Solved PLC Program

1. Write a ladder logic program to indicate the number of products sensed per minute.

Process Diagram

The sequence of operation is as follows:

 When the start button pressed, the timer timing starts.
 Proximity switch is used to sense the packing coming in conveyor line.
 Each false-to-true condition of proximity switch counter incremented by 1.
 Counter C5:1 counts the total number of parts coming on the conveyor for 1minute
time.
 Reset button is used to reset the counter.
2. Develop two ladder logic programs for control of traffic lights in one direction and
in two directions.
i) Control of Traffic Lights in One Direction

Sequence of Operation

Program of Traffic Light Control in One Direction

The sequence of operation is:

 When power supply is on, timer T4:0 is a energized and the EN bit is activated, at the
same red is on.
 After 30s delay, the timed contact T4:0 DN bit open to switch the red light off.
 At the same time, timer T4:0 DN bit is directly connected to second timer T4:1 input.
The timer T4:1 EN bit is activated and the green light is on.
 After 25s delay, the timed contact T4:1 DN bit is open to switch the green light off.
 Timer T4:1 DN bit is directly connected to the third timer T4:2 input. The timer T4:2
EN bit is activated and the amber light is on.
 After 5s delay, the timed contact T4:2 DN bit is open to switch the amber light off.
The sequence then repeats itself.
ii) Control of Traffic Lights in Two Direction

Sequence of Operation

Program of Traffic Light Control in Two Direction

3. Write a ladder logic program involving internal storage bits for the sequential task
as follows:
 Start push button is pressed and table motor is turned ON.
 Package moves on the table to the position of the limit switch and stops.
 Stop push button will stop the table during any emergency conditions.
 A red pilot light and green pilot light to indicate table is stopped and table
is running respectively.
4. Write a ladder logic program to implement the following process. Consider a single
tank system with discharge pump at its outlet. The sequence of operation is as
follows:
 A heater coil immersed in the tank containing liquid to increase its temperature.
Once the desired temperature is reached, the temperature sensor switch must be
closed before starting the pump.
 Start button is pushed, to turn ON the pump.
 Another button is pushed 8sec after the pump starts. Now the pump should stop
for 20sec after which it can be started again.
 An emergency stop button can be used to turn OFF the pump.
5. Design a PLC program to indicate a vessel over fill condition by energizing an alarm
when a supply system leaks 10 lb or more of raw material into the vessel after a
preset weight of 1000 lb has been reached. Also indicate by a pilot light when the
raw material exceeds its preset weight.

Sequence of operation:
 When the start button is pressed, the fill solenoid (rung 1) and filling indicating light
(rung 2) are turned on and raw material is allowed to flow into the vessel.
 The vessel has its weight monitored continuously by the PLC program (rung 3) as it
fills. When the weight reaches 1000 lb, the fill solenoid is de-energized and the flow is
cut off. At the same time, the filling pilot light indicator is turned off and the full pilot
light indicator (rung 3) is turned on.
 Should the fill solenoid leak 10 lb or more of raw material into the vessel, the alarm
(rung 5) will energize and stay energized until the overflow level is reduced below the
10 lb overflow limit.
6. Develop the ladder logic that will turn ON an output light after a switch has been
closed 10 times. Push button (PB) will reset the counter.

Sequence of Operation:
 Whenever the “SWITCH” close the count will be incremented by 1.
 When accumulated vale reached 10 count, the output light will TURN ON.
 When the push button “PB” is pressed, counter accumulated vale is reset to zero.

7. Develop ladder diagram for the following oven control application.

 Turn ON the heating element and cooling fan simultaneously for heating.
 Turn OFF the heating element when oven is turned OFF and an OFF-delay
timer for 10 secs starts counting down and then the cooling fan is turned OFF.

Sequence of operations:
 When START button is pressed, OVEN turn ON, simultaneously heating element
heater gets turn ON.
 The OFF-Delay timer (T4:5) is supplied with oven switch. Whenever the OFF-Delay
timer gets supply, the done (DN) bit becomes false to true. So cooling fan get supply
and turn ON.
 When STOP button is pressed, OVEN turn OFF immediately. After 10 seconds delay,
the Cooling Fan goes OFF through the OFF-Delay timer.
8. Develop the ladder logic diagram for the following application.

 Open V1 and V3 till LUp is reached.

 Turn ON stirrer and heater for 15 secs.
 Turn OFF stirrer and heater.
 Open V2 until LLow is reached and repeat the sequence.
9. Design a PLC program and prepare a typical I/O connection diagram and ladder
logic program for the following counter specification.
 Count the number of times a push button is closed.
 Decrement the accumulated value of the counter each time a second push
button is closed.
 Turn on the light any time the accumulated value of the counter is less than 20.
 Reset the counter to zero, when a selector switch is closed.
10. Write a program that will cause a light to come ON if a PLC counter value is less
than 10 or more than 30.
11. Two-part conveyor lines A and B feed a main conveyor line M. A third conveyor line
R, removes rejected parts a short distance away from the main conveyor. Conveyors
A, B, and R have parts counters connected to them. Construct a PLC program to
obtain the total parts output of main conveyor M.
Process Diagram

Ladder Diagram
12. Develop a PLC program to count the number of trucks entering and leaving a
parking garage and turn on the pilot light once the garage is full.
The sequence of operation is as follows:
• As a truck enters, it triggers the up-counter output instruction and increments
the accumulated count by 1.
• As a truck leaves, it triggers the down-counter output instruction and
decrements the accumulated count by 1.
• Since both the up- and down-counters have the same address, the accumulated
value will be the same in both.
• Whenever the accumulated value equals the preset value, the counter output
is energized to light up the garage Full sign.
13. Develop a Ladder logic program to implement a cock to display the time in 24-h
military format.

The sequence of operations as follows:

 An RTO timer instruction (T4:0) is programmed first with a preset value of 60 seconds.
 This timer times for a 60s period, after which its done bit is set.
 This, in turn, causes the up-counter (C5:0) of rung 02 to increment 1 count.
 On the next processor scan, the timer is reset and begins timing again.
 The C5:0 counter is preset to 60 counts, and each time the timer completes its time-
delay period, its count is incremented.
 When this counter reaches its preset value of 60, its done bit is set.
 This action causes the up-counter (C5:1) rung 03, which is preset for 24 counts, to
increment 1 count.
 Whenever the C5:1 counter reaches its preset value of 24, its done bit is set to reset
itself.
 The time of day is generated by examining the current, or accumulated, count or time
for each counter and the timer.
 Counter C5:1 indicates the hour of the day in 24h military format, while the current
minutes are represented by the accumulated count value of counter C5:0.
The timer displays the seconds of a minute as its current or accumulated time value.
14. Construct a ladder and relay logic for a 4-input conveyor ‘C’ has to run when any of
the four inputs is ON. Drive the necessary Boolean expression.

Boolean expression Y = A+B+C+D

15. Design a PLC program to operate a light according to the following sequence
 A momentary push button is pressed to start the sequence.
 The light is switched ON and remains ON for 2 sec.
 The light is switched OFF and remains OFF for 2 sec.
 A counter is incremented after this sequence.
 The sequence then repeats for a total of 4 counts.
 After fourth count, the sequence will stop and the counter will be reset to
zero.
16. Write a ladder logic program to implement the following process. Consider a single
tank system with discharge pump at its outlet. The sequence of operation is as follows:
 A heater coil immersed in the tank containing liquid to increase its temperature.
Once the desired temperature is reached, the temperature sensor switch must be
closed before starting the pump.
 Start button is pushed, to turn ON the pump.
 Another button is pushed 8sec after the pump starts. Now the pump should stop
for 20sec after which it can be started again.
 An emergency stop button can be used to turn OFF the pump.
17. Mention the inputs and outputs used in a bottling application and write a program
using ladder diagram.

Sequence of operation:
 Once the start push button is pushed, the motor (M2) will turn ON until the stop push
button is pushed.
 The feed motor M1 will be energized once the system starts (M2 ON); it will stop when
the limit switch detects a correct bottle position.
 When the bottle is in position and 7 seconds have elapsed, the solenoid (SOL) will open
the filling valve and remain ON until the photoeye (PE) detects a proper level.
 The bottle will remain in position for 4 seconds, then the energized internal coil will
start the feed motor. The feed motor will remain ON until the limit switch detects another
bottle.
18. Design a PLC Ladder program which converts the measurement of temperature in
i) Fahrenheit to Celsius and ii) Celsius to Fahrenheit to Celsius.
i) Converting Celsius to Fahrenheit
The program shows how to convert Celsius temperature to Fahrenheit. In this
application, the thumbwheel switch connected to the input module indicates Celsius
temperature. The program is designed to convert the recorded Celsius temperature in the data
table to Fahrenheit values for display. The formula: F = (9/5 x C) + 32 forms the basis for the
program. In this example, a current temperature reading of 60 °C is assumed. The MULTIPLY
instruction multiplies the temperature (60°C) by 9 and stores the product (540) in address N7:0.
Next, the DIVIDE instruction divides 5 into the 540 and stores the answer (108) in address
N7:1. Finally, the ADD instruction adds 32 to the value of 108 and stores the sum (140) in
address O:13. Thus 60°C = 140°F.

Figure Converting ºC to ºF Program

ii) Converting Fahrenheit to Celsius:

Formula C=5/9(F-32)

For ladder diagram as follows the instructions: Subtraction, Multiplication and Division
instruction.
19. Design a PLC Ladder program which control the oven temperature.
 The PLC calculates the upper and lower deadband or off/on limits about the set point. The
upper and lower limits are set automatically at ± 1% regardless of the set-point value.
 The set-point temperature is adjusted by means of the thumbwheel switch. An analog
thermocouple interface module is used to monitor the current temperature of the oven.
 The set-point temperature is 400 °F.
 Therefore, the electric heaters will be turned on when the temperature of the oven drops
to less than 396 °F and stay on until the temperature rises above 404 °F. The number
stored in word N7:1 represents the upper temperature limit, while the number stored in
word N7:2 represents the lower limit.

PLC Ladder Program:

20. Design a PLC program and prepare a typical I/O connection diagram and ladder program
for the following counter specifications: after a count of 15 from a sensor, a paint spray is to
run 25 seconds.

PLC Ladder Program:

Sequence of operation:
Rung1: When start button is pressed, output P get energize. It indicates the process is ON.
Rung2: Whenever receive signal from Sensor the up-counter count will be incremented by 1.
Rung3: Time delay is controlled by Timer.
Rung4: Spray gun is actuated, when the up-counter accumulator value reaches equal to preset value
and remain ON until 25 seconds.
Rung5: Reset switch is used to initialize the counter.
21. Draw PLC ladder program for sequentially energizing solenoids A, B, C, and D after every 5
second increment. Use data manipulation instructions.

PLC Ladder Program:

Sequence of operation:
When the start button is pushed, SOL A output will energize. As a result, solenoid A will switch
ON; SOL A contact will close to seal in output SOL A and to start on-delay timer T4:1. The
timer has been preset to 15s. Output SOL D will energize (through the timer done bit T4:1/DN)
after a total time delay of 15 s to energize solenoid D. Output SOL B will energize after a total
time delay of 5 s, when the accumulated time becomes equal to and then greater than 5 s. This,
in turn, will energize solenoid B. Output SOL C will energize after a total time delay of 10 s,
when the accumulated time becomes equal to and then greater than 10 s. This in turn, will
energize solenoid C.
22. A conveyor is supposed to have exactly 45 parts on it. You have three indicating lights to
indicate the conveyor count status: less than 45, YELLOW; exactly 45, GREEN; and more
than 45, RED. The count of parts on the conveyor is set at 45 each morning by an actual count
of parts. There are two sensors on the conveyor. One is actuated by parts entering the
conveyor, and the other is actuated by parts leaving. Develop a PLC program using compare
functions.

Process Diagram:

PLC Ladder Program:

Sequence of operation:
 When the start button is pushed, M output will energize. As a result, parts conveyor
starts running.
 Proxy switch1 detects the entering parts. Whenever sensor detects parts PS1 is actuated,
the UP Counter count will be incremented by 1.
 Proxy switch2 detects the leaving parts. Whenever sensor detects parts PS2 is actuated,
the DOWN Counter count will be decremented by 1.
 The counter C5:1 preset value is set by 45, the accumulated (C5:1 ACC) value is
compared with data compare instructions.
 When C5:1 ACC value is less than 45, the LES instruction become true. Output Yellow
PL will energize, this will turn ON Yellow light.
 When C5:1 ACC value becomes equal to 45, the EQU instruction become true. Output
Green PL will energize, this will turn ON Green light.
 When C5:1 ACC value is greater than 45, the GRT instruction become true. Output
Red PL will energize, this will turn ON Red light.
 Reset switch is used to initialize the counter.
23. Write a program to implement the process illustrated in Figure. The sequence of operation
is to be as follows:
• Normally open start and normally closed stop pushbuttons are used to start and
stop the process.
• When the start button is pressed, solenoid A energizes to start filling the tank.
• As the tank fills, the empty level sensor switch closes.
• When the tank is full, the full level sensor switch closes Solenoid A is de-
energized.
• The agitate motor starts automatically and runs for 3 min to mix the liquid.
• When the agitate motor stops, solenoid B is energized to empty the tank.
• When the tank is completely empty, the empty sensor switch opens to de-energize
solenoid B.
• The start button is pressed to repeat the sequence.

Refer class notes or book