Automation Lab Manual VIth Sem, B.

Tech (ICE 3261)

ICE-3261

Automation Lab
VIth Semester
B-Tech, Electronics and Instrumentation Engineering

Lab Manual

Student Name:
Roll No:
Registration Number:

Department of Instrumentation & Control Engineering

Manipal Institute of Technology, Manipal
A Constituent Institute of Manipal Academy of Higher Education

MANIPAL-576104
MIT/ICE/PLC-MNL/18
Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Department of Instrumentation & Control Engineering

Manipal Institute of Technology, Manipal
A Constituent Institute of Manipal Academy of Higher Education

MANIPAL-576104

CERTIFICATE

This is to certify that the Laboratory Manual for the lab titled Automation Laboratory

(ICE 3261) by Mr / Ms ______________________________________ (Reg.

No:__________________) of VIth Semester, B.Tech of Instrumentation and Control

Engineering for the academic year 2021 / 2022 has been submitted as per laboratory

course requirements, which has been evaluated and duly certified.

Place:

Date: Lab In-Charge

Dept of I&CE, MIT, Manipal Page 2

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

LIST OF EXPERIMENTS

Expt. Page
TITLE OF THE EXPERIMENT
No. No.
1 Introduction to LTPCM-DN30S1PLC and XL 5000 software 4
2
Implementation of combinational circuits 16

3 Timer functions and problems 20

4 Counter functions and problems 24

5 Compare and arithmetic instructions 30

6 Control of glass inspection station 35

7 Control of bottle filling machine 36

8 Control of traffic signal 37

9 38
Control of Cleaning System

10 Tank filling device simulation 39

Evaluation Plan:
Continuous Evaluation: 60% (Preparation, Lab performance, Journal, Assignments and
Regularity, Mini Project)
End Semester Lab Test: 40%

Dept of I&CE, MIT, Manipal Page 3

 Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

EXPERIMENT NO. 1 DATE:

Introduction
1. LTPCM-DN30S1 PLC :

The LTPCM-DN30S1 compact controller is the modular, space-saving controller for small
automation systems that require either simple or advanced functionality for logic, HMI and
networking. The compact design, low cost, and powerful features make the LTPCM-DN30S1 a
perfect solution for controlling small applications.

The LTPCM-DN30S1 controller provides the flexibility and power to control a wide variety of
devices in support of your automation needs. The compact design, flexible configuration, and
powerful instruction set combine to make LTPCM-DN30S1 a perfect solution for controlling a
wide variety of applications.

LTPCM-DN30S1 XLB series PLC support 2 PTO(Pulse and Direction) of 100KZ and 8 High
speed counters of same 100KZ pulse frequency it supports Linear and ring counter modes preset
and comparator option. These PTO can be used to control stepper motors and servo motors.

CPU

Analog I/O module

High speed Ethernet Fig 1 Components LTPCM-DN30S1 XLB series PLC

 The CPU combines a microprocessor, an integrated power supply, input and output
circuits, high-speed motion control I/O, and on-board digital inputs/outputs in a compact
housing to create a powerful controller.
 After you download your program, the CPU contains the logic required to monitor and
control the devices in your application.
 The CPU monitors the inputs and changes the outputs according to the logic of your user
program, which can include Boolean logic, counting, timing, complex math operations,
and communications with other intelligent devices.

Dept of I&CE, MIT, Manipal Page 4

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

2. Operating modes of the CPU

The CPU has two modes of operation: STOP mode and RUN mode.
Status LEDs on the front of the CPU indicate the current mode of operation.
● In STOP mode, the CPU is not executing the program, and you can download a project.
● In RUN mode, the scan cycle is executed repeatedly. Interrupt events can occur and be
processed at any point within the program cycle phase.

Note
You cannot download a project while the CPU is in RUN mode. You can download your
project only when the CPU is in STOP mode.

3. XL5000 software

This section will help get you familiar with the XL5000 design environment. As our goal to help
simplify your engineering efforts, Start the XL5000 software.

Double-click the XL5000 shortcut icon on your desktop

3.1 Creating new project:

Go to project tab select new project enter the project name and select the save directory.Here the
CPU series is fixed which is LTPCM(main module),CPU type is S (standard) type,you can also
give the program name also later can be renamed in properties

Dept of I&CE, MIT, Manipal Page 5

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

 Layout of XL5000 software working area.

Ladder Editing area

Variable monitoring
Project Tab
and result windows

3.2 Hardware configuration of CPU and expansion modules

Go to IO parameter where you have to select the CPU type which is LTPCM-DN30S1 mounted
in Lab kit 0(main) main slot will be fixed for CPU.

Dept of I&CE, MIT, Manipal Page 6

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Subsequently select the expansion modules in slot 1 LTPCL-EMTA11(Available in

communication module list) and slot 2 LTPCF-AH04A1 (Available in Special module
analog I/O module list). Cross check in the kit modules should be in the same order as
mounted in the PLC kit. Finally your configuration will look like below.

Dept of I&CE, MIT, Manipal Page 7

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

3.3 Brief Description and configuration of expansion modules added in the kit.
3.3.1 LTPCL-EMTA11 Fast Ethernet module
LTPCL-EMTA11 module provides fast Ethernet communication with L&T PLC’s. It
supports Ethernet II, IEEE 802.3 standard functions, HS link function for HS data
communication between L&T modules, Supports Modbus TCP/IP communication for third
party devices and Downloading function from PC to PLC. To Setup Ethernet module
double clicks the Ethernet module in IO parameter and enters the IP address as below.

To download the program from PC to PLC through Ethernet first Ethernet module setting
should be downloaded from USB or RS232 cable for the first time.

Dept of I&CE, MIT, Manipal Page 8

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

3.3.3 LTPCF-AH04A1 Analog Input Output combination module

LTPCF-AH04A1 module is 2 Analog inputs (Voltage/Current), 2 Analog Output

(Voltage/Current) combination modules. The module has a 12 bit resolution provides
different ranges of A/D conversion values for different ranges detailed setting of analog
module will be explained in analog module programming lab.

To set analog module double click the analog module LTPCL-AH04A1 in IO parameter
as show below.

Dept of I&CE, MIT, Manipal Page 9

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

4. Editing simple ladder program

To edit the ladder program click on the scan program in project window and open new
program.

To insert NO contact either press F3 or click on NO contact symbol in contacts tool bar and
click on ladder editing area to place the NO Contact.

Dept of I&CE, MIT, Manipal Page 10

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

After placing the NO contact enter the variable name by selecting Global variable for Ex.
Input0 click OK to give address IX0.0.0 which is the first input of test kit.

To add a coil either press F9 or click on coil symbol in contact tool bar edit variable name as
Ouptut0 and give address as QX0.0.0 which is first output of test kit. After adding NO contact
and Coil your ladder program looks like below and it’s ready to download

Dept of I&CE, MIT, Manipal Page 11

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

To view both address and variable name in ladder editing area go to view menu and select
Device/variables. Toggle between variables, Devices and Variables to experience how the
variables looks in ladder editing area.

5. Downloading the program to PLC.

5.1 Downloading through USB.

To download the program to PLC through USB make sure Mini USB cable is connected to PLC
USB port and any of USB port in PC.

Go to Online menu select connection settings select type as USB and depth Local and press connect
it will give a popup PLC connected successful if connected.

Dept of I&CE, MIT, Manipal Page 12

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

After connection is successful again go to online and click on write to start downloading the
program. Select all the section for downloading first time. Make sure that PLC RUN/STOP key
switch is in STOP mode to download the program after downloading PLC can be put it in RUN
mode through software though key switch is in STOP mode.

5.2 Downloading through Ethernet

To download the program to PLC through Ethernet, make sure Ethernet cable is connected to PLC
Ethernet module and PC Ethernet port and basic Ethernet settings is done in PLC Ethernet module
as explained in previous section.

For successful downloading both PLC and PC should be in same Ethernet subnet.To make the PC
to same subnet go to Network settings select change adaptor option and double click on Ethernet
port,Go to IPV4 and set same subnet IP address to PC. Remember both PC and PLC should be in
same IP series but not same IP address.

Dept of I&CE, MIT, Manipal Page 13

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Go to Online menu select connection settings select type as Ethernet and depth remote press
settings and enter IP address of the PLC which is already edited and press connect it will give a
popup PLC connected successful if connected. Make sure you have downloaded the program
through USB first.

After connection is successful again go to online and click on write to start downloading
the program.

Dept of I&CE, MIT, Manipal Page 14

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

6. Monitoring the Program and variables.

To start monitoring go to Monitor menu and press start monitoring. This will show the real
time status of PLC program.

Now turn on the PLC input IX0.0.0 in Lab kit and output QX0.0.0 will turn on as per the
Logic and your Ladder looks like below.

Sample program –

1. Turning on any one switch will activate the load

Dept of I&CE, MIT, Manipal Page 15

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Exercise Problems -
1. Develop PLC program for the Logic Gates

AND OR NOT

NAND NOR EXOR

Dept of I&CE, MIT, Manipal Page 16

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

EXPERIMENT NO. 2 DATE:

Implementation of combinational circuits

Aim: To understand the working of a Programmable Logic Controller and to implement
the digital circuits in PLC.

Sample Program –

Exercises problems:

1. Develop PLC Ladder logic for Boolean equation (don’t simplify the expression ):

2.

Dept of I&CE, MIT, Manipal Page 17

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

3.

4. Develop Ladder Logic for a car door/seat belt safety system. When the car door is open,
and the seatbelt is not done up, the ignition power must not be applied. If all is safe then
the key will start the engine.

5. Design a motor controller that has a forward and a reverse button. The motor forward and
reverse outputs will only be on when one of the buttons is pushed.

6. Write Boolean equation ladder logic for the following truth table.

Dept of I&CE, MIT, Manipal Page 18

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

7. Develop the Ladder logic for the following truth table.

Fig 1

In Figure a multiplexer is shown that will take one of four inputs bits D1, D2, D3 or D4 and
make it the output X, depending upon the values of the address bits, A1 and A2.

8. Develop the Ladder logic for the following truth table.

Dept of I&CE, MIT, Manipal Page 19

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Dept of I&CE, MIT, Manipal Page 20

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

EXPERIMENT NO.3 DATE:

Timer functions and problems

Aim: To understand and implement Timer functions in a PLC.

Working of Timers:
An on-delay timer will wait for a set time after a line of ladder logic has been true before
turning on, but it will turn off immediately. An off-delay timer will turn on immediately when a
line of ladder logic is true, but it will delay before turning off. Consider the example of an old car.
If you turn the key in the ignition and the car does not start immediately, that is an on-delay. If you
turn the key to stop the engine but the engine doesn’t stop for a few seconds that is an off delay.
An on-delay timer can be used to allow an oven to reach temperature before starting production.
An off delay timer can keep cooling fans on for a set time after the oven has been turned off.

TON: On delay :

Symbol

Parameter Data Memory area Description

type

IN BOOL I, Q, M, D, L Start input

PT TIME I, Q, M, D, L or Time by which the rising edge is

constant delayed at the IN input.

Q BOOL I, Q, M, D, L Output, which is delayed by the time

PT.

ET TIME I, Q, M, D, L Elapsed time

Description
You can use the "On delay" operation to delay a rising edge by the time set at PT. The "On delay"
operation is executed when the result of logic operation (RLO) changes from "0" to "1" at input
IN (rising edge). When the operation is started, the time set for PT starts running. When the PT
time expires, output Q has signal state "1". Output Q remains set as long as the start input is still
"1". If there is a signal change at the start input from "1" to "0", output Q is reset. The timer function
is started again when a new positive edge is detected at the start input.

Dept of I&CE, MIT, Manipal Page 21

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

The ET output supplies the time that has elapsed since the last rising edge at the IN input. This
time starts at T#0s and ends when the value set for the PT timer is reached. The elapsed time can
be queried at output ET as long as input IN has signal state "1".
'When inserting the "On delay" operation, an instance data block is created in which the
operation data is saved.
Timing Diagram

TOF: Off delay :

Symbol

Parameter Data Memory area Description

type

IN BOOL I, Q, M, D, L Start input

PT TIME I, Q, M, D, L Time by which the falling edge is

or constant delayed at the IN input. PT must be
positive.

Q BOOL I, Q, M, D, L Output, which is delayed by the time

PT.

ET TIME I, Q, M, D, L Elapsed time

Dept of I&CE, MIT, Manipal Page 22

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Description
You can use the "Off delay" operation to delay a falling edge by the time set at PT. The Q output
is set when the result of logic operation (RLO) at input IN changes from "0" to "1". When the
signal state at the IN input switches back to "0", the time set at PT starts. Output Q remains set as
long the time set at PT is running. The Q output is reset when the PT time expires. If the signal
state at the IN input changes to "1" before the time set at PT time expires, the timer is reset. The
signal state at the Q output will continue to be "1".
It is possible to query how long the current timer function has been running at output ET. This
time starts at T#0s and ends when the value set for the PT timer is reached. When the time set at
PT expires, output ET remains set to the current value until input IN changes back to "1". If the IN
input switches to "1" before the PT time has expired, the ET output is reset to the value T#0.
'When inserting the "OFF delay" operation, an instance data block is created in which the operation
data is saved.
The "Off delay" operation requires a preceding logic operation for the edge evaluation. It can
placed within or at the end of the network.

Timing diagram

Exercises

1. Develop the ladder logic that will run a cooling fan for 15 seconds after the machine has
been turned off.

2. Write a program that will turn on a flashing light for the first 15 seconds after a PLC is
turned on. The light should flash for half a second on and half a second off.

Dept of I&CE, MIT, Manipal Page 23

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

3. In dangerous processes it is common to use two palm buttons that require a operator to
use both hands to start a process . To develop this there are two inputs that must be turned
on within 0.25 sec of each other before a machine cycle may begin.

4. We are using a pneumatic cylinder in a process. The cylinder can become stuck, and we
need to detect this. Proximity sensors are added to both endpoints of the cylinder’s travel
to indicate when it has reached the end of motion. If the cylinder takes more than 2 seconds
to complete a motion this will indicate a problem. When this occurs the machine should be
shut down and a light turned on. Develop ladder logic that will cycle the cylinder in and
out repeatedly, and watch for failure.

5. Consider the control of a heating oven. The system is started with a Start button that seals
in the Auto mode. This can be stopped if the Stop button is pushed. (Remember: Stop
buttons are normally closed.) When the Auto goes on initially the TON timer is used to
sound the horn for the first 10 seconds to warn that the oven will start, and after that the
horn stops and the heating coils start. When the oven is turned off the fan continues to blow
for 300s or 5 minutes after.

6. Design a ladder diagram that will cause a stepper motor so that it moves 10 steps forward,
waits for 20 seconds and then cause the motor to move 10 steps in the reverse direction.[the
stepper input pulse is 0.5 second on and 0.5 second off.] the 2 inputs used are – a. start and
b. stop. the 2 outputs used are – a. output(motor forward/reverse) and b. Stepper pulse out.

Dept of I&CE, MIT, Manipal Page 24

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

EXPERIMENT NO. 4 DATE:

Counter functions and problems

Aim: To understand and implement counter functions of a PLC.

Working:
There are three counter types: count-up, count-down and counter up - down. When the input
to a count-up counter goes true the accumulator value will increase by 1 (no matter how long
the input is true.) If the accumulator value reaches the preset value the counter Q bit will be
set. A count-down counter will decrease the accumulator value until the preset value is reached.
Two different inputs will be available in a count up – down counter, either to increase or
decrease the accumulator value.
CTU: Count up:
Symbol

Parameter Data type Memory area Description

English

CU BOOL I, Q, M, D, L Count input

R BOOL I, Q, M, D, L Reset input

PV SINT, INT, DINT, USINT, I, Q, M, D, L or Preset count

UINT, UDINT constant

Q BOOL I, Q, M, D, L Counter status

CV SINT, INT, DINT, USINT, I, Q, M, D, L Actual count

UINT, UDINT value

You can select the data type for the operation from the "DT" drop-down list.

Dept of I&CE, MIT, Manipal Page 25

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Description
You can use the "Count up" operation to increment the value at the CV output. If the signal state
at the CU input changes from "0" to "1" (positive edge), the operation is executed and the current
count value at the CV output is incremented by one. The first time the operation is executed, the
current count at the CV output is set to zero. The count is incremented each time a positive edge
is detected, until it reaches the high limit for the specified data type at the CV output. When the
high limit is reached, the signal state at the CU input no longer has an effect on the operation.
The counter status can be queried at the Q output. The signal state at output Q is determined by
the PV parameter. If the current count value is greater than or equal to the value of the PV
parameter, the Q output is set to signal state "1". In all other cases, the signal state at the Q output
is "0".
The value at the CV output is reset to zero when the signal state at R input changes to "1". As long
as there is the signal state "1" at R input, the signal state at input CU has no effect on the operation.
'When inserting the "Count up" operation, an instance data block is created in which the operation
data is saved.
The "Count up" operation requires a preceding logic operation for the edge evaluation. It can
placed within or at the end of the network.

Example

When the signal state at the input I 0.0 changes from "0" to "1", the "Count up" operation is
executed and the current count at the MW30 output is increased by one. With each further positive
edge, the count value is incremented until the high limit value of the specified data type (32 767)
is reached.
The value at the MW20 parameter is applied as the limit for determining the output Q 4.0. Output
Q 4.0 has signal state "1" as long as the current count is greater than or equal to the value at the
MW20 parameter. In all other cases, output Q 4.0 has signal state "0".
CTD: Countdown :

Symbol

Dept of I&CE, MIT, Manipal Page 26

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Parameter Data type Memory area Description

English

CD BOOL I, Q, M, D, L Count input

LOAD BOOL I, Q, M, D, L Load input

PV SINT, UINT, DINT, USINT, I, Q, M, D, L or Preset count

UINT, UDINT constant

Q BOOL I, Q, M, D, L Counter status

CV SINT, UINT, DINT, USINT, I, Q, M, D, L Actual count

UINT, UDINT value

You can select the data type for the operation from the "DT" drop-down list.

Description
You can use the "Count down" operation to decrement the value at the CV output. If the signal
state at the CD input changes from "0" to "1" (positive edge), the operation is executed and the
current count value at the CV output is decremented by one. The first time the operation is
executed, the current count at the CV output is set to zero. Each time a positive edge is detected,
the count value is further decremented until it reaches the low limit value of the specified data
type. When the low limit value is reached, the signal state at the CD input has no further effect on
the operation.
The counter status can be queried at the Q output. If the current count value is less than or equal
to zero, output Q is set to signal state "1". In all other cases, the signal state at the Q output is "0".
The value at the CV output is set to the value of the PV parameter when the signal state at LOAD
input changes to "1". As long as there is the signal state "1" at the LOAD input, the signal state at
the CD input has no effect on the operation.
'When inserting the "Count down" operation, an instance data block is created in which the
operation data is saved.
The "Count down" operation requires a preceding logic operation for the edge evaluation. It can
placed within or at the end of the network.

Example

Dept of I&CE, MIT, Manipal Page 27

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

When the signal state at the input I 0.0 changes from "0" to "1", the "Count down" operation is
executed and the value at the MW30 output is decreased by one. With each further positive edge,
the count value is decremented until the low limit value of the specified data type (-32 768) is
reached.
Output Q 4.0 has signal state "1" as long as the current count value is less than or equal to zero. In
all other cases, output Q 4.0 has signal state "0".

CTUD: Count up and down

Symbol

Parameter Data type Memory area Description

English

CU BOOL I, Q, M, D, L Count up input

CD BOOL I, Q, M, D, L Count down input

R BOOL I, Q, M, D, L Reset input

LOAD BOOL I, Q, M, D, L Load input

PV SINT, UINT, DINT, I, Q, M, D, L or Preset count

USINT, UINT, UDINT constant

QU BOOL I, Q, M, D, L Status of the

incremental counter

QD BOOL I, Q, M, D, L Status of the

decremental counter

Dept of I&CE, MIT, Manipal Page 28

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

CV SINT, UINT, DINT, I, Q, M, D, L Actual count value

USINT, UINT, UDINT

You can select the data type for the operation from the "DT" drop-down list.

Description
You can use the "Count up and down" operation to increment and decrement the count value at
the CV output. If the signal state at CU input changes from "0" to "1" (positive edge), the current
count value is incremented by one and stored in the CV output. If the signal state at CD input
changes from "0" to "1" (positive edge), the count value at the CV output is decremented by one.
If there is a positive edge at the CU and CD inputs in one program cycle, the current count value
at the CV output remains unchanged.
The count value can be incremented until it reaches the high limit value of the data type specified
at the CV output. When the high limit value is reached, the count value is no longer incremented
on a positive edge. When the low limit value of the specified data type is reached, the count value
is not decremented any further.
When the signal state at the LOAD input changes to "1", the count value at the CV output is set to
the value of the PV parameter. As long as there is the signal state "1" at the LOAD input, the signal
state at the CU and CD inputs has no effect on the operation.
The count value is set to zero when the signal state at input R changes to "1". As long as the signal
state at the R input is "1", changes of signal state at inputs CU and CD and LOAD have no effect
on the "Count up and down" operation.
The incremental counter status can be queried at QU output. If the current count value is greater
than or equal to the value of the PV parameter, QU output has signal state "1". In all other cases,
the signal state at the QU output is "0".
The decremental counter status can be queried at QD output. If the current count value is less than
or equal to zero, output QD has signal state "1". In all other cases, the signal state at the QD output
is "0".
'When inserting the "Count up and down" operation, an instance data block is created in which the
operation data is saved.

Exercises:

1. An indicating light is to go on when the count reaches 12. The light is then to go off when
a count of 20 reached. Use reset to reset counters at any time.
2. A pneumatic cylinder is used to remove 5 out of every 10 parts from a conveyer. The
cycle repeats after every 10 parts. Realize it using PLC ladder logic.

Dept of I&CE, MIT, Manipal Page 29

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

3. In a glass manufacturing plant glasses are stacked in a double shelved trolley. Initially 15
glasses are stacked in first shelf and another 15 glasses in second shelf. Turn ON the output
motor of trolley to move it when it contains total 30 glasses.
4. A buffer can hold up to 10 parts. Parts enter the buffer on a conveyor controller by output
conveyor. As parts arrive they trigger an input sensor enter. When a part is removed from
the buffer they trigger the exit sensor. Write a program to stop the conveyor when the buffer
is full, and restart it when there are fewer than 10 parts in the buffer. As normal the system
should also include a start and stop button.
5. An auditorium consists of two entrances and one exit. Twenty seats are placed inside that
and both the entrances can allow the first 20 entries. After 20 entries both the doors shall
be closed automatically with a siren sound for 5 seconds. If there is an exit, then entrance
A shall be open and B remains closed. An indicating lamp will glow to indicate the door
opening. A reset switch shall reset all the system at any time.
6. A motor will be connected to a PLC and controlled by two switches. The GO switch will
start the motor, and the STOP switch will stop it. If the motor is going, and the GO switch
is thrown, this will also stop the motor. If the STOP switch was used to stop the motor, the
GO switch must be thrown twice to start the motor. When the motor is running, a light
should be turned on (a small lamp will be provided).
7. Develop a program that will latch on an output B (O/1), 20 seconds after input A (I/1) has
been turned on. The timer will continue to cycle up to 20 seconds, and reset itself, until
input A has been turned off. After the third time the timer has timed to 20 seconds, the
output B will be unlatched.
8. A conveyor is run by switching on or off a motor. We are positioning parts on the conveyor
with an optical detector. When the optical sensor goes on, we want to wait 1.5 seconds,
and then stop the conveyor. After a delay of 2 seconds the conveyor will start again. We
need to use a start and stop button - a light should be on when the system is active. Gages
have been attached that indicate good or bad. If the part is good, it continues on. If the part
is bad, we do not want to delay for 2 seconds, but instead actuate a pneumatic cylinder.

9. A handicap door opener has a button that will open two doors. When the button is pushed
(momentarily) the first door will start to open immediately, the second door will start to
open 2 seconds later. The first door power will stay open for a total of 10 seconds, and the
second door power will stay on for 14 seconds. Use a timing diagram to design the ladder
logic.

10. Design the ladder diagram for a device that will count parts as they pass by an inspection
stand. The sensing device for the PLC is a switch that will close each time a part passes.
This switch is connected to IN1 of the PLC. A reset switch, IN2, is also connected to the
PLC to allow the operator to manually reset the counter. After 15 parts have passed the
inspection stand, the PLC is to reset the counter to again begin counting parts and turn on

Dept of I&CE, MIT, Manipal Page 30

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

a light which must stay on until reset by a second reset switch connected to IN3. The output
from the PLC that lights the light is OUT111.

EXPERIMENT NO.5 DATE:

Compare and arithmetic instructions

Aim: To understand the compare and arithmetic operations of a PLC.

1. Compare operations:
The compare Byte instruction is used to compare two operands. Comparisons include:
Operand1 = Operand2, Operand1 >= Operand2, Operand1 <= Operand2, Operand1 >
Operand2, Operand1 < Operand2, Operand1 <> Operand2. The output is ON when the
comparison is true.

Consider a comparison where Operand1 > Operand2:

Symbol

Dept of I&CE, MIT, Manipal Page 31

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Example

Output Q X0.0.1 is set when the following conditions are fulfilled:

Dept of I&CE, MIT, Manipal Page 32

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

 Inputs I X0.0.2 has signal state "1".

 The condition of the comparison operation is fulfilled (MW0 = MW1).

2. Arithmetic functions :
2.1 ADD
Symbol

You can use the "Add" operation to add the value at the IN1 input to the value at the IN2
input and query the sum at the OUT output (OUT =IN1+IN2).
The operation is only executed if the signal state at the enable input EN is "1". If no
errors occur during execution of the operation, the ENO output also has signal state "1".

2.2 Subtract
Symbol

You can use the "Subtract" operation to subtract the value at input IN2 from the value at input
IN1 and query the difference at the OUT output (OUT =IN1-IN2).

2.3 Multiply
Symbol

You can use the "Multiply" operation to multiply the value at the IN1 input to the value at the
IN2 input and query the product at the OUT output (OUT =IN1*IN2).

2.4 Division
Symbol

Dept of I&CE, MIT, Manipal Page 33

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

You can use the "Divide" operation to divide the value at the IN1 input by the value at the IN2 input and
query the quotient at the OUT output (OUT =IN1/IN2).

2.5 Increment
Symbol

You can use the "Increment" operation to change the tag at the IN/OUT output to the next higher
value and query the result. The "Increment" operation can only be started when the signal state at
the EN enable input is "1". If no overflow error occurs during the execution, the ENO output also
has signal state "1".
If the signal state is "0" at the enable input EN, the operation is not executed. In this case, the ENO
enable output is reset.

2.6 Decrement
Symbol

With the "Decrement" operation, you can change the value of the tag at the output IN/OUT output
to the next lower value and query the result. Execution of the "Decrement" operation is started
when the signal state at the EN enable input is "1". If no underflow error occurs during the
execution, the ENO output also has signal state "1".

Example of ADD instruction:

Dept of I&CE, MIT, Manipal Page 34

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

If the input IX 0.0.12 has signal state "1", the "Add" operation is executed. The value at the
WW2 input is added to the value at the WW3 input. The result of the addition is stored at the
WW10 output. If no errors occur during execution of the operation, the ENO output has signal
state "1".

Exercises:

1. Compare the values of two counters and enable an output if the valves are same.

2. Increment / Decrement the valve in a memory register by enabling an input.

3. Implement the following function

4. A machine ejects parts into three chutes. Three optical sensors (A, B and C) are
positioned in each of the slots to count the parts. The count should start when the reset
(R) button is pushed. The count will stop, and an indicator light (L) turned on when
the average number of parts counted equals 10.

5. Create a ladder logic program that will start when input A is turned on and calculate
the series below. The value of n will start at 0 and with each scan of the ladder logic n
will increase by 2 until n=20. While the sequence is being incremented, any change in
A will be ignored.

Dept of I&CE, MIT, Manipal Page 35

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

EXPERIMENT NO. 6 DATE:

Control of Glass Inspection Station

Aim: To understand and simulate the control of glass inspection process using PLC.

Dept of I&CE, MIT, Manipal Page 36

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Description:

The objective is to control the inspection station of a glass manufacturing system for
automobiles. Glasses flow in regular intervals on conveyor.

The required cycle is as follows:

1. Master ON is pressed to start the operation.

2. If a glass is detected on conveyor, the conveyor will start to move.
3. If the glass reaches inspection station, then the conveyor will stop.
4. 15 seconds of time delay is given for operator to inspect. After time delay a lamp glows.
5. Now the operator needs to acknowledge if the glass is OK or NOTOK by pressing green
or red push buttons respectively. Lamp goes off then.
6. If the glass is NOTOK then another 3 seconds is delayed to unload it.
7. If the glass is OK then conveyor starts again thus continuing the operation.
8. Master OFF is pressed to stop the operation.
9. An emergency stop button will reset the operation at any instant.

Lamp

ON OFF OK NOTOK

Glass
Conveyor

Sensor
Motor

EXPERIMENT NO. 7 DATE:

Dept of I&CE, MIT, Manipal Page 37

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Control of bottle filling station

Aim: To understand and simulate the control of bottle filling process using PLC.

Description:

The objective is to control a bottle filling station. Bottles move on conveyor with equal space
separating each other. This system involves two operations – filling operation and sealing
operation.

1. Master ON push button is pressed to turn ON the system.

2. System is put in Auto mode by pressing Auto mode push button.
3. Conveyor starts to move.
4. Conveyor stops if bottle reaches filling station.
5. Bottle stays in filling station for 5 seconds.
6. After 5 seconds conveyor starts to move.
7. Bottle reaches the next station thus turning off the conveyor.
8. Here bottle is sealed in 5 seconds.
9. After 5 seconds conveyor starts to move.
10. Operation continues. Master OFF push button is used to turn off the system.
11. An emergency push button will reset the operation at any instant.
Filling Sealing
station station

Conveyor

Sensor 1 Sensor 2
Motor
Station 1 Station 2

EXPERIMENT NO. 8 DATE:

Dept of I&CE, MIT, Manipal Page 38

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Control of 4 way traffic signal

Aim: To understand and simulate the control of traffic signal using PLC.

Description:

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 1.

R Y G

R R
2 Y 4
Y

G G

R Y G

EXPERIMENT NO. 9 . DATE:

Dept of I&CE, MIT, Manipal Page 39

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Control of cleaning system

AIM: To understand and simulate the control of cleaning using PLC.

Description -

1. The tank of a cleaning system is to be lowered and lifted pneumatically. After the
lowering- lifting cycle has been completed 3 times, the basket is to remain at the double-
acting work cylinder in its retracted position.
2. During the cleaning process, the basket is to remain in the cleaning system for a period of
5 seconds. The system is switched on using the S1 pushbutton “Start” and switched off
using the S2 pushbutton “Stop”.
3. Using the mode S3, manual operation is possible, using S4, automatic operation can be
selected. If by accident, both buttons are activated, manual operation will take priority.
During automatic operation, the process proceeds automatically via the S1 pushbutton. In
manual operation, the cylinder is extended using the pushbutton S7 and retracted using
S8.
4. In manual operation, it must be guaranteed that the immersion process does not take
longer than 5 seconds and is automatically switched off after 3 cycles. The immersion
cycle is to be displayed by means of the LED H3.
5. The automatic operation must be re-started after each sequence (3 cycles) using the
pushbutton S1.

EXPERIMENT NO. 10. DATE:

Dept of I&CE, MIT, Manipal Page 40

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Tank filling device simulator system

Aim
To understand and simulate the control of inspection process using PLC.

Description:

A tank filling device simulator consists of 3 tanks that are equipped with signal encoders. The tank filling
device simulator system can be switched on using the S1 pushbutton called “Start”. For switching off the
device simulator system, S2 pushbutton “Stop” can be used. For the "Max" notifications of tank, the signal
encoders S3, S5 and S7 are used. For the "Min" notifications, signal encoders S4, S6 and S8 are used. The
storage tanks can be arbitrarily filled and emptied by hand manually.

Conditions:
1. For filling the tanks 1, 2 & 3, the valves Y1, Y2 and Y3 are used. Filling of the tanks must happen
in series i.e H1,H2,&H3.
2. A control is to secure that after a “empty” ( Ex: for tank 1, S3 & S4 both must be OFF ) notification
occurred, only 1 tank can be filled at a time in the specified order.
3. The filling of the next tank continues until the corresponding “full” notification has occurred.
(i.e for Ex : if S3 & S4 both are ON , then only H1 should stop filling & next H2 should start for
filling)
4. Once all the tank fills, its water should start to drain out one after the other from H4, H5 & H6.

Prepare the PLC program.

IN

MAX

MIN

OUT H4 OUT H5 OUT H6

Dept of I&CE, MIT, Manipal Page 41

Automation Lab Manual VIth Sem, B.Tech (ICE 3261)

Dept of I&CE, MIT, Manipal Page 42