Experiment No : 01
Experiment Name:
Implement logic for the automatic door open & close system in PLC
using ladder diagram programming language.
Objective:
To design and implement the logic of an automatic door open and
close system using a PLC and ladder diagram, where the door operates
automatically based on sensor inputs for safe and reliable control.
Theory:
A PLC (Programmable Logic Controller) controls input and output
devices using programmed ladder logic. In an automatic door system,
sensors detect a person or object, and the PLC processes this input to
control a motor/actuator that opens or closes the door. The ladder logic
ensures:
● The door opens when a sensor detects presence.
● The door closes automatically after a delay or when the path is clear.
● Safety interlocks prevent accidents.
This system is widely used in malls, offices, and industries for automation,
safety, and efficiency.
List of I/O:
1
PLC Ladder Diagram:
Program Description:
Step 1: Opening the Door
A. Infrared Sensor and Open Limit Switch:
When the infrared sensor detects an object (e.g., a
person), the PLC logic checks if the open limit switch is not
engaged. This indicates that the door is not already open.
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B. Activating the Opening Motor:
The opening motor is activated to move the door towards
the open position.
C. Timer for Safety:
The TON (Timer On Delay) is used to create a time delay,
ensuring that the door remains open for a specific time before
completing the cycle.
Step 2: Closing the Door
A. Infrared Sensor and Close Limit Switch:
After the door has been fully opened, the PLC monitors the
infrared sensor. If the sensor detects no object (meaning the
space is clear), the PLC checks whether the close limit switch is
not triggered.
B. Activating the Closing Motor:
The closing motor is activated to move the door towards
the closed position.
C. Timer for Delay:
Similar to the opening motor, the closing motor also uses
a TON timer to ensure the door remains fully closed for a
specified time.
Step 3: Safety Mechanism
The system uses limit switches and timers to ensure that the
door operates smoothly without hitting physical limits or causing
damage to the motors. The motors stop as soon as the door reaches
the fully open or closed positions, preventing overdriving.
3
Experiment No: 02
Experiment Name:
Implement logic for automatic continuous filling system in PLC using
ladder diagram programming language.
Objective:
To design and implement the logic for an automatic continuous
filling system using PLC and ladder diagram programming, where the
system automatically fills containers based on sensor inputs and
predefined conditions.
Theory:
A PLC (Programmable Logic Controller) uses ladder logic to control
industrial processes. In an automatic continuous filling system, level
sensors monitor the liquid level in containers. The ladder diagram logic
ensures:
● Filling starts when the container level is low.
● Filling stops when the container reaches the set level.
● Continuous and automated operation for efficient production.
This system is used in industries like food & beverage, pharmaceuticals,
and chemicals to automate the filling process.
List of I/O:
4
PLC Ladder Diagram:
5
Program Description:
1. Start/Stop Control:
● When the Start button is pressed, it activates the Run signal,
turning on the system.
● Pressing the Stop button disables the Run signal, stopping the
system.
2. Level & Full Conditions:
● The system checks the Level and Full sensors. If the Level sensor
is activated and the tank is not full, the system will proceed to
the next step.
3. Proximity Sensor & Full Signal:
● The Proximity sensor confirms if there is an object nearby (e.g.,
a tank or other equipment).
● If the Full sensor is not triggered, the program allows the Motor
to run, turning the motor on.
● Once the Full signal is received, the motor will stop.
4. Solenoid Control:
● When the Proximity sensor detects an object and the Full signal
is also activated, the solenoid is engaged.
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Experiment No: 03
Experiment Name:
A feeder drops material on the conveyor which sends material for
further process through one more conveyor. Conveyors must start
automatically when material is dropped. Implement PLC program for this
application using ladder diagram language.
Objective:
To implement a PLC program using a ladder diagram to
automatically start conveyors when material is dropped by the feeder,
ensuring seamless material transport for further processing.
Theory:
A PLC controls the operation of conveyors using input sensors that
detect when material is dropped onto the conveyor. The ladder diagram
logic triggers the conveyor motor to start automatically, transporting the
material to the next stage of the process. The system ensures automatic
and efficient material handling in industries.
List of I/O:
7
PLC Ladder Diagram:
8
Program Description:
1. Start Button (Cycle On):
When the "Start" button is pressed (%I0.0), it activates the "Cycle
On" output (%Q0.0), starting the process.
2. Stop Button (Cycle Off):
Pressing the "Stop" button (%I0.1) will deactivate the "Cycle On"
output (%Q0.0), stopping the process.
3. Feeder Motor Activation:
When the "Cycle On" output (%Q0.0) is active, the feeder motor
(%Q0.1) starts.
4. Load Cell 1 Check:
While the feeder motor is running, the Load Cell 1 sensor (%I0.2)
must be active for the next step.
5. Conveyor 1 Motor Activation:
Once Load Cell 1 is active (%I0.2), the Conveyor 1 motor (%Q0.2)
will be powered on.
6. Load Cell 2 Check:
The operation will also check Load Cell 2 (%I0.3). If active, the
Conveyor 2 motor (%Q0.3) will start.
9
Experiment No: 04
Experiment Name:
Implement logic for the automatic heating of liquid in a tank using a
heater in PLC using ladder diagram programming language.
Objective:
To implement a PLC program using a ladder diagram to
automatically control the heating of liquid in a tank by regulating a heater
based on temperature sensors.
Theory:
A PLC controls the heater based on inputs from temperature sensors
monitoring the liquid temperature in the tank. The ladder diagram logic
turns the heater on when the temperature drops below a set point and off
when the desired temperature is reached. This system ensures automatic
temperature control for efficient and safe heating processes in industries
like chemical processing and food & beverage.
List of I/O:
10
PLC Ladder Diagram:
11
Program Description:
1. Cycle Start / Stop:
● The "Cycle Start" button (%I0.0) initiates the process.
● If the "Main Contact" is closed (%Q0.0), the cycle continues;
otherwise, the cycle stops when "Cycle Stop" is activated.
2. Inlet Valve Control:
● The system checks for a "Low Level Switch" (%I0.2) and "High
Level Switch" (%I0.3).
● If both are satisfied, the "Inlet Valve" (%Q0.1) opens, allowing
fluid entry.
3. Heater Control:
● When the "High Level Switch" (%I0.3) is active, the "Heater"
(%Q0.2) is turned on, heating the system.
4. Outlet Valve Control:
● The "Outlet Valve" (%Q0.3) operates based on the status of the
"High Level Switch" (%I0.3) and "Temperature Sensor" (%I0.4).
5. Low Level Switch & Outlet Valve:
● The system monitors the "Low Level Switch" (%I0.2), and once
the low level condition is met, the "Outlet Valve" (%Q0.3) is
activated to release the contents.
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Experiment No: 05
Experiment Name:
Implement logic for the star delta starter for induction motor in PLC
using ladder diagram programming language.
Objective:
To implement a PLC program using a ladder diagram for controlling
the star-delta starter of an induction motor, enabling efficient starting by
reducing inrush current.
Theory:
A star-delta starter is used to reduce the initial current when starting
an induction motor. In the PLC-controlled system, contactors are switched
from star connection (low voltage) to delta connection (full voltage)
based on a timing sequence. The ladder diagram logic:
1. Initially connects the motor in star configuration.
2. After a preset time, switches to delta configuration for full voltage
operation.This method minimizes the starting current and ensures
smooth motor operation.
List of I/O:
13
PLC Ladder Diagram:
14
Program Description:
1. Start/Stop Control:
● The "Start" button (%I0.0) energizes the "Main Contractor"
(%Q0.0).
● The "Stop" button (%I0.1) de-energizes the "Main Contractor"
(%Q0.0) and stops the process.
● The "Overload Relay" (%I0.2) ensures the system shuts down if
an overload is detected.
2. Star to Delta Transition Timing:
● When the "Main Contractor" (%Q0.0) is energized, it activates
the "Star to Delta Time" timer (%DB2).
● The timer (%DB2) has a preset delay time (T#10S) for the
transition from star to delta configuration.
3. Star Contractor Activation:
● After the timer (%DB2) reaches the set time, the "Star
Contractor" (%Q0.1) is energized, activating the star connection.
4. Delta Contractor Activation:
● After the star connection, the "Delta Contractor" (%Q0.2) is
energized, completing the transition to the delta configuration.
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Experiment No: 06
Experiment Name:
Implement logic for Latch-Unlatch Circuit Using Ladder Diagram in
PLC
Objective:
To implement a latch-unlatch circuit in a PLC using a ladder diagram
to control an output device, maintaining its state until a reset action is
performed.
Theory:
A latch-unlatch circuit uses memory bits in a PLC to maintain an
output state (e.g., motor on) after an input triggers it. The latch (set) keeps
the output active until a second input (unlatch/reset) deactivates it. The
ladder diagram allows toggling the output without continuous input,
enabling more efficient control in automation systems.
List of I/O:
16
PLC Ladder Diagram:
17
Program Description:
1. Start Control:
● When the "Start" button (%I0.0) is pressed, the "Contactor 1"
(%Q0.0) is energized.
2. Timer T001 for Contactor 1:
● The "Contactor 1" energizes the timer T001 (%DB1), which has a
delay time set to 20 seconds (T#20S).
● Once the timer reaches its preset time, it activates output
T001.Q.
3. Contactor 2 Activation:
● The activation of T001.Q closes the circuit to energize "Contactor
2" (%Q0.1) and starts the second timer T002 (%DB2).
4. Timer T002 for Contactor 2:
● The timer T002 is set for a delay of 10 seconds (T#10S).
● Once T002 reaches its time, it activates the "Contactor 2" output
(%Q0.1).
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Experiment No: 07
Experiment Name:
Implement logic for Motor Control Using Ladder Diagram in PLC
Objective:
To design and implement motor control logic using a ladder diagram
in a PLC to start, stop, and control the motor based on various input
conditions.
Theory:
Motor control in PLCs uses ladder diagrams to control motor
operations like starting, stopping, and safety interlocks. Inputs (e.g.,
Start/Stop buttons, limit switches) trigger outputs (e.g., motor starters)
through relay logic. Timers and interlocks are used to manage safe motor
operation and ensure efficient control.
List of I/O:
19
PLC Ladder Diagram:
20
Program Description:
1. Motor Control:
● Pressing the "Start" button (%I0.0) energizes the "Motor" (%Q0.0).
● The "Stop" button (%I0.1) de-energizes the motor, stopping it
when pressed.
2. C001 Counter (CTU):
● The "Start" button (%I0.0) also triggers a counter (CTU) for C001
(%DB1).
● The counter increments each time it is triggered and stores the
count in the CV (Counter Value).
3. Counter Reset:
● When the "Stop" button (%I0.1) is pressed, the counter is reset.
● The preset value (PV) is 5, and the current count is displayed in
CV (%C001.CV).
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Experiment No: 08
Experiment Name:
Implement logic for Automatic Light Control (10 times ) Using PLC
Ladder Diagram
Objective:
To implement a ladder diagram using a PLC to control a light based
on the states of two input switches (A and B). The light will turn on or off
depending on the conditions set in the ladder diagram.
Theory:
This experiment demonstrates how a PLC can control output devices
like lights based on input conditions. The ladder diagram consists of two
input switches (A and B), controlling a relay (Q1). The state of the relay
determines the operation of the output device (Light, Q2).
1. Switch A (I1): Used to control the logic and start the sequence.
2. Switch B (I2): Works in combination with the relay (Q1) to set the
condition for the light.
3. Relay (Q1): Acts as an intermediary between the inputs and the
output. It closes or opens based on the conditions set in the ladder
logic.
4. Light (Q2): The final output, which is controlled by the PLC based on
the state of the input switches and relay.
List of I/O:
22
PLC Ladder Diagram:
23
Program Description:
1. Input A and Contact 1:
● When Input A (%I0.0) is activated, it energizes Contact 1 (%Q0.0),
turning on the output.
2. Counter C001:
● The Counter (CTU) starts counting when Input B (%I0.1) is
activated.
● The counter has a preset value of 5 (PV) and will count up until
it reaches the preset value.
● The current count is stored in C001.CV.
3. Contact 2 Activation:
● Once the counter reaches the preset value (5), it triggers
Contact 2 (%Q0.1).
● This contact is activated based on the counter’s Q output
(%C001.QU).
This program uses the inputs to control a counter, and when the counter
reaches its preset value, it activates the second contact.
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Experiment No: 09
Experiment Name:
Implement up and down counters in PLC using ladder diagram
programming language.
Objective:
To implement up and down counters in a PLC system using ladder
diagram programming to count events and control processes based on
predefined limits.
Theory:
An up counter increments its count each time an input condition is
met, while a down counter decrements its count. The PLC processes the
input signals and updates the counter values accordingly. The ladder
diagram logic:
● The up counter counts events when the input is triggered (e.g., part
passing a sensor).
● The down counter decreases the count based on another input (e.g.,
reset signal or another sensor).
The counters are used for tracking processes like production, inventory
control, and batch processing in industries.
List of I/O:
25
PLC Ladder Diagram:
UP Counter:
DOWN Counter:
Program Description:
CTU (Up Counter):
1. Start and Reset Inputs:
● %0.0 (Start) triggers the CTU (Up Counter), starting the
count.
● %0.1 (Reset) is used to reset the counter to 0.
2. Up Counter (CTU) Operation:
● The CTU function block takes the input count and adds it
each time the CU (Counter Up) input is triggered.
● CU: When this input is high (enabled), the counter
increments by 1.
● Q (Output): If the counter reaches the preset value (PV),
this output is set high.
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● CV (Current Value): Shows the current count value in the
counter.
3. Motor Control:
● %QQ0.0 (Motor_CT): When the counter reaches the preset
value (PV), this output is activated, controlling the motor.
CTD (Down Counter):
1. Counter and Load Input:
● %0.0 (Start_CTD) input is used to trigger the CTD (Down
Counter).
● %0.1 (Load Input) starts counting down from a preset
value.
2. Down Counter (CTD) Operation:
● The CTD function block decreases the counter value each
time the LD (Load) input is triggered.
● CD: This value sets the down counter’s initial value.
● Q (Output): When the counter reaches 0, this output
becomes high.
● CV (Current Value): Shows the current countdown value.
● PV (Preset Value): The set value from which the
countdown begins.
3. Motor Control:
● %QQ0.0 (Motor) is activated when the countdown reaches
0, controlling the motor accordingly.
Both counters, CTU (Up) and CTD (Down), monitor the count and
control the motor output depending on the counter's progress.
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Experiment No: 10
Experiment Name:
Implement AND, OR, NOT, NAND, NOR, XOR logic gates in PLC using
ladder diagram programming language.
Objective:
To implement AND, OR, NOT, NAND, and XOR logic gates in a PLC
system using ladder diagram programming for controlling digital
processes based on multiple conditions.
Theory:
In PLC programming, logic gates are represented using contacts and
coils in ladder diagrams, allowing for digital control of systems. The ladder
logic for each gate works as follows:
1. AND Gate: The output is ON only when all inputs are ON (parallel
contacts).
2. OR Gate: The output is ON if any input is ON (series contacts).
3. NOT Gate: The output is ON when the input is OFF (inverter logic).
4. NAND Gate: The output is the inverse of the AND gate (output is OFF
when all inputs are ON).
5. NOR Gate: The output is ON only when all inputs are OFF (inverted OR
gate).
6. XOR Gate: The output is ON when the number of ON inputs is odd.
These gates are essential in digital logic for control systems, automation,
and process regulation.
28
List of I/O:
PLC Ladder Diagram:
OR Gate:
29
AND Gate:
NOT Gate:
NAND Gate:
NOR Gate:
30
XOR:
Program Description:
1. OR Logic Gate:
This program outputs Q_OR when either I1_OR or I2_OR is activated.
2. AND Logic Gate:
This program outputs Q_AND when both I1_AND and I2_AND are
activated.
3. NOT Logic Gate:
This program outputs Q_NOT when I_NOT is off (inverted logic).
4. NAND Logic Gate:
This program outputs Q_NAND when both I1_NAND and I2_NAND are
activated. The output is inverted.
5. XOR Logic Gate:
This program outputs Q_XOR when an odd number of inputs (I1_XOR,
I2_XOR, I3_XOR, and I4_XOR) are high.
6. NOR Logic Gate:
This program outputs Q_NOR when both I1_NOR and I2_NOR are off.
31
Experiment No: 11
Experiment Name:
Implement Logic for On-Delay Timer, Off-Delay Timer, Using PLC
Ladder Diagram
Objective:
To implement the logic for On-Delay Timer, Off-Delay Timer in a PLC
system using ladder diagram programming for precise control of timing
operations.
Theory:
In PLC systems, timers are used to control processes based on time
delays. The ladder logic for each timer works as follows:
1. On-Delay Timer (TON): The output is delayed ON after the input
condition is true for a specified time.
2. Off-Delay Timer (TOF): The output is delayed OFF after the input
condition becomes false for a specified time.
These timers are essential for controlling processes with specific time
constraints, like delayed motor starts, batch processes, or delayed
shutdowns in automation and industrial applications.
PLC Ladder Diagram:
On-Delay Timer (TON):
32
Off-Delay Timer (TOF):
Program Description:
Off-Delay Timer (TOF):
● IN: Input %I0.0 (A) starts the timer.
● PT: Preset time of 5 seconds.
● Q: Output %Q0.0 (M) is activated after the delay.
On-Delay Timer (TON):
● IN: Input %I0.1 (B) starts the timer.
● PT: Preset time of 5 seconds.
● Q: Output %Q0.1 (M2) is activated after the delay.
●
Both programs utilize a 5-second preset delay before triggering the
respective outputs.
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