Programmable Logic Control LAB – MC1632 2020

DEPARTMENT OF MECHATRONICS ENGINEERING

SCHOOL OF AUTOMOBILE, MECHANICAL AND MECHATRONICS

ENGINEERING

PROGRAMMABLE LOGIC CONTROL LAB

Course Code: MC1632

LAB MANUAL

Sixth Semester
 Programmable Logic Control LAB – MC1632 2020

Mechatronics Engineering Department, Manipal University Jaipur

LAB CONTENT & EVALUATION REPORT

Name of Laboratory : Programmable Logic Control Lab code :

MC 1632
Student Name : Reg. No.: Batch : Group no.
Exp. Exp. Name Page Date of Date of Attendance Record Perfor.* Viva Total Teacher remark
No. No. allotment performance (01) (03) (03) (03) (10)
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
*Preparation of Sheet
**Overall Quality of performance , knowledge about application of experiment , technical detail of equipment’s, process and theories involved in practical
Max. Marks : Marks Obtained : Normalized score :
Programmable Logic Control LAB – MC1632

Contents
S.No. Contents Page No.

I Evaluation Scheme 4
II Do’s and Don’ts 4
III Laboratory Instructions 5
IV Introduction to Laboratory components 6
V Exercise 01: Study of Logic Gates and implementation using PLC ladder 13
diagram.
Exercise 02 Implementation of Latching circuit and study of its application. 16
Exercise 03: Implementation of Switching of Light circuit using PLC logic. 18
Exercise 04: Implementation of Door Bell. 20
Exercise 05: Study and implementation of Sequential Control of 23
Motors/Cylinders.
Exercise 06: To perform Stepper Motor Control using PLC ladder 26
programming.
Exercise 07: Implementation of Process control using PLC ladder diagram. 29
Exercise 08: To perform Traffic Light Control using PLC ladder diagram. 32

Exercise 09: To study and implement Bottle filling Plant using PLC ladder 36
diagram.
Exercise 10: To study and implementation of Conveyor Control System. 40
Exercise 11: Study of Industrial Process and implementation using PLC 43
ladder diagram.
Exercise 12: Drilling Tool 45
Exercise 13: Implementation of Analog PLC operations. 48
Exercise 14: Seven segment display using PLC ladder program. 50
Exercise 15: Implementation of Lift Control logic using PLC ladder diagram. 53
Exercise 16: Implementation of Density based traffic light system. 56

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I. Evaluation Scheme
Class: IV Semester B.Tech. Evaluation
Branch: Mechatronics Evaluation scheme followed as per lab session
Schedule per Week Viva-voce taken at each lab session (Internal)
Practical Hrs : 2 hr/week Main Examination Time = Three (3) Hours
Maximum Marks = 100
[Internal (60) & External (40)]

II. DO’S AND DONT’S

DO’S:
• Students should get the record of previous experiment checked before starting the new experiment.
• Read the manual carefully before starting the experiment.
• Before starting the experiment, get circuit diagram checked by the teacher.
• Before switching on the power supply, get the circuit connections checked.
• Get your program and connections checked by the teacher.
• Apparatus must be handled carefully.
• Maintain strict discipline.
• Keep your mobile phone switched off or in vibration mode.
• Students should get the experiment allotted for next turn, before leaving the lab.

DONT’S:
• Do not touch or attempt to touch the main power supply wire with bare hands.
• Do not overcrowd the tables.
• Do not tamper the equipment.
• Do not leave the lab without prior permission from the teacher.

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III. Instructions to the Students

General Instructions
• Maintain separate observation copy for each laboratory.
• PLC program layout and connection plan should be written in observation copy.
• Get the program counter signed by the faculty after the completion of the experiment.
• Maintain Index column in the observation copy and get the signature of the faculty before
leaving the lab.
Before Entering the Lab
• The previous experiment should have been written in the practical file, without which the
students will not be allowed to enter the lab.
• The students should have written the experiment in the observation copy that they are
supposed to perform in the lab.
• The experiment written in the observation copy should have aim, circuit
diagram/algorithm, formula (if any), program (if any), timing diagram (if any) and space
for result.
When Working in the Lab
• Necessary equipment/apparatus should be taken only from the lab assistant by making an
issuing slip, which would contain name of the experiment, names of batch members and
apparatus or components required.
• Never switch on the power supply before getting the permission from the faculty.
Before Leaving the Lab
• The equipment/components should be returned back to the lab assistant in good condition
after the completion of the experiment.
• The students should get the signature from the faculty in the observation copy.
• They should also check whether their file is checked and counter signed in the index.

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BASIC INTRODUCTION TO PLC

As the name indicates, programmable logic controllers (PLC's) are nothing but a type of solid state devices
designed to perform logic functions previously accomplished by electromechanical relays mainly used in
industrial equipment. These industrial equipment may range from a small ON-OFF switch to a heavy
machine. Any component in an industry that needs a control can be controlled by using a PLC. The main
advantage of using a PLC is that long and tedious programming can be eliminated. These PLC's differ not
only on the basis of programming but also it has the advantage of being available in portable sizes and
series. The programming for the PLC is done by using a ladder logic diagram. The ladder logic diagram
consists of blocks which are in the form of ladders. We will be discussing about it in detail in the later
parts.

PLC PROGRAMMING

The two most common language structures are ladder diagram language and Boolean language.
Here we will be using only the ladder diagram language. The ladder diagram language is basically a
symbolic set of instruction used to create the controller program. These ladder instructions are arranged
to obtain the desired control logic that is to be entered into the memory of the PLC. The main symbols
that are used in a PLC programming are as shown below:

It should be noted in a PLC ladder programming that continuous path is required for logic continuity, and
to energies the output. A ladder diagram can be represented as shown below.

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The main function of the logic ladder diagram is to control outputs based on input conditions. This control
is accomplished through the use of what is referred to as a ladder rung. For an output to be activated or
energized at least one left-to-right path of the contact must be closed. A complete closed path is referred
to as having logic continuity. When logic continuity exists in at least one path, the rung condition is said
to be true. The rung condition is false if no path has continuity.

MODE OF OPERATION

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POINT MICRO PLC

DESCRIPTION

Versa-Max Micro PLCs offer the perfect solution for smaller packaging machines, dispensing
machines, and relay replacement applications with up 8 Inputs and 6 Outputs. In spite of their small size,
these versatile controllers provide powerful programming features such as built-in high-speed counter
functionality, PID functions, support for floating-point function blocks and subroutines, ability to assign
passwords and privilege levels, and override capability.

It operates on +24VDC nominal Input power and accept Inputs from 8 No’s of Positive Logic
/Negative Logic Inputs. In IC200UDD104 model PLC having 6 No’s of Transistor Outputs. From Q1 t0
Q2 outputs at 1 Amps Max and then Q3 t0 Q6 outputs are at 0.75 Amps Max. It having 4 No’s of High
speed counter channels and 4 No’s of PWM outputs at 15Hz to 5 KHz.

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a) Run/Stop Switch
The Run/Stop switch can be configured as a run/stop switch, a memory protect switch, and used
for clearing faults when a fatal fault exists.

b) Serial Ports
Port 1 is an RS-232 serial port with an RJ-45 connector. Port 2, located behind a removable door
on the front of the Micro PLC, is an RS-485 serial port with a DB-15 connector. Both ports can be used
for programming. Only one port can be used at a time for programming, but both ports can be used for
monitoring at the same time. Port 1 uses SNP slave protocol. Port 2 is software configurable for SNP slave
or RTU slave operation. 4-wire and 2-wire RTU are supported.

c) Status LEDs
LEDs for Power, OK, and Run mode, plus individual LEDs for each I/O point.

d) Features

• 24V DC nominal input power.

• 24V DC output power available for field devices.
• Eight configurable DC inputs that can be used as positive or negative logic standard inputs or
High-speed Counter inputs.
• Six DC output that can be used as a standard, High-speed Counter, Pulse Width Modulation, or
Pulse Train output.
• Expandable to up 4 Expansion Units.
• Port 1 (RS-232) supports SNP/SNPX slave protocols.
• Run/Stop mode switch that can be configured as a run/stop switch, a memory protect switch, and
also used for clearing faults when a fatal fault exists.
• Full-featured programming Instruction Set with floating point math. The application program can
be either Ladder Diagram (LD) or Instruction List (IL) format.
• Time-of-Day Clock.
• 9K words of program memory, 2048 words of registers.

DC INPUTS

The DC inputs accept 24VDC input voltages. The 24 volt DC input circuits can have positive or
negative logic characteristics. Current into an input point results in a logic 1 in the input status table
(%I). Input characteristics are compatible with a wide range of input devices, such as pushbuttons,
limit switches, and electronic proximity switches. Power to operate field devices and the input circuits
is supplied by an isolated +24 VDC supply.

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DC Input Specifications

DC Outputs

24 VDC transistor output can be used as a normal DC output or as a High-speed Counter-controlled

output, Pulse Train output, or Pulse Width Modulation (PWM) output.

DC Output Specifications

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Block Diagram of PLC

S7-200 CPU
The S7-200 CPU combines a microprocessor, an integrated power supply, input circuits, and output circuits in
a compact housing to create a powerful Micro PLC. After you have downloaded your program, the S7-200
contains the logic required to monitor and control the input and output devices in your application.

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STEP 7--Micro/WIN Programming Package

The STEP 7--Micro/WIN programming package provides a user-friendly environment to develop, edit, and
monitor the logic needed to control your application. STEP 7--Micro/WIN provides three program editors for
convenience and efficiency in developing the control program for your application..

Computer Requirements
STEP 7--Micro/WIN runs on either a personal computer or a Siemens programming device, such as a PG 760.
Your computer or programming device should meet the following minimum requirements: - Operating system:
Windows 2000, Windows XP, Vista, or Windows 7 At least 350M bytes of free hard disk space Mouse
(recommended)

Communications Options
Siemens provides two programming options for connecting your computer to your S7-200: a direct connection
with a PPI Multi-Master Cable, or a Communications Processor (CP) card with an MPI cable. The PPI Multi-
Master programming cable is the most common and economical method of Connecting your computer to the
S7-200. This cable connects the communications port of the S7-200 to the serial communications of your
computer. The PPI Multi-Master programming cable can also be used to connect other communications
devices to the S7-200.

Connecting the RS-232/PPI Multi-Master Cable

1. Connect the RS-232 connector (marked “PC”) of the RS-232/PPI Multi-Master cable to the communications
port of the programming device. (For this example, connect to COM 1.)
2. Connect the RS-485 connector (marked “PPI”) of the RS-232/PPI Multi-Master cable to Port 0 or Port 1 of
theS7-200.
3. Ensure that the DIP switches of the RS-232/PPI Multi-Master cable1 2 3 4 5 6 7 8RS-232/PPI Multi-Master
Cable S7-200 Programming Device ↑1 – On↓0 – Off are set as shown in Figure. Connecting the RS-
232/PPI Multi-Master Cable.

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Exercise 01: Study of Logic Gates and implementation using PLC ladder diagram.

Objective: To understand the working of a programming logic controller and to implement the digital
logic in PLC

AND GATE OR GATE NOT GATE

NAND GATE NOR GATE XOR GATE

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Exercise 02 Implementation of Latching circuit and study of its application.

Exercise definition:

A latch is an electronic logic circuit that has two inputs and one output. One of the inputs is called
the SET input; the other is called the RESET input. Latch circuits can be either active-high or active-low.
The difference is determined by whether the operation of the latch circuit is triggered by HIGH or LOW
signals on the inputs.
Active-high circuit: Both inputs are normally tied to ground (LOW), and the latch is triggered by a
momentary HIGH signal on either of the inputs.
Active-low circuit: Both inputs are normally HIGH, and the latch is triggered by a momentary LOW
signal on either input.

Exercise tasks:

1. Prepare a clamp connection plan.

2. Prepare the PLC program.
3. Implement latch circuit with one start and one stop push button.
4. Implement the latch with single start\stop push button.

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Exercise 03: Implementation of Switching of Light circuit using PLC logic.

Definition: -

A light switch is a switch, most commonly used to operate electric lights, permanently connected
equipment, or electrical outlets. Portable lamps such as table lamps will have a light switch mounted on
the socket, base, or in-line with the cord. Manually operated on/off switches may be substituted by remote
control switches, or light dimmers that allow controlling the brightness of lamps as well as turning them
on or off. Light switches are also found in flashlights and automobiles and other vehicles.

Simulation Setup for switching of lights

Exercise tasks
With selector switch, a decision is made as which of the lamps (lamp1 or 2 lamp) is to be switched
ON. If selector switch is in OFF position (input =0) and active push button is actuated, then lamp 2 will
light. Similarly, if selector switch is in ON position (input signal = high) and active push button is actuated
then lamp 1 will light. Lamp will light even if the push button is released.

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Exercise 04: Implementation of Door Bell.

Definition:

When a visitor presses the doorbell button, the home’s doorbell rings as usual; however, additional
lamps and ceiling lights flash and/or loud beepers also sound wherever special PLC modules have been
installed. Any number of these modules can be installed in a home to flash a light and/or make a sound in
each room or even in a nearby home if a neighbor or caregiver is counted on to greet visitors. This system
can be helpful to people who are hearing impaired or deaf, as well as people who answer the door for
others but do not have a doorbell chime in their rooms. Hearing people who may need a flashing light or
louder chime close by in noisy spaces, such as in home workshops or when the stereo is on, will also find
the system useful.

Simulation setup for Door Bell System

Exercise tasks: A bell inside the flat is to ring if the door switch at the front door or gate switch at the
gate is pressed.

Sequence of task:
Press gate switch, Doorbell will ring for 2 sec after releasing the switch or press door switch, Doorbell
will ring for 2seconds after releasing the switch. Implement the task using both ON and OFF timers.

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Exercise 05: Study and implementation of Sequential Control of Motors/Cylinders.

Exercise Definition:

The PLC task is to operate motor 1 followed by motor 2 followed by motor 3. The sequence is motor 1,
2, 3, and 4.

Sequence of tasks:
The sequence of tasks is as follows:
i. When input switch (push button) is pressed motor 1 will start.
ii. Motor 2 will start after 5 seconds of motor 1.
iii. Motor 3 will start after 5 seconds of motor 2.
iv. Motor 4 will start after 5 seconds of motor 3.
v. Motor 5 will run for 5 seconds and after 5 seconds all the motors will stop. To restart the process,
input switch is pressed again.

Simulation setup for sequential control of motors

Exercise tasks -

1. Determine the timing diagram for sequential control of motors.

2. Prepare a clamp connection plan.
3. Prepare the PLC program.

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Exercise 06: To perform Stepper Motor Control using PLC ladder programming.

Objective: To understand the working of stepper motor in full step and half step mode.

Definition:

Stepper motors work on the principle of electromagnetism. There is a soft iron or magnetic rotor
shaft surrounded by the electromagnetic stators. The rotor and stator have poles which may be teethed or
not depending upon the type of stepper. When the stators are energized the rotor moves to align itself
along with the stator (in case of a permanent magnet type stepper) or moves to have a minimum gap with
the stator (in case of a variable reluctance stepper). This way the stators are energized in a sequence to
rotate the stepper motor.
Figure (a) shows a permanent magnet stepper motor with four stator windings. By pulsing the
stator coils in a desired sequence, it is possible to control the speed and direction of the motor. Figure (b)
shows the timing diagram for the pulses required to rotate the PM stepper motor illustrated in Figure (a).
This sequence of positive and negative pulses causes the motor shaft to rotate counterclockwise in 90°
steps. The waveforms of Figure (c) illustrate how the pulses can be overlapped and the motor made to
rotate counterclockwise at 45° intervals.

Exercise tasks:

1. Determine the timing sequence of excitation input.

2. Prepare a circuit connection plan.
3. Prepare the PLC program.
4. Draw the proper timing diagram of outputs.

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Exercise 07: Implementation of Process control trainer using PLC ladder diagram.

Definition:

Process control is arguably the largest area of control engineering application. It is used in the
manufacturing, infrastructure and service industries, and these are grouped under the common heading:
the process industries. Most of the things that we use or do are associated with a ‘process’ of some form.
For example, if you print this page on to paper, then you are immediately using two process industry
products: – for the paper, the papermaking industries, and for the ink, the chemical process industries.
Other typical products of process industries are: metals, textiles, rubber, polymers, paint, food and drinks,
pharmaceuticals and chemicals of all kinds. Of particular importance are the process industries that
extract, process and distribute natural resources: such as petrochemicals, gas, minerals and electricity.

Exercise tasks:

In a process control trainer PH valve of a solution is to be maintained constant by controlling the

flow of water in reaction tank. Water flow to reaction tank is controlled by a control valve. Continuous
stirring is required to make the solution of reaction tank uniform.

Process Control Simulation Setup

Sequence of Task

The sequence of operation is as follows:

1. Normally open and normally closed push buttons are used to start and stop the process.
2. When the start button is pressed, solenoid A energizes to start filling the tank.
3. As the tank fills the empty level sensor switch closes.
4. When the tank is full, the full level sensor switch closes and solenoid A is de-energized.
5. The agitate motor starts automatically and runs for 3 min to mix the liquid.

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6. When agitate motor stops, solenoid B is energized to empty the tank.

7. When the tank is completely empty, the empty sensor switch opens to de-energize solenoid
B.
8. The start button is pressed to repeat the sequence.

Exercise tasks:

1. Determine the type of the input and output devices.

2. Prepare a circuit connection plan and flow chart.
3. Prepare the PLC program.

Ladder Diagram:

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Exercise 08: To perform Traffic Light Control using PLC ladder diagram.

Definition:

The objective is to control the operation of a traffic signal. The working is as follows:

1. There are four roads connected as shown in fig. Each road consists of 3 signals green, yellow and
red.
2. Initially green signal of road 1 is ON. After 60 seconds Green signal of road 1 goes off and Yellow
signal of road 1 is ON. After 5 seconds Yellow signal of road 1 goes off and red signal is ON.
During this operation of road 1 other roads show red signal.
3. After road 1 shows red signal, cycle repeats for road 2. During this operation other roads show red
signal.
4. After road 2 shows red signal, cycle repeats for road 3. During this operation other roads show red
signal.
5. After road 3 shows red signal, cycle repeats for road 4.
6. The cycle will repeat.

Simulation setup for Traffic Light System

Exercise tasks

1. Determine the timing sequence of excitation input.

2. Prepare a circuit connection plan.
3. Prepare the PLC program.
4. Draw the proper timing diagram.

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Sequence of task
Only one green signal should ON at a time. Green signal should light for 60 sec .Before green
signal start there should be yellow signal for 5 sec. after green signal there should be red signal. Rotate
the signal sequentially in clock wise direction.

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Exercise 9: To study and implement Bottle filling Plant using PLC ladder diagram.

Definition:

Bottle Filling System: -

The bottle filling system is used to control the liquid level in bottle & moved to next bottle, it also
maintains the liquid level in process tank. Solenoid valves are used to maintain the process automatically
and continuously.
In this processing system, Low-level & High level sensors are used to sense the liquid level in
process tank. Then solenoid valve will open & stepper motor will stop the rotation whenever Bottle sensor
& Bottle position sensor will get the output value. After average value of time fill the liquid in Bottle,
automatically solenoid valve will close & stepper motor rotates now. This process repeated again and
again.

Working of the System: -

First of all, in the process tank is in low level switch will get control. It causes for switch ON the
motor, then fill the liquid to process tank, liquid level increases continuously. The motor will goes to OFF
state, whenever the liquid level will reach the high level.

Hardware Setup for Bottle Filling Plant

Stepper motor is rotating now. It will stop depending upon two factors such as result of bottle
sensor [Proximity Inductive Sensor] and result of bottle position sensor [Opto-Coupler]. If the two sensors
sense the bottle, the stepper motor will be in stop mode, then it will fill the liquid. Simultaneously, solenoid
valve will open, which depends upon the output value of two sensors. We will set into particular time-

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delay in PLC, after the time delay, solenoid valve will move into close position, which depends upon the
average value of time to fill the bottle. Simultaneously, stepper motor starts now to rotate the platform,
whenever the two sensor will sense, then stop the stepper motor and solenoid valve will open. This process
is going on continuously. If the process reach up to the low level of liquid in process tank then turn ON
the pump to fill the process tank.

Exercise tasks:

1. Determine the timing sequence of excitation input.

2. Prepare a circuit connection plan.
3. Prepare the PLC program.
4. Draw a proper timing diagram.

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Exercise 10: To study and implementation of Conveyor Control System.

Definition:-
The conveyor control system deals with the flow of material in an Industrial setup. Beginning
rights from the raw material in the store to the finished product. The most common application of conveyor
system is in material handling process.

Construction: -
The conveyor control systems trainer consists of the following parts
1. Conveyor
2. Stepper Motor
3. Sensor

Conveyor control setup

1. Conveyor
This mechanical setup consists of belt, rotated using a stepper motor and a rotor on the other side when
the stepper motor rotates the rotor on the other side also rotates and a continuous motion is produced.

2. Stepper motor

Two number of stepper motors are used one is used to rotate the conveyor, and the other one to pick
the material from the conveyor and drop in the storage tank. The stepper motor in the trainer kit produces
the required rotating motion to the bottle platform. The stepper motor windings Coil 1, Coil 2, Coil 3, Coil
4 can be cylindrically excited with the DC current to run the motor in the clock wise direction. By reversing
the phase sequences Coil 1, Coil 4, Coil 3, Coil 2. The 4 Coils of the stepper motor are arranged in a
fashion to rotate in steps. The steps angle for rotation of stepper motor is governed by numbering of stator
and rotors.

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Working principle
The materials are loaded on the conveyor and the various sensors are used to sense their Respective
Materials. When the metal is sensed, the Conveyer is stopped for particular time delay then the number of
metals are counting, again stepper motor is moving. That process continues.

Exercise tasks:-
1. Determine the timing diagram for control of stepper motor.
2. Control the operation of PLC based on proximity sensor
3. Prepare a clamp connection plan.
4. Prepare the PLC program.

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Exercise 11: Study of Industrial Process and implementation using PLC ladder diagram.

Sequence of task:

In an industrial application there is machine with a large steel shaft supported by bearings. This shaft is
coupled to a large electric motor. The bearings need lubrication, which is supplied by an oil pump driven
by a small electric motor. The sequence is as follows:
1. To start the machine, the operator turns switch on.
2. Before the motor shaft starts to turn, the bearings are supplied with oil by the pump for 10
sec.
3. The bearings also receive oil when the machine is running.
4. When the operator turns switch off to stop the machine, the oil pump continues to supply
oil for 15 sec.
5. A timer is used to track the total running time of the pump. When the total running time is
3h, the motor is shut down and a pilot light is turned on to indicate that the filter and oil
need to be changed.
6. A reset button is provided to reset the process after the filter and oil have been changed.

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Exercise 12: Drilling tool

Exercise definition:

Work pieces are to be drilled by a drilling tool. When a start pushbutton is pressed, a work piece from
the magazine is pushed under the drill by cylinder 1. Afterwards, cylinder 3 with drilling machine will
drill the work piece. When the cylinder 3 is retracted again, cylinder 2 lifts the work piece while
simultaneously, valve of blower opens and blows the work piece off the work bench.

Basic position:
• Cylinder 1 is retracted (Home position).
• Cylinder 2 is retracted (Home position).
• Cylinder 3 is retracted (Home position).

The drill tool's operating mode is defined as follows: The system is put into operation by means of the
start command via the “Start pushbutton (P1)” of the control panel. After activation of P1, Cylinder 1 is
extended and holds the work piece in the drilling position. As soon as the limit sensor LS1 "Cylinder 1
extend" is reached, the cylinder moves back to the basic position. Cylinder 3 with drill is extended and
drills the work piece. If the limit sensor LS4 "Cylinder 3 extend" is reached, Cylinder 3 moves back into
the basic position. Cylinder 2 is extended and lifts the work piece. If the limit sensor LS5 "Cylinder 2
extend" is reached, the compressed air blows the work piece off the work bench. After a delay time of 2
seconds, Cylinder 2 moves back into the starting position. The system has reached its basic position. As
soon as the limit sensor LS6 "Cylinder 2 retract" is confirmed, the process is repeated. It must be
possible to stop the system at any time using the P2 pushbutton “Stop”. Restart shall only be possible to
stop the system at any time using the P2 pushbutton “Stop”.

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Exercise 13: Implementation of Analog PLC Operations.

Objective:
A PLC (Programmable Logic Controller) is used for the control of industrial machines and process
installations. The PLC was designed especially for this purpose and offers the possibility of a flexible
configuration by means of hardware and software to be adapted to the machine or process which needs
to be controlled. Analog signals such as pressure, flow and temperature from the process are evaluated
by the PLC and based on these signals the process is controlled by the PLC.

AN ANALOG INPUT “SYSTEM”:-

Although “PLC people” might refer to an analog input as a single item, it takes several steps and sub-
systems to convert a real-world measurement into a discrete digital signal. Several steps need to occur
and several devices will be involved. The sub-systems are: sensor (transducer), transmitter, and analog
input module.
A transducer converts a real world physical variable into a very low-level electrical current or voltage.

COMMON PHYSICAL VARIABLES TO BE MEASURED: -

• Flow
• Pressure
• Temperature
• Vibration

Exercise tasks:

1. Determine the addresses of inputs and outputs used.

2. Determine the type of instructions used to carry out the analog operations.
3. Prepare the PLC program.

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Exercise 14: Seven segment display using PLC ladder program.

Definition:-

A seven-segment display (SSD), or seven-segment indicator, is a form of electronic display device for
displaying decimal numerals that is an alternative to the more complex dot matrix displays. Seven-
segment displays are widely used in digital clocks, electronic meters, basic calculators, and other
electronic devices that display numerical information.

Exercise tasks:
Convert 3 bit binary coded number into equivalent BCD number and display the number in seven
segment display form on display window.

Simulation Setup for seven segment display

Sequence of task

Each segment of the seven segment display is connected to individual output. To display any
number, the output required for that number is to be made ON. Suppose the number to display is 1.The
segment required for 1 is a and b.so to display 1, output 2 and 3 is to be made ON. Number on display
depends on the combination of S1, S2and S3 switch .S1 stands for first bit of binary coded number.
Similarly, S2 and S3 are the 2nd and 3rd bit.

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Exercise 15: Implementation of Lift Control logic using PLC ladder diagram.

Hardware: -

Description of the front panel: -

Simulation set up for lift control

Hardware Description: -

1. Floor sensors
Roller Switches are used as floor sensors. When lift car crosses the roller, the roller holder moves
inside and the push button will be pressed. The sensor delivers +5V .when the push button is pressed. This
voltage is given to the TTL Input of the PLC Trainer. Ground Floor and Second Floor have one roller
switch each First Floor feedback is taken from two roller switches to detect Top and Bottom edges of the
Lift Car. This is necessary to stop the lift car at same position in both directions.

2. Lift car setup

The Lift car is fixed to two guide rods to determine the lift car movement in a fixed path. The rods
are fixed to the top and the bottom of the lift setup. The rear side of the lift car is mounted on a belt which
is connected to the shaft of the Stepper or DC Motor.

Exercise tasks:

1. Determine the type of the signal encoders and receivers and prepare an assignment list.
2. Prepare a circuit connection plan and flow chart.
3. Prepare the PLC program.

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Exercise 16: Implementation of Density based traffic light system.

Definition:

Density based traffic light system can be implanted where the problem of high traffic is present.
Conventional traffic light system is based on fixed time concept allotted to each side of the junction which
cannot be varied as per varying traffic density. Junction timings allotted are fixed. Sometimes higher
traffic density at one side of the junction demands longer green time as compared to standard allotted time.
In density based traffic light system, the signal timing changes automatically on sensing the traffic density
at the junction.

Sequence of task:

There are pair of IR sensors used at each road. Whenever the output of any of these pair of IR sensor is
high, the green signal for that road remain high for higher time. If there is no sensor giving the high output,
the sequence will go normally as in experiment 8.

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