Nettur Technical Training Foundation: Programmable Logic Controller Lab W /CP15 /7516

NETTUR TECHNICAL TRAINING FOUNDATION
DIPLOMA IN MECHATRONICS – CP15
WORK INSTRUCTION
FOR
PROGRAMMABLE LOGIC CONTROLLER LAB
W /CP15 /7516
SEMESTER V
SUBJECT CODE: CP 00 05 08
COMPILED BY: RAHUL V A APPROVED BY:Mr.R. AYYAPPAN

TTC COURSE CO-ORDINATOR, CP15
Rev.4 RELEASE – JUNE 2016
NTTF _ CP 15_ WORK INSTRUCTION. PROGRAMMABLE LOGIC CONTROLLER LAB_JUNE 2016_ Page 1
DETAILED SYLLABUS
FOR
PROGRAMMABLE LOGIC CONTROLLER LAB
SUBJECT CODE CP 00 05 08*
SEMESTER 5
HOURS PER SEMESTER 80
REV. NO. 4
REV. DATE 12- 05- 2016
MAJORTOPICS
SL.No Major Topics Time Allotted
1. Basic programming Hrs 20h
2. Digital programming 6h
3 Familiarization of different timers 14h
4 Familiarization of different counters 16h
5. Familiarization of analog and jump function 08h
6 Any real time application projects. 8h
7 Familiarization of different programmable controller 8h
Total Hours: 80h
SUBJECT CONTENT
Sl.No TOPICS Hrs.
1.0 Basic Programming 20
1.1 1.1 Design a PLC Program for the following condition 2

1.2 Switch – ON Light – Glows
Switch – OFF Light - Puts Off
1.2 Design a program DOL Starter for motor. 2
1.3 Design a program for forward – Reverse – stop with mutual interlock. 2
1.4 Design a program for forward – Reverse – stop with direct reversal. 2
1.5 Design a program for start – stop – jog. 2
1.6 Design an Alarm system. 2
1.7 Design a program for motor start & stop by using Set & Reset Function 2
1.8 Design a program for switching on & off of light using Flip-flop 2
1.9 Design a program that there are three machines, each with its own start and 2
stop functions, only one may run at a time
1.10 Design a program that the circuit consist of two start and stop button,when 2
any one button is pressed ,the motor runs , even it is released and the stop
button is used to stop the motor
2.0 Digital Programming 06
2.1 Design a program 2

(a) AND, OR and NOT gate.
(b) NAND and NOR gate.
(c) Ex-or and Ex-Nor Gate
2.2 Design a conveyer control system in which conveyer ‘C’ is to run when Any 2
one of the 4 inputs is ON & it should stop when any one of the 4 other inputs
are ON.
2.3 Write a program that a fan ‘P’ will run the equation is getting satisfied. 1
(I1) (I2+I3) (I5.I6) = P
2.4 Draw a program file for following expression 1
(L+M+N) + (Q.R) R = S
3.0 Familiarization of different Timers 14
3.1 1) Design a program to start a machine after 5 seconds. 3
2) Design a program to start 3 machines consequently after 3 seconds
3.2 1) Design a program, when input A is on, Light L should on for 10 seconds, 3
later it will off
2) ) Design a program, when input A is on, Light L should on for 10 seconds,
later it will off for 2 seconds and again it will turn on continuously, until a stop
button is pressed
3.3 Design a program for a grinding operation of a metal part, the coolant flow 2
on the part must be on for an interval before the grinding process starts.
When the process circuit is turned on, the coolant motor is turned on. 8
seconds later the grinding process starts.
3.4 Design program, When a switch is turned on, C goes on immediately and D 2
goes on 9 sec later. Opening the switch turn both C and D off
3.5 A wood saw, W, a fan F and a lubricating pump P, all go on when a start 2
button is pressed. A stop button stops the saw only. The fan has to run
additional 5 sec to blow off the chips away. The lube pump is to run for 8sec
after the shutdown of W.
3.6 Write a program, to flash an LED with 1 sec interval (1 second off and 2
1second on ) continuously until a stop button is pressed
4.0 Familiarization of different Counters 16
4.1 When a sensor had sensed 5 bottles the machine should ON. 3
4.2 Design a program such that the output indicator should go on when 6 of part 3
C and 8 of part D are on the conveyor
4.3 After the count of 15 from a sensor , a paint spray is to run for 25 sec 3
4.4 Design a program such that Counting starts 10 min after the process starts. 3
4.5 Write a program, when a machine M goes on, either when A goes on upto 2
11 or when B goes on upto 16, stop button is to reset the entire process
4.6 Write a program, An indicating light is to go on, when a count reaches 23 2
and the light goes off, when a count reaches 31
5.0 Familiarization of analog and jump function 8
6.0 Any Real time application projects 8
7.0 Familiarization of different programmable controller 8
7.1 Products, Features, Addressing methods of 8
1.Siemens
2.Mitsubhishi
3.ABB
4.Allen-Bradly
GENERAL SAFETY RULES
Cleanliness
Cleanliness is very important aspect while doing any kind of work. It has been
scientifically proven that a clean working environment enhances your work out put.As
soon as you reach your work place clean it and arranges all the equipments onyour
table in a proper manner so that all your equipment is easily accessible.
Equipment check
Before starting your experiment make sure that your equipments are present on
the table and check if all their knobs and push buttons are in good condition and fixed
properly on the equipment. Then you should check if the equipments are in proper
condition or not. If the equipments are not ok make arrangements to send the
equipments for maintenance as soon as possible
Component check
Before starting your experiment make sure that components are present on the
table. Then you should check if the components are in good condition using aCRO/multi
meter. If they are in good condition fix them properly on the bread board.
Behavior
1. Do not run in the laboratory.

2. No yelling, no loud noises or no swearing allowed.
3. Do not engage in horseplay of any kind.
4. Do not operate any electronic devices without permission.
Safety check
The most important factor of working with electronics is safety, not only for
yourself, but also for everyone around you .Check if your table mounted sockets are in
good condition and none of them are loosely fixed .If required then make adequate
arrangements to fix them . Follow all safety guide lines.
All sensible people take interest in their health and safety. Electricity cannot be
seen, heard or smelt. But it is very rapid in action and its effect may be fatal.
An electric current flowing through the body causes electric shock. The degree of
shock depends upon the current flowing (which depends on the voltage) and the
electrical resistance of the body, factor that varies in different persons and is much
reduced if the skin is wet.
Shocks are possible from voltages as low as 15V and 20-25V may cause pain.
Shocks are usually not fatal below about 70V AC. The normal mains supply 0f 240V
AC and currents of 25-30mA or more are the most common cause of serious and fatal
shocks. A current passing through the body causes contraction of muscles. This may
result in the person being unable to let go of the equipment.
The voltage supplies encountered in electronic equipment in general range from

voltages as low as 10V to as high as 25KV or more, thus great care should be
exercised.
The designations of voltages of different ranges are as follows:
Low Tension (L.T) - Below 250V
Medium Tension (M.T) - 250 - 650V
High Tension (H.T) - 650 – 3000V
Extra High Tension (E.H.T) - Above 3000V
When working on high voltages, it is prudent to use only one hand, the safest
place for the other being in your pocket. If a shock is received it is then across your
hand or between fingers, which is not usually serious. Do not hold the chassis or the
frame of test equipment with one hand whilst probing live conductors with the other; any
shock received is now between hands and is much more serious because the current
passes near the heart. Always work on a rubber mat, never on a concrete floor (a good
conductor to earth). Floor covering in a workshop should be made of an insulating
material & benches constructed of insulating material.
E.g.wood, Formica or leno tops. Also the bench top should be covered with an insulator.
Effects of Electricity on the Human Body
The brain via very small electrical impulses controls all muscles .When an
external electrical current of value greater than that generated by brain passes through
the body; it effectively takes over control of the muscles
There are 3 major consequences of these:
1. First a current passing through the heart (which is itself a muscle) may cause it to
cease its pumping action, the commands from the brain being overwhelmed. Thus, a
person suffers from a cardiac arrest.
2. The second consequence may be that a person becomes stuck to the live conductor.
This occurs when a person touches a live conductor with his hand and the polarity is
such that the signal to the muscles in the hand is effectively saying contract. The hand
now grabs the conductor and the person is unable to let go, ever though they may try to
do so; the small let go command from the brain being totally swamping. Left in contact
with the conductor, heat is generated and the person may receive severe burns,
especially if the voltage is very high (>50V).
3. The third consequence may be that, on touching the live conductor the polarity ofthe
current commands in the muscle in the arm to reflex. The person appears tothrow
himself or herself from the conductor, although he/she has no control over thisaction. A
danger with this is that there are no guarantees where the person will land& serious
physical injury may result.
In both second and third cases, cardiac arrest could occur if the current takes
path through the heart and the value of current is high enough.
General rule is: Current Kills, voltage burns
A current of less than one amp is enough to kill a person & many safety cutouts
are designed to trip at 30mA. (0.03 Of 1 Amp).The greatest electrical shock hazard for
electronic service engineers is on when working on live equipment that has a high
voltage DC source (found in TV’s , microwaves & large audio amplifiers) especially if the
current path is around the chest. Main supplies have an earth terminal which is
connected to the neutral pole at the power station.
Recommended first aid action
Symptoms Action
Shock Move casualty as little as possible. Loosen all tight cloths (belts, Ties,
(suffered by etc.). If possible lay him/her down and raise legs overhead Level. Keep
Most casualty warm with blankets or coats. Reassure Casualty. Send for
casualties) medical help.
Burns Immerse burnt areas in cold water. Treat for shock. Do not remove burnt
clothing. Do not apply oil or grease to burns. Cover burns with clean dry
cloth. Arrange for medical help if burns are severe
Cuts and Small cuts and grazes should be washed in running water and
Grazes addressing applied. Applying pressure to the wound should stop more
severe bleeding of deep cuts. Treat for shock. Call for medicinal
assistance.
Bruising Applying ice bag or damp cloth until the pain stops
Falling Make causality lie still. Check for obvious injuries. If necessary treat for
shock. If in doubt call for medical help.
Contact Wash affected area with water. Cover with dry dressing. Get casualty to
with hospital
chemicals
Contact Remove casualty from gas – laden or oxygen – deficient area. Loosen
with tight clothing. Apply resuscitation, if breathing has stopped.
toxic fumes
It is clearly essential that prompt action be taken in the case of severe electric
shock.
The following procedure must be adopted.
1. Do not touch the casualty with hands.

2. Switch off supply.
3. If this is not possible, pull the casualty away from contact using insulating material,
i.e. a scarf, piece of wood, newspaper etc.
4. If heart or breathing or both have stopped, apply resuscitation and cardiac massage
until the casualty recovers.
5. Treat for burns.
6. Check for other injuries, treat as necessary.
7. Treat for shock.
8. Call for medical assistance.
Note: If possible, get a third person to call for medical help as soon as the casualtyis
discovered.
Methods of resuscitation:
Cardiopulmonary resuscitation (CPR)Place victim flat on back of a hard surface
A. Open the airway, if unconscious and not breathing
B. Breathing. Look, listen and feel for breathing. If not breathing give mouth tomouth
resuscitation.
C. Close nostrils with fingers and blow into mouth. Make sure there is no air leakand
the chest expands. Give 2 normal breaths.
D. Perform chest compressions
E. Place both hands on the lowest third of breastbone. Depress sternum 1½-
1inches at a rate of 80 compressions per minute. Alternate 2 breaths. Check
pulse after 1 minute and every 3 minutes.
UNIT -1
BASIC PROGRAMMING
Exp: No.1 .1 Switching Light On – Off
AIM
To design a ladder diagram for the following condition
Switch ON - light glows
Switch OFF- light off
APPARATUS REQUIRED:
1. Siemens S7 200 PLC
2. Step 7 Micro/win software
3. RS 485 communication cable
4. Personal computer with WINDOWS OS
THEORY:
1. When normally open (NO) contact I1 is open, the output coil Q1 will not be
active.
2. Whenever the NO contact I1 is closed the output coil Q1 will be active.
3. The normally open contact (NO) I1 acts like an input switch to control the output
light Q1.
PROCEDURE:
1. Design the ladder diagram in STEP 7 MICROWIN application software
2. Upload the program to the PLC
3. Execute the program by using input switches in the input module and verify the
output from output module.
RESULT
Thus the ladder diagram for switch ON – OFF was designed and executed
Switching Light On – Off
PLC WIRING CIRCUIT
Fig No.1
LADDER DIAGRAM
Expt No 1.2 DOL Starter For Motor

AIM
To design a program DOL starter for motor
APPARATUS REQUIRED
2. Step 7 Microwin software
THEORY
1. To make a 3 phase motor to start and stop, the output of the PLC Q1 is
connected to therelay R.
2 The startpush button I1 is used to start the motor.As the motor starts, the
continuous Signal to the motor is bypassed through the latchQ1 and the relay will
get energized And activate the contactor of R, Y, B phases to run the motor.
3 The stop push button I2 is used to stop the motor. When this button is pressed
the relay getdenergized and deactivate the contactor of R, Y, B phases to stop the
motor.
PROCEDURE
3. Execute the program by using input switches in the input module and verify the
output from output module.
RESULT
Thus the program for DOL starter was designed and executed.
DOL Starter For Motor

PLC WIRING CIRCUIT
LADDER DIAGRAM
Expt No 1.3 Forward – Reverse – Stop With

Mutual Interlock
AIM
To design a program for forward –reverse-stop with mutual interlock.
APPARATUS REQUIRED
THEORY
1. To make a 3 phase motor to run in both directions two relays R1 and R2 are
connected to the output of the PLC Q1 and Q2 respectively. This control the R,
Y, B phases of the motor.
2. To run the motor in forward direction I1 switch is pressed. As the motor starts,
the continuous signal to the motor is bypassed through the latch Q1. So the
relayR1 get energized and activate the contactor 1of R, Y, B phases to make
the motor to run in forward direction.
3. When the motor is running in the forward direction a normally closed switch
I2gets opened and the relay R2 get de-energized.
4. To run the motor in reverse direction I3 switch is pressed. As the motor starts,
the continuous signal to the motor is bypassed through the latch Q2. So the
relay R2 get energized and activate the contactor 2 of Y, R, B phases to make
the motor to run in reverse direction.
5. When the motor is running in the reverse direction a normally closed switch I4
get opened and the relay R1 get de energized.
PROCEDURE
1. Design the ladder diagram in STEP 7 MICRO/WIN application software.
2. Upload the program to the PLC.
3. Execute the program by using input switches in the input module and verify
the output from output module.
RESULT
Thus the program for forward-reverse-stop with mutual interlock is designed and
executed.
Forward – Reverse – Stop with Mutual Interlock
LADDER DIAGRAM
Expt No 1.4 Forward – Reverse – Stop With Direct
Reversal
AIM
To design a program for forward-reverse-stop with direct reversal
APPARATUS REQUIRED
THEORY
1. To make a 3 phase motor to run in both directions two relays R1 and R2 are
connected to the output of the PLC Q1 and Q2 respectively. This control the R,
Y, B phases of the motor.
2. To run the motor in forward direction I1 switch is pressed. As the motor starts,
the continuous signal to the motor is bypassed through the latch Q1. Sothe relay
R1 get energized and activate the contactor 1 of R, Y, B phases to make the
motor to run in forward direction.
3. When the motor is running in the forward direction a normally closed switch I2
gets opened and the relay R2 get de-energized.
4. To run the motor in reverse direction I3 switch is pressed. The motor stops
running in forward direction and Q2 coil which is for reverse direction energizes..
5. When the motor is running in the reverse direction a normally closed switch Q4
get opened and the relay R1 get de-energized.
PROCEDURE

3. Execute the program by using input switches in the input module
RESULT
Thus the program for forward – reverse – stop with direct reversal is designed
and executed.
Forward – Reverse – Stop with Direct Reversal
LADDER DIAGRAM
Expt No 1.5 Start – Stop – Jog

AIM
To design a program for forward –reverse-stop with mutual interlock.
APPARATUS REQUIRED
THEORY
1. Jog function allows the user to manually control the motor during
maintenance and for making adjustments in sequence operation.
connected to the relay R.
3. The start push button I1 is used to start the motor. As the motor starts, the
continuous signal to the motor is bypassed through the latch M1 and the relay
will get energized and activate the contactor of R, Y, B phases to run the
motor.
4. The stop push button I2 is used to stop the motor. When this button is
pressed the relay get de-energized and deactivate the contactor of R, Y, B
phases to stop the motor.
5. I3 is used to jog the motor.
PROCEDURE
RESULT
Thus the program for program for forward –reverse-stop with mutual interlock is
executed.
Start – Stop – Jog
LADDER DIAGRAM
Expt No 1.6 Alarm System

AIM
To design an alarm system.
There are four inputs in the Alarm System.
1. If one input is ON, No outputs should be ON.
2. If two inputs are ON, A red pilot light should be ON.
3. If any three inputs are On, A Siren should be ON.
4. If all the four inputs are ON, Main alarm should be ON.
APPARATUS REQUIRED
THEORY
1. In alarm system the four input switches represent the fire sensors and it have
three outputs Pilot switch, Siren and Alarm.
2. The circuit is designed such a way that if any one of the sensors I1, I2, I3, and
I4are ON the outputs will not get activated.
3. If any two sensors I1andI2 or I1andI3 or I1andI4 or I2andI3 or I2andI4 or I3andI4
are sensed the alternate normally open switch get closed and the Red Pilot
lightwill be ON.
4. If any three sensors I1, I2, I3 or I1, I2, I4 or I2, I3, I4 are ON the siren as well as
red pilot light will be ON.
5. If all the sensors are ON the Alarm, siren and red pilot light will be ON.
PROCEDURE
1 Design the ladder diagram in STEP 7 MICROWIN application software
2 Upload the program to the PLC
3 Execute the program by using input switches in the input module
RESULT
Thus the alarm system is designed and executed.
Expt No 1.6 Alarm System
LADDER DIAGRAM
Expt No 1.7 Set & Reset Function For Motor
Start & Stop
AIM
To design a program for motor start & stop by using Set & Reset Function.
APPARATUS REQUIRED
THEORY
connected to the relay R.
2. The switch I1 is used to start the motor when this switch is ON, the set coil
Q0.0 gets activated and the motor get started. As the motor starts, the
continuous signal to the motor is bypassed through the latch Q1. So the relay
gets energized and activates the contactor of R, Y, B phases to run the motor.
3. The stop switch I2 is used to stop the motor. When this switch is ON the reset
coil gets activated so the relay get de-energized and deactivate the contactor
of R, Y, B phases to stop the motor.
PROCEDURE
RESULT
Thus the programs for motor start& stop by using Set & Reset Function is
designed and executed.
Set & Reset Function For Motor

Start & Stop
LADDER DIAGRAM
Expt No 1.8 Design Ladder Diagram Using

FlipFlop(D Flip Flop)
AIM
To Design a Ladder diagram for following condition Using Flip Flop
(i) When switch- pressed, output light- glows.
(ii) When switch – again pressed, output light – puts off.
THEORY
For ON/OFF the lights we are going for the D Flip Flop as it is having only one
input along with the clock signal for enable the Flip Flop.
When we are applying a HIGH signal to the input, the output Q produces a HIGH
output signal. When the input condition changes to LOW, the same time output will be
LOW.
D Flip Flop
D
G1 Q
G3
P
T
G4 Q’
G2
Truth Table For D Flip Flop
D CLK Q Q’
1 HIGH 1 0
0 HIGH 0 1
LADDER DIAGRAM
RESULT
Thus the Ladder diagram had created for the function for D Flip Flop
Expt No 1.9
program that there are three machines, each with its own start and stop
functions, only one may run at a time.
AIM
To design a program that there are three machines, each with its own start and
stop functions, only one may run at a time.
APPARATUS REQUIRED

THEORY
There are three machines each one is having its own start and stop buttons, actuating any one
input device, output has to actuate, if trying to actuate the other output is not possible because
the circuit is in interlock condition.
PROCEDURE
RESULT
Thus the program is designed and executed.
LADDER DIAGRAM
Expt No 1.10 a program that the circuit consists of two start and two
stop buttons, when anyone button is pressed, the motor runs, even it is released
and the stop button is used to stop the motor.
AIM
To design a program that the circuit consists of two start and two stop buttons,
when anyone button is pressed, the motor runs, even it is released and the stop button
is used to stop the motor.
APPARATUS REQUIRED

THEORY
The output is to ON, when anyone of the input device is actuated, the output is on using latching
circuit, and output has to go off when stop button is pressed.
PROCEDURE
RESULT
Thus the program is designed and executed.
LADDER DIAGRAM
UNIT 2
DIGITAL PROGRAMMING
Expt No.2.1 Implementation Of Gates Using PLC

AIM
To design a program
(a). AND, OR, and NOT gate.
(b). NAND and NOR gate.
(c) Ex-or Gate and Ex-Nor Gate
APPARATUS REQUIRED
THEORY
i. AND Gate
In AND gate logic when both inputs are high the output will be high and for all
the inputs the output will be low.
ii. OR Gate
In OR gate the output will be high if all the input or anyone of the input is high
and will be low when both outputs are low.
iii. NOT Gate
The output of the NOT gate is inverted so this gate is called inverter gate.
The output of this gate will be high when the input is low and vice versa.
iv. NAND Gate
1. NAND gate is the combination of AND and NOT gate.
2. The output of the NAND gate is low only when both inputs are high
v. NOR Gate
1. NOR gate is a combination of OR and NOT gate.
2. The output of NOR gate is high only when both the inputs are low.
vi. EX-OR Gate
1. In EX-OR gate logic the output is high when the input is an odd multiple of
one’s.
2. In remaining all conditions the output is low.
vii. EX-NOR Gate
1. EX-NOR Gate is a combination of EX-OR gate and NOT gate.
2. In EX-NOR gate logic the output will high when both the inputs are same
3. In remaining all conditions the output is low.
PROCEDURE
RESULT
Thus the program for AND, OR, NOT, NAND, NOR, EX-OR, EX-NOR are
designed and executed.
Implementation Of Gates Using PLC (Expt No.2.1 )

1.) AND GATE
TRUTH TABLE
Input 1 Input 2 Output

0 0 0
0 1 0
1 0 0
1 1 1
LADDER DIAGRAM
2.) OR GATE
TRUTH TABLE
0 0 0
0 1 1
1 0 1
1 1 1
LADDER DIAGRAM
3.) INVERTER or NOT GATE
TRUTH TABLE
Output
Input
1 0
0 1
LADDER DIAGRAM
4) NOR GATE
TRUTH TABLE Input 1 Input 2 Output

0 0 1
0 1 0
1 0 0
1 1 0
LADDER DIAGRAM
5) NAND GATE

TRUTH TABLE
0 0 1
0 1 1
1 0 1
1 1 0
LADDER DIAGRAM
6) EX-OR GATE

0 0 0
0 1 1
1 0 1
1 1 0
TRUTH TABLE
LADDER DIAGRAM
7) EX-NOR GATE Input 1 Input 2 Output
0 0 1
0 1 0
1 0 0
1 1 1
TRUTH TABLE
LADDER DIAGRAM
Expt No.2.2 Conveyer Control System

AIM
To design a conveyer control system in which conveyer ‘C’ is to run when any
one of the 4 inputs is ON & it should stop when any one of the 4 other inputs are ON
APPARATUS REQUIRED
THEORY
1. In conveyor control system I1.4, I1.5, I1.6 and I1.7 are normally open switches
are connected in parallel. When these switches are ON the conveyor motor starts
to run.
2. The normally closed switches I1.0, I1.1, I1.2, and I1.3are connected in series
used to stop the conveyor. When these switches are ON the whole circuit gets
open so the motor connected to the output stops.
PROCEDURE
RESULT
Thus the conveyor control system is designed and executed.
Conveyer Control System (Expt No.2.2)
LADDER DIAGRAM
Expt No.2.3 Fan On – Off Function
AIM
To write a program that a fan ‘P’ will run the equation is getting satisfied.
(I1) (I2+I3) (I5.I6) = P
APPARATUS REQUIRED
THEORY
1. The output fan is switched ON/OFF using digital logic.

2. I1, I5, I6 are OR logic inputs and are connected in series to the output fan. The
output will be ON only when all these inputs are activated.
3. I1 and I2 are AND logic inputs and are connected in parallel to the output fan.
The output will turn ON if any one of this output is activated.
PROCEDURE
RESULT
Thus the program for fan is designed and executed.
LADDER DIAGRAM
Expt No.2.4 Solving Expression
AIM
To draw a program file for following expression
(L+M+N) + (Q.R) R = S
APPARATUS REQUIRED
THEORY
1. The output S should be ON based on different digital inputs, L, M, N are
designed using OR logic. M is the complement input so it is represented by
normally closed switch.
2. Q and R inputs are dot product so it is designed by OR gate. The whole circuit is
complemented so the closed switch is used for the memory address location.
3. Finally the whole circuit is controlled using OR logic R. So this switch acts as an
Emergency stop.
PROCEDURE
RESULT
Thus the program the given expression is designed and executed.
Logic Expression
(L+M+N) + (Q.R) R = S
LADDER DIAGRAM
UNIT – 3
Familiarization Of Different Timers
Expt No.3.1. Start a machine using timers
AIM
1.To design a program for following condition
 Start a machine after 5 seconds.
2. To design a program for following condition
Start 3 machines consequently after 3 seconds
APPARATUS REQUIRED
THEORY
1. Time delay is given by Td=Preset (PT)*Time Base (TB).

a. For e.g. If T100 timer is selected then,
b. Preset (PT) =500
c. Time base (TB) =10 ms
d. I.e. Time delay, Td= 500*10=5000 ms
2. Input I1 is the input to the timer when this switch is ON timer starts running.
When the timer reaches 5000 ms the T100 normally open switch gets closed and
output Q1.0 activated.
3. The timer will run continuously, to stop the timer a normally closed switch is
connected to the timer input. So that it opens when the Q1 get activated.
PROCEDURE
RESULT
Thus the program for controlling the motor using timer is designed and executed.
LADDER DIAGRAM
Expt No.3.2
AIM
To design a program for following condition
 When input A is on, Light L should on for 10 seconds later it will off.
 Design a program, when input A is turned on, light should be on for
10seconds, later it will off for 2 seconds and again continuously on until a
stop button is pressed.
APPARATUS REQUIRED

PROCEDURE
RESULT
LADDER DIAGRAM
Expt. No: 3.3
AIM
Design a program for a grinding operation of a metal part, the coolant flow on
the part must be on for an interval before the grinding process starts. When the
process circuit is turned on, the coolant motor is turned on. 8 seconds later the
grinding process starts.
APPARATUS REQUIRED
THEORY
1. When the process starts coolant will be on first & after 8 seconds the grinding will
be starts.
Coolant Motor : Q1
Grinding Motor: Q2.
2. To stop the timer a normally close switch is connected to the input of timer.
PROCEDURE
RESULT
LADDER DIAGRAM
Expt . No: 3.4
AIM
Design program, when a switch is turned on, C goes on immediately and D

goes on 9 sec later. Opening the switch turns both C and D off.
APPARATUS REQUIRED
THEORY
1. When the process starts C will goes immediately on and D will be on after 9
second.
2. D will be start working with the help of timer.
3. The start switch will not be latched in order to off C & D after releasing start
switch.
PROCEDURE
RESULT
Thus the program for controlling C&D using timer is designed and executed.
LADDER DIAGRAM
Expt . No: 3.5
AIM
A wood saw, W, a fan F and a lubricating pump P, all go on when a start button is
pressed. A stop button stops the saw only. The fan has to run additional 5 sec to
blow off the chips away. The lube pump is to run for 8sec after the shutdown of W
APPARATUS REQUIRED
THEORY
1. When the process starts all the machines are started together.
2. The each machine is latched separately for the satisfaction of the demand.
3. Two timers are used for controlling the machines.
PROCEDURE
RESULT
LADDER DIAGRAM
EXPT NO:3.6
AIM
Write a program to flash an LED WITH 1 SEC INTERVAL continuously until a stop button is
pressed
APPARATUS REQUIRED
THEORY
1. When actuating a start button LED has to blink continuously until a stop
button is pressed.
PROCEDURE
RESULT
Thus the program for blinking an LED is done and executed.
LADDER DIAGRAM
UNIT – 4. Familiarization Of Different Counters
Expt.No.4.1
AIM
To design a ladder diagram when a sensor had sensed 5 bottles the machine
should ON.
APPARATUS REQUIRED
THEORY
1. Counters are used in PLC’s to count the number of parts. Here we are using UP
COUNTER for counting the number parts.
2. The input I1.0 will be a proximity sensor to sense number of object. As the
sensor senses the parts the counter starts counting and when the counter
reaches 5 the output gets ON.
3. The normally open switch I1.1 is used to reset the counter. By providing a NO
switch with the address of output the counter resets automatically.
PROCEDURE
RESULT
Thus the program using count up timer is designed and executed.
LADDER DIAGRAM
Expt.No.4.2.
AIM
Design a program such that the output indicator should go on when 6 of part C
and 8 of part D are on the conveyor.
APPARATUS REQUIRED
THEORY
1. Counters are used in PLC’s to count the number of parts.
2. The input I1&I2 will be proximity sensors to sense number of object. As the sensor
senses the parts the counter starts counting and when the 1st counter reaches 6 and
the second counter reaches 8, then the output gets ON.
3. output the counter resets automatically.
PROCEDURE
o Design the ladder diagram in STEP 7 MICROWIN application software
o Upload the program to the PLC
o Execute the program by using input switches in the input module
RESULT
LADDER DIAGRAM
Expt.No.4.3
AIM
After the count of 15 from a sensor, a paint spray is to run for 25 sec.
APPARATUS REQUIRED
THEORY
1. Counters are used in PLC’s to count the number of parts. Here we are using timer
to off the spray painting.
2. The input I1.0 will be a proximity sensor to sense number of object. As the sensor
sense the parts the counter starts counting and when the counter reaches 15 then
the output gets ON.
3. Output the counter resets automatically.
PROCEDURE
1 .Design the ladder diagram in STEP 7 MICROWIN application software

RESULT
LADDER DIAGRAM
Expt.No.4.4
AIM
Design a program such that Counting starts 10 min after the process starts.
APPARATUS REQUIRED
 Siemens S7 200 PLC
 Step 7 Microwin software
 RS 485 communication cable
 Personal computer with WINDOWS OS
THEORY
1. We are using timer to on the counter after 10 minutes.
2. The input I.4 will be a proximity sensor to sense number of object.
3. The normally open switch I1.1 is used to reset the counter. By providing a NO
switch with the address of output the counter resets automatically.
PROCEDURE
RESULT
Thus the program using counter&timer is designed and executed.
LADDER DIAGRAM
Expt.No.4.5
AIM
Design a program such that a machine M goes on, either when A goes on upto
11 or when B goes on upto 16, stop button is to reset the entire process.
APPARATUS REQUIRED
PROCEDURE
RESULT
Thus the program using counter is designed and executed.
LADDER DIAGRAM
Expt.No.4.6
AIM
Design a program such that an indicating light is to go on, when a count reaches
23 and the light goes off when a count reaches 31.
APPARATUS REQUIRED
PROCEDURE
RESULT
Thus the program using counter is designed and executed.
LADDER DIAGRAM
UNIT – 5
Familiarization of Analog and jump function
Expt.No.5.0
AIM
Compare two analog input, the output should come such that when input 1 is less
than or equal to analog input 2.
APPARATUS REQUIRED
THEORY
1. We are using two analog input function for accessing analog inputs
2. The input AI1 and AI2 are connected to analog inputs.
3. An analog comparator function is used to compare these two analog functions
PROCEDURE
RESULT
Thus the program using analog function are designed and the output is verified.
LADDER DIAGRAM
Expt. No. 5.1.
AIM
Familiarization of jump function.
APPARATUS REQUIRED
THEORY
1. We are using jump function with no return
2. Label is has to placed where the function has to jump
3. The execution sequence is transferred to label after enabling the jump function
PROCEDURE
RESULT
Thus the program using analog function are designed and the output is verified.
LADDER DIAGRAM
UNIT - 6
Real Time Application Project
AUTOMATIC CAR WASHING SYSTEM
AIM
To design an automatic car washing system using PLC.
THEORY
1. Switch on the master ON switch. It will turn ON the conveyer mechanism as
a manual operation.
2. The machine will ON and then the indicator indicates (RED) the status as
car is moving into the platforms carried by the conveyer belt.
3. When the car entering to the platform1 then the sensor will senses the
availability of the car.
4. The P1 solenoid will actuate and start spraying the soap water (sprayer 1)
on to the car. As the car moves on, when the car disappears from the
vicinity of the sensor, sensor goes off and hence the soap water sprayer
stops its functioning.
5. When the car is about to reach the platform2 then sensor will sense the
availability of the car and the conveyor stops for 5 Second.
6. At the same instant, motor driven brush will start to rotate. The cleaning
process is done through this platform2. After the delay As the car moves on,
when the car disappears from the vicinity of the sensor, sensor goes off.
Hence the brush driven motor turns off and the car moves to the next
platform.
7. When the car is about to reaches the platform3 then sensor will sense the
availability of the car.
8. Then the P2 solenoid valve will actuate and start spraying (Sprayer2) the
water onto the car. As the car moves on, when the car disappears from the
vicinity of the sensor, sensor goes off and hence the water sprayer stops its
functioning.
9. When the car entering to the next, the sensor will senses the availability of
the car.
10. Then the hot air passes in order to dry the surface of the washed car. As the
car moves on, when the car disappears from the vicinity of the sensor,
sensor goes off and hence the hot air passage stops and finally the car
moves to the exit station.
11. Then the indicator will indicate (GREEN) as car is leaving from the station.
Overall Diagram
D3
D2
M2
M1
D1
R1
R2
R3
RLY1
RLY2
RLY3
+5V
RLY5
RLY4
12V
Q Q Q Q Q
PLC
1. 1. 1. 1. 1.
4 6 7 3 5
OP1
OP2
I0 I1. I1. I1. I0 I0 I0 M

LED1
D5
2.2K
RL
.0 1 2 3 .0 .1 .2
0.1µF
C4
24V
S1
S3
S2
+
Connector
330µF
25V
C3
IN OUT
7824
COM
Gnd
0.1µF
C2
1000µF
45V
C1
+
1N4007 1N4007
1N4007 1N4007
D2
D4
D1
D3
230V/33V AC
T1
PS1 PS2 PS3 PS4

IP1
IP2
Model Design
DC MOTOR WITH
SOAP WATER HOT

WATER
PLATF
PLATF
ORM
ORM 1
2
PROXIMITY
Ladder Diagram
UNIT – 7
FAMILIARISATION OF DIFFERENT PROGRAMMABLE CONTROLLERS
7.1 Products, Features, Addressing methods of
1.Siemens
2.Mitsubhishi
3.ABB
4.Allen-Bradly
1.Siemens
LOGO
LOGO! impresses customers due to the wide variety of possible applications and
it allows the easy implementation of comprehensive applications – last but not least due
to the possibility of selecting from among 38 integrated functions and linking them to up
to 200 blocks. When operating and monitoring, the 4-line backlit display with a
maximum of 32 characters per line ensures a high degree of user-friendliness. The
message text allows the display of text, set points and actual values, bar graphs and
status parameters. Of course, parameters can be adjusted in the message text.
Flexibility is always assured due to the diverse expansion options.
• Different voltages, i. e. 12 V DC, 24 V AC / DC, 115 / 240 V AC / DC – Can be used for
a wide range of applications
• Automatic changeover for configured daylight saving time – Reduces maintenance
overhead
• Password protection – Protects your engineering IP
• 38 integrated, pre-tested functions – No additional devices, such as elapsed time
counter, are required
• Linking of 200 functions is possible – Extensive applications can be implemented
without restrictions
• Eight digital inputs (incl. four AIs at 12 / 24 V DC) and four digital outputs on board
• Display of message texts, action items and current values as well as direct modification
of the values on the display (except for Pure versions)
• Retentive data memory – Protects current values against loss in the event of a power
failure
• Flexibly expandable up to 24 DIs, 16 DOs, 8 AIs and 2 AOs– Protects original
investment– Suitable for a wide variety of applications
• Software LOGO! Soft Comfort V6 for user-friendly generation of control programs on
PC; suitable for a variety of operating systems, such as Windows 95/98, NT 4.0, Me,
2000, XP, Vista, MAC OS X 10.4 with J2SE 1.5.0 and SUSE LINUX 10.0
• Connection facility for remote text display on all 0BA6 basic devices
The highlight of the 0BA7 basic devices is without a doubt the standard Ethernet
interface, as a programming interface and for communicating with other LOGO! 0BA7
basic devices or SIMATIC automation components such as SIMATIC S7 CPUs, HMI
Panels, and PCs.
• A maximum of 9 LOGO!s can be networked
• Data logging
• Standard SD cards as the storage medium
• Program and connection compatible with LOGO! 0BA6
• 400 blocks program memory
• New function blocks Astronomical clock, Average value, Analog filter, Stopwatch and
Min/Max Function
• Editing of „User defined Functions“ (macro function blocks)
• Additional reference options and display features in the function blocks
S7-200 Micro PLC
Description
The SIMATIC S7-200 Micro PLC is in a class by itself:
Exceptionally compact yet remarkably capable – especially with respect to its real-time
performance – it is fast, features great communication options, and comes with easy to
operate hardware and software. But there's more to it than that:
The SIMATIC S7-200 Micro PLC has a consistently modular design – for customized
solutions which are not too large for the present but open-ended enough to be
expanded anytime in the future. All this makes the SIMATIC S7-200 Micro PLC a highly
effective and economical solution for automated control in the compact performance
range.
Area of application
SIMATICS7-200Micro PLC for simple automation tasks
The fields of application of the SIMATIC S7-200 extend from replacement of relays and
contactors up to more complex automation tasks in stand-alone mode, in networks, and
within distributed configurations. The S7-200 also increasingly provides access to areas
in which special electronics was previously developed for economic reasons.
In addition to the comprehensive basic functionality of the five different CPUs, the
modular system technology of the SIMATIC S7-200 offers a wide range of scalable and
specific expansion modules for an extremely high range of functionalities in accordance
with requirements. The S7-200 has been proven worldwide in applications covering all
sectors as a result of its wide range of exceptional features:
CPU 221
Compact CPU for simple automation tasks - The best compact device if you want
to change to an effective solution that performs simple automation tasks very
economically. Also available with an extended temperature range.
CPU 222
Expandable compact CPU for more complex tasks - The capable, compact
package for more complex machines and small system solutions.
CPU 224
CPU for higher communication and computing requirements - The high-
performance CPU for complex tasks that require speed and special communication
capabilities.
CPU 224 XP
CPU for simple drive tasks - The CPU 224 version for convenient implementation
of simple drive tasks – with two interfaces, two analog inputs and one analog output, as
well as two 100-kHz pulse outputs and two high-speed 200-kHz counters.
CPU 226
High-performance CPU for larger technical tasks - The versatile high-performance
CPU for complex automation tasks with expanded inputs and outputs as well as two
RS485 interfaces.
• Benefits
SIMATIC S7-200 delivers consistently economical solutions. The entire system family
features
• powerful performance,
• optimum modularity and
• open communications.
• Small and compact – ideal for any applications where space is tight
• Basic and advanced functionality in all CPU models
• Large program and data memory
• Outstanding real-time response – being in total command of the entire process at
any time means increased quality, efficiency and safety
• Easy-to-use STEP 7-Micro/WIN engineering software – ideal for both beginners
and experts
• Integrated R-S 485-interface or use as system bus
• Extremely fast and precise operational sequence and process control
• Complete control of time-critical processes by time interrupts
S7 300
A graded CPU range with a wide performance range is available for configuring the
controller.
The product range comprises 7 standard CPUs,
7 compact CPUs, 5 fail-safe CPUs and 3 technology CPUs.
The CPUs are available from a width of only 40 mm
SIMATIC S7-300 is within Totally Integrated Automation the most sold Controller.
• Range of application
• In the first instance SIMATIC S7-300 is used for innovative system solutions in
manufacturing technology, especially for automobile industry, mechanical
engineering in general and especially for special machine building and serial
production of machines (OEM), at plastics processing, packaging industry, food
and beverage industry and process engineering
• As an all-purpose automation system is S7-300 the ideal solution for applications,

which need a flexible concept for central as well as local configuration
• For applications, which require a especial robustness because of surrounding

conditions, we have the SIPLUS extreme devices
• Benefits
• Thanks to their high processing speed, the CPUs enable short machine cycle
times.
• The S7-300's range of CPUs provides the right solution for every application, and
customers only pay for the performance actually required for a specific task
• The S7-300 can be set up in a modular configuration without the need for slot rules
for I/O modules
• There is a wide range of modules available both for the centralized and the
distributed configuration with ET 200M.
• Integral PROFINET interfaces enable simple networking of the controllers, and

simple data exchange with the operations management level
• The narrow module width results in a compact controller design or a small control
cabinet.
• The ability to integrate powerful CPUs with Industrial Ethernet/PROFINET

interface, integrated technological functions, or fail-safe designs make additional
investments unnecessary.
S7-400
There is a graded range of CPUs from the entry-level CPU right up to the high-
performance CPU for configuring the controller. All CPUs control large quantity structures;
several CPUs can work together in a multicomputing configuration to boost performance.
Thanks to their high processing speed and deterministic response times, the CPUs
enable short machine cycle times.
The different CPUs are distinguished by, for example, work memory, address range,
number of connections and execution time. As well as the standard CPUs, there are also
two failsafe and three fault-tolerant CPUs available.
• Applications
• The S7-400 is especially suitable for data-intensive tasks in the process industry.
High processing speeds and deterministic response times guarantee short
machine cycle times on high-speed machines in the manufacturing industry.
• The S7-400 is used preferably to coordinate overall plants and to control lower-
level systems. This is guaranteed by the high communication power and the
integral interfaces.
• Many of the S7-400 components are also available in a SIPLUS version for
extreme environmental conditions.
• Benefit
• The power of the S7-400 is scalable thanks to a graded range of CPUs; the
capacity for I/O is almost unlimited.
• The power reserves of the CPUs enable new functions to be integrated without
further hardware investment, e.g. processing of quality data, user-friendly
diagnosis, integration into higher-level MES solutions or high-speed
communication via bus systems.
• The S7-400 can be structured in a modular way; there is a widely varied range of
modules available both for centralized configurations and distributed structures.
This results in very cost-effective spare parts handling.
• The configuration of the distributed I/O of the S7-400 can be modified during
operation (Configuration in Run). In addition signal modules can be removed and
inserted while live (hot swapping). This makes it very easy to expand the system or
replace modules in the event of a fault.
• The storage of the complete project data including symbols and comments on the
CPU simplifies service and maintenance calls.
• Safety engineering and standard automation can be integrated into a single S7-
400 controller; plant availability can be increased through the redundant structure
of the S7-400.
• Many of the S7-400 components are also available in a SIPLUS version for
external environmental conditions, e.g. extended temperature range (-25?+60°C)
and for use where there is aggressive atmosphere/condensation.
• The high-speed backplane bus of S7-400 ensures efficient linking of central I/O
modules
2.Mitsubhishi
FX1S Base Units
MITSUBISHI PLC FX1S series base units are available with 10 to 30 input/output points.
It is possible to choose between relay and transistor output type.
Special Features of MITSUBISHI PLC FX1S series
• Integrated power supply (AC or DC powered)
• Maintenance-free EEPROM memory
• Ample memory capacity (2000 steps) and device ranges
• High-speed operations
• Incorporated positioning control
• Integrated real-time clock
• System upgrades by exchangeable interface and I/O adapter boards for base unit
• LEDs for indicating the input and output status
• Standard programming unit interface
• User-friendly programming systems, including IEC 61131.3 (EN 61131.3)-

compatible programming software, HMIs and hand-held programming units
FX1N Base Units
MITSUBISHI PLC
FX1N series base units are available with 24 to 60 input/output points.

It is possible to choose between relay and transistor output type.
Special Features of MITSUBISHI PLC FX1N series
• Integrated serial interface for communication between Personal computer
• Detachable terminal blocks for units with 24, 40, and 60 I/Os
• Slot for memory cassettes
• All DC models with variable voltage from 12 up to 24 V
• Exchangeable interface and I/O adapter boards for direct fitting into the base unit.
FX2N Base Units
MITSUBISHI PLC FX2N series base units are available with 16, 32, 48, 64, 80 or 128
input/output points. It is possible to choose between relay and transistor output type.
Output types for 110 V AC for sink/source is also available.
Special Features of MITSUBISHI PLC FX2N series
• Exchangeable interface modules for direct mounting into a base unit
• Detachable terminal blocks (except for 16 k steps PLC Program)
FX2NC Base Units
MITSUBISHI PLC FX2NC series are available in versions with 16, 32, 64 or 96 I/Os.
Nine output types are available: eight different transistor output types and one
Special Features of MITSUBISHI PLC FX2NC series
• Very compact dimensions
• Removable terminal blocks (screw terminals for the relay output type) connectors
(for the transistor output types) for system cabling
• Slot for memory boards for up to 16 k steps PLC program
• Adapter modules and system cabling sets available for units with ribbon.
FX3U Base Units
MITSUBISHI PLC FX3U series base units are available with 16, 32, 48, 64, 80
input/output points. It is possible to choose between relay and transistor type.
Special Features of MITSUBISHI PLC FX3U series
• Exchangeable interface modules for direct mounting into a base unit (LRS485)
• Skit fir nenirt cassettes for up to 64k steps PLC program
• Enduser programming by new commands and table configuration
• High speed processing (0.065µs per bit instruction)
3.ABB
AC500-eCo - Affordable PLC solution for small machines
• An entry level PLC for small to medium applications

• CPUs are complete with onboard digital and analog
I/Os
• Compatible with Modbus and CS31 networks
• Optional SD card is available for data logging and
software updates without a PC
• Fully compatible with existing AC500, PS501 Control
Builder Software
• Expandable with all S500 I/O, in a centralized
configuration
AC500-S Safety PLC
• AC500-S Safety PLC (certified for SIL3, PL e) is

the ideal choice to handle complex safety solutions in
Functional Safety applications
• Proven in demanding applications like cranes, hoist,
robots and wind turbines
• Capable to
execute trigonometric functions and floating point
calculations
• Programmable with powerful Structured Text editor
as well as Function Block Diagram and Ladder
Diagram methods
• TÜV certified Safety Code Analysis tool PS501-
SCA opens the door to writing well-structured and
easily understandable program codes
• Extreme condition version available for harsh
environments
• Extensive safety libraries including PLCopen library
blocks
AC500 - Flexible and Scalable PLC Solution
• The PLC for mid to high end solutions with multiple

integrated communication interfaces: Ethernet,
RS485, RS232 and universal FieldBusPlug from
ABB
• Optional Communication Modules for interfacing with
common open industrial networks via Ethernet,
PROFINET, EtherCAT, ARCNET, Profibus,
CANopen, DeviceNet, Modbus and CS31
• Integrated diagnostic screen
• SD card for data logging and software updates
4.Allen-Bradly
Pico System
The standard Pico controllers are small, simple and flexible. They fit a wide variety of
applications. The PicoGFX™ controllers offer graphical, multi-function displays and
options for inter-connectivity. These controllers lead the Pico controller family in
flexibility and capability. The Allen-Bradley Pico controller performs simple logic, timing,
counting, and real-time clock operations. For enhanced functionality and performance,
the Pico GFX controller adds the use of a graphic display while offering advanced
programming features like PID control, a high-speed counter, and Boolean sequences.
Splitting the difference between a timing relay and a low-end programmable controller,
the Pico controllers are ideal for relay replacement applications where simple control
applications such as building, HVAC, and parking lot lighting, and applications in which
cost is a primary design issue. The Pico controllers were designed with ease-of-use in
mind. All programming and data adjustments can be done via the on-board keypad and
display, or with Allen-Bradley PicoSoft and PicoSoft Pro configuration software.
Features
Flexible installation
Easier programming
Expanded control with simple HMI
Inter-connectivity among PicoGFX™ controllers via Pico-Link network
Modularity
Increased capacity available through expansion I/O modules
User-friendly, intuitive programming software.
Addressing in an Allen-Bradley PLC

There are a number of addressing schemes used by PLC manufacturers. Let’s take a
quick look at how memory locations (including hardware I/O) are accessed with
RSLogix 500. Along the way, I will define some terms.
INSTRUCTION – RSLogix’s command language is comprised of “instructions”. An XIC

(it looks like a normally open contact –] [-- ) is an instruction. A timer is an instruction. A
few of the most common instructions are described below.
BIT - an address within the PLC. It can be an input, output or internal coil, among
others.
In RSLogix, there are a couple of ways to show the address of a bit. The default is:
[type]:[word]/[bit]
For example, an address that references an output of an SLC 500 is O:5/0. That is:
O:5/0 means that it is a physical output.

O:5/0 means that it uses Slot 5 (the 6th physical slot) in the rack.
O:5/0 means that it is the first output on the card.
Remember that the first slot in an SLC 500 rack is Slot 0. That means a card that is
installed in the 6th physical slot is addressed as Slot 5.
Allen-Bradley PLC slots, like many computers, always start with 0.
By the way, don’t get the capital “O’s” confused with zeroes.
RUNG – A section of the PLC ladder program that terminates in an output function of
some type. Just like in an electrical ladder diagram, a rung has some type of output that
is turned on or turned off by the preceding entities in the rung. The first rung in a ladder
program is always 0000.
HARDWIRED INPUT – a physical connection to the PLC from an input device (switch
or sensor, etc.).
Allen-Bradley uses the capital letter “I” to designate a hardwired input. An address that
describes an input on an SLC 500 is I:4/0.
Similar to the output structure,
I:4/0 means that it is a physical input.

I:4/0 means that it uses Slot 4 (the 5th slot in the rack).
I:4/0 means that it is the first input on the card.
MicroLogix Systems
Features
Five levels of control available, providing a wide variety of features to suit most
applications
Offers similar functionality as traditional SLCs and PLCs, only in a smaller, packaged
form factor
Compatible with our PanelView™ Component graphic terminals
Shares common RSLogix™ 500 programming software and RSLogix Micro

programming software, providing an instruction set that is common to the MicroLogix™
and SLC™ 500 controller families
MicroLogix 1000 Controller
Based on the architecture of the market-leading SLC 500 controller family, the
MicroLogix 1000 controller brings high-speed, powerful instructions and flexible
communication to applications that demand compact, cost-effective solutions. The
MicroLogix 1000 controller is available in 10-point, 16-point, or 32-point digital I/O
versions. Analog versions are also available with 20 digital I/O points, with 4 analog
inputs (2 voltage and 2 current) and 1 analog output (configurable for either voltage or
current). The analog I/O circuitry for the MicroLogix 1000 controller is embedded into
the base controller, not accomplished through add-on modules: so, it provides very
high-speed, cost-effective analog performance. The MicroLogix 1000 controller uses
Rockwell Software RSLogix 500 and RSMicro programming software and shares a
common instruction set with the MicroLogix and SLC 500 families of controllers
Advantages for the MicroLogix 1000 Controllers
• Preconfigured 1 KB program and data memory to ease configuration (for example,

preconfigured bit, integer, timers, and counters).
• Fast processing allows for typical throughput time of 1.5 ms for a 500-instruction
program.
• Built-in EEPROM memory retains all of your ladder logic and data if the controller
loses power, eliminating the need for battery back-up or separate memory module.
• Multiple input commons lets you use the controller for either sinking or sourcing
input devices and multiple output commons provide isolation in multi-voltage output
applications.
• RS-232 communication channel allows for simple connectivity to a personal
computer for program upload, download, and monitoring by using multiple protocols,
including DF1 full-duplex.
The MicroLogix 1100 controller is designed to broaden application coverage

through embedded analog inputs, Ethernet communication, and visualization
capabilities. MicroLogix 1100 controllers maintain the same critical features you have
come to expect from the MicroLogix family, and expand that capability to include true
online editing. MicroLogix 1100 controllers complement our low-end controllers for
applications that require up to 144 digital I/O.Each MicroLogix 1100 controller contains 2
embedded analog inputs, with 10 digital inputs and 6 digital outputs. The controller can
also expand its I/O capabilities by using the same modules as the MicroLogix 1200
controller. Up to four of the 1762 I/O modules can be used with a single MicroLogix
1100 controller. Using the latest version of our world-class RSLogix 500 programming
software, the MicroLogix 1100 controller can be programmed.Each controller supports a
built-in RS-232/RS-485 combo port for serial and networked communication and a
second built-in EtherNet/IP port, which supports Ethernet peer-to-peer messaging.An
embedded LCD screen lets you monitor controller and I/O status, as well as make
changes to bit and integer data.
Advantages for the MicroLogix 1100 Controllers
• Large 8 KB memory (4 KB user program with 4 KB user data) to solve a variety of

applications.
• True online editing allows tuning of program, including PID, without going offline.
• Support for MicroLogix 1100 controller online editing in all current versions of
RSLogix 500 and RSLogix Micro Starter and Developer software.
• Mode switch for Run/Remote/Program.
• Time-based or event-triggered data logging capability stores controller data records

with optional time stamp in a separate 128 Kbyte memory area for later analysis (for
example, trending and I/O status during alarm condition data).
• Recipe storage (up to 64 KB that is deducted from Data Logging memory) that is
accessible by your ladder program, enabling quick and easy batch changes of program
data for timers, counters, and other data types.
• High performance expansion I/O options (up to four 1762 I/O modules, in any
combination).
• Four high-speed inputs (except 1763-L16AWA controller) that can be used individually
as latching (pulse-catch) inputs, event interrupts, or alternately combined as one 40 kHz
high-speed counter featuring 8 modes of operation.
• Two built-in 0...10V DC analog inputs with 10-bit resolution (not isolated).
The MicroLogix 1200 controller provides more computing power and flexibility
than the MicroLogix 1000 controller to solve a variety of application needs. Available in
24- and 40-point versions, the I/O count can be expanded by using rackless I/O
modules. This results in larger control systems, greater application flexibility and
expandability at a lower cost and reduced parts inventory.A field-upgradable flash
operating system that helps to make sure you will always be up-to-date with the latest
features, without having to replace hardware. The controller can be easily updated with
the latest firmware via a website download.
Advantages for the MicroLogix 1200 Controller
• Large 6 KB memory (4 KB User Program with 2 KB User Data) to solve a variety of

applications.
• High performance expansion I/O options (up to six modules depending on
current/power budget).
• Four high-speed inputs (for controllers with 24V DC inputs) that can be used
individually as latching (pulse-catch) inputs, event interrupts,or alternately combined as
one 20 kHz high-speed counter featuring eight modes of operation.
• One high-speed output that can be configured as 20 kHz pulse train output (PTO) or
as pulse width modulated (PWM) output (availableon controllers with embedded 24V
DC outputs).
• One, 1 ms, selectable timed interrupt (STI).
• High-resolution, 1 ms timers.
The MicroLogix 1400 controller is our newest family of controllers to join the
popular MicroLogix 1000, MicroLogix 1100, MicroLogix 1200, and MicroLogix 1500
controllers, and is designed to broaden application coverage through available
embedded analog inputs, Ethernet communication, faster high-speed counter (HSC),
and pulse train output (PTO) capabilities. MicroLogix 1400 controllers maintain the
same critical features you have come to expect from the MicroLogix 1100 controller,
and expands that capability with more I/O, faster HSC/PTO, and an additional serial
port. MicroLogix 1400 controllers complement our low-end controllers for applications
that require up to 256 digital I/O.Each MicroLogix 1400 controller includes 20 digital
inputs and 12 digital outputs. In addition, several models include 4 embedded analog
inputs and 2 embedded analog outputs. The controller can also expand its I/O
capabilities by using the same modules as the MicroLogix 1100 and 1200 controllers.
Up to 7 of the 1762 I/O modules can be used with a single MicroLogix 1400
controller.Using the latest version of our world-class RSLogix 500 programming
software, the MicroLogix 1400 controller can be programmed with an instruction set that
is common with the MicroLogix 1000, MicroLogix 1100, MicroLogix 1200, MicroLogix
1500, and SLC 500 families of controllers. RSLogix 500 Starter, Standard, and
Professional applications, as well as RSLogix Micro software, all support the MicroLogix
1400 controller, including its online editing capabilities.Each controller has 2 serial ports
with DF1/DH485/Modbus RTU/DNP3/ASCII protocol support and a built-in Ethernet
port, which supports EtherNet/IP, Modbus TCP/IP and DNP3 over IP.An embedded
LCD screen lets you monitor controller and I/O status, as well as make changes to bit
and integer data.
The MicroLogix 1500 controller is a world-class programmable logic control

platform with even more advanced features and performance than the MicroLogix 1200
controller. Many of these features allow this controller to be used in applications where
much larger controllers were required in the past.MicroLogix 1500 architecture features
an innovative two-piece design with a small footprint. The processor and base units
slide together to form the complete controller. The processor and base are
independently replaceable, allowing you to maximize your embedded I/O, memory, and
communication options while minimizing inventory stocking costs.Bulletin 1769
Compact I/O modules expand the controller’s embedded I/O offerings and provide the
additional flexibility to cover a wide range of applications. This high-performance
modular and rackless I/O platform provides front accessibility for removal and insertion.
Removable terminal blocks further lower the total system cost by reducing start-up and
maintenance time.New features are provided with an enhanced user interface that uses
function files to consolidate programming parameters. This simplifies the user interface
and increases controller performance.The MicroLogix 1500 controller includes all the
features of the MicroLogix 1200 controller, plus more.
The PLC has to be able to identify each particular input and output. Itdoes this by
allocating addresses to each input and output. With a smallPLC this is likely to be just a
number, prefixed by a letter to indicatewhether it is an input or an output. Thus for the
Mitsubishi PLC we mighthave inputs with addresses X400, X401, X402, etc., and
outputs withaddresses Y430, Y431, Y432, etc., the X indicating an input and the Y
anoutput. Toshiba use a similar system.
With larger PLCs having several racks of input and output channels,the racks are
numbered. With the Allen-Bradley PLC-5, the rackcontaining the processor is given the
number 0 and the addresses of theother racks are numbered 1, 2, 3, etc. according to
how set-up switchesare set. Each rack can have a number of modules and each one
deals witha number of inputs and/or outputs.
I:012/03. This would indicate an input, rack 01, module 2 and terminal 03.
X: X X X / X X
With the Siemens SIMATIC S5, the inputs and outputs are arranged ingroups of 8. Each
8 group is termed a byte and each input or output withinan 8 is termed a bit. The inputs
and outputs thus have their addresses interms of the byte and bit numbers, effectively
giving a module numberfollowed by a terminal number, a full stop (.) separating the two
numbers.
Q2.0 is an output at bit 0 in byte 2.
XXX.X
I = input
Q = output

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NETTUR TECHNICAL TRAINING FOUNDATION

DIPLOMA IN MECHATRONICS – CP15

COMPILED BY: RAHUL V A APPROVED BY:Mr.R. AYYAPPAN

Rev.4 RELEASE – JUNE 2016

PROGRAMMABLE LOGIC CONTROLLER LAB

SUBJECT CODE CP 00 05 08*

HOURS PER SEMESTER 80

REV. DATE 12- 05- 2016

1.0 Basic Programming 20

1.1 1.1 Design a PLC Program for the following condition 2

1.2 Design a program DOL Starter for motor. 2

1.5 Design a program for start – stop – jog. 2

1.6 Design an Alarm system. 2

2.0 Digital Programming 06

2.1 Design a program 2

(I1) (I2+I3) (I5.I6) = P

2.4 Draw a program file for following expression 1

3.0 Familiarization of different Timers 14

3.1 1) Design a program to start a machine after 5 seconds. 3

2) Design a program to start 3 machines consequently after 3 seconds

GENERAL SAFETY RULES

1. Do not run in the laboratory.

The voltage supplies encountered in electronic equipment in general range from

The designations of voltages of different ranges are as follows:

Low Tension (L.T) - Below 250V

Medium Tension (M.T) - 250 - 650V

High Tension (H.T) - 650 – 3000V

Extra High Tension (E.H.T) - Above 3000V

Effects of Electricity on the Human Body

There are 3 major consequences of these:

General rule is: Current Kills, voltage burns

Recommended first aid action

The following procedure must be adopted.

1. Do not touch the casualty with hands.

Cardiopulmonary resuscitation (CPR)Place victim flat on back of a hard surface

A. Open the airway, if unconscious and not breathing

Exp: No.1 .1 Switching Light On – Off

Switch OFF- light off

2. Step 7 Micro/win software

3. RS 485 communication cable

4. Personal computer with WINDOWS OS

2. Whenever the NO contact I1 is closed the output coil Q1 will be active.

2. Upload the program to the PLC

Switching Light On – Off

PLC WIRING CIRCUIT

Expt No 1.2 DOL Starter For Motor

2. Step 7 Microwin software

3. RS 485 communication cable

4. Personal computer with WINDOWS OS

2. Upload the program to the PLC

DOL Starter For Motor

Expt No 1.3 Forward – Reverse – Stop With

2. Upload the program to the PLC.

Forward – Reverse – Stop with Mutual Interlock

1. Design the ladder diagram in STEP 7 MICROWIN application software

Expt No 1.5 Start – Stop – Jog

1. Design the ladder diagram in STEP 7 MICROWIN application software

2. Upload the program to the PLC

3. Execute the program by using input switches in the input module