PLC Manual

PROGRAMMABLE LOGIC CONTROLLER
INSTRUCTION MANUAL
Realization of AND Logic
Aim:
To realize the AND logic gate.
Logic Diagram:
Truth Table
A B Y=A.B
0 0 0
0 1 0
1 0 0
1 1 1
Components Used:
For Input: Switches Connected to inputs 0 and 1 of the PLC

For output: LED 0 is connected to Output (Y0) of the PLC.
Procedure:
Switch ON the PLC Trainer.
Make sure PLC Cable is connected the serial port of the Computer.
Write the Ladder Diagram in the Ladder Programmer and download the program into PLC.
RUN the program from the software.
Operate the corresponding switches as per truth table and observe the Output LED.
For more details refer the Delta PLC Programming Manual
Ladder Logic Diagram:

Realization of OR Logic
Aim:
To realize the OR logic gate.
Logic Diagram:
Truth Table
A B Y=A+B
0 0 0
Components Used:
0 1 1
1 0 1 For Input: Switches Connected to inputs 0 and 1 of the
PLC
1 1 1 For output: LED 0 is connected to Output (Y0) of the PLC.
Procedure:

Realization of NOT Logic
Aim:
To realize the NOT logic gate.
Logic Diagram:
Truth Table
0 1
Components Used:
1 0
For Input: Switch Connected to the input 0 of the PLC
Procedure:

Realization of NAND Logic
Aim:
To realize the NAND logic gate.
Logic Diagram:
Truth Table
A B
Y=AB
Components Used:
0 0 1
PLC
1 0 1 For output: LED 0 is connected to Output (Y0) of the PLC.
1 1 0
Procedure:

Realization of NOR Logic
Aim:
To realize the NOR logic gate.
Logic Diagram:
Truth Table
A B
Y=A+B
Components Used:
0 1 0 PLC
1 0 0
1 1 0 Procedure:

Realization of EX-OR Logic
Aim:
To realize the EX-OR logic gate.
Logic Diagram:
Truth Table
A B
Y=AB + BA
Components Used:
0 0 0 For Input: Switches Connected to inputs 0 and 1 of
0 1 1 the PLC
For output: LED 0 is connected to Output (Y0) of the
1 0 1 PLC.
1 1 0
Procedure:
Timer Operation
Aim:
Timer operation in a Program.
Program Description:
When Input 0 and Input 1 are on, the outputs Y0 should on after 10 Seconds. When Input 2 and 3 are
on, the output Y0 should off after 5 seconds.
Components Used:
For Input: Switches Connected to inputs 0, 1, 2 and 3 of the PLC
Procedure:
Ladder Diagram:
Rising Edge & Falling Edge detection
Aim:
Introduction to Rising Edge input and Falling Edge Input and writing program for Rising Edge Input and
Falling Edge Input.
Program Description:
When rising edge of the Input 0 detected the Output Y0 should be on after 10 Seconds. When falling
edge of the Input 0 detected the Output Y0 should be Off.
Components Used:
For Input: Switch Connected to input X0 of the PLC
Procedure:
Ladder Diagram:
Introduction to Counter
Aim:
Introduction to counter. Using counter in a Ladder program.
Program:
Write a program for a counter when Input X0 is On & Off for 10 times then output Y0 should be ON.
After 10 Seconds the Y0 Should be off and Counter will be reset and ready for next operation.
Components Used:
For Input: Switch Connected to input X0 of the PLC
Procedure:
Ladder Diagram:
Interfacing Liquid Level Control Model to PLC
Aim:
Interfacing Liquid level control application module to PLC and writing ladder diagram to Controlling the
liquid level in the transparent vessel.
Liquid Level Control Model:

This apparatus is designed for students to understand the level control operation using PLC. It consists
following parts:
a) Sump Tank
b) Transparent Collecting tank/Vessel
c) Small Pump installed in the Sump tank to supply water to collecting tank
d) Magnetic float switches for sensing the water level of the collecting tank (one sensor (Sensor1)
is installed in collecting tank at lower position to sense the water in the lower position and
another sensor (Sensor2) is installed in collecting tank at upper position to sense the upper
position of the water level)
e) Relay interface box for interfacing the pump to PLC (As pump works on AC supply and output of
the PLC is DC Supply. A relay is used to control the pump from DC Output)
Program:
Write a program for Liquid level control model when water/liquid level less then Sensor1 the output Y0
should ON and when the water level reaches the upper Sensor (Sensor2) the output should be OFF.
Procedure:
Switch on the Relay box by plug in the power chord of the relay box
Connect the Pump (inside the sump tank) terminals to Relay box at Output terminals
Connect the Level Switches to PLC inputs. The lower level switch (Marked I0) should be
connected to I0 / X0 and the upper level switch( Marked I1) should be connected to I1 and
remaining terminal should be connected to + 24V.
Connect the Output Y0 and Ground signal of the 24V supply to relay box at PLC Connection.
RUN the program from the software and observe the liquid level control module. When water is
below the lower level switch, the pump will be ON and the pump supplies water to collecting
tank. When water reaches the upper level switch the Pump will be OFF.
Ladder Program:
Interfacing Traffic Signal model to PLC
Aim:
Interfacing Traffic signal application module to PLC and write ladder diagram to Control the traffic
signals.
Traffic Signal Model:

This apparatus is designed for students to understand the traffic signal operation using PLC. It consists
following parts:
a) A traffic signal pole with 12 LED (03 LED Each side, one Red, one Yellow and One green LED
each side)
b) All LED Connections are terminated on the Panel of the Traffic Signal Model to interface with the
PLC
c) The PLC output no. Y0, Y1, Y2, Y3 will be connected to the corresponding Terminals of the
Traffic Signal control model.
d) A 24V dc power Supply from PLC should be connected to corresponding terminals of Traffic
Signal Control model.
e) A microcontroller is installed in the traffic light control model to get signal from the PLC
outputs. According to PLC output Signal the traffic lights will be controlled by microcontroller
for Example when Output Y0 ON, one side of the Traffic signal Green light will be ON and
remaining 03 sides the Red light will be ON).
Program:
Write a program for traffic signal lights control model when input X0 is switch ON, the output Y0 should
ON for 10 Seconds. After 10 Seconds Y0 should switch OFF and Y1 should switch ON. After 10 seconds
the output Y1 should switch OFF and Y2 should switch ON. After 10 seconds the Output Y2 Should
switch OFF and Output Y3 should switch ON. After 10 Seconds Y3 Should Switch OFF and Y0 Should
Switch ON. The process should be continued until the Input X0 will be OFF.
Procedure:
Connect the PLC Outputs Y0, Y1, Y2 & Y3 Terminals to corresponding marked terminals of
Traffic Signal Controller Model.
Connect +24V DC and Ground signals of PLC Trainer to corresponding marked terminals of
Traffic Signal Controller Model.
RUN the program from the software and observe the Traffic Signals.
Ladder Program:
Temperature Controller Using PLC
Aim:
Write a program for Controlling Temperature of an Oven.
Temperature Oven:
This apparatus is designed for students to understand the Temperature control operation using PLC. It
consists following parts:
a) Temperature oven
b) A 60/100W incandescent lamp/bulb to generate heat.
c) A 03 terminal temperature sensor (PT 100) to sense the temperature of the bulb heater and it
will give feed back to the PLC. The temperature sensor acts as a feedback device.
d) Relay interface box for interfacing the Bulb to PLC (As incandescent lamp works on AC supply
and output of the PLC is DC Supply. A relay is used to control the incandescent from DC Output)
Program:
Write a program for control the temperature of an oven. When the temperature of an oven is less than
set temperature the output Y0 should ON (the lamp will glow) and when the temperature exceeds the
set value the output should be OFF.
Procedure:
Switch on the Relay box by plug in the power chord of the relay box
Connect the incandescent Lamp (inside the Oven) terminals to Relay box at Output terminals
Connect the Temperature Sensor (PT100) to terminal (02 mm banana sockets) provided on the
front panel of the PLC trainer. The red color connector should be connected to red color
terminal and remaining two white color/green color connectors should be connected to green
color terminals.
Connect the Output Y0 and Ground signal of the 24V supply to relay box at PLC Connection.
Write the Ladder Diagram in the Ladder Programmer and download the program into PLC. RUN
the program from the software and observe the temperature of the Oven. When the temperature
of the oven is less than set temperature the output Y0 is ON (the lamp will glow) and when the
temperature exceeds the set value the output will be OFF.
Ladder Program
Interfacing & Controlling DOL Starter with PLC
Aim:
Interfacing & Controlling DOL Starter with PLC
DOL Starter Kit:

This apparatus is designed for students to understand the working principle of DOL Starter and
controlling the DOL starter using PLC. It consists following parts:
S0 : OFF Push button to off the Motor

S1 : ON Push button to ON the motor
K1 : Main contactor
F2 : Overload relay
F3 : Control circuit fuse
Input Power Connector for 3 Phase Power.
Output connector for Motor connection.
Banana terminals for interfacing the DOL starter kit to the PLC.
This is by far the most common starting method available on the market. The starting equipment
consists of only a main contactor and thermal or electronic overload relay. The disadvantage with this
method is that it gives the highest possible starting current. A normal value is between 6 to 7 times the
rated motor current but values of up to 9 or 10 times the rated current exist. Besides the starting
current there also exists a current peak that can rise up to 14 times the rated current since the motor is
not energized from the first moment when starting. The values are dependent on the design and size of
the motor, but in general, a smaller motor gives higher values than a larger one. During a direct-on-line
start, the starting torque is also very high, and is higher than necessary for most applications. The
torque is the same as the force, and an unnecessary high force gives unnecessary high stresses on
couplings and the driven application. Naturally, there are cases where this starting method works
perfectly and in some cases also the only starting method that works.
Program:
Write a program for controlling the DOL starter by PLC. When the start push button of the DOL Starter
Kit is pressed (this push button is connected to input X0) the output of the PLC, Y0 Should ON (This
output is connected to Main contactor of the DOL starter). When the stop push button is pressed (this
push button is connected to input X1) the output of the PLC, Y0 Should OFF.
Procedure:
Connect the PLC Output Y0 Terminals to corresponding marked terminals of DOL starter kit.
Connect the inputs from DOL Starter kit to X0 and X1 inputs of PLC Trainer.
Connect +24V DC and Ground signals of PLC Trainer to corresponding marked terminals of DOL
starter kit.
RUN the program from the software and observe the DOL Starter by activating start push button
and stop push button.
Ladder Program
Interfacing & Controlling Star Delta Starter with PLC
Aim:
Interfacing & Controlling Star Delta Starter with PLC
DOL Starter Kit:

This apparatus is designed for students to understand the working principle of Star Delta Starter and
controlling the Star Delta starter using PLC. It consists following parts:
S0 = OFF Push button to Off the Starter

S1 = ON Push button to ON the starter
K1 = Line contactor
K2 = Star contactor
K3 = Delta contactor
F2 = Overload relay
This is a starting method that reduces the starting current and starting torque. The device normally
consists of three contactors, an overload relay and a timer (in our case timer function will be
implemented thru PLC program) for setting the time in the star-position (starting position). The motor
must be delta connected during a normal run, in order to be able to use this starting method. The
received starting current is about 30 % of the starting current during direct on line start and the
starting torque is reduced to about 25 % of the torque available at a D.O.L start. This starting method
only works when the application is light loaded during the start. If the motor is too heavily loaded, there
will not be enough torque to accelerate the motor up to speed before switching over to the delta
position. When starting up pumps and fans for example, the load torque is low at the beginning of the
start and increases with the square of the speed. When reaching approx. 80-85 % of the motor rated
speed the load torque is equal to the motor torque and the acceleration ceases. To reach the rated
speed, a switch over to delta position is necessary, and this will very often result in high transmission
and current peaks. In some cases the current peak can reach a value that is even bigger than for a D.O.L
start. Applications with a load torque higher than 50 % of the motor rated torque will not be able to
start using the start-delta starter.
Program:
Write a program for controlling the Star Delta starter by PLC. When the start push button of the Star
Delta Starter Kit is pressed (this push button is connected to input X0) the output of the PLC, Y0 and Y1
Should ON (These outputs are connected to Main contactor and star contactors respectively of Star
Delta Starter). After 10 seconds the output Y1 will be OFF and output Y2 (This output of the PLC is
connected to Delta Starter of star delta starter) should turned ON. When the stop push button is pressed
(this push button is connected to input X1) all output of the PLC Should be OFF.
Procedure:
Connect the PLC Output Y0, Y1 & Y2 Terminals to corresponding marked terminals of Star Delta
starter kit.
Connect the inputs from Star Delta Starter kit to X0 and X1 inputs of PLC Trainer.
Connect +24V DC and Ground signals of PLC Trainer to corresponding marked terminals of Star
Delta starter kit.
RUN the program from the software and observe the Star Delta Starter by activating start push
button and stop push button.
Ladder Program:

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PROGRAMMABLE LOGIC CONTROLLER

For Input: Switches Connected to inputs 0 and 1 of the PLC

Ladder Logic Diagram:

Ladder Logic Diagram:

Ladder Logic Diagram:

Ladder Logic Diagram:

Ladder Logic Diagram:

Ladder Logic Diagram:

Liquid Level Control Model:

Traffic Signal Model:

DOL Starter Kit:

S0 : OFF Push button to off the Motor

DOL Starter Kit:

S0 = OFF Push button to Off the Starter

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