STUDY OF PLC SYSTEM AND ITS ELEMENTS

AIM:
To study about PLC system and its elements.
PROGRAMMABLE LOGIC CONTROLLERS (PLC)
A programmable logic controller is a solid-state system designed to perform the logic functions previously accomplished
by components such as electromechanical relays, drum switches, mechanical timers/counters, etc., for the control and operation of
manufacturing process and machinery.
PLCs are designed to be operated by plant engineers and maintenance personnel with limited knowledge of computers.
Like a computer, which has an internal memory for its operation and storage of a programmed, the PLC also has memory for storing
the user programme, or LOGIC, as well as a memory for controlling the operation of a process machine or driven equipment. But
unlike a computer the PLC is programmed in RELAY LADDER LOGIC, not one of the computer languages. It should be stated,
however, that some PLCs will use a form of Boolean Algebra to enter the RELAY LADDER LOGIC.
The PLC is also designed to operate in the industrial environment with wide ranges of ambient temperature, vibration,
and humidity, and not usually affected by the electrical noise that is inherent in most industrial locations.
Advantages of Ladder Logic over Relay logic
There are significant advantages in using a PLC rather than conventional relays, timers, counters and other hardware elements.
These advantages include:
Programming the PLC is easier than wiring the relay control panel;
The PLC can be reprogrammed whereas conventional controls must be rewired and are often scrapped instead;
PLCs take less floor space than do relay control panels.
Reliability of the PLC is greater and maintenance is easier.
The PLC can be connected to computer systems more easily than relays,
PLCs can perform a greater variety of control functions than can relay controls.
Components of PLC
A typical PLC can be divided into four components each of which has a unique job in its operation.
1. Processor unit
2. Input / Output section
3. Programming terminal
4. Power supply
1. Processor Unit
The processor or CPU unit houses the processor which is the decision-maker, or brain of the system. The brain is a
microprocessor-based system that replaces control relays, counters, timers, sequencers, and so forth, and is designed so that the user can
enter the desired program in RELAY LADDER LOGIC. The processor then makes all the decisions necessary to carry out the user
program, based on the status of the inputs and outputs for control of a machine or process. It can also perform arithmetic functions, data
manipulations, and communications between the local input/output section, remotely located I/O sections, and/or other networked PLC
systems.

Block Diagram of a PLC

2. Input / Output section

Input and output modules, referred to as the I/O (I for input and O for output) are where the real-world devices are
connected. The real-world input (I) devices can be push button, limit switches, analog sensors, thumbwheels, selector switches, etc.,
while the real world output devices (O) can be hard-wired coils, solenoid valves, indicator lights, positioning valves, and the like.
The I/O section contains the circuitry necessary to convert input voltages of 120 240 V AC or 0 24 V DC, etc., from
discrete input devices to low-level DC voltages (typically 5 V) that the processor uses internally to represent the status or condition
(ON or OFF). The I/O section can also convert 4 20 milli ampere (mA) input signals to low-level DC voltages for the processor.
Similarly, the output module changes low-level DC signals from the processor to 120 240 V or DC voltages required to operate the
discrete output devices. This is a brief overview of the I/O section and its function.
3. Programming Terminal
The programming device is used to enter the desired programme or sequence of operation into the PLC memory. The
programme is entered using RELAY LADDER LOGIC, and it is this programme that determines the sequence of operation and
ultimate control of the process equipment or driven machinery. The programming device can be any one of three types; hand-held;
dedicated; or personal computer. The personal computer, or PC, is the most common Programming device.
The hand-held programmers are small, lightweight, and convenient to use in the field. The small size, however, limits the display
capabilities, which in turn limits its effectiveness for reviewing the programme or using the programmer for troubleshooting.
4. Power Supply
The power supply is necessary to convert 120 or 240 volts AC voltages to the low voltage DC required for the logic
circuits of the processor, and for the internal power required for the I/O modules. The power supply can be a separate unit or one,
depending on the manufacturer, that is an integral part of the processor.
Input module
Field Wiring for Ac Input Module
Input module serves as the link between field devices and the PLCs CPU. Each input module has a terminal block for attaching input
wiring from each individual field input device. Typical input modules have either 8, 16 or 32 input terminals.
The main function of an input module is to take the field device input signal, convert it to a signal level that the CPU can work
with electrically isolate it, and send the signal by way of the back plane board, to the CPU
Output module
Output modules serve as the link between the PLCs microprocessor and hardware field device. Each output module has a
terminal block for attaching output wiring to go to each individual field output device. Typical output modules have either 8, 16 or 32
output terminals.
The output signal, once received from the CPU, must be stored before being sent to each output modules output screw
terminals. The main function of an output module is to take the CPUs control signal (sent by way of the backplane), electrically isolate
it and energise or de-energise the modules switch in device to turn on (or turn off) the output field device.
STUDY OF PNEUMATIC SYSTEMS
INTRODUCTION
Pneumatics is also used a lot in industry and you would expect to see pneumatic systems in factories, production lines
and processing plants. It can be used to do lots of different jobs such as moving, holding or shaping objects.
ADVANTAGES OF PNEUMATICS
There are usually lots of different ways to carry out a task, so it is important to understand some of the reasons for
choosing pneumatic systems.

Clean - Pneumatic systems are clean because they use compressed air.
Safe - Pneumatic systems are very safe compared to other systems.
Reliable - Pneumatic systems are very reliable and can keep Theory for a long time.
Economical - If we compare pneumatic systems to other systems, we find that they are cheaper to run. This is because the
components last for a long time and because we are using compressed air.
Flexible - Pneumatic systems are easy to install and they do not need to be insulated or protected like electronic systems.

SUPPLYING COMPRESSED AIR

In order to supply pneumatic systems with compressed air we use a machine called a compressor. A pump that is driven
by a motor, sucks in air from the room and stores it in a tank called the receiver.
SAFETY RULES
Safety rules help to keep us safe. They highlight dangers and this helps to prevent accidents. When we are using pneumatics we must
follow these rules.
1. Never blow compressed air at anyone, not even yourself.
2. Never let compressed air come into contact with your skin, as this can be very dangerous.
3. Always wear safety goggles when youa are connecting and operating circuits.
4. Check that all airlines are connected before turning on the main air supply.
5. Always turn off the main air supply before changing a circuit.
6. Keep your hands away from moving parts.
7. Avoid having airlines trailing across the floor or where someone could trip or become entangled.
STUDY OF STEPPER MOTOR
A stepper motor is a brushless, synchronous electric motor that can divide a full rotation into a large number of steps, for
example, 200 steps. Thus the motor can be turned to a precise angle. Stepper motors operate differently from normal DC motors, which
simply spin when voltage is applied to their terminals. Stepper motors, on the other hand, effectively have multiple "toothed"
electromagnets arranged around a central metal gear. To make the motor shaft turn, first one electromagnet is given power, which
makes the gear's teeth magnetically attracted to the electromagnet's teeth. When the gear's teeth are thus aligned to the first
electromagnet, they are slightly offset from the next electromagnet. So when the next electromagnet is turned on and the first is turned
off, the gear rotates slightly to align with the next one, and from there the process is repeated. Each of those slight rotations is called a
"step." In that way, the motor can be turned a precise angle

RESULT:
Thus the PLC system and its elements have been studied.

Ex: No: 1
DIRECT OPERATION OF A MOTOR USING LATCHING CIRCUIT.
Aim:
To draw a ladder logic diagram and operate a motor using latching circuit.
Apparatus Required:
1. PLC Trainer kit.
2. 24V power supply.
3. Motor, Switches and wires.
Theory:
There are often situation where it is necessary to hold coil energized even when the input which energized it ceases. The
term latch circuit is used for the circuit to carry out such an operation of motor.
Ladder diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.
Result:
Thus the Direct operation of a motor is operated by using latching circuit.

Ex:No: 2
OPERATION OF A MOTOR USING AND LOGIC CONTROL
Aim:
To draw a AND ladder logic diagram and operate a motor using AND logic control.
Apparatus Required:
1. PLC Trainer kit.
2. 24V power supply.
3. Motor, Switches and wires.
Theory:
Diagram shows the situation where the coil is not energized when two normally open switches are both closed. Switch A
and B have both to be closed which thus gives and AND logic situation. The ladder diagram start with it labeled input 4 to
represent switch A and in series with it, labeled input 5 to represent switch B. the line then terminates with O to represent the
motor.
Ladder

diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.
Result:
Thus the motor is operated by using AND logic control.

Ex:No: 3
OPERATION OF A MOTOR USING OR CONTROL.
Aim:
To draw an OR ladder logic diagram and operate a motor using OR logic control.
Apparatus Required:
1. PLC Trainer kit.
2. 24V power supply.
3. Motor, Switches and wires.
Theory:
Ladder diagram shows a situation where a coil is not energized until either normally opens. Switch input 1 or input 2 is
closed. The situation is an OR gate logic gate The ladder diagram start with it labeled input 1 to represent switch 1 and in parallel
with it, labeled input 2 represent switch 2. The line then terminates with motor to run.
Ladder Diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.
Result:
Thus the motor is operated by using OR logic control.

Ex: No: 4
ON DELAY CONTROL OF A MOTOR
Aim:
To draw an ON Delay ladder logic diagram and operate a motor using timer function.
Apparatus Required:
1. PLC Trainer kit.
2. 24V power supply.
3. Motor, Switches and wires.
Theory:
When start button is pressed the timer ON Delay gets energized. The timer starts running similarly motor is at stable after
some time the time
period closes then timer contact in
rung 2 gets closes
and the motor gets started. The
timer is reset when
the stop button is activated.
Ladder Diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.
Result :
Thus the motor is controlled by using ON delay timer function.

Ex: No: 5
OFF DELAY CONTROL OF A MOTOR.
Aim:
To draw an OFF Delay ladder logic diagram and control a motor using timer function.
Apparatus Required:
1. PLC Trainer kit.
2. 24V power supply.
3. Motor, Switches and wires.
Theory:
When start button is pressed the timer OFF Delay gets energized. The timer starts running similarly motor starts after
some time the time period closes then timer contact in rung 2 gets closes and the motor gets stopped. The timer is reset when the
stop button is activated.
Ladder Diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.
Result:
Thus the motor is controlled by using OFF delay timer function.

Ex: No: 6
AUTOMATIC OPERATION OF A DOUBLE ACTING CYLINDER SINGLE CYCLE.
Aim:
To draw the ladder diagram and to carry out its automatic operation at a double acting cylinder - single cycle.
Apparatus Required:
1. PLC Trainer kit.
2. 24V power supply.
3. Motor, Switches and wires.
4. Double acting cylinder.
5. 5/2 double solenoid valve.
6. Limit switches.
7. Compressor & FRL Unit.
8. Connectors.
Theory:
A start switch
first rung. Thus the
solenoid valve energized,
and a limit switch is
cylinder is retraced. When
extending after some time
extend and after the
becomes retract. Thus the
single cycle in a double
Ladder diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.

input has been included in the

cylinder extend and the
then the start switch is closed
closed indicates that the
the
cylinder
piston
is
it touches the piston and it
switch releases the cylinder
operation is preceded for the
acting cylinder.

Switch the PLC in to RUN mode.

Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.

Result:
Thus the double acting pneumatic cylinder is automatically operated in single cycle by using PLC.

Ex: No: 7
AUTOMATIC OPERATION OF A DOUBLE ACTING CYLINDER SINGLE CYCLE FORWARD, TIME
DELAY, RETURN.
Aim:
To develop a ladder logic diagram for double acting cylinder single cycle forward, time delay, return and execute it
by using PLC.
Apparatus Required:
1.
2.
3.
4.
5.
6.
7.

PLC Trainer kit.

PC Software
Double acting cylinder.
5/2 double solenoid valve.
Limit switches.
Compressor & FRL Unit.
Connectors.

Theory:
A start switch input has been included in the first rung. Thus the cylinder extension for solenoid valve is energized, then
the start switch is closed, that indicating cylinder is retracted. When the cylinder is extend the limit switch which indicates the
extension of cylinder. At that time the timer is ON and set the timer to be extracted and after some times the cylinder acts as a
forward and reverse functioning at a given time period.
Ladder diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.
Result:
Thus the double acting cylinder single cycle forward, time delay, and return is operated and executed using PLC.

Ex:No: 8
AUTOMATIC OPERATION OF A DOUBLE ACTING CYLINDER MULTI CYCLE
Aim:
To develop the ladder logic diagram for automatic operation of a double acting cylinder multi cycle and execute it by
using PLC.
Apparatus Required:
1. PLC Trainer kit.
2. PC Software
3. Double acting cylinder.
4. 5/2 double solenoid valve.
5. Limit switches.
6. Compressor & FRL Unit.
7. Connectors.
Theory:
A start switch input has been included in the first rung. Thus the cylinder extension for solenoid valve is energized, then
the start switch is closed, that indicating cylinder is retracted. When the cylinder is extend the limit switch which indicates the
extension of cylinder. At that time the timer is ON and set the timer to be extracted and after some times the cylinder acts as a
forward and reverse functioning at a given time period by touching the limit switches. This process is repeated continuously as
known to be multi cycle operation.
Ladder diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.
Result:
Thus the double acting cylinder multi cycle is operated automatically and executed using PLC.

Ex:No: 9
AUTOMATIC OPERATION OF A DOUBLE ACTING CYLINDER N CYCLE (USING COUNTER BLOCK)
Aim:
To develop the ladder logic diagram for automatic operation of double acting cylinder N cycle (using counter block) and
execute it using PLC.
Apparatus Required:
1. PLC Trainer kit.
2. PC Software
3. Double acting cylinder.
4. 5/2 double solenoid valve.
5. Limit switches.
6. Compressor & FRL Unit.
7. Connectors.
Theory:
The ladder diagram is represented by a rectangle spanning of two lines. On one line is reset the counter, the other line is
out line if counter is preset for 10 means the counter contact will change the state on the 10th pulse. When the cylinder extracts
and retracts that count is called to be one full count similarly when one count completes the second cycle of extracts and retracts
start that is mentioned to be second count like it needs to be complete the 10 counts.
Ladder diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.
Result:
Thus the automatic operation of double acting cylinder N cycle using counter function is executed using PLC.

Ex:No: 10
SEQUENTIAL OPERATION OF DOUBLE ACTING CYLINDER AND A MOTOR
Aim:
To develop the ladder logic diagram for sequential operation of double acting cylinder N and a motor and execute it
using PLC.
Apparatus Required:
1. PLC Trainer kit.
2. PC Software
3. Double acting cylinder & Stepper motor.
4. 5/2 double solenoid valve.
5. Limit switches.
6. Compressor & FRL Unit.
7. Connectors.
Theory:
When the start button is closed, the motor is activated, this energies the solenoid which results the piston cylinder is
extracted when the limit switch closed the motor runs. When motor is running the internal relay is activated as a result solenoid is
energized and the piston retracts. This process is continued at a single cycle.
Ladder diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.
Result:
Thus the sequential operation of pneumatic double acting cylinder and a motor is activated and executed in PLC.

Ex No: 11
SEQUENTIAL OPERATION OF TWO DOUBLE ACTING CYLINDERS FOR SEQUENCE A+ B+B-AAim:
To develop a ladder logic diagram for the sequential operation of two double acting cylinder for sequence of A+ B+B-Aand execute using PLC.
Apparatus Required:
1. PLC Trainer kit.
2. PC Software
3. Double acting cylinder.
4. 5/2 double solenoid valve.
5. Limit switches.
6. Compressor & FRL Unit.
7. Connectors.
Theory:
When the start switch is closed the limit switch is also closed. The solenoid is activated and energizes thus the piston is
opened when it closes the limit switch the other piston is also extends and the first cylinder gets retracted and it goes to the initial
position the second piston gets retracted again this cycle continues till closed switch is activated manually.
Ladder Diagram:

Procedure:
Develop the Ladder circuit diagram.
Connect the devices with power supply, input and output knobs.
Connect this arrangement to the developing software using RS232 cable.
Construct the ladder logic using developer software.
Switch ON the power supply.
Upload the developed program.
Switch the PLC in to RUN mode.
Activate the START Button.
Verify the Output.
Switch off the power supply and disconnect the devices.

Result:

Thus the sequential operation of two double acting cylinders for sequence of A+ B+B-A- is activated and executed in
PLC.