MIT ACADEMY SDN. BHD.

NO:26, JALAN ANGGERIK VANILLA Y31/Y

SEKSYEN 31, KOTA KEMUNING
40460 SHAH ALAM, SELANGOR

WORK BOOK
PROGRAMMABLE LOGIC
CONTROLLER (PLC)

NAME : ___________________________
NRIC : ___________________________
CLASS : ___________________________
COURSE : ___________________________
INSTRUCTOR: ___________________________
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INTRODUCTION:

1. The programmable logic controller (PLC) is a microprocessor based control unit

designed to be used to control various types of industrial processes.
2. The first PLC was designed in the late 1960s, to replace hardwired relay controls used in
auto manufacturing plants.
3. The PLC avoided this problem because the logic could be quickly changed by
reprogramming the PLC software programmer. This greatly reduced the amount of time
and simplified the process of changing the machine's operation sequence.

Fig.1 Block Diagram of PLC

Central Processing Unit

The Central Processing (CPU) is a microprocessor that co-ordinates the activities of the PLC
system. It executes the program, processes I/O signals & communicates with external devices.

Memory
There are various types of memory unit. It is the areas that hold the operating system and user
memory. The operating system is actually system software that co-ordinates the PLC.Ladder
program, timer and counter values are stored in the use memory. Depending on user’s need,
various types of memory are available for choice:

i) Read – Only Memory (ROM)

ii) Random Access Memory (RAM)
iii) Erasable Programmable Read Only Memory (EPROM)
iv) Electrically Erasable Programmable Read Only Memory (EEPROM)
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INPUT DEVICE

OUTPUT DEVICE
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SHORT ANSWER
Order: Give short answer based on the question given.

1. Define PLC according to National Electrical Manufacturers Association of America (NEMA).

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2. List THREE ( 3 ) advantages using PLC.

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3. Give 4 advantage of PLC than Logical Relay.

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4. State 5 languages PLC.

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5. Give 4 criteria when selecting of PLC.

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6. Draw the symbol and explain the instruction below:

i. Timer
ii. Counter

7. Draw the symbol of contactor in normally open and normally close system. Explain the
operation bit condition when the condition contactor is in normally open and in normally
close.
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FILL IN THE BLANK

INSTRUCTION NAME LADDER

(MNEMONIC)
LD B

LD 00000
LD B

LD NOT 00001

LD AND

B B
LD NOT 00001
LD AND NOT

B B
LD 00003
AND NOT CNT 000
LD B

OR B

LD 00004
OR HR 0000
LD B

OR NOT B

LD 00005
OR NOT LR
0000
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INSTRUCTION NAME LADDER

(MNEMONIC)
OUT
B

OUT 10000
OUT

B
OUT 10000
LD AND

LD AND

OR LD
LD LD

OR OR

AND LD
SET RESET HR

ITSELF

SET
TIM 000/127
#0000/9999
TIMER

PULSE
CNT 000/127
#0000/9999

RESET

END
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LAMP CIRCUIT
Problem description:
Actuation of a push button (S1) is to cause a lamp (H1) to be switched on. The lamp is to be illuminated
as long as the push button is actuated.

Positional sketch:

1. Drawing up the circuit diagram and assembling the equipment

Complete the electrical circuit diagram and enter the available input and output addresses of your
PLC.

Circuit diagram, electrical

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2. Describing the control task by means of the function table and the Boolean equation

Create the function table:

Function Table
S1 H1
0
1

3. Declaration of PLC program variables

Declare the variables required in the PLC program:

Designation Data type Address Comment

4. Formulation of the PLC program into one of the

PLC programming languages

Formulate the solution of the control task in one of these languages:

Function block diagram (FBD)
Ladder diagram (LD)
Instruction list (IL)
Structured text (ST)
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Problem description:

A press stamp 1.0 is to advance only if a push button S1 is actuated and a protective guard is closed. If
one of these conditions is not met, the press tool is to return immediately.
The position of the closed protective guard B1 is monitored by a proximity switch B1. The press tool is
advanced or retracted by means of a spring return solenoid valve (coil Y1).

Positional sketch:

Circuit diagram, Electro-pneumatic

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1. Drawing up the electro-pneumatic and the electrical circuit diagram and assembling the
equipment.
Complete the electro-pneumatic circuit diagram

2. Complete the electrical circuit diagram and enter the available input and output addresses for your
PLC.
Circuit diagram, electrical
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3. Describing the control task by means of the function table and the Boolean equation
Create the function table:

Function Table
S1 B1 Y1
0
1

4. Declaration of PLC program variables

Declare the variables required in the PLC program:

Designation Data type Address Comment

5. Formulate the solution of the control task in one of these languages:

Function block diagram (FBD)
Ladder diagram (LD)
Instruction list (IL)
Structured text (ST)
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Problem description:

An apartment bell is to ring if bell button S1 at the front door is pressed or bell button S2 at the apartment
door.
Positional sketch:

Circuit diagram, electrical

1. Complete the electrical circuit diagram and enter the input and output addresses available for your
PLC.
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2. Describing the control task by means of the function table and the Boolean equation

Create the function table:

Function Table

S1 S1 H1
0
1

3. Declaration of PLC program variables

Declare the variables required in the PLC program:

Designation Data type Address Comment

4. Formulate the solution of the control task in one of these languages:

Function block diagram (FBD)
Ladder diagram (LD)
Instruction list (IL)
Structured text (ST)
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Problem description:

A stamping device can be operated from three sides. A work piece is inserted via a guide, whereby it
touches two of the three proximity switches B1,B2 and B3.This causes a pneumatic cylinder1.0 to extend
via a solenoid valve (coil Y1), whereby a recess is to be stamped into the work piece. The stamping cycle
is to be triggered only if two signal generators are addressed. For reasons of safety the cylinder must be
prevented from advancing, if all three proximity sensors are contacted.

Positional sketch:
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1. Drawing up the electrical circuit diagram

Complete the electrical circuit diagram and enter the input and output addresses available for your PLC.

Circuit diagram, electrical

2. Assembling the equipment with the help of the electro-pneumatic and the electrical circuit
diagram

Configure the control system

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3. Describing the control task by means of the function table and the Boolean equation

Create the function table:

Function Table

B1 B2 B3 Y1
0 0 0
0 0 1
0 1 0
0 1 1
1 0 0
1 0 1
1 1 0
1 1 1

4. Declaration of PLC program variables

Declare the variables required in the PLC program:

Designation Data type Address Comment

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5. Formulate the solution of the control task in one of these languages:

Function block diagram (FBD)
Ladder diagram (LD)
Instruction list (IL)
Structured text (ST)
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Problem description:
A mixing plant permits a selection between two bulk materials per selector switch
(S2).In switch position 1(S2=0 signal), bulk material A reaches a mixing container, if push button S1 is
actuated simultaneously. Similarly, bulk material is conveyed, if selector switch S2 is in position 2 (S2 =
1 signal) and push button S1 is actuated. Silo A is opened via cylinder 1.0 (solenoid valve Y1), Silo B via
cylinder 2.0 (solenoid valve Y2).

Positional sketch:

1. Drawing up the electrical circuit diagram

Complete the electrical circuit diagram and enter the input and output addresses available for your PLC.
Circuit diagram, electrical
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2. Assembling the equipment with the help of the electro-pneumatic and the electrical circuit
diagram
Configure the control system

3. Describing the control task by means of the function table and the Boolean equation

Create the function table:

Function Table
S1 S2 Y1 Y2
0 0
0 1
1 0
1 1

4. Declaration of PLC program variables

Declare the variables required in the PLC program:

Designation Data type Address Comment

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5. Formulate the solution of the control task in one of these languages:

Function block diagram (FBD)
Ladder diagram (LD)
Instruction list (IL)
Structured text (ST)

MNEMONIC CODE
1. Identify and fix the programs below:

ADDRESS INSTRUCTION DATA

00000 LD 00001
00001 AND TIM 003
#0100
00002 LD TIM 00003
00003 AND NOT TIM 00004
00004 OUT 01001
00005 LD 01002
00006 OR TIM 0005
00007 TIM 005
00008 END 01
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2. Draw the Ladder Logic for the mnemonic program below.

ADDRESS INSTRUCTION DATA LADDER DIAGRAM:
00000 LD NOT 00000
00001 LD NOT 00001
00002 LD 00002
00003 AND NOT 00001
00004 OR LD
00005 AND LD
00006 AND 00003
00007 OUT 01004
00008 LD NOT 00004
00009 LD 00005
00010 OR 00006
00011 LD NOT 00007
00012 AND 00008
00013 OR 00009
00014 AND LD
00015 AND LD
00016 OUT 01005
00017 FUN 01

3. Draw a ladder diagram based on the mnemonic code given below.

ADDRESS INSTRUCTION DATA LADDER DIAGRAM:

00000 LD 00000
00001 OR 01000
00002 AND NOT 00001
00003 OUT 01000
00004 LD 00003
00005 AND NOT 00004
00006 OUT 01001
00007 LD 00005
00008 LD NOT 00006
00009 CNT 011
#0011
00010 LD CNT 011
00011 OR NOT 00002
00012 AND 00009
00013 OUT 01003
00014 FUN 01
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4. Write a mnemonic program for the Ladder Logic below.

ADDRESS INSTRUCTION DATA

00000
00001
00002
00003
00004
00005
00006
00007
00008
00009
00010
00011
00012
00013
00014
00015
00016
00017
00018

COUNTER
1. Write the mnemonic code for the ladder diagram below, indicate also operations (operating
circuit) for the ladder diagram.

00000
CNT
003 ADDRESS INSTRUCTION DATA
00000
00001 #0010 00001
00002
00003
CNT 03 01000 00004
00005
00006
00007
END
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2. Write the ladder diagram and mnemonic code use the chart below:

1 2 3

1 2 3 4 5 6 7 8 9 10
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TIMER

1
5s

5s

2
10s
10s

3
5s
10s
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4
5s 5s
5s

5. ON/OFF delay circuit

Motor (10000) will start 5 second after start push button (00000) being pressed, and it will stop 5 second
after stop push button being pressed.
Input / Output Assignment

Input assignment Devices Output Assignment Devices

Ladder Diagram Mnemonic code

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6. Proximity Sensor Detection

When the Sensor 1 (S1) scans the metal object 5 (five) times. Pilot Light (L1) will be ON
condition and Pilot Light L2 will be OFF condition. After 5 (five) seconds Pilot Indicator L2 will
be ON and L1 will be OFF and similarly counter will be reset.

Object

Conveyer belt

S1
L1 L2

Input / Output Assignment

Output Assignment Devices

Input assignment Devices

Ladder Diagram Mnemonic code

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7. Traffic Light System.

When the Sensor 1 (S1) scans, immediately Pilot Light (L1) will be ON and after five (5) seconds Pilot
Light (L2) will be ON and L1 will be OFF. Then after five (5) second L3 will be ON and L1 and L2 will
be OFF. This condition will be continuously when S1 will scan.

L3

L2

L1

Input / Output Assignment

Output Assignment Devices

Input assignment Devices

Ladder Diagram Mnemonic code

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PRIORITY DETERMATION DESIGN

Directive questions:
1. After the host finishes reading the question.
2. Three players are racing for the most pressing push button in front of them early to
answer questions from host.
3. Buzzer will sound for 10 seconds after pressing the push-button Player.
4. The indicator lights are lit in front of players and just hose will be "reset"

I/O Assignment

DEVICE DATA
PUSH BUTTON 1
PUSH BUTTON 2
PUSH BUTTON 3
RESET
BUZZER
INDICATOR 1
INDICATOR 2
INDICATOR 3
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LADDER DIAGRAM:
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MNEMONIC CODE
ADDRESS INSTRUCTION DATA
00000
00001
00002
00003
00004
00005
00006
00007
00008
00009
00010
00011
00012
00013
00014
00015
00016
00017
00018
00019
00020
00021
00022
00023
00024
00025
00026
00027
00028
00029
00030
00031
00032
00033
00034
00035
00036
00037
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EQUIPMENT AND MATERIALS REQUIRED

1. PLC 1
2. PC/Notebook 1
3. Double Acting Cylinder 1
4. 5 / 2 Way Double Solenoid Valve 1
5. Push Button 2
6. Magnetic Sensor @ Limit Switch 2
7. Indicator 2

Cylinder A a0 a1

Y1 A B Y2

R S
P
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QUESTION:

1. Sequence: A+ A-

 START PUSH BUTTON: When press start push button indicator 1 will be always “on”

 STOP PUSH BUTTON: When press push button stop indicator 2 will be blink-blink “2
sec”

2. Please draw displacement – step diagram follow the sequence.

DISPLACEMENT - STEP DIAGRAM

Example:
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I / O ALLOCATION LIST

INPUT

NO INPUT DEVICES SYMBOL ADDRESS REMARKS

OUTPUT

NO OUTPUT DEVICES SYMBOL ADDRESS REMARKS

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Circuit diagram, electrical

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LADDER DIAGRAM
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LADDER DIAGRAM
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EQUIPMENT AND MATERIALS REQUIRED

1. PLC 1
2. PC/Notebook 1
3. Double Acting Cylinder 3
4. 5 / 2 Way Double Solenoid Valve 2
5. 5 / 2 Way Single Solenoid Valve 1
6. Push Button 2
7. Magnetic Sensor @ Limit Switch 6

Cylinder A a0 a1 Cylinder B b0 b1

Y1 A B Y2 Y3 A B Y4

R S
R S P
P
Cylinder C C0 C1

Y5 A B

R S
P
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QUESTION:
A bending press is used to form sheet metal. The sheet metal is to be placed in the press by hand.
When the start button is pressed, cylinder A is to clamp the work piece; then cylinder B is to
move out and bend the work piece and then returns, triggering the forward stroke of cylinder C,
which concludes the bending process before returning to its initial position. When cylinder C is
in its initial position, cylinder A is to release the work piece.

Cylinder B
Initial bending Cylinder A
Clamp

Cylinder C
Secondary bending
bending

DISPLACEMENT - STEP DIAGRAM

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I / O ALLOCATION LIST

INPUT

NO INPUT DEVICES SYMBOL ADDRESS REMARKS

OUTPUT

NO OUTPUT DEVICES SYMBOL ADDRESS REMARKS

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Circuit diagram, electrical

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LADDER DIAGRAM
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LADDER DIAGRAM
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PERALATAN DAN BAHAN YANG DIPERLUKAN

1. PLC 1
2. Console 1
3. Double Acting Cylinder 4
4. 5 / 2 Way Double Solenoid Valve 2
5. 5 / 2 Way Single Solenoid Valve 2
6. Push Button 2
7. Magnetic Sensor @ Limit Switch 8

Cylinder A a0 a1 Cylinder C c0 c1

Y1 A B Y2 Y3 A B Y4

R S
R S P
P

Cylinder B1 b0 b1 Cylinder B2

Y5 A B Y5 A B

R S R S
P P
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QUESTION
The parts are loaded by hand. Cylinder A clamps. The two cylinders B push the rivets in and
hold them firmly. Cylinder C produces the second half – round head. The completed parts can be
removed by hand.

Cylinder A

Cylinder B

Cylinder B

Cylinder C

DISPLACEMENT - STEP DIAGRAM

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I / O ALLOCATION LIST

INPUT

NO INPUT DEVICES SYMBOL ADDRESS

OUTPUT

NO OUTPUT DEVICES SYMBOL ADDRESS

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Circuit diagram, electrical

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LADDER DIAGRAM
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LADDER DIAGRAM
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Problem description:
The drill on a drilling unit is monitored by means of a drill breakage sensor (B1).If the drill is broken, the
sensor interrupts the circuit. A buzzer (H1) is to sound in this event. The buzzer can only be switched off
via push button S1.

Positional sketch:

1. Drawing up the circuit diagram and assembling the equipment

Complete the electrical circuit diagram and enter the input and output addresses available for your PLC.
Circuit diagram, electrical
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2. Declaration of PLC program variables

Declare the variables required in the PLC program:

Designation Data type Address Comment

1. Formulate the solution of the control task in one of these languages:

Function block diagram (FBD)
Ladder diagram (LD)
Instruction list (IL)
Structured text (ST)
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