WORKBOOK
PROGRAMMABLE LOGIC
CONTROLLERS (PLC)
The programmable logic controller (PLC) is a microprocessor based control unit designed to be
used to control various types of industrial processes.
The first PLC were designed in the late 1960s, to replace hardwired relay controls used in auto
manufacturing plants.
The PLC avoided this problem because the logic could be quickly changed by reprogramming the
PLC software programmer. This greatly reduced the amount of time and simplified the process of
changing the machine's operation sequence.
OMRON
SIEMENS
FESTO
MITSUBISHI
NAIS
Define PLC according to National Electrical Manufacturers
Association of America (NEMA).
List THREE ( 3 ) advantages using PLC.
Identify and fix the programs below:
ADDRESS INSTRUCTION DATA
00000 LD 00001
00001 AND TIM 003
#0100
00002 LD TIM 00003
00003 AND NOT TIM 00004
00004 OUT 01001
00005 LD 01002
00006 OR TIM 0005
00007 TIM 005
00008 END 01
Draw the symbol of contactor in normally open and normally close
system. Explain the operation bit condition when the condition
contactor is in Normally open and in normally close.
Draw the Ladder Logic for the mnemonic program below.
ADDRESS INSTRUCTION DATA
00000 LD NOT 00000
00001 LD NOT 00001
00002 LD 00002
00003 AND NOT 00001
00004 OR LD
00005 AND LD
00006 AND 00003
00007 OUT 01004
00008 LD NOT 00004
00009 LD 00005
00010 OR 00006
00011 LD NOT 00007
00012 AND 00008
00013 OR 00009
00014 AND LD
00015 AND LD
00016 OUT 01005
00017 FUN 01
Draw the symbol and explain the instruction below:
i. Timer
ii. Counter
Write a mnemonic program for the Ladder Logic below.
Refer to figure 2, the box on conveyor will move when PB1 is turn
ON. When the sensor detect the box, the box conveyor will stop
and the apple conveyor will turn ON. Part sensor will count up to
10 apples. After that the apple conveyor stop and box conveyor
will move again. Counter is set and the process repeat until PB2
switch is turn ON.
According to the above packaging control :
i. List the input and output device for the system.
ii. Draw a Ladder Diagram
iii. Write a mnemonic code.
Figure 3 shows the use of PLC to start and stop the conveyor motor.
This part is to move any object like zinc plat from one side to
another side. Limit Switch (Sensor - proximity switch )is use to
detect the plat on conveyor. Conveyor is ON in the fix range of
sensor. The conveyor will stop if the plat move over the range of
sensor or timer will active when the time ended.
Conveyor motor operation
a) Motor 2 will ON after Sensor 3 detect the object.
b) Motor 2 will OFF when Motor 1 is ON and the object is out of
range for sensor 2.
c) Motor 1 will ON when sensor 2 detect the object.
d) Motor 1 will OFF when the object is out of range of Sensor 1.
Draw a Ladder Diagram according to the above PLC system.
List THREE ( 3 ) cause of failure below:
i. Input and output device failure.
ii. Wiring failure. ( 6 marks )
c) List FIVE ( 5 ) wiring guide that can be use to reduce the failure of
Automation Control system, PLC wiring and installation. ( 5 marks )
e) Explain THREE ( 3 ) matter that must be taken before planning the
use of PLC.
e) Explain THREE ( 3 ) steps of preventive maintenance can be used
for PLC.
Directive questions:
1. After the host finishes reading the question.
2. Three players are racing for the most pressing push button in front of them early to answer
questions from host.
3. Buzzer will sound for 10 seconds after pressing the push-button Player.
4. The indicator lights are lit in front of players and just hose will be "reset"
I/O Assignment
DEVICE DATA
PUSH BUTTON 1
PUSH BUTTON 2
PUSH BUTTON 3
RESET
BUZZER
INDICATOR 1
INDICATOR 2
INDICATOR 3
MNEMONIC CODE
ADDRESS INSTRUCTION DATA
1. ON/OFF delay circuit
Motor (10000) will start 5 second after start push button (00000) being pressed, and it
will stop 5 second after stop push button being pressed.
Input / Output Assignment
Input
Devices
assignment
Output Assignment Devices
Ladder Diagram Mnemonic code
2. Proximity Sensor Detection
When the Sensor 1 (S1) scans the metal object 5 (five) times. Pilot Light (L1) will be ON
condition and Pilot Light L2 will be OFF condition. After 5 (five) seconds Pilot Indicator
L2 will be ON and L1 will be OFF and similarly counter will be reset.
Object
Conveyer belt
S1
L1 L2
Input / Output Assignment
Input
Devices
assignment
Output Assignment Devices
Ladder Diagram Mnemonic code
3. Traffic Light System.
When the Sensor 1 (S1) scans, immediately Pilot Light (L1) will be ON and after five (5)
seconds Pilot Light (L2) will be ON and L1 will be OFF. Then after five (5) second L3 will
be ON and L1 and L2 will be OFF. This condition will be continuously when S1 will scan.
L3
L2
L1
Input / Output Assignment
Input
Devices
assignment
Output Assignment Devices
Ladder Diagram Mnemonic code
