PLC Applications

Applications :1: Problem Description : Level control in Tank

One open tank is installed in the plant of which liquid level is to be controlled. When
level reaches the Level Low, Outlet flow is blocked and inlet flow is allowed until high
level is achieved. And when Level High is detected, outlet flow is allowed and inlet flow
is blocked.
Problem Solution

• To detect high and low level of liquid in the tank, two level switches are used which gives
output in digital terms, that is when corresponding levels are detected, it gives output
high otherwise remain low.
• To control level of this system, Single Acting piston valve can be used which has two
states, either fully open or fully close.
• Low Level Switch is mounted at the bottom of the tank and Level High switch mounted
at the side upper most position.
• When this inputs are detected, output to Control Valve has to be latched in order to
continuously fill or empty the system.
• Master start/stop is also provided to shut down or start the entire process.
PLC Program
Here is PLC program to Control Level of a Single Tank, along with program explanation and run time test
cases.
List of Inputs and Outputs
I:1/0 = Level High Switch (Input)
I:1/1 = Level Low Switch (Input)
O:2/0 = Inlet Valve (Output)
O:2/1 = Outlet Valve (Output)
I:1/14 = Start (Input)
I:1/15 = Stop (Input)
Program Description
• RUNG000 is simply for latching a coil and master start-stop buttons.
• RUNG001 is to control the outlet valve through O:2/1. This is done when Level High is detected.
• Latching of Output O:2/1 is done because when High Level is detected, input to RUNG001 is temporary,
like Push Button. So in order to keep outlet valve open until the Level Low I:1/1 is detected, latching is
done. XIO of Level Low Switch is connected in series so that when Level Low is detected, it goes true
closing the outlet valve.
• Similarly in RUNG002, it works exactly same. The only difference in RUNG002 is that extra I:1/14 contact
in parallel with LLS.
• Suppose when the system is started and the tank is partially filled, neither LHS nor LLS is detected, in this
case, outlet and inlet valves remain closed while inlet valve should open to start filling the tank because
it’s partially filled.
• To eliminate this error, I:1/14 (Start) is connected in parallel to LLS I:1/1 contact. This checks if LHS (I:1/0)
is detected or not. If LHS is not detected, then it opens the inlet valve until LHS is detected.
 Applications :2: PLC Program for Counting of Parts from Conveyor
This is a PLC Program for Counting of Parts from Conveyor.
Problem Description
Parts are moved on the conveyor. Count the number of parts collected at the end of the
conveyor and display it on the display in PLC using Ladder Diagram programming language.
Problem Solution
• Mount Proximity Switch to detect the parts.
• Use output of proximity to counter as an input to increment data.
• Convert this number into appropriate numerical and show number of parts
collected.
• Most widely Inductive and Capacitive Proximity switches are used to detect parts.
• Inductive Proximity are used to detect metal objects while to detect other objects,
Capacitive Proximity Switch is most widely used.
• Capacitive Proximity detection capability ranges from 1 to 25mm distance.
• Mount this sensor according to the size of parts present on the conveyor and
width of conveyor so that this sensor can detect parts easily.
• CUP is used to increment the number of parts collected.
PLC Program
Here is PLC program for Counting of Parts from Conveyor, along with program
explanation and run time test cases.
List of Inputs and Outputs
I:1/0 = Start (Input)
I:1/1 = Stop (Input)
I:1/5 = Proximity (Part detection) (Input)
C5:0 = Counter Up (Counter)
O:6 = Display address (Output)
TOD = Hexadecimal to BCD conversion instruction (Compute)
B3:0/0 = Latching Bit (Bit)
Program Description
• RUNG000 is the master start/stop rung used to start and stop the counting process.
• RUNG001 is to count the number parts collected. Counter Up with address C5:0 is to
count the number of parts collected. Whenever a part is detected by Proximity Switch,
I:1/5 goes true momentarily and it increments accumulator value of the counter.
• RUNG002 is used to convert Decimal numbers into Binary Coded Decimal. Source
address is given as C5:0.ACC and destination address is given as O:6 which is of Display.
Converted BCD number is decoded by the display and the value present in accumulator
of CUP C5:0 is displayed.
Applications :3: PLC Program to Remove Empty Detected Bottle on Conveyor

This is a PLC Program to Remove Empty Detected Bottle on Conveyor.

Problem Description
After filling process, bottles are moved on the conveyor belt for packing process. Detect if any empty bottle is
left on the conveyor and remove it from the conveyor. Implement automation of this in PLC using Ladder
Diagram programming language.
Problem Solution
• Proximity sensors are used to detect bottles.
• One proximity is calibrated such that it detects all the bottles passing on the
conveyor. And other proximity is used such that it detects only empty bottle.
• Use Bit Shift Register to shift a bit which is set when an empty bottle is detected.
• Use a piston or blower is used to throw an empty bottle out of the conveyor.
List of Inputs and Outputs
I:1/0 = Start (Input)
I:1/1 = Stop (Input)
I:1/2 = Bottle Proximity (Input)
I:1/3 = Empty bottle proximity (Input)
O:2/0 = Master coil / Run (Output)
O:2/1 = Conveyor motor (Output)
O:2/2 = Blower (Output)
BSL = Bit shift left instruction (Logical)
B3:0 = Bit shift Register (Register)
B3:0/3 = Bit to energize capping machine (Bit)
R6:0 = Control register (Register)
Program Description
• When the system is started, conveyor motor coil with address O:2/1 is energized.
• RUNG002 and RUNG003 are used to operate bit shift register and Blower with
address O:2/2.
• Whenever conveyor motor is in RUN mode, empty bottles detected by the proximity
sensor with input I:1/3, it sets B3:0/0 bit and is shifted left every time a bottle is
detected by bottle proximity with address I:1/2.
• From proximity to blower, distance is 4 steps. Hence bit B3:0/3 of B3:0 register is
used to operate blower.
• When B3:3/0 bit is set that is when empty bottle is detected by input I:1/3, after 4
steps, blower is activated and the empty bottle is removed.
Applications :4: PLC Ladder Program to Control of
Escalators
Description
1. Let’s assume that the escalator does not move until someone approaches it.
2. When someone approaches the escalator and turns on pass detection
switch: 0, the illumination lamp lights and the escalator starts to move. (Escalator
movement is up only).
3. The person is carried up by the escalator, and when that person moves off
the escalator, pass detection switch: 1 turns ON, and the illumination lamp and
escalator return to a non-operating state.
In this PLC ladder program example, consider both pass detection switches: 0 and 1 as
non-hold type switches.
Another assumption in this PLC Ladder Program example is that people do
not continue to get on this escalator
PLC Input and Output assignment:
PLC Input Pass detection switch: 0 X000
PLC Input Pass detection switch: 1 X003
PLC Output Illumination lamp Y000
PLC Output Escalator drive output Y003
PLC Ladder Program for Control of
Escalators 1
 PLC Ladder Program for Control of
Escalators 2

PLC program Explanation for Control of

Escalators:
When input X001 is turned ON, outputs Y000 and Y003 operate. Next,
Applications :5:
Problem Solution
1. They are so many ways to write a program for traffic light control ex:
sequencer output method but in this normal input, outputs and timers are
used.
2. Timers are used to give time delay for output to turn ON and OFF.
3. Reset coil is used at the end to run the program continuously.
4. Comparator blocks are used to reduce the number of timers used.
5. Program done in AB RSLogix 500 Software.
Below tabular column gives the Steps or sequence of outputs to
turn ON
PLC Logic Description for 3-way Traffic Control System
RUNG000 :
This is a Latching rung to operate the system through Master Start and Stop PB.
RUNG001 and RUNG0002 :
Starting the timer to turn ON first output West Green so east and west should be in red.
Comparators in Parallel rung are used to turn OFF East red after 15 sec. Timer
T4:2 timing bit in parallel contact used to turn ON East red again in 5th and
6Th Step. (Refer Above Tabular column for clarification)
RUNG 0003 :
Turning ON North Red up to 3rd step using T4:0 and T4:1’s timer timing bit and
comparator blocks.
Rung 0004 :
Turn ON East yellow for 5 sec using comparator blocks. (Step 2nd)
Rung 0005-0006-0007-0008-0009-0010 :
The same procedures followed to turn ON further outputs. ( Refer Tabular
column for a sequence of operation)
RUNG 0011 :
Reset coil is turned ON using T4:2 ‘s done bit to restart the cycle from
Beginning
The program runs continuously until STOP PB is pressed
Applications :6:
Conclusion:
The above-explained 3 ways traffic light control using PLC is for
example only.
It may vary from real-time. We can use this example program to
understand the
working of timers and comparator block function in AB PLC.
Problem Logic
Step Conditions:
• Start and Stop PB is used to start and stop the process.
• Start is pressed Conveyor starts moving until the Proximity Sensor is ON.
• Then solenoid valve is open for 5 seconds. After 5s Conveyor should startmoving.
• The above process should continue unto 3 bottles.
• Process should continue still stop push button pressed.

List of Inputs and Outputs

Program Description
RUNG 0000
Latching rung to operate the system through Master Start and Stop PB.
RUNG 0001
To turn ON Conveyor motor, memory bit (B3:0/1 ) is used .
RUNG 0002
To turn on Conveyor motor using memory bit of start latching PB and B3:0/1, it willautomatically turn off
when B3:0/2 turns on once Proximity sensor activates.
Timer done is connected in parallel to turn conveyor motor ON again.
RUNG 0003
Proximity sensor output saved in memory bit to use in previous rung.
RUNG 0004 and Rung 0005
To store the status of proximity sensor B3:0/3 is used, Comparator block is used to
compare counter accumulator value to stop the process once three bottle process
hadfilled.
Rung 0006
To count the number of bottles, proximity sensor is given to up counter with preset
value sets to 3.
RUNG 0007
Stop input
Note:
Memory bits are used to store the sensor output, since it is the simulation, sensor
Applications :6:
Elevator Logic Description
RUNG 0000
Latching rung to operate the system through Master Start and Stop PB.
RUNG 0001
Starting the Operation using start latch, Ground floor PB is pushed to turn on latch coil to
store the output of status when the ground limit switch is off.
RUNG 0002
First floor PB is pushed to turn on the latch coil to store the output of status when the First
limit switch is off.
Rung 0003
Second floor PB is pushed to turn on the latch coil to store the output of status when the
Second limit switch is off.
Rung 0004, 0005, 0006
In some cases,if someone pressed ground floor PB/First floor PB, the program will check
where the lift is if it is in the second floor or the first floor, Down Motor will turn ON to get
the lift to the respective floor.
For interlocking, normally closed switch of ground limit switch and first-floor switch is used
in Rung 0006
Rung 0007, 0008, 0009
In some cases, if someone pressed the second floor PB/First-floor Pushbuttons (PB), the
RUNG 0010, 0011
To open the lift door when it reaching floor Binary bits are used to store the status of ground floor PB
and ground Limit switch.
RUNG 0012, 0013
To open the lift door when it reaching the floor , Binary bits are used to store the status of First floor
PB and First Limit switch.
RUNG 0014, 0015
To open the lift door when it reaching the floor , Binary bits are used to store the status of Third floor
PB and third-floor Limit switch.
RUNG 0016
From the previous rungs memories, an Open door motor is turned ON with three interlocking like
closed-door motor, Timer enables, UP/DOWN motor.
RUNG 0017
When the open door limit switch is turned to on, the Open motor door should stop and timer needs to
turn on to give time delay of 5s to close door motor.
RUNG 0018
When timer done turned on, close door motor should ON until closed limit switch is turned ON.
RUNG 0019
If no PB is turned on after getting into lift takes 10secs delay to open lift door again. If any PB is
pressed, it will perform the respective operations.
The program runs continuously until STOP PB is pressed
Note: We can reduce the number of memories used.
Applications :7
Applications :5: Multiple Pumps Control
using PLC
1.The start/stop push button is provided for control of the two input
pump motors P1 and P2.
2.The Start/Stop pushbutton station is operated to control pump P1.
3.When the tank is full drain pump motor P3 is started automatically and
runs until the low-level sensor is actuated.
4.After 3 fillings of the tank by pump P1 control automatically shifts to
pump P2.
5.The operation of the start/stop pushbutton now controls pump P2.
6.After 3 fillings of the tank by pump P2, the sequence is repeated.
Program Description:
Rung 0000:
Start/Stop PB latched with memory B3:0/0.
Rung 0001:
B3:0/0 enabled to turn on B3:0/1 which is to turn ON PUMP P1 (O:0/0) when low-level sensor(I:0/3)
turn ON and High-level sensor (I:0/2) is in off condition.B3:0/1 is latched with low-level sensor
because pump p1 should not go off once water started rising.

Rung 0002:
Memory contacts used to turn on PUMP P1 (O: 0/0) with counter (C5:0).
Since we are going to shift pump operation from P1 to P2, two counters are used to shift between
Pl and P2.
Counter C5:1 is used to turn on PUMP P2(O:0/2).
Rung 0003 & 0004:
B3:0/0 enabled to turn on B3:0/2 which is to turn on PUMP P3(O:0/1) when high-level sensor(I:0/2)
turn ON and low-level sensor (I:0/3) is in off condition.B3:0/2 is latched with high-level sensor
because pump p3 should not go off once water started reducing.
Rung 0005:
When Pump 3 (O: 0/1) is running, the low-level sensor turns on will make Pump p3 off and pump
P1(O:0/0) ON.

Rung 0006:
Both Counter reset is done once the second counter (C5:1) done bit turns ON.