Al-Nahrain University

Information Engineering
Systems Department

PLC (Programmable Logic Controller) LAB

Gemo PLC Module

Kit Made by:

Eng. Yousif Ahmed Saeed
Eng. Elaf Ahmed Saeed
1 Introduction to PLC

Introduction
In Automated systems, the PLC is commonly regarded as the heart of the control
system. With a control application program (stored within the PLC memory) the
PLC constantly monitors the state of the system through the field input devices,
feedback signals.
The PLC may be used to control a simple and repetitive task, or a few of them may
be interconnected together with other host controllers or host computer through a
sort of communication network, in order to integrate the control of complex process.
Motivations of using PLCs
When the first electronic machine controls were designed, they used relays to control
the machine logic (i e. press "Start" to start the machine and press "Stop" to stop the
machine). A complex machine might need a wall covered in relays to control all of
its functions. As well as of that, there are a few limitations to this type of control.
Relays fail
The delay when the relay turns on/off
There is an entire wall of relays to design/wire/troubleshoot.
The PLC overcomes all these limitations; it is a machine-controlled operation.
Advantages of PLCs
Reliability.
Flexibility in programming and reprogramming.
Cost effective for controlling complex systems.
High speed of operation.
Ability to communicate with computer systems in the plant.
Ease of maintenance /troubleshooting.
Reduced space.
Energy saving.
2 Introduction to PLC

Disadvantages of PLCs
PLC devices are proprietary it means that part or software of
one manufacturer can’t be used in combination with parts of
another manufacturer.
Debugging the PLC sometimes consumes a lot of time.
PLCs manufacturers offer only closed architectures.
Major components of a common PLC

Inputs and Outputs Modules

3 Introduction to PLC

The two major types of PLC

When it comes to the types of PLC, these two are the most common answer that you
will find in any source from the internet simply because they are the least subtle of
all the classifications available.
a- Fixed/Integrated/Compact PLC
4 Introduction to PLC

This type of PLC is most commonly called the Fixed I/O PLC.
“Fixed I/O” actually stands for Fixed “Input/Output”. When you buy Compact
PLCs, you will notice that the input section and the output sections of the PLC are
integrated into the microcontroller itself.
This means that every type of output or input is fixed and is determined by the
manufacturer.
Furthermore, the number of inputs and outputs may not be expanded in this type of
PLC.
b- Modular PLC

The modular PLC is a type that allows multiple expansions of the PLC system
through the use of modules, hence the term “modular”.
Modules give the programmable logic controller additional features like increased
number of I/O units, and they are usually easier to use because each component is
independent of each other.
The power supply, communications module, Input/Output module are all separate to
the actual microcontroller so you have to manually connect them to each other to
create your PLC control system.
5 Introduction to PLC

A type of modular PLC is the rack-mounted or rack mount PLC. In a rack mount
PLC, the communications module of the PLC resides in the rack itself, so all
connections are centralized.
PLC models

Siemens PLC

The PLC which is used in this laboratory is a modular GEMO

6 Introduction to PLC

PLC GEMON Characteristics

• Free of charge Ladder Logic Editor with GUI running on PC, “GEMO
LADDER EDITOR”; programming, simulation, download.
• 256 lines, 5 contact column, 1 coil column
• Rising / Falling Edge option for contacts
• Up to 28 Discrete Inputs, built-in filter for each input
• Up to 20 Discrete Outputs
• 32 Timers (11 modes, 9-time bases)
• 2 Timer Ticks (Event Counting)
• 32 Counters (16 bits, Up/Down)
• 32 Counter Comparators (with Offset feature)
• 2 Fast Input Counters
• 2 Independent State Machines (Internal Timer)
• 3 Front Panel F Keys, with built in filter for each
• 48 Auxiliary Relays
• 16 Analog Comparators (with hysteresis)
• Up to 4 x 0-10V Analog Inputs
• Up to 2 x PTC Temperature Sensor Input
• 32 Run Time Screens with internal timer; each having 4 sub screens
• Welcome screen with 4 sub screens
• 3 Level user programmable menu system
• 4 Password contacts
• 4 Configuration contacts
7 Introduction to PLC

• Real Time Clock - optional

• Weekly / Yearly Alarms (for RTC option)
• RS-485 port to connect to extension modules
• Communicates with a MOSBUS RTU Master via AR2 MODBUS Gateway
(AR2-S-24VDC-MB1)
• Scan time < 10msec.
• 2x16 character back-light LCD display
• 18...32VDC or 100...240VAC supply options, 18Vdc Auxiliary Supply Out
for discrete inputs

Simulation software
The Simulation software used in this laboratory is GEMO programming software
which is used to develop the ladder programs “off‐line”.
PLC Programming Language
1. Ladder Diagram (LD)
Ladder Diagram was originally modeled from relay-logic which used physical
devices, such as switches and mechanical relays to control processes. Ladder
Diagram utilizes internal logic to replace all, except the physical devices that need
an electrical signal to activate them.
Ladder Diagram is built in the form of horizontal rungs with two vertical rails that
represent the electrical connection on relay-logic schematics.
You can program all the necessary input conditions to affect the output conditions,
whether logical or physical.
8 Introduction to PLC

1-1. Ladder Diagram Advantages

The main advantages of the Ladder Diagram language are:
1. The rungs allow it to be organized and easy to follow.
2. It also lets you document comments that are readily visible.
3. It supports online editing very successfully.
1-2. Ladder Diagram Disadvantages
The main disadvantage is that there are some instructions that are not available,
which might make it more difficult for programming such as motion or batching.
2. Sequential Function Charts (SFC)
If you have any experience with flowcharts, then this PLC Programming language
will feel familiar to you. In Sequential Function Charts, you use steps and transitions
to achieve your end results.
9 Introduction to PLC

Unlike traditional flowcharts, the Sequential Function Charts can have multiple
paths. You can use branches to initiate multiple steps at one time.
2-1. Sequential Function Charts Advantages
A couple of the advantages of Sequential Function Charts are:
1. Processes can be broken into major steps that can make troubleshooting faster
and easier.
2. You have direct access in the logic to see where a piece of equipment faulted.
3. It can be faster to design and write the logic due to the ability to use repeated
executions of individual pieces of logic.
2-2. Sequential Function Charts Disadvantages
Even when you consider the advantages of the Sequential Function Charts, this
PLC Programming Language does not always fit every application.
3. Function Block Diagram (FBD)
The Function Block Diagram which is also a graphical type of language. The
Function Block Diagram describes a function between inputs and outputs that are
connected in blocks by connection lines.
10 Introduction to PLC

Function Blocks were originally developed to create a system that you could set up
many of the common, repeatable tasks, such as counters, timers, PID Loops, etc.

3-1. Function Block Diagram Disadvantages

The code can get disorganized using this PLC Programming Language because you
can place the function blocks anywhere on the sheet. This can also make it more
difficult to troubleshoot.
3-2. Function Block Diagram Advantages
1. The Function Block Diagram does work well with motion controls.
2. The visual method is easier for some users.
3. The biggest advantage of Function Block Diagram is that you can take many
lines of programming and put it into one or several function blocks.
4. Structured Text (ST)
The 4th PLC Programming Language is the Structured Text. This language is a
textual based language.
Structured Text is a high-level language that is like Basic, Pascal and “C”.
11 Introduction to PLC

It is a very powerful tool that can execute complex tasks utilizing algorithms and
mathematical functions along with repetitive tasks.
The code uses statements that are separated by semicolons and then either inputs,
outputs, or variables are changed by these statements.
You must write out each line of code and it uses functions such as FOR, WHILE,
IF, ELSE, ELSEIF AND CASE.
If you have experience with Basic or C languages, this PLC Programming Language
will come easier than some of the other types of PLC languages.

4-1. Structured Text Advantages

Some of the advantages of Structured Text are:
1. It is very organized and good at computing large mathematical calculations.
2. It will enable you to cover some instructions that are not available in some
other languages like the Ladder Diagram.
4-2. Structured Text Disadvantages
The disadvantages of the Structured Text PLC programming language are:
1. The syntax can be difficult.
2. It is hard to debug.
12 Introduction to PLC

3. It is difficult to edit online.

5. Instruction List (IL)
I will now show you the 5th and final PLC Programming Language which is
Instruction List. The Instruction List is also a textual based language.
The Instruction List language resembles Assembly Language. When you use this
PLC Programming Language, you will use mnemonic codes such as LD (Load),
AND, OR, etc.
The Instruction List contains instructions with each instruction on a new line with
any comments you might want to annotate at the end of each line.
5-1. Instruction List Advantages
The Instruction List language is valuable for applications that need code that is
compact and time critical.

5-2. Instruction List Disadvantages

The main disadvantages of this PLC Programming Language are:
1. There are few structuring possibilities with the “Goto” command being one of
them.
2. There can also be many errors that are more difficult to deal with in comparison
to many of the other languages that I have previously reviewed.
13 Introduction to PLC

In the laboratory we use the ladder programming language.

Ladder Editor
Main Screen
Main screen is seen after the application starts. Main screen is composed of; main
menu, Editor & Simulation Buttons, 5 Contact columns, 5 Link columns, Coil
column and Comment Column.
14 Introduction to PLC

Main Menu
Main menu is composed of the following sub menu items.
File
File sub menu item is composed of the following sub menu items;
• New : Starts a new/empty diagram
• Open : Opens a previously saved diagram
• Save : Saves current/open diagram
• Save as : Saves current/open diagram with a new/different name
• Print : Opens print dialog.
• Search Contact : Use to search a specific contact in the diagram. Use F3 for
• the next one.
• Search Coil : Use to search a specific coil in the diagram. Use F4 for the
• next one.
• Save As Ver2.2 : Use to save file in Ver2.2. format
• Exit : Ends application
15 Introduction to PLC

Settings
Settings sub menu item is composed of the following sub menu items.
• Discrete Inputs : Opens Discrete Inputs sub screen.
• Discrete Outputs : Opens Discrete Outputs sub screen.
• Auxiliary Relays : Opens Auxiliary Relays sub screen.
• Timers : Opens Timers sub screen.
• Timer Ticks : Opens Timer Ticks sub screen.
• Counters : Opens Counters sub screen.
• Counter Comparators : Opens Counter Comparators sub screen.
• Fast Input Counters : Opens Fast Input Counters sub screen.
• State Machines A/B : Opens State Machines sub screen.
• Front Panel F Keys : Opens Front Panel F Keys sub screen.
• 0-10V Analog Inputs : Opens 0-10V Analog Inputs sub screen.
• Analog Comparators : Opens Analog Comparators sub screen.
• Special Password Flags: Opens Special Password Flags sub screen.
• Configuration Flags : Opens Configuration Flags sub screen.
• MODBUS Setting : Opens MODBUS Setting sub screen.
• System Settings : Opens System Settings sub screen.
• Yearly Alarms : Opens Yearly Alarms sub screen.
• Weekly Alarms : Opens Weekly Alarms sub screen.
• Run Time Screens : Opens Run Time Screens sub screen.
• Menu Designer : Opens LCD Menu Designer sub screen.
16 Introduction to PLC

Diagram
Diagram sub menu item is composed of the following sub menu items.
• Ladder Symbols : Diagram is drawn with ladder symbols.
• Electrical Symbols : Diagram is drawn with electrical symbols.

View
This sub menu is active in simulation mode. User selects show/hide of relevant
simulation sub screens via this sub menu.
• Discrete Inputs : Show / Hide
• Discrete Outputs : Show / Hide
• Auxiliary Relays : Show / Hide
• Timers : Show / Hide
• Counters : Show / Hide
17 Introduction to PLC

• Counter Comparators : Show / Hide

• State Machine A : Show / Hide
• State Machine B : Show / Hide
• Front Panel F Keys : Show / Hide
• Analog Comparators : Show / Hide
• Special Password Flags: Show / Hide
• Weekly Alarms : Show / Hide
• MODBUS Contacts : Show / Hide
• Analog Inputs : Show / Hide
• LCD Module : Show / Hide

Dil / Language
Dil / Language sub menu item is composed of the following sub menu items.
• Türkçe : Editor Language is Turkish.
• English : Editor Language is English.

Data Transfer
Data Transfer sub menu item is composed of the following sub menu items.
18 Introduction to PLC

• Select Communication Port : Selects RS-232 port to download; COM1,

• COM2, COM3, COM4, COM20 or COM21.
• Set Communication Speed : Selects communication speed; Fast or normal.
• Fast is introduced with Ver2.3.
• Download New Program : Starts downloading current ladder
• diagram/program to Smart Relay. Previously stored diagram/program in
smart
• relay is permanently replaced with the new one.
• Erase Device Program : Previously stored diagram/program in smart
• relay is permanently erased. User can download a new one any time later on.
• Check Device Type/Version : Used to check type and version of connected
• device.
• Reset (Reboot) Device : Used to soft-reset device.
• Calibration : Used after production or maintenance.

Miscellaneous
Miscellaneous sub menu item is composed of the following sub menu items.
• About : Displays information about editor.
• Conversion Calculator: Starts 4..20mA → 0..10 V Conversion Calculator for
• AR2.
19 Introduction to PLC

• Read License : Displays license information

PLC Kit for Training

In the Fig.1 below that shown the PLC Kit Tanning.

Fig.1
This kit is the design of a set of experiments that linked with PLC. Parts of this
design will be displayed as follows:
20 Introduction to PLC

I/O ports:

Fig.2
1- Inputs Parts: this used to supply voltage to components.
2- Outputs Parts: this used to input voltage.
3- Variable Voltage: Potentiometer that is used to supply analog voltage.
4- Display Voltage (3 Digits).
5- 12 Volts Supply Voltage.
6- 5 Volts Supply Voltage.
7- Analog Inputs Parts.
8- DC Motor Forward and Reverse Movements.

Microcontroller that is used in Kit:

In fig.3 that shown the PLC Gemo Microcontroller Which is the controller that was
used in the kit.
21 Introduction to PLC

Fig.3

The List of Experiments

Fig.4
This process in Fig.4 requires that boxes moving on a conveyor be automatically
positioned and filled. The sequence of operation for the continuous filling operation
is as follows:
• Start the conveyor when the start button is momentarily pressed.
• Stop the conveyor when the stop button is momentarily pressed.
• Energize the run status light when the process is operating.
• Energize the standby status light when the process is stopped.
22 Introduction to PLC

• Stop the conveyor when the right edge of the box is first sensed by the photosensor.
• With the box in position and the conveyor stopped, open the solenoid valve and
allow the box to fill. Filling should stop when the level sensor goes true.
• Energize the full light when the box is full. The full light should remain energized
until the box is moved clear of the photosensor.

Fig.5
As in Fig.5, a coin is inserted into the coin slot. Once detected, if a drink button is
pressed, the correct drink will be dispensed and the coin kept or if the reject button
is pressed, the coin will be rejected and no drink will be dispensed.

Fig.6
23 Introduction to PLC

As in Fig.6, a Job is travels down a conveyor. Size of the job is identified by the help
of job length sensor I/P s (I/P 0 and I/P 1). If both the sensor sensed at a time when
job is passed then the job will be treated as big job. Or if only one sensor is sensed
at a time then job will be treated as small job. When job is reached to the rotary table,
the table should turn either left or right depending upon the size of job. The relevant
piston should move the box to the correct conveyor and the box should then continue
to the end of that conveyor.

Fig.7
In Fig.7 that shown the paint spraying system where boxes are fed by gravity through
a feeder magazine one at a time onto a moving conveyor belt.

Fig.8
24 Introduction to PLC

In Fig.8 that shown the Product Package System. Once the photoelectric sensor (X0)
detects 10 products, the robotic arm (Y0) will begin to pack up. When the action is
completed, the robotic arm and the counter will be reset.

Fig.9
In Fig.9 that shown the Motor Forward and Reverse Movement.
25 PLC Ladder Programming with Logic Gates

LADDER Diagram
Ladder logic (also known as ladder diagram or LD) is a programming language used
to program a PLC (Programmable Logic Controller). It is a graphical PLC
programming language which expresses logic operations with symbolic notation.
Ladder logic is made out of rungs of logic, forming what looks like a ladder – hence
the name ‘Ladder Logic’.
And if we were to draw a ladder scheme for lighting a flashlight with a flashlight, it
would look like this:

Digital logic functions:

1- OR Gate

2- AND Gate
26 PLC Ladder Programming with Logic Gates

3- NOT Gate

4- NAND Gate
27 PLC Ladder Programming with Logic Gates

5- Exclusive-OR Gate

Block Diagram of a PLC

Ladder programming example

Ladder Logic Program for Start/Stop of Motor:
28 PLC Ladder Programming with Logic Gates

Programming a PLC

Starting of motor
29 PLC Ladder Programming with Logic Gates

Continuous Running of motor when Start Button is released

30 PLC Ladder Programming with Logic Gates

To Stop the Motor

31 PLC Experiment No.1

Objectives
At the end of the session, students will be able to design PLC program to controlling
motors and design logic circuits.
Problems Description
1. Converting Hardwired relay logic circuits into a PLC based logic diagrams:
a) Design the PLC ladder diagrams for the given hardwired relay logic circuits:

b)
32 PLC Experiment No.1

c) In a certain bank each, of three bank officers has a unique switch key to the vault.
The bank rules require that two out of three officer's switches be activated to open
the vault. Draw the PLC basic ladder logic diagram for hardwired relay logic circuit
that will unlatch the door and turn on a light when two of three switches are activated.

2. Converting the Boolean expressions into ladder logic diagrams:

a) Draw the digital circuit and the ladder logic diagram for the following Boolean
expression (do not simplify):

b) Suppose we were given the task of designing a flame detection circuit for a toxic
waste incinerator. The intense heat of the fire is intended to neutralize the toxicity
of the waste introduced into the incinerator. Such combustion-based techniques are
33 PLC Experiment No.1

commonly used to neutralize medical waste, which may be infected with deadly
viruses or bacteria:

So long as a flame is maintained in the incinerator, it is safe to inject waste into it to

be neutralized. If the flame were to be extinguished, however, it would be unsafe to
continue to inject waste into the combustion chamber. What we need in this system
is a sure way of detecting the presence of a flame, and permitting waste to be injected
only if a flame is “proven” by the flame detection system. Suppose that due to the
high degree of hazard involved with potentially passing un-neutralized waste out the
exhaust of this incinerator, it is decided that the flame detection system be made
redundant (multiple sensors), so that failure of a single sensor does not lead to an
emission of toxins out the exhaust. Each sensor comes equipped with a normally-
open contact (open if no flame, closed if flame detected) which we will use to
activate the inputs of a logic system:
34 PLC Experiment No.1

Design the circuitry of the logic system to open the waste valve if and only if there
is good flame proven by the sensors, first when the three sensors are detects flame.
As the following truth table:
35 PLC Experiment No.1

The output of the circuit will be “high” if and only if input A AND input B AND
input C are all “high".

If using relay circuitry, we could create this AND function by wiring three relay
contacts in series, or simply by wiring the three sensor contacts in series, so that the
only way electrical power could be sent to open the waste valve is if all three sensors
indicate flame:
36 PLC Experiment No.1

Secondly suppose that any single sensor failed “high”. That mean if “two out of
three” sensor logic were detects flame, the waste valve is opened. The truth table
for such a system would look like this:

Now that we have a Boolean Sum-Of-Products expression for the truth table’s
function, and the logic gate or relay logic circuit based on that expression:
37 PLC Experiment No.1
38 PLC Experiment No.1

Discussion
Draw the logic symbol, construct a truth table, ladder logic program, and state the
Boolean equation for each of the following:
1-

2-

3-
39 PLC Experiment No.1

4-

5-

6- A motor control circuit with two start/stop buttons. When either start button is
depressed, the motor runs. By use of a seal-in contact, it continues to run when the
start button is released. Either stop button stops the motor when it is depressed.
40 PLC Experiment No.2

Die Stamping Application

Objectives
At the end of the session, students will be able to design PLC program to controlling
automatic Die Stamp.
Problems Description

1. Define the task:

A master switch is used to start the process and to shut it down. Two sensors: an
upper limit switch that indicates when the piston is fully retracted, and a lower limit
switch that indicates when the piston is fully extended.

When the master switch is turn on the piston reciprocates between the extended and
retracted positions. When the master switch is turned off, the piston returns to the
retracted position and all solenoids are off.

2. Define inputs and outputs:

41 PLC Experiment No.2

Inputs
Address Type Function
X0 Pushbutton Master switch
X1 Limit Switch Upper limit switch
X2 Limit Switch Lower limit switch

Outputs
Address Type Function
Y0 solenoid Up solenoid
Y1 solenoid Down Solenoid
3. Develop the PLC ladder diagram program and test its function.

Discussion
1- Repeat the Procedure above.
2- Explain the following:
i) What is limit switch?
ii) The Application of limit switch.
42 PLC Experiment No.3

Continuous filling operation

Objectives
At the end of the session, students will be able to design PLC program to controlling
automatic Continuous filling operation.
Problems Description

1. Define the task:

This process requires that boxes moving on a conveyor be automatically positioned

and filled. The sequence of operation for the continuous filling operation is as
follows:
• Start the conveyor when the start button is momentarily pressed.
• Stop the conveyor when the stop button is momentarily pressed.
• Energize the run status light when the process is operating.
• Energize the standby status light when the process is stopped.
• Stop the conveyor when the right edge of the box is first sensed by the
43 PLC Experiment No.3

photosensor.
• With the box in position and the conveyor stopped, open the solenoid
valve and allow the box to fill. Filling should stop when the level sensor
goes true.
• Energize the full light when the box is full. The full light should remain
energized until the box is moved clear of the photosensor.
2. Define inputs and outputs:

Inputs
Address Type Function
Start Pushbutton Start process
Stop Pushbutton Stop process
Photo Switch Sensor Sense boxes
Level Switch Sensor Sense liquid levels
Outputs
Address Type Function
Motor Coil Conveyor motor
Solenoid solenoid Control liquid gate
Run Pilot Led Process operating
indicator
Standby Pilot Led Process stopping
indicator
Full Pilot Led Box full indicator
3. Develop the PLC ladder diagram program and test its function.

Discussion
1. What is a logic gate?
2. Explain the basic operating principle of an electromagnetic control relay.
3. What is the operating difference between a normally open and a normally closed
relay contact?
4. Compare the method of operation of each of the following types of switches:
44 PLC Experiment No.3

a. Manually operated switch

b. Mechanically operated switch
c. Proximity switch
5. Draw the ladder diagram for the following problem:
Switching on/off the Lamp whether from the bottom or the top of the staircase
switches.
45 PLC Experiment No.4

Soft Drink Machine

Objectives
At the end of the session, students will be able to design PLC program to controlling
automatic Soft Drink Machine.
Problems Description

1. Define the task:

A coin is inserted into the coin slot. Once detected, if a drink button is pressed, the
correct drink will be dispensed and the coin kept or if the reject button is pressed,
the coin will be rejected and no drink will be dispensed.
2. Define inputs and outputs:
Inputs
Address Type Function
I0 Infra-red sensor Coin sensing
I1 Pushbutton Cola dispenses
I2 Pushbutton Lemon dispenses
I3 Pushbutton Cherry dispenses
I4 Pushbutton Lime dispenses
I5 Pushbutton Reject
46 PLC Experiment No.4

Outputs
Address Type Function
O0 Solenoid Coin hold
O1 Solenoid Coin accepts
O2 Solenoid Cola release
O3 Solenoid Lemon release
O4 Solenoid Cherry release
O5 Solenoid Lime release
3. Develop the PLC ladder diagram program and test its function.

Discussion
1. Explain the function of each of the following actuators:
a. Solenoid
b. Stepper motor
2. How does an ultrasonic sensor operate?
3. How does a photoelectric sensor operate?
4. A temperature control system consists of four thermostats controlling three
heating units. The thermostat contacts are set to close at 50°, 60°, 70°, and 80°F,
respectively. The PLC ladder logic program is to be designed so that at a temperature
below 50°F, three heaters are to be ON. Between 50° to 60°F, two heaters are to be
ON. For 60° to 70°F, one heater is to be ON. Above 80°F, there is a safety shutoff
for all three heaters in case one stays on because of a malfunction. A master switch
is to be used to turn the system ON and OFF. Prepare a typical PLC program for this
control process.
47 PLC Experiment No.5

Timers
Sorting Device for Packages
Objectives
At the end of the session, students will be able to design PLC program to controlling
automatic Sorting Device for Packages and they have knowledge of timers.
Problems Description
1. Define the task:
Job is travels down a conveyor. Size of the job is identified by the help of job length
sensor I/P s (I/P 0 and I/P 1). If both the sensor sensed at a time when job is passed
then the job will be treated as big job. Or if only one sensor is sensed at a time then
job will be treated as small job. When job is reached to the rotary table, the table
should turn either left or right depending upon the size of job. The relevant piston
should move the box to the correct conveyor and the box should then continue to the
end of that conveyor.
48 PLC Experiment No.5

2. Define inputs and outputs:

Inputs
Address Type Function
I0 Proxy sensor Box length sensor
I1 Proxy sensor Box length sensor
I2 Proxy sensor Rotary table sensor
I3 Proxy sensor Horizontal conv.sensor
I4 Proxy sensor Vertical conv. Sensor
I5 Push button Start button
Outputs
Address Type Function
O0 Solenoid Push to vertical conv.
O1 Solenoid Push to horizontal conv.
O2 Motor Starting conveyor
O3 Motor Horizontal conveyor
O4 Motor Vertical conveyor
O5 Motor Turn rotary table right
O6 Motor Turn rotary table left
3. Develop the PLC ladder diagram program and test its function.

Discussion
Q: Develop the PLC ladder diagram program and test its function for the following
problem that doing an automatic traffic light control: The sequence of the traffic
lights is as follows:
RED
5 seconds later
RED & AMBER
5 seconds later
GREEN
5 seconds delay
The sequence should be fully automatic and start with the RED 'ON' immediately
49 PLC Experiment No.5
50 PLC Experiment No.6

Counter
Product Packaging
Objectives
At the end of the session, students will be able to design PLC program to controlling
automatic Product Packaging and they have knowledge of counters.
Problems Description
1. Define the task:

Once the photoelectric sensor (X0) detects 10 products, the robotic arm (Y0) will
begin to pack up. When the action is completed, the robotic arm and the counter will
be reset.
2. Define inputs and outputs.
Inputs
 X0 - Photoelectric sensor for counting products.
 X1 - Robotic arm action completed sensor.
Outputs
 Y0 - Robotic arm for packing
3. Develop the PLC ladder diagram program and test its function.
51 PLC Experiment No.6

Discussion
1- Repeat the procedure above.
2- Explain the following:
a- What is counter?
b- Applications that the counter is used for, with examples.
52 PLC Experiment No.7

Paint Spraying
Objectives
At the end of the session, students will be able to design PLC program to controlling
automatic Paint Spraying.
Problems Description
1. Define the task:

Paint spraying system where boxes are fed by gravity through a feeder magazine one
at a time onto a moving conveyor belt. Upon the start signal, boxes are pushed
towards the conveyor by valve 1. This is a cylinder which extends and retracts which
operates switches S1 and S2 respectfully. A spraying nozzle paints each box as it
passes under the paint spray controlled by valve 2. A sensor (S3) counts each box
being sprayed. When 6 boxes have been painted the valve 2 shuts off (paint spray)
and valve 1 (cylinder) stops moving boxes onto the conveyor. Three seconds later
the conveyor stops moving and the hopper with its load moves forward (valve 3)
where it is emptied. Ten seconds later the hopper returns to the original position. The
cycle is then complete and waits for a start signal again.
53 PLC Experiment No.7

2. Define the Inputs and Outputs:

Inputs
 Start Switch – On/Off (Normally Open) – NO
 Stop Switch – On/Off (Normally Closed) – NC
 S1 – cylinder retract sensor (NO)
 S2 –cylinder extend sensor (NO)
 S3 – Box Detected sensor (NO)
Outputs
 Y0- Motor – On/Off (Conveyor Run)
 Y1- Cylinder to feed boxes – On/Off
 Y2- Paint Spray – On/Off
 Y3- Cylinder to move hopper – On/Off
3. Develop the PLC ladder diagram program and test its function.

Discussion
1- Repeat the procedure above.