PLC Lab Manual

Andhra University
Department of Electrical Engineering

B.Tech Degree Semester -IV
PROGRAMMABLE LOGIC CONTROLLERS (PLC) LABORATORY
Sl.No. LIST OF EXPERIMENTS
1 Introduction of PLC and Simatic S7 1200 kit

2 Logic Gates
3 Direct On-line Starter
4 Star Delta Starter
5 Verification of ladder diagrams for Boolean Expressions
6 Verification of ladder diagrams for staircase wiring
7 Verification of ladder diagrams for traffic light control
8 Implementation of Counters
9 Execute ladder diagram for water level control
10 Blinking of LED
1
Dept. of Electrical Engineering College of Engineering, AU
EXPERIMENT: 01
INTRODUCTION TO PLC'S (SIEMENS S7-1200)
PLC is an acronym for programmable logic controller. It is a type of tiny computer that can receive data through
the inputs and sends the operating instructions through its outputs. Fundamentally, a PLC's job is to control a system's
functions using the internal logic programmed into it.
PLC's are used to automatic processes in business around the world.
DIFFERENT COMPONENTS OF PLC :
1. POWER SUPPLY MODULE :-
The AC Main supply connected to power supply provides DC power for PLC Modules.
2.INPUT OUTPUT MODULES:
It is used to control PLC with field analog (or) digital devices input field devices include switches, encoders,
and transmitters etc....
Output field devices include Relays, lamps, and valves.
3.PROCESSOR: -
The processor consists of the CPU and the memory of the PLC. CPU is where the logic is run and processed.
Memory is where logic is stored.
4. COMMUNICATION MODULE:
It is the part useful for connecting our PLC with other programming device like PC's, laptops, etc... which are
useful in loading a certain logic in PLC. These connections are made using the profinet cables.
PROFINET:
It is an industry technical standard for data communication over industrial ethernet designed for collecting data from
and controlling equipment in the industrial systems.
Some of the most popular PLC manufacturing companies are ABB, siemens. Allen Bradley.
SIEMENS SIMATIC S7-1200:
Simatic S7-1200 controllers are the ideal choice when it comes to flexible and efficiently performing automation tasks
in the lower to medium performance range. These are useful for high pressure automatization.
2
COMPONENTS OF S7-1200:
POWER MODULE:-
It accepts of supply voltage of range of 85 V to 26 V AC to module convert it to 24 V for the operation of

PLC.
The frequency of the supply is in between 47 Hz to 53 Hz but 50 Hz is ideal.
INPUT/OUTPUT MODULE [1/0 MODULE] :-
S7-1200 has 14-inputs of 24 V each and 6 mA per point. It has 10 outputs each of 30 V DC voltage with 2A
current per point. All the inputs are controlled by switches.
These are two pairs of input switches marked I0.0 to I0.7 and I1.0 to I1.5 and outputs marked Q0.0 to Q0.7 and Q1.0 to
Q1.1. If outputs and inputs are not sufficient, we can even connect more I/O modules to right of the module. There are
two (or) more pins for the analog signals. Every input and output are marked by small LED on the module.
COMMUNICATION MODULE:
There are 5 parts of communication even can be extended by adding few more modules to the left of the module.
HMI
Human Machine Interface is the user Interface for the PLC. All the functions that can be done using manual operation
can also be done by using HMI, the features of PLC can be controlled.
PLC PROGRAMMING
Different PLC's use different programming software for SCIMATIC S7-1200 we use S7.0 (or) some different version.
We are going to use ladder logic.
STEPS FOR PLC PROGRAMMING.
Create New project
↓
Project Name
↓
Click on Create
↓
Configure a device
↓
3
Add a new device
↓
Controller S7-1200
↓
CPU 1214 AC/DC/Relay 6ES7214-18-640-0X130
↓
Version 4.0
↓
Add Click on program blocks
↓
Main [OBJ]
↓
tag %I0.1-name to input
↓
O/p→Q0.7
↓
Save Project
↓
Download to device Load Stop all Finish Monitoring ON/OFF
↓
Start Search
↓
Flash LED
↓
Load
4
↓
Stop all
↓
Finish
↓
Monitoring ON/OFF
↓
Go offline
↓
Stop CPU
↓
OK.
Result:
5
Experiment-02
LOGIC GATES
Aim: To design a ladder circuit for the logic gates and to verify the outputs with respect to
their truth tables.
Apparatus:
1. Compute with TIA-V13 software, where TIA is totally integrated automation
2. Siemens S7-1200 PLC
3. Profinet cable
4. Blocks used to construct the logic gates are:
NC switch
a) NO switch
b) Output block (LED’s)
Ladder diagrams:
AND GATE:
OR GATE
6
NOT GATE
NAND GATE
NOR GATE
7
XOR GATE
Theory:
1. NOT gate: logic gate truth table of NOT gate
Input(I1) Output(Q1)
0 1
8
1 0
2. OR gate: logic gate truth table of OR gate
Input
Output
A B
0 0 0
0 1 1
1 0 1
1 1 1
3. AND gate: logic gate truth table of AND gate
Input
Output
A B
0 0 0
0 1 0
1 0 0
1 1 1
4. NAND gate: logic gate truth table of NAND gate
Input
9
Output
A B
0 0 1
0 1 1
1 0 1
1 1 0
5. NOR gate: logic gate truth table of NOR gate
Input
Output
A B
0 0 1
0 1 0
1 0 0
1 1 0
6. XOR gate: logic gate truth table of XOR gate
Input
Output
A B
10
0 0 0
0 1 1
1 0 1
1 1 0
Procedure:
1. Switch on the power supply of the personal computer and S7-1200 test kit.
2. Now open the TIA-V13 software and connect the ladder diagram using normally open (NO) and
normally closed (NC) switches as shown.
3. Then give names to the input and outputs respectively.
4. Now save the project and click on download to device.
5. After downloading, click on start search then you will be able to locate the device and
click on the device.
6. To check whether we connected device click on the flash LED option.
7. Click on the start/stop to get the output.
8. Use monitoring on/off to check the current flow through the circuit.
9. Click on the go offline after verification of ladder diagram and stop CPU.
Precautions:
1. Ensure the PLC S7-1200 kit is handled with proper care.
2. Make sure to select the name plate details correctly.
3. Make sure to select all blocks for opening logic lab.
4. Use flash LED options to verify.
Result:
11
Experiment-03
DOL STARTER
Aim: To execute the ladder diagram of DOL starter.
Apparatus:
3. Profinet cable
a) NC switch
b) NO switch
c) Output block (LED’s)
Ladder diagram:
THEORY:
DOL Starter is used for small capacity motors having rating less than 5 HP the motor can with stand high starting current
due to robust construction which protects the motor from overload and low voltage condition
The NO contact is normally open in normally closed is NC when NC is pressed the circuit and motor gets switched
off from the supply
Procedure:
Precautions:
12
Result:
13
Experiment-04
STAR-DELTA STARTER
Aim: To execute the ladder diagram of STAR-DELTA starter.
Apparatus:
3. Profinet cable
a) NC switch
b) NO switch
Ladder diagram:
14
THEORY:
It was TPDT switch connects the start winding in start at the star and the delta in run hens the starter is suitable only for
motor which are designed to run with a delta connected stator winding. When the motor picks up speed, which is thrown
to run on delta position in this Vph gets rated voltage.
Procedure:
Precautions:
Result:
15
Experiment-05
BOOLEAN EXPRESSIONS
Aim: To verify and execute the ladder diagram for given Boolean expression,
AB’C+AB’C’+A’BC
Apparatus:
3. Profinet cable
a) NC switch
b) NO switch
Ladder diagram:
THEORY:
A Boolean expression is a logic statement that is either true or false Boolean expressions can compare data of any type
as long as both parts of the expression have the same basic data type. The Boolean algebra is also known as switching
algebra. It is a convenient way of expressing the operation in digital circuits and systems.
A Boolean expression is composed of a combination of the Boolean constants, Boolean variables and logical
connectives; each Boolean in expression represents a Boolean function.
There are some certain laws, rules which are used to define and these rates are the following:
1. Annulment Rule→A+1=1
2. Identity Rule→A+0=A
3. Annulment Rule→A.0=0
4. Idempotent Rule →A+A=A
5. Identity Rule →A.1=A
6. Idempotent Rule→A.A=A
7. Complement Rule→A.𝐴=0, A+𝐴=1
8. Commutative Rule→A+B=B+A , A.B=B.A
9. De Morgan’s Theorem→𝐴 + 𝐵=𝐴. 𝐵, 𝐴. 𝐵=𝐴+𝐵
16
10. Double Negation→𝐴̿=A
11. Auxiliary Laws→A+A.B=A, A+𝐴.B=A+B, AB+BC+𝐵C=AB+C
By using these laws/rules we can reduce the Boolean expression of a logic circuit.Here A,B,C are three inputs
Considered.
The expression is “A𝐵C+A𝐵 𝐶+𝐴BC”.
Procedure:
Precautions:
Result:
17
Experiment-06
STAIR-CASE WIRING
Aim: To verify and execute the ladder diagram for STAIR-CASE wiring.
Apparatus:
3. Profinet cable
a) NC switch
b) NO switch
Ladder diagram:
Theory :
Staircase wiring is a common multiway switching or two-way light switching connection.
e.g. one light bulb is operated with two switches wiring. This is mostly used to operate the
load from separate positions. Such as above or below the staircase or from inside or outside
of a room.
In PLC we can execute the ladder diagram for the Staircase wiring Using Ex-OR Switch.
Truth Table:
Procedure:
18
Precautions:
Result:
19
Experiment-07
TRAFFIC LIGHT CONTROL
Aim: To verify and execute the ladder diagram for TRAFFIC LIGHT CONTROL.
Apparatus:
3. Profinet cable
a) NC switch
b) NO switch
Ladder diagram:
Theory :
Ther are so many ways to write a program for traffic light control. For sequence output method in which
normal input, output, timers are used.
To give time delay for output, to turn ON and OFF timers are used. Reset coil is used to end the program
cycle whenever required. Input given with Syntax ‘M' are used to hold the outputs.
Procedure:
20
Precautions:
Result:
21
Experiment-08
IMPLEMENTATION OF COUNTERS
Aim: To implement and learn about the various types of counters.
Apparatus:
3. Profinet cable
a) NC switch
b) NO switch
d) UP counter
e) DOWN counter
Ladder diagram:
UP COUNTER:
DOWN COUNTER:
22
Theory :
Counters are used to count number of objects or to count cycles of a typical process. Consider an example of
bottle filling plant, in which the Canter is used to count number of bottles filled in a particular batch.
These are two types of Counters.
1. Up-Counter
Up counters count from zero up to preset value i.e. events ae added until the number reaches the preset
value. when the counter reaches the set value, it contacts change state. The accumulated Value is maintained
even during FALSE running, conditions and can only be reset back to 0 by applying the ‘reset ‘command.
2. Down-Counter
Down Counter counts down from the preset value to zero i.e. events are subtracted from the set value. when
the counter reaches the zero value, its contacts change state.
Procedure:
Precautions:
Result:
23
Experiment-09
WATER LEVEL CONTROL
Aim: To execute the ladder diagram for water level control.
Apparatus:
3. Profinet cable
a) NC switch
b) NO switch
d) Timer
Ladder diagram:
Theory:
Water level controller using PLC is designed to control the level of water and avoid the wastage of water in the tank.
The system has an automatic pumping system attached to it. We are controlling the water by using PLC, Sensor and
motors.
To detect high and low level of liquid in the tank, two switches are used to corresponding levels.
Low level switch is mounted at the bottom of the tank and high level switch is mounted at the uppermost Position of
the tank.
Procedure:
24
Precautions:
Result:
25
Experiment-10
BLINKING OF LED
Aim: To verify and execute the ladder diagram for blinking of LED.
Apparatus:
3. Profinet cable
a) NC switch
b) NO switch
d) Timer
Ladder diagram:
Procedure:
26
Precautions:
Result:
27

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Andhra University

Department of Electrical Engineering

PROGRAMMABLE LOGIC CONTROLLERS (PLC) LABORATORY

Sl.No. LIST OF EXPERIMENTS

1 Introduction of PLC and Simatic S7 1200 kit

PLC's are used to automatic processes in business around the world.

DIFFERENT COMPONENTS OF PLC :

1. POWER SUPPLY MODULE :-

2.INPUT OUTPUT MODULES:

Output field devices include Relays, lamps, and valves.

Memory is where logic is stored.

SIEMENS SIMATIC S7-1200:

It accepts of supply voltage of range of 85 V to 26 V AC to module convert it to 24 V for the operation of

The frequency of the supply is in between 47 Hz to 53 Hz but 50 Hz is ideal.

INPUT/OUTPUT MODULE [1/0 MODULE] :-

STEPS FOR PLC PROGRAMMING.

Create New project

2. OR gate: logic gate truth table of OR gate

3. AND gate: logic gate truth table of AND gate

4. NAND gate: logic gate truth table of NAND gate

5. NOR gate: logic gate truth table of NOR gate

6. XOR gate: logic gate truth table of XOR gate

The expression is “A𝐵C+A𝐵 𝐶+𝐴BC”.

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