PLC Assignment

1. Switching of Lamps

- When Input 1 (I1) and Input 2 (I2) are OFF, Lamp 1 (Q1)
- should become ON and Lamp 2 (Q2) should become OFF.

- When Input 1 (I1) and Input 2 (I2) are ON,

Lamp 2 (Q2) should become ON and Lamp 1
(Q1) should become OFF.
I9
- When ---- I1 is ON & I2 is OFF 8
Or When – I1 is OFF & I2 is ON
Both Q1 & Q2 should be OFF.

I1 I2 Q1 Q2
0 0 1 0
0 1 0 0
1 0 0 0
1 1 0 1
2. Control of Motors

- When Input 1 (I1) and Input 2 (I2) are OFF,

Motor 1 (Q1) should become ON and Motor 2 (Q2)
Motor 3 (Q3) & Motor 4 (Q4) should become OFF.

- When Input 1 (I1) is OFF & Input 2 (I2) is ON,

Motor 2 (Q2) should become ON and Motor 1 (Q1)
Motor 3 (Q3) & Motor 4 (Q4) should become OFF.

- When Input 1 (I1) is ON & Input 2 (I2) is OFF,

Motor 3 (Q3) should become ON and Motor 1 (Q1)
Motor 2 (Q2) & Motor 4 (Q4) should become OFF.

- When Input 1 (I1) and Input 2 (I2) are ON,

Motor 4 (Q4) should become ON and Motor 1 (Q1)
Motor 2 (Q2) & Motor 3 (Q3) should become OFF.

I1 I2 Q1 Q2 Q3 Q4
0 0 1 0 0 0
0 1 0 1 0 0
1 0 0 0 1 0
1 1 0 0 0 1
3. Control of Motors

- When Input 1 (I1) and Input 2 (I2) are OFF,

Motor 1 (Q1) & Motor 2 (Q2) should become ON and
Motor 3 (Q3) & Motor 4 (Q4) should become OFF.

- When Input 1 (I1) is OFF and Input 2 (I2) is ON, Motor 2 (Q2) & Motor 3 (Q3) should become
ON and Motor 1 (Q1) & Motor 4 (Q4) should become OFF.

- When Input 1 (I1) is ON and Input 2 (I2) is OFF, Motor 3 (Q3) & Motor 4 (Q4) should become
ON and Motor 1 (Q1) & Motor 2 (Q2) should become OFF.

- When Input 1 (I1) and Input 2 (I2) are ON,

Motor 1 (Q1) & Motor 4 (Q4) should become ON and
Motor 2 (Q2) & Motor 3 (Q3) should become OFF.

I1 I2 Q1 Q2 Q3 Q4
0 0 1 1 0 0
0 1 0 1 1 0
1 0 0 0 1 1
1 1 1 0 0 1
4. Control of Motors

- When Start Switch (I1) is ON,

Motor 1 (Q1) should be ON for 5 Sec.
- After 5 Sec, Motor 1 should stop
And Motor 2 (Q2) should start and remain
ON for 5 Sec.
- After 5 Sec, Motor 2 should stop
And Motor 3 (Q3) should start and remain
ON for 5 Sec.
--- After 5 Sec, Motor 3 should stop
And Motor 4 (Q4) should start and remain
ON for 5 Sec.
- After 5 Sec, Motor 4 should stop
And again Motor 1 (Q1) should start and
The process should be repeated till STOP
switch (I2) is pressed. When I2 is presses,
the complete process should stop.
I1 Timer Q1 Q2 Q3 Q4

1 T1 1 0 0 0

1 T2 0 1 0 0

1 T3 0 0 1 0

1 T4 0 0 0 1
5. Digital Lock

Password for Digital Lock is –

PASSWORD Enter Key Open Alarm
–
I2 I3 I4 I5 I6 I7 I1 Q1 Q2
1 1 1 1 1 1 1 1 0
X X X X X X 1 0 1

When password is OK i.e. 111 111 and ENTER KEY – I1 is pressed, Lock should Open i.e. – Q1
should be ON & Q2 i.e. ALARM should be OFF.

When password is WRONG i.e. either I2 / I3 / I4 / I5 / I6 / I9 is not ‘1’ , and ENTER KEY – I1 is
pressed, Lock should NOT OPEN i.e. – Q1 should be OFF & Q2 i.e. ALARM should be ON.

HINT :- Store I2 & I3 & I4 in M-1;

Store I5 & I6 & I7 in M-2;
Compare M-1 & M-2 to decide
whether to OPEN the LOCK (Q1)
or to give ALARM (Q2)

5A
Once ALARM starts ringing, it should STOP only after I2
is pressed , otherwise it should keep on ringing.
6. Car Parking
1.7 I-1 – Car wants to ENTER - Sensor
2.0 I-2 – Car ENTRY OVER Sensor
2.1 I-3 – Car wants to EXIT -Sensor
2.2 I-4 – Car EXIT OVER Sensor
2.3 I-5 - Parking Space for Car
2.4 I-6 - Parking Space for Car
2.5 I-9 - Parking Space for Car
2.6 I-10- Parking Space for Car

Q-1 – Parking FULL indication

Q-2 – Parking SPACE available indication
Q-3 – ENTRY GATE OPEN / CLOSE indication
Q-4 – EXIT GATE OPEN / CLOSE indication

When a car comes at the Entry Gate, ONLY IF there is SPACE available for Parking, the Entry
Gate should Open.ONLY when the Car passes from Entry Over Sensor I2, the Entry Gate should
close.

When a car wants to EXIT from the Parking area, it will come at the EXIT GATE. When a Car is
sensed by Input I3, EXIT Gate will open. ONLY when the Car passes from I4 i.e. Exit Over
Sensor, the EXIT Gate should close.

When Space is available for parking the Car/s at either I5 / I6 / I9 / I10, SPACE indication Q2
should be ON and FULL indication Q1 should be OFF.

When the Parking area is fully occupied FULL indication Q1 should be ON and SPACE indication
should be OFF.
7. Bottling Plant
I11- Start Conveyor
[I124.0] 2.7 I1- Milk Filling position sensor
[I124.1] 3.0 I2- Milk filled till expected level sensor
[I124.2] 3.1 I3- Capping position sensor
[I124.3] 3.2 I4- Capping plunger limit switch sensor.
[I124.4] 3.3 I5- Labeling Position sensor
[I124.5] 3.4 I6- Label detection sensor

[Q124.0] Q1- Conveyor

[Q124.1] Q2- Milk Filler valve
[Q124.2] Q3- Capping Piston
[Q124.3] Q4- Labeling Piston

Start the conveyor with I-1 1.

When Bottle is sensed by I1, i.e. I1 becomes ON,
Stop the conveyor & Start (Open) Milk Filler valve.
When I2 becomes ON, Stop the Valve & Start Conveyor.

When Bottle is sensed by I3, i.e. I3 becomes ON,

Stop the conveyor & Start Capping Piston.
When I4 is ON i.e a Cap is detected on the Bottle,
Stop Capping Piston & Start Conveyor.

When Bottle is sensed by I5, i.e. I5 becomes ON,

Stop the conveyor & Start Labeling Piston
When I6 becomes ON i.e. a Label is detected
Stop the Labeling piston & Start Conveyor.

7A
Write above program using Timers for Q1, Q2, Q3 &
Q4.
Count the number of Bottles being filled.
 8. 7Segment Display
I1 I2 I3 Decimal
0 0 0 0 M10 Q1, Q2,Q3,Q4,Q5,Q6
0 0 1 1 M1 Q2,Q3
0 1 0 2 M2 Q1, Q2, Q4,Q5, Q7
0 1 1 3 M3 Q1, Q2,,Q3,Q4 Q7
1 0 0 4 M4 Q2,Q3 Q6,Q7,
1 0 1 5 M5 Q1, Q3,Q4 ,Q6,Q7
1 1 0 6 M6 Q1, Q3,Q4,Q5,Q6,Q7
1 1 1 7 M7 Q1, Q2,Q3

When the switch position is 0 0 0 ,

Decimal 0 should appear on the 7-segment display.

For this Initially store the switch positions

in M10, M1 , M2 …. As per above table.

When M10 is on Q1,Q2,Q3,Q4,Q5 & Q6 should be On

Similarly for M1, M2 M3….. as per above table make corresponding outputs ON as per switch
positions.

8A
Add one Input I4 and write program for displaying
Hexa-decimal values from 0 to F
9. Door Bell (Timers)

I-1 – Push button at the Gate

I-2 – Switch at the Door

I-3 – Acknowledge Switch inside the House.

Q-1 – Bell / Buzzer

When I-1 is Pressed and released, Q1 should be

ON for 5 Seconds and then it should
automatically become OFF.

When I-2 is ON, Q1 should become ON after 2

Seconds and it should remain ON.

When I-3 is ON Q-1 should become OFF.

Hint :- Trigger OFF-Delay or Pulse Timer using I-1

Trigger On-Delay Timer using I-2
Reset Q-1 by either resetting T-2 or I-3 ON.
10. SILO Control

I-1 – Start
I-2 - Stop

Q-1 – Valve of Chemical – 1

Q-2 – Valve of Chemical - 2

[8-A] When I1 is ON, Q1 and Q2 should alternately

become ON & OFF continuously for two seconds.

When I-2 is ON, the process should STOP.

Hint :- Use Flashing Timer

10 A
Use two different Timers and do the following -
When I1 is ON, Q1 and Q2 should alternately
become ON & OFF continuously for two seconds.

When I-2 is ON, the process should STOP.

11. Traffic Light Control

I-1 – start
I-2 – Stop

Q-1 – Red Light

Q-2 – Green Light
Q-3 - Yellow Light

When Start button is pressed, RED light should become ON and should remain ON for 5 Seconds.

After 5 Seconds, RED light should become OFF and GREEN light should become ON and should
remain ON for next 7 Seconds.

After 7 Seconds, Green Light should become OFF and YELLOW light should become ON and
should remain ON for 2 Seconds.

After 2 Seconds, YELLOW light should become OFF and again RED light should become ON and
the Cycle should repeat, till I-2 i.e. STOP button is pressed

11 A
Write program for signal of 4 directions with
different Timing for the Green Lights.
12. Star-Delta Control
I-1 – Start
I-2 – Stop

Q-1 - Main Contactor

Q-2 – Star Contactor
Q-3 – Delta Contactor
Q-4 – Motor ON/OFF indication.

When start button is pressed, Q1, Q2 & Q4 should start.

After 5 seconds, Q2 should Stop and Q3 should start and should remain ON (Q1 & Q4 should
remain ON).

If Stop button is pressed at any stage, the entire process should stop.
13. Starter Control

I-1 – Start
I-2 – Stop

Q-1 – Main Contactor

Q-2 – Rotor resistance (High)
Q-3 – Rotor resistance (Medium)
Q-4 – Rotor resistance (Low)
Q-5 – Motor ON/ OFF indication.

When Start button is pressed, Q1, Q2 & Q5 should become ON.

After 5 seconds, Q2 should become OFF and Q3 should become ON.

After next 5 seconds, Q3 should become OFF and Q4 should become ON.

Hence we reduce the Rotor resistance step-by-step,

till we attain the rated Speed of the Motor.

If I-2 i.e. Stop button is pressed at any stage of the cycle, the entire cycle should Stop.
14. Reaction Vessel

I124.0 I-1 – Start

I124.1 I-2 – Low Level
I124.2 I-3 – High Level
I124.3 I-4 – Low Pressure
I124.4 I-5 – High Pressure
I124.5 I-6 - Low Temperature
I124.6 I-9 – High Temperature
I124.7 I-10- Stop

Q124.0 Q-1 – Inlet Valve

Q124.1 Q-2 – Outlet Valve
Q124.2 Q-3 – Cooling Water Pump (for reducing Temp.)
Q124.3 Q-4 – Safety Valve (for releasing excess Pressure)
Q124.4 Q-5 – Heater
Q124.5 Q-6 – Stirrer
Q124.6 Q-7 – Normal Conditions (indication)
Q124.7 Q-8 – Alarm (Indication)

When Start button is pressed, if the level is Low, Start Inlet Valve.

When Temperature or Pressure is Low, Give an Alarm and Start Heater and Stirrer.

If Pressure is High, give an Alarm, Stop Heater and Open Safety Valve.

If Temp. is High, give an Alarm, Stop Heater and start Cooling Water Pump.

When there is no Alarm, Give Normal Indication.

When High Level is attained, Stop Inlet Valve.
When it is High Level and Normal Condition, Start Outlet Valve.

When Low Level is reached, Stop Outlet Valve, start inlet valve
and repeat the process.
 15. Elevator Control

I-1 I124.0 Door Limit I-5 I124.4 Request Buttons I-2 I125.0 Request buttons
Switch L/S on the Floors inside the Lift

I-2 I124.1 L/S of 2nd I-6 I124.5 Request Button I-3 I125.1 Request to go to
Floor on 2nd Floor 2nd Floor from Lift
cabin

I-3 I124.2 L/S of Ist Floor I-7 I124.6 Request Button I-4 I125.2 Request to go to
on Ist Floor Ist Floor from Lift
Cabin
I-4 I124.3 L/S of Ground I-1 I124.7 Request Button I-5 I125.3 Request to go to
Floor on Gnd. Floor Gnd Floor from
Lift Cabin

Q-1 q124.0 Move Lift in Q-2 Q125.1 Move Lift in

UP direction Down Direction

If the Lift is on Ground Floor and the request comes from 2 nd Floor i.e. I5 or I12, the Lift should move
UP till it reaches 2nd Floor and then it should stop there.

If the Lift is on Ground Floor and the request comes from Ist Floor i.e. I6 or I9, the Lift should move UP
till it reaches Ist Floor and then it should stop there.

Similarly write program for requests from different Floors, when the Lift is either on Gnd. Or Ist Or 2 nd
Floor.
16. Resistance Welding
I-1 – Start process in Manual Mode (Reset after 1 cycle)
I-2 – Start process in Automatic Mode (Repeat Cycles)
I-3 – Low Pressure
I-4 – Normal Pressure
I-5 – Normal Temperature
I-6 – High Temperature

Q-1 – Valve V1
Q-2 – Squeeze Timer indication (Timer - T2)
Q-3 – Weld Timer indication (Timer – T3)
Q-4 – Hold Timer indication (Timer – T4)
Q-5 – Off Timer indication (Timer – T5)
Q-6 – Cooling Pump.
Q-7 – Air Compressor

If Pressure is Low, Keep Air Compressor ON till Normal Pressure is reached.

Then Start Squeeze Timer T2 for 5 Seconds during that period pen Valve V1 so that the Plates will be
squeezed near each other.
Then Start Weld Timer for 5 Seconds duration, during which the plates will be welded to each other.
During Welding if Temp. becomes High start Cooling Water Pump.
If Temp. is Low, stop Cooling Water Pump.
After Welding, start Hold Timer for 5 Seconds to allow the joint to settle.
In case of Manual Mode Stop the Process here.
In case of Auto Mode, Repeat the process automatically
17. Soft Drink Dispensor / Vending Machine
I-1 – Coin Sensor
I-2 – Coin Rejection Sensor
I-3 – Coke requested sensor
I-4 – Pepsi requested sensor
I-5 – Thumps-up requested sensor
I-6 – Limca requested sensor

Q-1 – Coin Accepted indication

Q-2 – Coin rejected indication
Q-3 – Coke delivered indication
Q-4 – Pepsi delivered indication
Q-5 – Thumps-up delivered indication
Q-6 – Limca delivered indication

When a valid Coin is inserted and it is accepted, any one softdrink should be delivered as requested by
the customer. (It should take only 2 seconds for the selected softdrink to be delivered after that the
corresponding output should become OFF).

For e.g. If a Valid Coin is inserted and I3 is pressed (i.e. Coke is requested by the customer) Q3 i.e.
Coke Output should be ON for 2 Seconds and then it should automatically become OFF.

Note :- Only 1 softdrink to be given for 1 coin inserted.

If more than 1 softdrinks are requested at a time,
only the one which is selected first should be delivered.
18. Tank Level Control

I-1 – Start / Stop the process

I-2 – Low Level
I-3 – High Level

Q-1 – Inlet Valve ON / OFF

Q-2 – Outlet Valve ON / OFF
Q-3 – Stirrer ON / OFF

When Start switch is ON,

If Low Level is ON, Make Inlet Valve Q1 ON.
When High Level is reached, Make Inlet Valve Q1 OFF.

Once High Level is reached and Inlet Valve has become OFF, make Stirrer ON for 5 Seconds (during
this Outlet valve should be OFF).

After 5 seconds when the stirrer has switched OFF, if High Level is ON, Start Outlet Valve till Low
level is reached.

When Low level is reached, stop Outlet Valve and again start inlet valve and repeat the process.

18 A
Instead of I2 & I3 as Low and High Levels,
use Analog Input A1 (I7<=1.0 as Low Level)
A2 (I7>=9.0 as High Level)
Other conditions will remain the same.
19. Process (pH) Control

I-1 – Start / Stop the process

I-2 – Low Level
I-3 – High Level

A-1 – pH Sensor (Analog)

Q-1 – Pump ON / OFF

Q-2 – Stirrer ON / OFF
Q-3 – Drain Valve
Q-4 – ACID Tank Valve ON / OFF

When Start switch is pressed, the Pump should become ON for 5 seconds and then it should
automatically become Off. During these 5 seconds it will transfer the water from Main Storage Tank
into the Reaction Tank.

After 5 seconds, sense the pH of the Liquid in the Reaction Tank. If pH>=7.0, start Acid Tank Valve Q-
4 and start the Stirrer, till pH<=4.0. When pH<=4.0 stop Acid Tank Valve, stop the stirrer and Start
Drain Valve.
20. Microwave Oven Control

I-1 – Start / Power ON

I-2 – Stop
I-4 – Door Open / Close input
I-5 – Input for making Oven ON for 1 Minute (Timer T5)
I-6 – Input for making Oven ON for 2 Minutes (Timer T6)
I-7 - Input for making Oven ON for 3 Minutes (Timer T7)

Q-1 – Oven ON / OFF indication

Q-2 – View Lamp On / OFF indication
Q-3 – ‘a’ Segment of 7-segment Display
Q-4 – ‘b’ Segment of 7-segment Display
Q-5 – ‘c’ Segment of 7-segment Display
Q-6 – ‘d’ Segment of 7-segment Display
Q-7 – ‘e’ Segment of 7-segment Display
Q-8 – ‘g’ Segment of 7-segment Display

I1 is Only for Power ON. Oven should become ON only if Door is Closed and either I5 / I6 / I7 is
Pressed.

If I5 is Pressed Oven Should be ON for 1 Minute ( ‘1’ should be displayed on 7-Segment Display) and
then automatically it should
become OFF after 1 Minute (7 segment display should also become OFF). Similarly for I6 & I7, Oven
should be ON for 2 or 3 minutes.

If the Door is Opened, Oven should become OFF and View Lamp Should become ON. If the door is
Closed, the View Lamp should become OFF and Oven should again become ON if the respective Timer
is still ON.

Only One Input I5 or I6 or I7 should be Accepted at a Time. Till request of I5 is being executed I6 / I7
requests should not be accepted. Similarly during I6, I5 & I7 should not be accepted & so on.
21. Washing Machine

I-1 – Start / Power ON

I-2 – Stop
I-3 – High Level
I-4 – Door Open / Close input
I-5 – Low Level

Q-1 – Wash Cycle Indication

Q-2 – Rinse Cycle Indication
Q-3 – Spin Cycle Indication
Q-4 – Spin Action Indication
Q-5 – Motor running Clock-wise Indication
Q-6 – Motor running Anti-Clockwise Indication
Q-7 – Inlet Valve ON / OFF Indication
Q-8 – Drain Valve ON / OFF Indication

When Start button (I1) is pressed if Door (I4) of the Washing Machine is Closed, and Level of Water is
Low (I5), Start Inlet Valve (Q7). When level of Water reaches High Level (I3), Stop Inlet Valve (Q7)
and Start Washing Cycle i.e. make the Motor run Clock-wise (Q5) for 2 Seconds and then Anti-Clock-
wise (Q6) for 2 Seconds. Repeat this CW / ACW process till Q5 operates for 5 times (Use Counter for
Counting). When Q5 has operated for 5 times, Reset Washing Cycle. Drain the water till Low Level is
reached. Fill new Water till High Level is Reached again.

Now since Wash Cycle is Over, Start Rinse Cycle (Q2). i.e. make the Motor run Clock-wise (Q5) for 2
Seconds and then Anti-Clock-wise (Q6) for 2 Seconds. Repeat this CW / ACW process till Q5 operates
for 5 times (Use separate Counter for Counting). When Q5 has operated for
5 times, Reset Rinse Cycle. Start Drain valve and keep it ON till Spin Cycle is Over.

Now since Wash & Rinse Cycles are over, Start Spin Cycle (Q3) & Spin Action (Q4), i.e. make the
Motor run Clock-wise (Q5) for 2 Seconds and then Anti-Clock-wise (Q6) for 2 Seconds. Repeat this
CW / ACW process till Q5 operates for 5 times (Use Counter for Counting). When Q5 has operated for
5 times, Reset Spin Cycle. Stop Drain valve when Low water level is reached and then stop the entire
process.

During the process whenever I2 (STOP button) is pressed the entire process should stop.
22. Boiler Automation

I1 – Low Level of water in Boiler

I2 – Extra Low Level of water in Boiler
I3 – Power Supply
I4 – Burner Switch
I5 – Emergency Stop (i.e. Stop Q1, Q2, Q3, Q4, Q5, Q6 & Q9)
I6 – Photocell Sensor (Flame Sensor)
I7 – Reset (Alarms stop / Unlatch)
I8 – High Level of Water in Boiler
I9 – Pressure Switch for Fuel Oil
I10- Limit Switch for Damper Open
I11- Limit Switch for Damper Close

Q1 – Boiler ON indication
Q2 – Feed Water Pump –1
Q3 – Feed Water Pump –2
Q4 – Air Blower
Q5 – Ignition
Q6 – Solenoid Valve for Fuel Oil
Q7 – Alarm
Q8 – Hooter
Q9 – Damper Motor
Q10 – Fuel Oil Pump
Q11 - Pressure switch for Fuel Oil

Initialization process of Feed Water Pump –

When Start (I3) is Pressed, Make Feed Water Pump –1 (Q2) ON.
If it is not functioning, give Alarm and Start Feed Water Pump –2 (Q3)
If it is not functioning, give Alarm and go to Lockout condition.
If Q2 or Q3 become ON, Keep them ON till Hill Level is reached, then Stop Feed Water Pump. When
either Q2 or Q3 becomes ON, start Normal Process.

Initialization of Fuel Oil –

Start Fuel Oil Pump and open Solenoid Valve for Fuel Oil.
If Pressure Switch is ON Start Normal Process.
If Pressure Switch does not become ON, Stop Pump and give Alarm.

Normal Process –
When Steam Pressure is <= 5.0 Start Blower Motor.
PRE-PURGE - After 5 Sec, Start Damper Motor (CW) which should remain ON for 30 Sec or till I10 is
reached. Then the Motor should move ACW till I11 is reached. Then Stop Damper Motor.

Then Start Ignition Q5.

After 2 Sec, Start Fuel Oil Valve Q6
After 10 seconds, if Flame is detected, make Q1 & Q6 ON; Stop Q5.
If Flame is not detected stop both Q5 & Q6 and give Alarm.

IF Extra Low Level of Water is reached, Give Alarm & go to Lockout.

If Extra Low Level is not reached, if Pressure (A1) >= 9.0 Stop Q6 &
Start Post-PURGE cycle.

POST PURGE – Q9 ON till I10 operates, wait for 30 Sec, then when I11 operates, Restart the Normal
Process.