AIN SHAMS UNIVERSITY

FACULTY OF ENGINEERING
MECHATRONICS ENGINEERING DEPARTMENT

Spring, 2022

MCT312: Industrial Automation

Sheet 3: PLC Programming Ladder Diagram

1- Design a PLC ladder diagram to run three motors sequentially. M1 will start, then M2 starts,
then M3. Motors should be interlocked in order to achieve the desired sequence.

2- The process shown in Figure 1 is to be used to control the level of water in a storage tank by
turning a discharge pump on or off. The modes of operation are to be programmed as follows:
OFF Position—The water pump will stop if it is running and will not start if it is stopped.
Manual Mode—The pump will start if the water in the tank is at any level except low.
Automatic Mode—If the level of water in the tank reaches a high point, the water pump will
start so that water can be removed from the tank, thus lowering the level.
- When the water level reaches a low point, the pump will stop.
Status Indicating Lights—Water pump running light
(green)
- Low water level status light (red)
- High water level status light (yellow)

Figure 1

3- Figure 2 shows the sketch of a drilling process that requires the drill press to turn on only if
there is a part present and the operator has one hand on each of the start switches. This
precaution will ensure that the operator’s hands are not in the way of the drill.
The sequence of operation requires that switches 1 and 2 and the part sensor all be activated
to make the drill motor operate. Design the PLC ladder diagram needed to perform the task.

Figure 2

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4- A motorized overhead garage door is to be operated automatically to preset open and closed
positions. The field devices include one of each of the following:
• Reversing motor contactor for the up and down directions.
• Normally open down limit switch to sense when the door is fully closed.
• Normally open-held closed up limit switch to sense when the door is fully opened.
• Normally open door up button for the up direction.
• Normally open door down button for the down direction.
• Normally closed door stop button for stopping the door.
• Red door ajar light to signal when the door is partially open.
• Green door open light to signal when the door is fully open.
• Yellow door closed light to signal when the door is fully closed. The sequence of operation
requires that:
• When the up button is pushed, the up-motor contactor energizes and the door travels upward
until the up-limit switch is actuated.
• When the down button is pushed, the down motor contactor energizes and the door travels
down until the down limit switch is actuated.
• When the stop button is pushed, the motor stops. The motor must be stopped before it can
change direction.

❖ Design the ladder logic program required for the operation.

5- Figure 3 shows the sketch of a continuous filling operation. This process requires that boxes
moving on a conveyor be automatically positioned and filled.

The sequence of operation for the continuous filling

operation is as follows:
• Start the conveyor when the start button is momentarily pressed.
• Stop the conveyor when the stop button is momentarily pressed.
• Energize the run status light when the process is operating.
• Energize the standby status light when the process is stopped.
• Stop the conveyor when the right edge of the box is first sensed by the photosensor.
• With the box in position and the conveyor stopped, open the solenoid valve and allow the
box to fill. Filling should stop when the level sensor goes true.
• Energize the full light when the box is full. The full light should remain energized until the
box is moved clear of the photosensor.
❖ Design the ladder logic program required for the operation.

Figure 3

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6- Figure 4 shows how three motors can be started automatically in sequence with a 20s time delay.

Figure 4

between each using two hardwired on-delay timers. The operation of the circuit can be summarized
as follows:
• Motor starter coil M1 is energized when the momentary start pushbutton PB2 is actuated.
• As a result, motor 1 starts, contact M1-1 closes to seal in M1, and timer coil TD1 is
energized to begin the first time-delay period.
• After the preset time period of 20 s, TD1-1 contact closes to energize motor starter coil M2.
• As a result, motor 2 starts and timer coil TD2 is energized to begin the second time-delay
period.
• After the preset time period of 20 s, TD2-1 contact closes to energize motor starter coil M3,
and so motor 3 starts.

❖ Design the ladder logic program required for the operation.

7- Figure 5 shows a hardwired off-delay timer relay circuit with both instantaneous and timed contacts.
The operation of the circuit can be summarized as follows:

• When power is first applied (limit switch LS open), motor starter coil M1 is energized and the
green
pilot light is on.
• At the same time, motor starter coil M2 is deenergized, and the red pilot light is off.
• When limit switch LS closes, off-delay timer coil TD energizes.
• As a result, timed contact TD-1 opens to deenergize motor starter coil M1, timed contact TD-2
closes to energize motor starter coil M2, instantaneous contact TD-3 opens to switch the green light
off, and instantaneous contact TD-4 closes to switch the red light on. The circuit remains in this state
as long as limit switch LS1 is closed.
• When limit switch LS1 is opened, the off-delay timer coil TD de-energizes and the time-delay
period is started.

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 Figure 5

8- Figure 6. The process involves pumping fluid from tank A to tank B. The operation of the process
can be summarized as follows:
• Before starting, PS1 must be closed.
• When the start button is pushed, the pump starts. The button can then be released and the pump
continues to operate.
• When the stop button is pushed, the pump stops.
• PS2 and PS3 must be closed 5 s after the pump starts. If either PS2 or PS3 opens, the pump will
shut off and will not be able to start again for another 14 s.

Figure 6

9- Write the PLC code to control the traffic lights. The operation should go as below:
• Transition from red light to green light to amber light is accomplished by the interconnection
of the three TON timer instructions.
• The timed sequence of the lights is:
Red—30 s on
Green—25 s on
Amber—5 s on
• The sequence then repeats itself.

10- Write the PLC code snippet required to count 10 products on a conveyor using IR-Sensor. If 10
Products are counted the motor should be stopped to allow other process to happen.

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11- We want to control the room temperature using a Temperature sensor as a feedback. If the
temperature is greater than 20 oC, the air conditioner will be on.

Note: The sensor works in a range from 0 oC to 100 oC and produces an analogous voltage from 0 to
10 volts respectively.

❖ Sketch by hand the PLC ladder program (Using Siemens Syntax) required for the
operation.

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