Manufacturing Automation Lab (MT 451L)

MT 451L: Manufacturing
Automation Lab

Lab Manual No.8

Name Muhammad Saud Dar

Reg. ID 211277

Section BEMTS-8B

Submitted To: Mam Mahnoor Zahid

Department of Mechatronics and

Biomedical Engineering
Air University

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 Manufacturing Automation Lab (MT 451L)

Lab # 08
Sequencers
Objective
 To know operation of sequencer instruction
 To simulate tasks in Allen Bradley PLC

Software
 LogixPro
 RSLogix500

Experiment Setup
1. A PLC (Programmable Logic Controller)
2. A power supply for the PLC
3. Input and output devices (switches, sensors, relays, etc.)
4. A computer with PLC programming software
5. A programming cable to connect the PLC to the computer.

Introduction to Sequencer
The Sequencer instruction is used when a repeating sequence of outputs is required. The
Sequencer instruction allows the PLC to implement this common control strategy.
Operation
The desired output-bit patterns for each step are stored (sequentially) as words in memory as
usual; each bit in the word corresponds to a specific terminal of the output module. Every
time the Sequencer instruction steps, it c01mects the next output pattern in memory to the
designated output module. The address of the fust pattern (word) in the sequence is given in
the Sequencer instruction as the Sequencer File Adr. The Sequencer steps when the rung
makes a FALSE-to-TRUE transition. Other versions of the Sequencer instruction allow the
programmer to insert a time value for each step.
Symbol

Symbol Details
Sequencer File Adr: The first address of the Sequence file, which stores the sets of outputs.
Destination Adr: The output address (or slot) to which the Sequence file words are
transferred with each step.
Length: The length of the Sequence file, that is, the number of steps in the sequence.
EN Goes T RU E when the Sequencer rung is TRUE.

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 Manufacturing Automation Lab (MT 451L)

ON Stands for done--goes TRU E when it has operated on the last word in the Sequence file.
Control Adr: Address that stores the control bits (EN, ON) and words (length) of the
sequencer.

Lab Tasks
Exercise No. 1
System has a Push button LS 1, when user press the LS 1. ((Implement Using Sequencer)
• 1st time Fan goes ON
• 2nd time Bulb ON and Fan goes OFF
• 3rd time Bulb OFF

1. Created a Sequencer Output (SQO) instruction in RSLogix500 to control outputs

in steps based on LS1 push button presses.
2. Defined a Sequence File (e.g., B3:10) with 3 steps:
o Step 0: Fan ON (e.g., output bit O:0/0 = 1)
o Step 1: Bulb ON, Fan OFF (e.g., O:0/1 = 1, O:0/0 = 0)
o Step 2: All OFF (e.g., O:0/0 = 0, O:0/1 = 0)
3. Configured LS1 (e.g., I:0/0) as the trigger input that causes the sequencer to step
on each press (false-to-true transition).
4. Set the Destination Address to the output module (e.g., O:0).

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 Manufacturing Automation Lab (MT 451L)

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Department of Mechatronics and Biomedical Engineering
 Manufacturing Automation Lab (MT 451L)

Exercise No. 2
Write a program that will turn on a flashing light one after another for 1 sec.
1. Created a Sequencer Output (SQO) instruction to control a set of lights (e.g., 3
lights on O:0/0, O:0/1, O:0/2) in a sequential pattern.
2. Defined a Sequence File (e.g., B3:20) with steps like:
3. Step 0: Light 1 ON (O:0/0 = 1)
4. Step 1: Light 2 ON (O:0/1 = 1)
5. Step 2: Light 3 ON (O:0/2 = 1)
6. Step 3: All OFF (to reset before looping)
7. Used a Timer (TON) with a preset of 1 second (e.g., T4:0.PRE = 10) to create the
delay between steps.
8. Connected the done bit (T4:0/DN) of the timer to trigger the sequencer step,
ensuring the sequence advances every 1 second.

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Department of Mechatronics and Biomedical Engineering
 Manufacturing Automation Lab (MT 451L)

Exercise No. 3
Using ladder logic: Use only one start stop station consisting of only one NC contact and one
NO contact, two motor starters and three control relays create the following cycle. (No timers
or counters)
1. When the start button is pressed motor 1 will start and run until stopped by pressing
the stop button.
2. When the start button is pressed again motor 2 will run until stopped by pressing the
stop button.
3. When the start button is pressed again motors 1 & 2 will run until stopped by pressing
the stop button. Pressing the start button again will now start the cycle over.
1. Used CR1, CR2, and CR3 as memory elements to track the current cycle stage
(toggle behavior).
o First start press → latch CR1 → start Motor 1.
o Second press → unlatch CR1, latch CR2 → start Motor 2.
o Third press → unlatch CR2, latch CR3 → start both Motor 1 and Motor 2.
o Fourth press → unlatch CR3 → reset all → back to Motor 1 on next press.
2. Designed logic such that each start button press toggles between control relays
(CR1 → CR2 → CR3 → reset), using interlocking to ensure only one relay is
latched at a time.
3. Used output logic:
o CR1 → energizes Motor 1
o CR2 → energizes Motor 2
o CR3 → energizes both Motor 1 & Motor 2
4. Stop button (NC) breaks the holding circuit of all relays and motors, stopping
everything.
5. Ensured the start button (NO) momentarily energizes a relay, which then latches
itself using a parallel holding contact.

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 Manufacturing Automation Lab (MT 451L)

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 Manufacturing Automation Lab (MT 451L)

Exercise No. 4
Write a program for two-way traffic signals.
1. Defined Output Bits
o N-S Red: O:0/0
o N-S Yellow: O:0/1
o N-S Green: O:0/2
o E-W Red: O:0/3
o E-W Yellow: O:0/4
o E-W Green: O:0/5
2. Created a Sequence File (e.g., B3:30) with 6 steps to cycle through states:
o Step 0: N-S Green, E-W Red
o Step 1: N-S Yellow, E-W Red
o Step 2: N-S Red, E-W Green
o Step 3: N-S Red, E-W Yellow
o Step 4: All Red (transition state)
o Step 5: Repeat from Step 0
3. Used a Timer (T4:0) to trigger the SQO instruction every few seconds (e.g., 5
seconds for green, 2 seconds for yellow).
4. Connected the Timer.DN bit to advance the SQO instruction and restart the timer.
5. Destination Address: O:0 (output module); Control Word: R6:0

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 Manufacturing Automation Lab (MT 451L)

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 Manufacturing Automation Lab (MT 451L)

Sources of Errors

1. Incorrect Sequence File Configuration – Errors in defining output patterns or step

order can lead to malfunctioning sequences.
2. Wiring or Output Address Mistakes – Using wrong I/O addresses for devices can
prevent correct output operation.
3. Button Debouncing Issues – In physical PLCs, mechanical bounce from pushbuttons
can cause unintended multiple steps.
4. Improper Use of Control Bits – Misunderstanding how the EN, DN, and control
registers function can disrupt the logic.
5. Simulation Limitations – LogixPro may not perfectly represent all real-world
behaviors of PLC systems.

Applications in Industry

1. Traffic Light Control Systems – Sequencers are widely used to manage multi-
directional traffic signals.
2. Packaging Lines – Stepwise control of filling, sealing, and labeling processes.
3. Batch Processing – Automated mixing, heating, and transferring operations in
chemical or food industries.
4. Manufacturing Assembly Lines – Coordinating machines and robotic arms in
specific sequences.
5. Elevator Control – Managing floor selection and door opening/closing operations
step by step.

Conclusion

This lab demonstrated how Sequencer instructions (SQO) are used in PLC programming to
control systems that require step-by-step output transitions, such as traffic signals or
process cycles. By simulating real industrial tasks in LogixPro and programming in
RSLogix500, we gained practical insight into the logic and operation of sequencers.
Understanding and applying this logic is essential for developing efficient, reliable, and
automated control systems in modern industry.

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