proper operation.

● Press the start button via HMI display and detect a specific color. Observe the

operation of the experiment, and write the findings in the table under data and

results.

P a g e | 117
Notes:

● Double-check all wiring connections before powering the system to prevent damage.

In case of an emergency, immediately press the Emergency stop located at the left side

of the trainer to stop the trainer's operation.

● Always verify that the PLC is in the correct mode (Stop/Run) before uploading or

downloading programs.

DATA AND RESULTS

Manual Operation

Output Components Type of Operation Result (Run/Stop)

Press (Start)
Single Phase Motor RUN
Green (Detect)
STOP
Red (Detect)

Yellow Indicator Lamp 1 Yellow (Detect) RUN

Red Indicator Lamp 2 Red (Detect) RUN

Green Indicator Lamp 3 Green (Detect) RUN

Blue Indicator Lamp 4 Blue (Detect) RUN

P a g e | 118
 Integrating HMI Operation

Output Components Type of Operation Result (Run/Stop)

Press (Start)
Single Phase Motor RUN
Green (Detect)
STOP
Red (Detect)

Yellow Indicator Lamp 1 Yellow (Detect) RUN

Red Indicator Lamp 2 Red (Detect) RUN

Green Indicator Lamp 3 Green (Detect) RUN

Blue Indicator Lamp 4 Blue (Detect) RUN

ANALYSIS

1. How does the response time of the system vary with different paper colors?

● The response time of the system can vary with different paper colors depending

on the sensitivity and calibration of the color sensors used in the system. Lighter

or brighter colors, like yellow, may be detected faster due to higher reflectivity,

whereas darker colors, blue, may have slower response times due to lower

reflectivity. Additionally, colors like green or red could have varying detection

times depending on how the sensor distinguishes between these colors.

2. What is the correlation between the activation of the motor and the detection of a green

paper?

P a g e | 119
 ● The correlation between the activation of the motor and the detection of green

paper by the color sensor is a direct cause-and-effect relationship: when the

color sensor detects green, it generates a signal that is processed by a control

system, which immediately activates the motor in response. This setup ensures

that the motor runs as soon as the green color is identified.

3. What is the efficiency of the manual stop button (PB2) compared to using the HMI

interface to halt the system?

● The efficiency of the manual stop button (PB2) is typically faster and more

direct compared to using the HMI (Human-Machine Interface) to stop the

system. PB2 provides a physical, immediate stop command to the motor or

system, ideal in emergency situations, as it is a dedicated circuit with minimal

delay. The HMI, on the other hand, involves a series of interactions, such as

navigating through screens or confirming commands, which introduces latency.

While HMI offers more control and monitoring options, the manual stop button

is more efficient for emergency stops, providing instantaneous feedback and

control.

4. How do user preference and ease of operation differ between HMI control and manual

pushbutton control?

● User preference between HMI control and manual pushbutton control varies

based on comfort with technology and task complexity. HMI control offers a

comprehensive visual interface for monitoring and automating processes,

making it ideal for tasks requiring detailed control, although it may involve a

P a g e | 120
 learning curve. In contrast, manual pushbutton control is simpler and provides

immediate feedback, making it preferable for basic tasks or emergency

situations. While pushbuttons are intuitive for quick actions, HMI systems are

more versatile but require additional steps for operation.

5. What is the overall success rate of the system in accurately detecting paper colors and

controlling the motor?

● The overall success rate of the system in detecting paper colors and controlling

the motor is highly dependent on the precision of the sensors, programming

logic, and environmental conditions like lighting and distance.

SUPPLEMENTAL ACTIVITY: UTILIZING COLOR SENSOR APPLICATION WITH

INDICATOR LIGHTS AND ACTUATOR OUTPUTS

In this supplemental activity, students will explore the practical applications of a color

sensor in an automated sorting system that utilizes indicator lights and actuators for efficient

operation. The scenario simulates a packaging facility where items need to be sorted based on

their color before being packaged for distribution. The color sensor will detect the color of

items passing through a conveyor belt and send signals to the PLC. Based on the detected color,

the PLC will control actuators that will sort the items into designated bins. For example, when

the color sensor detects a red item, the PLC will activate an actuator to push the item into the

"red" bin, while simultaneously illuminating a red indicator light to confirm the sorting action.

Similarly, if a blue item is detected, the actuator will push it into the "blue" bin, with a blue

indicator light signaling the successful operation.

P a g e | 121
OBSERVATION

In the color sensor activity, it was shown that the system effectively illuminated the

corresponding colored lamp whenever a color was detected. When the sensor identified green,

both the green lamp illuminated and the motor activated simultaneously, indicating a successful

trigger mechanism for the task at hand. In contrast, when the sensor detected red, the red lamp

lit up, and the motor immediately stopped, demonstrating an effective response to halt

operation. This seamless interaction between color detection, lamp illumination, and motor

activation showcased the system's reliable functionality and clear feedback mechanism,

allowing users to easily monitor and understand the status of the operation.

CONCLUSION

In conclusion, the color sensor activity demonstrated a reliable system for color

detection and response. The corresponding lamps illuminated accurately upon detection,

providing clear feedback to users. The motor activated with green detection and stopped with

red detection, showcasing the system's responsiveness and efficiency. Additionally, this

activity helped students enhance their understanding of automation concepts, fostered hands-

on experience with technology, and encouraged problem-solving skills by allowing them to

observe real-time interactions.

P a g e | 122
LABORATORY ACTIVITY 6: ELEVATOR CONTROL APPLICATION

DISCUSSION

The elevator control application using a PLC trainer, such as GX Works 2, provides

students with hands-on experience in automation and control systems, essential for

understanding real-world industrial applications. This activity allows students to design,

program, and troubleshoot PLC-based systems, enhancing their practical understanding of

PLCs, control logic, and safety mechanisms. By simulating an elevator's operation, students

learn to manage inputs and outputs, create ladder diagrams, and implement safety features,

bridging the gap between theoretical knowledge and real-world application. This practical

approach develops critical thinking, problem-solving skills, and prepares students for careers

in industries that rely on automation and control technologies.

OBJECTIVES

This activity aims to:

 Design a ladder diagram for the elevator control system.

 Enhance the skills and understanding of proper wiring of components.

 Demonstrate the operation and control mechanism of a basic elevator system using push

buttons and indicators.

P a g e | 123
MATERIALS

 Terminal  Wires  Pushbutton  Indicator

Block Lamps

 Programmable  Screwdrivers  Gloves  Multimeter

Logic
Controller
 I/O: 4/6

PROCEDURES: Simulation of Elevator Control Application

1. Initial Setup M8002 First Rung:

● Create a rung based on the image below, incorporating open contacts and an

instruction output coils for setting and resetting the output. Arrange the elements

and address each element according to the image below.

2. Handling Inputs (Floor Selection) Second Rung:

● Add contacts X001, M12, M13, and M14 which represent floor selection

buttons and internal conditions. Then add the instruction MOV K1 D1101 to

moves the constant 1 into register D1101. Followed by adding SET M11 that

turns on memory bit M11 and RST M12 resets memory bit M12. Follow the

arrangement of the elements from the image below.

P a g e | 124
Third Rung:

● Mimics the second rung by adding MOV K2 D1101 output that moves the

constant 2 into D1101. Then add RST M11, SET M12, RST M13 and RST

M14 to control the memory bits for managing different floors. Followed the

image below.

Fourth Rung:

● Similar to third rung, add an output MOV K3 D1101 that moves the constant 3

into D1101. Then add RST M11, RST M12, SET M13 and RST M14 to control

the memory bits for managing different floors. Arrange the elements based on

the image below.

P a g e | 125
Fifth Rung:

● Lastly, add MOV K4 D1101 output to move the constant 4 into D11, same with

the fourth rung. Then add SET M14 as well as RST M11, RST M12, and RST

M13 to reset the memory bits for the other floors. Follow the arrangement in

the image below.

Sub Operation:

● Add the input conditions X001, X002, X003, and X004, then add subtraction

instruction SUB. The contents of register D1100 are subtracted from D1101,

and the result is stored in D1102. Arrange the elements based on the image

below.

P a g e | 126
 CMP Operation:

● Add an instruction output CMP where the value in D1101 is compared to

D1100. Based on the result, the state of M0 is determined. If the condition is

met, the next stage of logic (possibly controlling an actuator) will proceed.

Followed the arrangement of elements in the image below.

MUL Operation:

● Add two MUL instructions present in this diagram, triggered by the M0 and M2

internal relays. When M0 and M2 is active, the value in D1102 is multiplied by

a constant (K50), and the result is stored in D1103. Arrange the elements

according to the image below.

3. Rung with M10 and M1:

 Add internal relay M10 and M1 and an output T10 D1103 for the timer

controlling time delays. Then add ZRST Y004 that resets output Y004 and

output Y007. Arrange the elements based on the image below.

P a g e | 127
4. Rung with M11 and T10:

● Add M11, M12, M13, M14 for this rung to set memory bits based on certain

conditions. Then add instruction output MOV D1101 D1100 to transfers values

between registers, controlling elevator movement. Add outputs Y004, Y005,

Y006, Y007 for elevator’s position on different floors controlled by adding

timer contacts T10. Followed the arrangement of the elements from the image

below.

5. Timer Configuration

● Add the instruction output MOV T10, T11, T12 that moves a preset value from

register D200, D202, D204 to set the delay. Arrange the elements based on the

image below.

P a g e | 128
6. The ladder diagram of the elevator control application was shown below.

P a g e | 129
P a g e | 130
Figure xx.

P a g e | 131
PROCEDURES: Actual Wiring of Elevator Control Application

1. PLC and Power Supply Wiring

● Connect the 24V supply of the PLC to the Sink/source (S/S), 0V supply of the

PLC to the DC terminal block (blue); Connect the 220V (black) supply to the

AC (red) terminal block and (red) supply to the AC (blue) terminal block.

2. Indicator Lamp Wiring:

● Connect the NO black terminal to the AC blue terminal block. Connect the NO

red terminal to the corresponding input terminal (Y0 for GL1, Y1 for RL1, Y4

for RL2, Y5 for GL2, Y6 for YL2, Y7 for BL2).

3. Push Button Wiring:

● Connect the NO black terminal to the DC blue terminal block. Connect the NO

red terminal to the corresponding input terminal (X1 for PB1(1st floor), X2 for

PB2 (2nd floor), X3 for PB4 (3rd floor), X4 for PB5 (4th floor).

4. PLC Common Connections:

● Connect Com0, Com1, and Com3 of the PLC to the AC (red) terminal block.

P a g e | 132
5. Provide Wiring Diagram of the Elevator Control Application.

P a g e | 133
PROCEDURES: Operating the HMI

1. Connect the HMI to the PLC:

 Use cable to connect the HMI to the PLC.

 Use a USB cable to connect the HMI to the laptop.

 Edit the created ladder diagram, insert a new rung to the top, with an open

contact address as M8002, and an instruction output icon [ MOV K0 D8120]

 Use the Kinco software to control the components

OVERALL EXPERIMENTAL PROCEDURES:

1. Launch GX Works on the Laptop

● Open the GX Works software to begin programming the PLC ladder diagram.

Go to File > New Project.

P a g e | 134
 Note: Select FXCPU for PLC series and FX3G/FX3GC for CPU Type, then click OK

to create the project.

2. Create the Ladder Diagram

● Design the ladder diagram for the elevator control application, where once PB

is pressed, the elevator will go to the designated floor.

● Compile the program to check for errors.

● The ladder diagram for this experiment is shown in the ladder diagram

procedure.

3. Wiring of Components

● Make sure the trainer is turned off before beginning any wiring.

● Connect the components as shown in the actual wiring diagram, including the

pushbuttons, and indicator lamps.

4. Perform a Continuity Test

● Utilize a multimeter to check that all connections are accurate.

● Look for any loose connections or short circuits to ensure safe operation.

5. Power On the Trainer

● After completing the continuity test and confirming all connections, turn on the

trainer.

6. Upload the Ladder Diagram to the PLC

● Connect the PLC to the laptop via USB port. Check the connection destination

of the Serial Port in GX Works. Make sure that it is on USB.

● Confirm that the PLC is not in running mode before proceeding to the next step.

● Go to Online > Write to PLC in GX Works.

P a g e | 135
 ● Check only the applicable data (PLC Data and Parameter) before proceeding.

● Execute the upload to transfer the ladder diagram to the PLC.

7. Create the HMI Display Using Kinco DTools

● Open Kinco DTools and follow the configuration procedure to connect the HMI

with the PLC.

● Create the HMI interface, adding all the inputs and outputs from the ladder

diagram to the HMI window, addressing them accordingly.

8. Download the HMI Program

● Connect the HMI to the PLC

● After completing the HMI display, go to Tools > Download.

● Set the port to USB and download the HMI program to the HMI device.

● Wait for the download to complete successfully.

9. Operational Testing

● After completing the wiring and programming, test the experiment by first using

the manual pushbuttons.

● Press a specific manual push button and observe the elevator control operation

of the experiment, and write the findings in the table under data and results.

● Then test the motor control using the HMI interface to ensure proper operation.

● Press a specific button on the HMI display and observe the elevator control

operation of the experiment, and write the findings in the table under data and

results.

P a g e | 136
Notes:

● Double-check all wiring connections before powering the system to prevent damage.

In case of an emergency, immediately press the Emergency stop located at the left side

of the trainer to stop the trainer's operation.

● Always verify that the PLC is in the correct mode (Stop/Run) before uploading or

downloading programs.

DATA AND RESULTS

Manual Operation

Output Components Type of Operation Result (Run/Stop)

1st Floor Indicator Lamp PB1 (Press) RUN

Timer (Start) RUN

Timer (Stop) STOP

Indicator Lamp (Open)
Timer (Start) RUN

Indicator Lamp (Close) Timer (Stop) STOP

Timer (Start) RUN

Timer (Stop) STOP

P a g e | 137
2nd Floor Indicator Lamp PB1 (Press) RUN

Timer (Start) RUN

Timer (Stop) STOP

Indicator Lamp (Open)
Timer (Start) RUN

Indicator Lamp (Close) Timer (Stop) STOP

Timer (Start) RUN

Timer (Stop) STOP

3rd Floor Indicator Lamp PB1 (Press) RUN

Timer (Start)
RUN
Indicator Lamp (Open)
Timer (Stop)
STOP

Timer (Start) RUN

Indicator Lamp (Close)
Timer (Stop) STOP

Timer (Start) RUN

Timer (Stop) STOP

4th Floor Indicator Lamp PB1 (Press) RUN

Timer (Start) RUN

Timer (Stop) STOP

Indicator Lamp (Open) Timer (Start) RUN

Timer (Stop) STOP

Indicator Lamp (Close) Timer (Start) RUN

Timer (Stop) STOP

P a g e | 138
 Integrating HMI Operation

Output Components Type of Operation Result (Run/Stop)

1st Floor Indicator Lamp PB1 (Press) RUN

Timer (Start) RUN

Timer (Stop) STOP

Indicator Lamp (Open)
Timer (Start) RUN

Indicator Lamp (Close) Timer (Stop) STOP

Timer (Start) RUN

Timer (Stop) STOP

2nd Floor Indicator Lamp PB1 (Press) RUN

Timer (Start) RUN

Timer (Stop) STOP

Indicator Lamp (Open)
Timer (Start) RUN

Indicator Lamp (Close) Timer (Stop) STOP

Timer (Start) RUN

Timer (Stop) STOP

P a g e | 139
 3rd Floor Indicator Lamp PB1 (Press) RUN

Timer (Start)
RUN
Indicator Lamp (Open)
Timer (Stop)
STOP

Timer (Start) RUN

Indicator Lamp (Close)
Timer (Stop) STOP

Timer (Start) RUN

Timer (Stop) STOP

4th Floor Indicator Lamp PB1 (Press) RUN

Timer (Start) RUN

Timer (Stop) STOP

Indicator Lamp (Open) Timer (Start) RUN

Timer (Stop) STOP

Indicator Lamp (Close) Timer (Start) RUN

Timer (Stop) STOP

ANALYSIS

1. How can the performance of the elevator control system be evaluated using the PLC

trainer, and what metrics are used to assess its efficiency and reliability?

 The performance of the elevator control system using a PLC trainer can be

evaluated based on response time (how quickly the elevator reacts to button

presses) and stopping accuracy (how precisely it aligns with each floor). Other

P a g e | 140
 key factors include the effectiveness of timer settings for stop durations, error

frequency, and energy efficiency.

2. What is the difference between using a manual push button (PB) and HMI in terms of

elevator control?

 Manual push buttons offer simple, immediate control through direct presses,

making them ideal for quick actions like selecting floors. In contrast, an HMI

provides a graphical interface, allowing users to manage multiple floor requests,

view the elevator’s status, and receive detailed feedback. Additionally, the HMI

enables users to set and monitor timer values for floor approaches, enhancing

overall control of the elevator system

3. How does the timer influence the elevator's operation in terms of stopping duration at

each floor, response time to user requests, and overall efficiency of service?

● The timer significantly impacts the elevator's operation by regulating the

stopping duration at each floor, which allows passengers sufficient time to enter

or exit safely.

P a g e | 141
SUPPLEMENTAL ACTIVITY: MOTOR-DRIVEN ELEVATOR CONTROL WITH

VISUAL INDICATORS

In this supplemental activity, students will design and implement a motor-driven

elevator control system that incorporates visual indicators to enhance understanding of its

operation. The scenario simulates an elevator system in a two-story building, allowing students

to explore the integration of motor control and user feedback in a practical application. Initially,

students will program the PLC to control the elevator’s operation. They will create a control

panel with two push buttons—one for each floor. When a button is pressed, the motor will

activate, driving the elevator to the selected floor. The limit switches will signal when the

elevator has reached its destination, ensuring safe and accurate positioning. As part of the visual

feedback system, a red light will illuminate to signal that the elevator is moving, a green light

will indicate that it has arrived at the selected floor.

OBSERVATION

The elevator control experiment demonstrated the integration of pushbuttons, indicator

lamps, and timers to enhance user interaction and safety. Users could select floors one through

four, with indicator lamps illuminating after a delay that simulated real-world elevator

operations, fostering patience. Green and red lights for door status provided clear safety cues,

preventing confusion in busy settings. The introduction of a touchscreen interface emphasized

modern, accessible, and intuitive design. Overall, the experiment highlighted the importance

of clear communication and safety in automated systems.

P a g e | 142
CONCLUSION

The elevator control experiment highlighted essential design principles aimed at

enhancing user experience, safety, and efficiency in automated systems. It demonstrated the

effective integration of pushbuttons, timers, and indicator lamps to provide intuitive navigation

and mimic the realistic functionality of an elevator. By focusing on user-friendly interfaces,

the experiment showcased how simple control devices can streamline interactions while

ensuring safety and reliability. Additionally, the introduction of a touchscreen interface

underscored the potential for future advancements in user interaction, pointing towards more

sophisticated and seamless control methods in elevator systems and beyond, thus improving

overall automation technology.

P a g e | 143
LABORATORY ACTIVITY 7: TRAFFIC LIGHT CONTROL APPLICATION

DISCUSSION

Controlling traffic lights using PLC (Programmable Logic Controller) trainers offers

significant advantages over traditional relay-based systems by providing flexibility, reliability,

and advanced integration capabilities. PLCs can be programmed for basic traffic light

sequencing and adaptive control, adjusting green light durations based on real-time traffic data

to optimize flow and reduce congestion. Additionally, PLCs enhance safety with pedestrian

signals and emergency vehicle preemption, ensuring safe and efficient traffic management. In

an urban setting, a PLC-based system dynamically adjusts to changing traffic patterns,

improving efficiency without requiring manual intervention, and offering a scalable, efficient

solution for modern traffic control.

OBJECTIVES

This activity aims to:

 Design and program a ladder diagram for traffic light sequencing at a two-lane

intersection.

 Provide hands-on wiring experience with PLC trainer with the traffic control system

design.

 Demonstrate the operation and control mechanism of a two-way traffic light control

system using push buttons and indicators.

P a g e | 144
MATERIALS

 Terminal  Wires  Pushbutton  Indicator

Block Lamps

 Programmable  Screwdrivers  Gloves  Multimeter

Logic
Controller
 I/O: 2/6

PROCEDURES: Simulation of Traffic Light Control Application

1. Initialization:

● Add the M8002 as the system initialization relay. It activates when the PLC

starts up, triggering the MOV K0 D8120 instruction.

2. Start and Stop Button Activation

● Add X000 that triggers the SET M1 instruction output, which turns on memory

bit M1. This memory bit M1 controls the start of the traffic light sequence,

activating the main operation.

● Resets M1 by adding the RST M1 instruction output, halting the traffic light

control operation and turning off the corresponding outputs. Then add reset RST

M2 and RST M3 to reset the internal relays M2 and M3. Arrange the elements

based on the image below.

P a g e | 145
3. Stop Button (X001) Resetting Logic:

● Add ZRST (Reset) instruction output ensures that both D1 and D4 are reset to

OFF states, turning off the traffic lights.

4. Automatic Traffic Light Sequence:

● Green Light Sequence for Line 1

o Add contacts for internal relays M1 and M2, include the DECP D1

instruction output, and a SET M2 output to advance the sequence to the

next memory relay, M2. Build the ladder diagram based on the image

and address all contacts and outputs accordingly.

P a g e | 146
 ● Standby (or Next Phase) Sequence for Line 2

o Similar to the green light sequence, include contacts for internal relays

M2 and M3, along with the DECP D2 and SET M3 outputs to shift the

sequence to M3. Build the ladder diagram based on the image,

addressing all contacts and outputs accordingly.

5. Alternation between different states lane 1

● Add open contacts M1, M2, and M3, and the instruction output DECP D12 to

triggers M1, which decrease a value or control related to "LINE 1 GO." Create

the ladder diagram from the image, ensuring all contacts and outputs are

correctly addressed.

● Add rising pulse M2 to moves the data to D2 output. Add rising pulse M1 to

performs an ADD operation output, modifying the state of the system between

D1, D222, and D12. Then add rising pulse M3 that resets D12 through the RST

P a g e | 147
 instruction output. Arrange the elements based on the image, addressing all

contacts and outputs accordingly.

6. Next Phase Sequence

● Add M3 and M4 to starts the sequence to control the red light for Line 2, the

add DECP D3 to set control Line 2 Red, turning the green light ON for Line 1

when the conditions are satisfied; setting M4 ON by adding the SET M4

instruction output, transitioning to the next light phase.

P a g e | 148
 ● Repeat the ladderby adding M3 and M4 with the DECP D22 instruction. Add

the SET M1 instruction output to moves the sequence to the next memory relay,

as well as ZRST M3 and M4 to reset the internal relays. Create the ladder

diagram from the image, ensuring all contacts and outputs are correctly

addressed.

7. Alternation between different state lane 2

● Again add contacts M1, M3, and M4, and the instruction output DECP D32 to

to decrease a value or control related to "LINE 2 RED." Add a rising pulse M3

that moves a value to D3, which controls "LINE 2 GO." Arrange the elements

based on the image below and address accordingly.

P a g e | 149
  Add rising pulse M4 to moves the data to D22 output. Add rising pulse M1

to moves the data to D222 output. Then add rising pulse M3 to performs an

ADD operation output to performs operation for D3, D222, and D32. Follow

the image below to create the ladder diagram.

8. Placing outputs processes

 Add M1 and M2 is active, the Y000 output (green lamp for Lane 1) to

triggers the green output lamp. Then add a branch circuit M2 with a Y005

output to triggers the red lamp from lane 2.

P a g e | 150
  Add M2, and the Y001 output (yellow lamp for Lane 1) to triggers the

yellow output lamp.

● Add M4, the Y004 output (yellow lamp for Lane 2) as well as M3 and the Y002

output (red lamp for Lane 1) to triggers yellow lamps of line 2 and red lamp of

line 1.

P a g e | 151
9. The ladder diagram of the Traffic Light Control Application was shown below

P a g e | 152
P a g e | 153
P a g e | 154
P a g e | 155
PROCEDURES: Actual Wiring of Traffic Light Control Application

1. PLC and Power Supply Wiring

● Connect the 24V supply of the PLC to the Sink/source (S/S), 0V supply of the

PLC to the DC terminal block (blue). Connect the 220V (black) supply to the

AC (red) terminal block and (red) supply to the AC (blue) terminal block.

2. Indicator Lamp Wiring:

● Connect the NO black terminal to the AC blue terminal block. Connect the NO

red terminal to the corresponding output terminal (Y2 for RL1, Y5 for RL2, Y0

for GL1, Y3 for GL2, Y1 for YL1, Y4 for YL2).

3. Push Button Wiring:

● Connect the NO black terminal to the DC blue terminal block. Connect the NO

red terminal to the corresponding input terminal (X0 for Green PB, X1 for Red

PB).

4. PLC Common Connections:

● Connect Com0, Com1, Com2, Com3 of the PLC to the AC (red) terminal block.

P a g e | 156
5. The wiring diagram of the Traffic Light Control Application was shown below

P a g e | 157
PROCEDURES (Operating the HMI to Trainer Power-On):

1. Connect the HMI to the PLC:

 Use cable to connect the HMI to the PLC.

 Use a USB cable to connect the HMI to the laptop.

 Edit the created ladder diagram, insert a new rung to the top, with an open

contact address as M8002, and an instruction output icon [ MOV K0 D8120] .

 Use the Kinco software to control the components

OVERALL EXPERIMENTAL PROCEDURES:

1. Launch GX Works on the Laptop

● Open the GX Works software to begin programming the PLC ladder diagram.

Go to File > New Project.

P a g e | 158
 Note: Select FXCPU for PLC series and FX3G/FX3GC for CPU Type, then click OK

to create the project.

2. Create the Ladder Diagram

● Design a ladder diagram for a traffic light system that activates when the start

pushbutton is pressed. This will illuminate the Green Light in Lane 1 and the

Red Light in Lane 2.

● Compile the program to check for errors.

● The ladder diagram for this experiment is shown in the ladder diagram

procedure.

3. Wiring of Components

● Make sure the trainer is turned off before beginning any wiring.

● Connect the components as shown in the actual wiring diagram, including the

pushbuttons, and indicator lamps.

4. Perform a Continuity Test

● Utilize a multimeter to check that all connections are accurate.

● Look for any loose connections or short circuits to ensure safe operation.

5. Power On the Trainer

● After completing the continuity test and confirming all connections, turn on the

trainer.

6. Upload the Ladder Diagram to the PLC

● Connect the PLC to the laptop via USB port. Check the connection destination

of the Serial Port in GX Works. Make sure that it is on USB.

● Confirm that the PLC is not in running mode before proceeding to the next step.

P a g e | 159
 ● Go to Online > Write to PLC in GX Works.

● Check only the applicable data (PLC Data and Parameter) before proceeding.

● Execute the upload to transfer the ladder diagram to the PLC.

7. Create the HMI Display Using Kinco DTools

● Open Kinco DTools and follow the configuration procedure to connect the HMI

with the PLC.

● Create the HMI interface, adding all the inputs and outputs from the ladder

diagram to the HMI window, addressing them accordingly.

8. Download the HMI Program

● Connect the HMI to the PLC

● After completing the HMI display, go to Tools > Download.

● Set the port to USB and download the HMI program to the HMI device.

● Wait for the download to complete successfully.

9. Operational Testing

● After completing the wiring and programming, test the experiment by first using

the manual pushbuttons.

● Press the manual start button and observe the operation of the traffic light

experiment and write the findings in the table under data and results.

● Then test the motor control using the HMI interface to ensure proper operation.

P a g e | 160
 ● Press the start button via HMI display and observe the operation of the traffic

light experiment and write the findings in the table under data and results.

Notes:

● Double-check all wiring connections before powering the system to prevent damage.

In case of an emergency, immediately press the Emergency stop located at the left side

of the trainer to stop the trainer's operation.

● Always verify that the PLC is in the correct mode (Stop/Run) before uploading or

downloading programs.

DATA AND RESULTS

Manual Operation

Output Components Type of Operation Result (Run/Stop)

Green Indicator Lamp 1 Start (Press) RUN

Red Indicator Lamp 2 Timer (Start) RUN

Timer (Stop) STOP

Yellow Indicator Lamp 1 Timer (Start) RUN

Red Indicator Lamp 2 Timer (Stop) STOP

Red Indicator Lamp 1 Timer (Start) RUN

Green Indicator Lamp 2 Timer (Stop) STOP

P a g e | 161
 Red Indicator Lamp 1 Timer (Start) RUN

Yellow Indicator Lamp 2 Timer (Stop) STOP

Integrating HMI Operation

Output Components Type of Operation Result (Run/Stop)

Green Indicator Lamp 1 Start (Press) RUN

Red Indicator Lamp 2 Timer (Start) RUN

Timer (Stop) STOP

Yellow Indicator Lamp 1 Timer (Start) RUN

Red Indicator Lamp 2 Timer (Stop) STOP

Red Indicator Lamp 1 Timer (Start) RUN

Green Indicator Lamp 2 Timer (Stop) STOP

Red Indicator Lamp 1 Timer (Start) RUN

Yellow Indicator Lamp 2 Timer (Stop) STOP

ANALYSIS

1. How does the timer contribute to the traffic light control system's effectiveness?

● The timer is important to the traffic light control system's effectiveness as it

regulates the duration of each light phase—green, yellow, and red—ensuring

P a g e | 162
 that vehicles receive predictable and timely signals. Additionally, the timer can

be adjusted to accommodate varying traffic conditions, helping to optimize

traffic flow.

2. What is the impact of the stop button (PB2) on the overall safety of the intersection
when compared to a system without such a feature?

● The stop button (PB2) significantly enhances the overall safety of the
intersection by providing operators with the ability to manually halt traffic
signals in emergencies or unexpected situations. In contrast to systems without
this feature, the stop button serves as a critical safety mechanism, enabling
operators to intervene during malfunctions and facilitating communication with
emergency services, thereby improving situational awareness and reducing
risks associated with faulty signals.

3. How does the HMI improve usability and visibility for operators managing the traffic
control system?

● The Human-Machine Interface (HMI) improves usability and visibility for

operators managing the traffic control system by providing real-time displays
of the current state of each traffic light, including countdown timers for
transitions.

4. How does the alternating pattern of the traffic light control system promote continuous
traffic flow?

● The alternating pattern of the traffic light control system promotes continuous
traffic flow by systematically allocating time to each lane, thereby reducing
congestion and minimizing waiting times at the intersection. This structured
approach ensures clear signaling transitions from green to yellow to red, which
helps to prevent driver confusion and encourages timely responses.

P a g e | 163
SUPPLEMENTAL ACTIVITY: DESIGNING A ONE-LANE TRAFFIC LIGHT

CONTROL SYSTEM WITH MOTOR AS VEHICLE

In this supplemental activity, students will design and implement a one-lane traffic light

control system using a motor to represent the vehicle's movement. This scenario allows

students to explore the fundamentals of traffic light control systems while simplifying the

complexity by focusing on a single lane of traffic. The goal is to create a system where the

motor (vehicle) can only move when the green light is illuminated, while the red light indicates

a stop. The green light will be activated for a specific duration (e.g., 10 seconds) to allow the

motor to move forward. Following this, the yellow light will activate for 2 seconds to signal

the vehicle to prepare to stop. Finally, the red light will illuminate for 10 seconds, indicating

that the motor must remain stationary.

OBSERVATION

The traffic light control application implemented using a PLC trainer demonstrates a

well-structured approach to managing vehicular flow at intersections. The systematic

alternation of light phases—green, yellow, and red—along with the use of a timer, ensures

predictability and safety for drivers. The integration of a stop button (PB2) adds a layer of

manual control, enabling operators to address emergencies effectively. Additionally, the

Human-Machine Interface (HMI) provides operators with real-time data and user-friendly

controls, enhancing their ability to monitor and adjust the system based on current traffic

conditions. Overall, the application effectively balances efficiency with safety, minimizing

congestion while facilitating smooth transitions for vehicles.

P a g e | 164
CONCLUSION

The traffic light control system illustrates the crucial role of timing and signal changes

in managing traffic effectively. By using a systematic approach to alternate between lanes and

incorporating features like a stop button and Human-Machine Interface (HMI), the system

improves both safety and efficiency at intersections. This activity not only teaches students

essential concepts of automation and control systems but also gives them hands-on experience

with programming and operating PLCs. Through this practical engagement, students enhance

their problem-solving skills and gain a better understanding of how traffic management

technologies work in the real world. Future improvements, such as integrating real-time traffic

data, could further enhance the system’s performance by adapting signal timing to current

traffic conditions. Overall, this activity highlights how automated traffic control systems can

enhance roadway safety and efficiency, while also preparing students for future careers in

technology and engineering fields.

P a g e | 165
LABORATORY 8: PRESSURIZED WATER TANK CONTROL APPLICATION

DISCUSSION

In this laboratory activity, we will delve into the control and automation of a pressurized

water tank using a Programmable Logic Controller (PLC) system. The setup mirrors real-world

applications in industrial settings where a pressure pump is used to fill a tank, and limit switches

are employed to monitor and regulate the water level. The PLC plays a central role by sending

control signals to relays, which act as intermediaries between the PLC and the actuator (in this

case, the pressure pump). When the PLC activates the relays, they energize the pump to fill the

tank. Once the water reaches predetermined levels, the system relies on mechanical limit

switches to provide feedback, ensuring efficient and safe operation. This seamless feedback

loop demonstrates the integration of automation technology with fluid control systems,

highlighting the PLC’s versatility in industrial applications.

OBJECTIVES

This activity aims:

● To understand how a PLC can control a pressurized water tank system using a pressure

pump (actuator) and limit switches.

● To design and program, a PLC system for water level control, where pressing the start

button activates the pump to fill the tank, and the pump automatically stops when the

water reaches the high level. Additionally, pressing a release button will drain the water,

and the pump will stop once the water drops below the low level. The system will also

include an emergency stop button for manually halting the entire operation at any time.

P a g e | 166
MATERIALS

 Relays  Wires  Pushbutton  Actuator

 Limit  Screwdrivers  Gloves  Multimeter

Switches

 Programmable
Logic
Controller
 I/O: 5/4

PROCEDURES: Ladder Diagram Simulation of the Pressurized Water Tank Control

Application

1. Create and insert the first rung:

● Create a rung based on the image below, incorporating open contacts X000,

closed contacts XOO2, X003, X004 and an output coil that represents the relay.

Also add latching Y000.

P a g e | 167
2. Create and insert the second rung:

● Create a rung based on the image below, incorporating open contacts X001 and

close contacts X002, X004, AND X000 and an output coil Y001 representing

the output component. Also add a latching Y001.

3. The image below shows the ladder diagram of the Pressurized Water Tank Control

Application.

P a g e | 168
PROCEDURES: Actual Wiring of the External Timer Approach

1. PLC and Power Supply Wiring:

 Connect the 220V black supply to the AC (red) terminal block, the 220V red

supply to the AC (blue) terminal block, the 0V PLC supply to the DC (blue)

terminal block, and the 24V PLC supply to the Sink/Source (S/S) of the PLC.

2. Filling Push Button Wiring:

 Connect the Green Normally Open Push Button (black) to the DC (blue)

terminal block and the Green Normally Open PB (red) to X0 of the PLC.

3. Down Push Button Wiring:

 Connect the Red Normally Open Push Button (black) to the DC (blue) terminal

block and the Red Normally Open PB (red) to X1 of the PLC.

4. Emergency Stop Pushbutton:

● Connect the E-stop Normally Open PB (black) to the DC (blue) terminal block

and (red) to X2 of the PLC.

5. Relay Supply Wiring:

● Relay 1 Supply Wiring: Connect the 0V PLC supply to the DC (blue) terminal

block, 24V supply to Sink/Source (S/S), 220V (red) to Relay 1 terminal 13,

220V (black) to COMM0, 24V (red) to Relay 1 terminal 10, 24V (black) to

Relay 1 terminal 9, and Relay 1 terminal 14 to Y0 on the PLC.

P a g e | 169
 ● Relay 2 Supply Wiring: Connect the positive 220V (red) to Relay 2 terminal 13,

negative 220V (black) to COMM1, and Relay 2 terminal 14 to Y1 on the PLC.

● Relay 1 to Relay 2 Connection: Connect Relay 1 terminal 6 to Relay 2 terminal

5, and Relay 1 terminal 5 to Relay 2 terminal 6.

6. Actuator Power Connection:

● Connect Relay 2 terminal 5 to the black wire of the actuator and Relay 2

terminal 6 to the red wire of the actuator.

7. Limit Switches Connection:

● Connect the sixth terminal from the actuator to X3 and the fifth terminal to the

DC (blue) terminal block for the Up Limit Switch. Connect the fourth terminal

to X4 and the third terminal to the DC (blue) terminal block for the Down Limit

Switch.

P a g e | 170
8. The image below shows the wiring diagram of the External Timer Application in PLC

for Stopping a Motor.

P a g e | 171
PROCEDURES: Operating the HMI

1. Connect the HMI to the PLC:

● Use cable to connect the HMI to the PLC.

● Use a USB cable to connect the HMI to the laptop.

● Edit the created ladder diagram, insert a new rung to the top, with an open

contact address as M8002, and an instruction output icon [ MOV K0 D8120]

● Use the Kinco software to control the components

OVERALL EXPERIMENTAL PROCEDURES:

1. Launch GX Works on the Laptop

● Open the GX Works software to begin programming the PLC ladder diagram.

Go to File > New Project.

Note: Select FXCPU for PLC series and FX3G/FX3GC for CPU Type, then click OK

to create the project.

P a g e | 172
2. Create the Ladder Diagram

● Design the ladder diagram to control the water level system. The system should:

○ Start the pump when the start button is pressed.

○ Stop the pump when the water reaches the high-level sensor.

○ Start draining the tank when the release button is pressed.

○ Stop the draining process when the water drops below the low-level

sensor.

○ Include an emergency stop button to halt all operations at any point.

● Compile the program to ensure there are no errors.

● The ladder diagram for the water level control system is shown in the ladder

diagram procedure.

3. Wiring of Components

● Make sure the trainer is turned off before beginning any wiring.

● Connect the components as shown in the actual wiring diagram, including the

pushbuttons, contactor, and motor.

4. Perform a Continuity Test

● Utilize a multimeter to check that all connections are accurate.

● Look for any loose connections or short circuits to ensure safe operation.

5. Power On the Trainer

● After completing the continuity test and confirming all connections, turn on the

trainer.

P a g e | 173
6. Upload the Ladder Diagram to the PLC

● Connect the PLC to the laptop via USB port. Check the connection destination

of the Serial Port in GX Works. Make sure that it is on USB.

● Confirm that the PLC is not in running mode before proceeding to the next step.

● Go to Online > Write to PLC in GX Works.

● Check only the applicable data (PLC Data and Parameter) before proceeding.

● Execute the upload to transfer the ladder diagram to the PLC.

7. Create the HMI Display Using Kinco DTools

● Open Kinco DTools and follow the configuration procedure to connect the HMI

with the PLC.

● Create the HMI interface, adding all the inputs and outputs from the ladder

diagram to the HMI window, addressing them accordingly.

8. Download the HMI Program

● Connect the HMI to the PLC

● After completing the HMI display, go to Tools > Download.

● Set the port to USB and download the HMI program to the HMI device.

● Wait for the download to complete successfully.

9. Operational Testing

● After completing the wiring and programming, test the experiment by first using

the manual pushbuttons.

● Press the filling push button to initiate the first operation. Next, press the

releasing pushbutton to initiate the second operation. After then, examine the

experiment's operation outcome and record your observations in the data and

results table.

P a g e | 174
 ● While conducting either an initial or second operation, press the emergency stop

push button. Observe and record the result of the operation in the table.

● Then test the motor control using the HMI interface to ensure proper operation.

● Press the filling push button on the HMI display to initiate the first operation.

Followed by pressing the releasing pushbutton. Observe the result of the

experiment, then note your findings in the data and results table.

● Press the emergency stop button in the HMI display while performing the first

or second procedure. Examine the outcome of the operation and record it in the

table.

Notes:

● Double-check all wiring connections before powering the system to prevent damage.

In case of an emergency, immediately press the Emergency stop located at the left side

of the trainer to stop the trainer's operation.

● Always verify that the PLC is in the correct mode (Stop/Run) before uploading or

downloading programs.

P a g e | 175
DATA AND RESULTS

Manual Operation

Output Components Type of Operation Result (Run/Stop)

ACTUATOR Filling Button (Press) RUN

High Limit (Triggered) STOP

Releasing Button (Press) RUN

Low Limit (Triggered) STOP

Emergency Stop (Press) STOP

Integrating HMIOperation

Output Components Type of Operation Result (Run/Stop)

ACTUATOR Filling Button (Press) RUN

High Limit (Triggered) STOP

Releasing Button (Press) RUN

Low Limit (Triggered) STOP

Emergency Stop (Press) STOP

P a g e | 176
ANALYSIS

1. How does the PLC decide when to start and stop the actuator (pressure pump)?

● The PLC controls the actuator (pressure pump) by starting and stopping it based

on input signals from sensors or limit switches to maintain the desired water

levels.

2. What role do the limit switches play in this application, and how do they ensure

system safety?

● Limit switches give feedback to the PLC when the actuator hits specific

thresholds, ensuring safe operation by preventing overfilling or dry running

during the experiment.

3. What are the advantages of using relays to control the actuator instead of directly

wiring it to the PLC?

● Relays provide electrical isolation between the actuator and PLC, protecting the

PLC from high current loads and extending its life by reducing direct wear on

its components.

4. What is the importance of automating this water level control system using a PLC?

● Automating the water level control system with a PLC increases efficiency,

reduces manual intervention, and ensures precise and consistent water

management.

P a g e | 177
OBSERVATION

The pressurized water tank control application uses an actuator as a pump to automate

water level management. By integrating limit switches with PLC logic, the system ensures

precise regulation of water pressure while allowing for real-time monitoring and adjustments.

CONCLUSION

In conclusion, the experiment of the pressurized water tank control application

demonstrated the effectiveness of automating water level management through the integration

of PLCs, actuators, limit switches, and HMIs. Overall, the experiment highlighted how

automation not only streamlines operations but also mitigates risks associated with manual

management, leading to safer and more efficient water management solutions.

P a g e | 178
 APPENDIX A

TROUBLESHOOTING GUIDE

P a g e | 179
APPENDIX A: TROUBLE SHOOTING GUIDE

PLC-Based Motor Control Trainer Troubleshooting Guide

This troubleshooting guide is designed to help students or users identify and resolve

common issues encountered with a PLC-based motor control trainer. The system includes a

PLC, HMI, pushbuttons, indicator lights, actuator, relay, timer relay, color sensor, motor

(forward and reverse), motor starter, and contactor.

1. Power Issues

Problem: The system does not start when power is applied.

Solution:

 Verify that the main power supply to the PLC and motor starter is active.

 Check if the circuit breaker or fuse for the PLC or motor circuit is tripped or

blown.

 Ensure that all devices, including the HMI, PLC, and motor starter, are properly

powered.

 Confirm that the PLC is not in "STOP" mode; switch to "RUN" mode if

necessary.

2. Motor Not Running

Problem: The motor does not run even though power is supplied.

Solution:

 Inspect the motor connections for loose or damaged wires.

 Verify the motor starter and contactor are receiving the correct signals from the

PLC.

P a g e | 180
  Ensure the PLC output to the motor starter is correctly programmed and active.

 Check the motor overload relay for a tripped condition and reset if necessary.

 Test the motor windings for continuity with a multimeter to ensure they are

intact.

 Confirm that the appropriate pushbuttons (e.g., "Start") are functioning and

signaling the PLC correctly.

3. Motor Reversal Issues

Problem: The motor runs in the wrong direction when activated.

Solution:

 Check the motor wiring connections to the motor starter terminals. Reverse any

two of the three-phase wires connected to the motor to change the direction.

 Confirm the PLC output is properly configured to switch the forward and

reverse contacts on the motor starter.

 Inspect the control devices such as the reversing pushbuttons and relays for

proper operation and wiring.

 Verify the HMI settings, if applicable, for motor direction configuration.

4. HMI Malfunction

Problem: The HMI does not respond or display information properly.

Solution:

 Verify that the HMI is receiving power and is properly connected to the PLC.

 Check the communication settings between the HMI and PLC (e.g., IP address,

communication protocol).

P a g e | 181
  Inspect the HMI programming for correct configurations of buttons, indicators,

and data fields.

 Ensure the touch screen or buttons on the HMI are not physically damaged or

unresponsive.

5. Pushbutton and Indicator Light Issues

Problem: Pushbuttons or indicator lights do not function as expected.

Solution:

 Check if the pushbuttons are connected correctly to the PLC inputs and verify

they are sending signals when pressed.

 Test the indicator lights by manually activating the output in the PLC program

to verify proper operation.

 Inspect the wiring to the pushbuttons and indicator lights for loose connections

or damage.

 Ensure the PLC program is correctly interpreting pushbutton signals and

controlling the indicator lights.

6. Actuator and Relay Problems

Problem: The actuator or relay does not activate as expected.

Solution:

 Confirm that the actuator and relay are wired correctly to the PLC output

terminals.

 Verify that the PLC is sending the correct output signals to activate the relay or

actuator.

 Inspect the relay for any signs of wear or damage and replace if necessary.

P a g e | 182
  Check for any logic issues in the PLC program that might prevent the actuator

or relay from activating.

7. Timer Relay Malfunction

Problem: The timer relay does not trigger or operates incorrectly.

Solution:

 Verify the timer settings in the PLC program and ensure they are set according

to the desired sequence.

 Check the wiring connections to the timer relay for loose or incorrect

terminations.

 Test the timer relay operation by manually adjusting the PLC program to

confirm the correct timing sequence.

 Ensure the PLC’s output to the timer relay is not interrupted by any faulty logic

or sensor inputs.

8. Color Sensor Malfunction

Problem: The color sensor fails to detect the correct colors or does not respond.

Solution:

 Clean the color sensor to ensure that dust or debris is not interfering with its

operation.

 Check the wiring connections between the color sensor and the PLC.

 Ensure that the sensor range and detection parameters are correctly configured

in the PLC program.

 Test the sensor in a controlled environment to verify it is detecting colors

accurately.

P a g e | 183
9. Motor Overheating

Problem: The motor becomes excessively hot during operation.

Solution:

 Check for obstructions blocking the motor's ventilation openings and remove

them.

 Ensure that the ambient temperature is within the motor's rated limits.

 Reduce the load on the motor if it is operating beyond its rated capacity.

 Verify that the motor's cooling fan is functioning properly and clean any

accumulated dust or debris.

 Check if the PLC is continuously running the motor without necessary pauses

or breaks in the sequence.

10. Overload Tripping

Problem: The motor overload relay trips frequently.

Solution:

 Reduce the load on the motor by checking for blockages or mechanical

resistance.

 Ensure the motor is not overloaded by adjusting the PLC program for proper

motor duty cycle.

 Adjust the motor overload relay settings to match the motor's rated current and

operating conditions.

 Check the motor's cooling system to ensure proper ventilation and cooling.

P a g e | 184
11. Control Circuit Malfunction

Problem: The control circuit fails to operate the motor starter or contactor.

Solution:

 Inspect the control wiring for any loose connections or damaged insulation.

 Check the control devices such as pushbuttons, relays, or timers for proper

operation.

 Verify that the control voltage supplied to the motor starter coil or contactor is

within the rated range.

 Review the PLC program logic to ensure that the correct signals are being sent

to the control circuit.

12. Contactor Issues

Problem: The motor starter's contactor fails to close or open.

Solution:

 Inspect the contactor for any signs of arcing, pitting, or damage to the contacts.

 Clean the contactor contacts and ensure they are making proper contact when

energized.

 Verify the PLC output signal to the contactor coil is functioning correctly.

 Check the control circuit for any faults or improper wiring that may prevent the

contactor from being energized.

13. Color Sensor Malfunction

Problem: If the sensor still does not respond.

Solution:

 Connect to a Laptop

P a g e | 185
  Use a USB cable to connect the color sensor (Arduino-based) to your laptop

through the USB port.

 Ensure the Arduino is powered and properly connected to the sensor.

 Open Arduino IDE:

o Launch the Arduino IDE software on your laptop.

o Configure Board Settings: In the Arduino IDE, navigate to Tools >

Board.

o Select Arduino Nano as the board type.

o Select the Correct Port: From the Tools > Port menu, choose the

appropriate COM port that corresponds to the Arduino Nano.

By following this guide, users can systematically identify and resolve issues with the PLC-

based motor control trainer, ensuring optimal performance and safety in motor control and

industrial automation demonstrations.

P a g e | 186
 APPENDIX B

MAINTENANCE GUIDE

P a g e | 187
APPENDIX B: MAINTENANCE GUIDE

Routine Maintenance Protocol for Basic Programmable Logic Controller (PLC) Trainer

To ensure the reliability and longevity of a Basic PLC Trainer, it is important to establish and

follow a systematic maintenance procedure. The frequency of maintenance should be based on

the equipment's usage and environmental factors, typically performed quarterly or semi-

annually.

Maintenance Schedule:

 Frequency: Quarterly or semi-annually, depending on usage and environmental factors.

 Duration: Allocate sufficient time for a thorough inspection, testing, and servicing.

Tools and Materials:

 Digital multimeter

 Insulation resistance tester (if applicable)

 Infrared thermometer

 Screwdrivers and wrenches

 Compressed air and soft cloth for cleaning

 Lubricants for moving parts (if applicable)

 Programming laptop or device for PLC/HMI troubleshooting

Safety Precautions:

Prioritize safety by adhering to the following precautions:

 Disconnect Power: Ensure power to the PLC trainer is completely disconnected and

locked out/tagged out before beginning any maintenance work.

P a g e | 188
  PPE: Wear appropriate personal protective equipment (PPE) such as safety glasses,

gloves, and insulated tools.

 Ventilation: Work in well-ventilated areas to avoid exposure to hazardous fumes or

gases

 Discharge Stored Energy: Ensure any stored electrical energy in the system, such as

capacitors, has been properly discharged.

Maintenance Procedure:

1. Visual Inspection:

 Perform a thorough visual inspection of the PLC trainer, including wiring,

components, pushbuttons, and indicator lights.

 Check for:

o Loose or damaged wiring connections.

o Signs of overheating, corrosion, or wear on components such as relays,

sensors, and contactors.

o Any physical damage to the PLC, HMI, pushbuttons, or other system

elements.

2. Electrical Testing:

 PLC Power Supply Check:

o Use a digital multimeter to verify that the power supply to the PLC is within

the rated voltage range.

o Inspect the power supply unit for proper functionality and any signs of

overheating.

P a g e | 189
  Input/Output Testing:

o Verify that all PLC inputs (e.g., pushbuttons, sensors) and outputs (e.g.,

relays, motors, indicator lights) are functioning properly.

o Use the PLC’s diagnostic tools or software to check for faults or errors.

 Insulation Resistance (Optional):

o Use an insulation resistance tester to measure insulation resistance in critical

circuits. Low readings may indicate insulation degradation.

3. Component Evaluation:

 PLC Modules:

o Inspect the PLC modules (CPU, I/O cards) for signs of wear or damage.

o erify that all modules are properly seated and secure in their slots.

 HMI:

o Check the HMI screen for responsiveness and clear display output.

o Ensure proper communication between the PLC and HMI.

 Relays and Contactors:

o Inspect relays and contactors for any mechanical wear, arcing, or damage to

the contacts. Replace if necessary.

 Fuses and Circuit Breakers:

o Inspect and test fuses and circuit breakers. Replace blown fuses and reset

tripped breakers if applicable.

 Sensors and Actuators:

o Check sensors, actuators, and associated wiring for any damage or loose

connections.

P a g e | 190
 o Test their function by simulating normal operation through the PLC

program.

4. Cleaning and Lubrication:

 Cleaning:

o Use compressed air and a soft cloth to clean the PLC, HMI, wiring

enclosures, and other components, ensuring that dust and debris are

removed.

o Be cautious around sensitive electronic components, avoiding the use of

abrasive materials.

 Lubrication:

o Apply appropriate lubricants to any moving mechanical components, such

as actuator bearings or hinges, to reduce friction and ensure smooth

operation.

5. Grounding System Inspection:

 Inspect the grounding system, including all grounding conductors and bonding

points, to ensure proper grounding continuity.

 Look for signs of corrosion or wear and verify that all connections are tight and

secure.

 Use a digital multimeter to verify the grounding integrity by checking for proper

continuity.

6. Programming and Communication Check:

 PLC Program:

P a g e | 191
 o Check the PLC program for any errors or faults. Verify that all inputs,

outputs, timers, and counters are functioning as expected.

o Backup the existing program and configurations to a safe location.

 Communication:

o Ensure that communication between the PLC and HMI, sensors, actuators,

and any external devices is stable and uninterrupted.

o Verify the integrity of communication cables and connectors.

7. Temperature Monitoring:

 Use an infrared thermometer to check for hotspots on components such as the power

supply, PLC CPU, relays, and motors.

Note: Any unusually high temperatures may indicate an overloaded component or

improper ventilation.

8. Voltage Regulation and Harmonics Mitigation:

 Monitor voltage levels at key points in the system to ensure they remain within

acceptable operating limits.

 Check for any signs of voltage fluctuations or harmonics that could affect the

performance of the PLC trainer,

 If necessary, install voltage regulators or harmonic filters to maintain stable voltage

levels and minimize distortion.

Documentation and Record-Keeping

Maintain detailed records of all maintenance activities, including:

 Dates of maintenance.

 Tasks performed (e.g., component checks, electrical testing).

P a g e | 192
  Findings (e.g., faults identified, repairs made).

 Any corrective actions taken and recommendations for future maintenance or system

upgrades.

 Ensure that backup copies of the PLC program, HMI settings, and other critical data

are stored securely.

By following this maintenance procedure, users can ensure that the PLC Trainer remains

in optimal working condition, minimizing downtime and maximizing the educational value of

the system.

P a g e | 193
 APPENDIX C

SAFETY GUIDELINES

P a g e | 194
APPENDIX C: SAFETY GUIDELINES

Basic Programmable Logic Controller (PLC) Trainer Safety Guidelines for Batangas

State University Students:

1. Personal Protective Equipment (PPE):

 Always wear appropriate PPE, including safety glasses, gloves, and closed-toe

shoes, when working with the PLC trainer.

 Additional PPE may be required based on specific tasks or exposure to electrical

components.

2. Training and Supervision:

 Only students who have undergone proper training and have been authorized should

operate the PLC trainer.

 Ensure students receive thorough instruction on the usage of the PLC trainer, safety

protocols, and emergency procedures before independent work is permitted.

 Supervise students closely, particularly during hands-on activities involving the

PLC trainer and electrical systems.

3. Electrical Safety:

 Before beginning any work, ensure that the power supply to the PLC trainer is

switched off, and the main power switch is secured in the off position.

 Never perform repairs, modifications, or troubleshooting on the PLC trainer while

it is powered on.

 Use insulated tools and take extreme caution when handling live electrical circuits

to avoid electric shock.

P a g e | 195
4. Fire Safety:

 Ensure the area around the PLC trainer is clear of flammable materials, and that fire

extinguishers are accessible and in working condition.

 In case of fire or smoke detection, evacuate the area immediately and follow the

university's established emergency procedures.

5. Mechanical Safety:

 Avoid wearing loose clothing, jewelry, or accessories that may become entangled

with any parts of the PLC trainer or related equipment.

 Confirm that all safety guards, shields, and covers are properly installed before

operating the equipment.

6. Emergency Procedures:

 Familiarize yourself with the location of emergency stop buttons, fire alarms, and

exits in the PLC training area.

 In the event of an emergency, stay calm, evacuate the area promptly, and inform

the instructor or designated personnel immediately.

7. Housekeeping:

 Keep the area around the PLC trainer clean and organized to avoid trip hazards and

to ensure easy access to emergency equipment.

 Promptly clean up spills and ensure proper disposal of waste materials to maintain

a safe working environment.

8. Proper Usage:

 Use the PLC trainer only for its intended educational purpose and always follow

the instructions and guidelines set by the instructor.

P a g e | 196
  Never attempt to disable, tamper with, or bypass safety features, interlocks, or

protective devices on the equipment.

9. Report Hazards:

 Immediately report any potential safety hazards, equipment malfunctions, or near-

miss incidents to the instructor or relevant university personnel.

 Encourage a proactive safety culture by promoting hazard reporting and awareness

among fellow students.

10. Continuous Learning:

 Keep updated with the latest safety practices and guidelines specific to PLCs and

electrical systems.

 Participate in regular safety training and refresher courses provided by the

university to stay informed of any updates or new safety procedures.

By following these safety guidelines, Batangas State University students will be able

to minimize the risk of accidents and injuries while working with the PLC trainer, fostering a

safe and effective learning environment.

P a g e | 197