Dedicated to the memory of my dad

Dayanand Gopaul

Other Books in the Series

 Content
1. Introduction 7
2. Example [ How to use this book ] 8
3. Exercise 1 [ Direct Online Starter ] 17
4. Exercise 2 [ Fwd – Rev Starter ] 27
5. Exercise 3 [ Sequence Starting #1 ] 29
6. Exercise 4 [ Sequence Starting #2 ] 35
7. Exercise 5 [ PLC Counter ] 43
8. Exercise 6 [ Tank Level Control ] 52
9. Exercise 7 [ Electro Hydraulic Control ] 58
10. Exercise 8 [ Traffic Intersection ] 66
11. Exercise 9 [ Process Control #1 ] 74
12. Exercise 10 [ Elevator Control ] 82
13. Exercise 11 [ Process Control #2 ] 90
14. Exercise 12 [Automatic Change Over ] 98
15. Exercise 13 [ PLC control of an AC Drive ] 107
16. Exercise 14 [ Star Delta Starter ] 115
17. Exercise 15 [ Slip Ring Starter ] 123
18. Exercise 1 Solution [ Direct Online Starter ] 132
19. Exercise 2 Solution [ Fwd – Rev Starter ] 137
20. Exercise 3 Solution [ Sequence Starting #1 ] 142
21. Exercise 4 Solution [ Sequence Starting #2 ] 147
22. Exercise 5 Solution [ PLC Counter ] 152
23. Exercise 6 Solution [ Tank Level Control ] 157
24. Exercise 7 Solution [ Electro Hydraulic Control ] 161
25. Exercise 8 Solution [ Traffic Intersection ] 168
26. Exercise 9 Solution [ Process Control #1 ] 174
27. Exercise 10 Solution [ Elevator Control ] 180
28. Exercise 11 Solution [ Process Control #2 ] 186
29. Exercise 12 Solution [Automatic Change Over ] 192
30. Exercise 13 Solution [ PLC control of an AC Drive ] 198
31. Exercise 14 Solution [ Star Delta Starter ] 203
32. Exercise 15 Solution [ Slip Ring Starter ] 208
 Introduction

This book is aimed at persons that are currently learning PLCs and wish to relate this new
knowledge to the real industrial world. It is a workbook containing 15 exercises, together with the
relevant solutions. It is assumed the reader has an understanding of electrical circuits and can
read an electrical drawing. It is required that the reader be able to “connect “the PLC to the
equipment in the form of a PLC connection diagram. Finally the reader is required to draw out the
ladder diagram. (Write the program).

There are process flow charts to help the reader understand the sequence of the process at hand.
 Example
(Guide on how to use this workbook)

Manual Light Control

In its normal state when push button PB1 is not activated light L1 is on and light L2 is off. When PB1 is pressed Light
L1 goes off and light L2 comes on.
 Example

(Guide on how to use this workbook)

Manual Light Control

In its normal state when push button PB1 is not activated light L1 is on and light L2 is off. When PB1 is pressed Light
L1 goes off and light L2 comes on.
 I/P Description
X0 Switch S1 [Normally Open ]
X1 Switch S1 [Normally Closed ]
X2
X3
X4
X5 Step 1 . Create an
O/P Description Input / Output List
Y0 Lamp L1
Y1 Lamp L2
Y2
 Exercise 1

Direct Online Starter

Push the start button and the motor must run. Push either the emergency
stop or the normal stop button and the motor must stop. In the event of the overload tripping the motor must stop and
a light must come on.
Convert this old relay logic DOL starter to be controlled by a PLC.

Step 1 . Create an Input / Output List

I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 2
 Fwd-Rev Starter
Push the FWD start button and the motor must run clockwise. Push the REV start button and the motor must run
anticlockwise. Push either the emergency stop or the normal stop button and the motor must stop. In the event of the
overload tripping the motor must stop and a light must come on.
Convert this old relay logic FWD-REV starter to be controlled by a PLC.
 Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X8
X9
X10

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
 Exercise 3

Sequence Starting #1
A common application for sequence starting is in a series of conveyors where the 1st conveyor needs to start before
the 2nd and so on to prevent a “Pile up” of material. In this exercise, Motor 1 must start before Motor 2. In the event of
Motor 1 stopping, Motor2 must also stop. In the event of either motor tripping on overload, the trip light must come on.
Convert this old relay logic SEQUENCE STARTING to be controlled by a
PLC.
 Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
 Exercise 4

Sequence Starting #2
A common application for sequence starting is in a series of conveyors where the 1st conveyor needs to start before
the 2nd and so on to prevent a “Pile up” of material. In this exercise, Motor 2 must start 20 seconds after Motor 1. In
the event of motor 1 stopping, Motor2 must also stop. In the event of either motor tripping on overload the trip light
must come on. Help is given on the Timer function of the PLC
Convert this old relay logic SEQUENCE STARTING to be controlled by a
PLC.
Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
 Exercise 5

PLC Counter
In this exercise we have a machine with a cam assembly. 10 revolution of the cam indicates a finished component
and the valve for the ejector arm needs to be activated. The function of the electronic counter is now been replaced
by the PLC. Two wiring diagrams are given one for the original counter and the second for the PLC. You can skip the
PLC wiring diagram as it is given just as an aid. Also Help is given on the Counter function of the PLC
 Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 6
 Tank Level Control
In this application the pump is used to maintain a minimum level at X1 and a maximum level at X0. Sensor X1
initiates the pump and Sensor X0 stops it.

Step 1 . Create an Input / Output List

I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 7
 Electro Hydraulic Control
Press Push Button X3 to initiate the cycle and Push Button X4 to stop the cycle. The cycle starts with the cylinder in
the back position and sensor X0 activated. The cylinder then extends until sensor X1 is made. It then dwells in the
extended position for 2 sec and then retracts until X0 is made. The cycle then stops. The cycle can now be restarted
again. If the Cycle is stopped via Push Button X4 then the cylinder will stop at any position.

Process Flow
Start the Cycle

Push PB X3
 Start Hydraulic Motor

Activate Output Y2

Sensor X0 Made

If cylinder is not in the back position i.e. Sensor X0

is not made. Activate valve Y1 until cylinder is back

Move cylinder forward

Activate valve Y0 until cylinder is fully forward ie

.Sensor X1 is made.

Dwell @ Forward Position for 2 sec

 When cylinder is fully extended , wait for 2 secs

Retract cylinder

Activate valve Y1 until cylinder is back

End the cycle

When the cylinder is fully retracted ie. Sensor X0 is

made end the cycle.

Step 1 . Create an Input / Output List

I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12
O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
 Exercise 8

Traffic Intersection
This is a typical traffic intersection. Please refer to the process flow diagram on the next page to get the correct
sequence and timing.

Process Flow
 Step 1 . Create an Output List

O/P Description
Y0 R1 Red 1
Y1 A1 Amber 1
Y2 G1 Green 1
Y3 R2 Red 2
Y4 A2 Amber 2
Y5 G2 Green 2
Y6
Y7
Step 2 . Wire up PLC
Step 3 . Write Program ( ladder Logic )
Exercise 9
 Process Control #1
This application involves the control of a drilling jig. Please refer to the Process flow diagram on the next page for the
sequence and timing of the machine.

Process Flow
Start Drill Motor Interlocks

Limit X2 to be made
Push PB X5 to activate Relay Y0 before Index Y3
 Sensor X0 to be made
before Drill Down Y2

Start the Cycle

Push PB X3 to start cycle..Cycle Lamp Y4 on

Reset Holes Drilled Counter

Reset internal Counter C1 to 0

 Move Drill Head Down

Activate valve Y2 until Drilling head is fully Down ie. Limit X1 is

made.
 Dwell @ Down Position for 1 sec End the cycle

Turn Off internal Cycle

Busy Relay and cycle
When Drilling head is fully down , wait for 1 sec lamp Y4
 Move Drill Head Up

Activate valve Y1 until Drill Head is fully Up ie. X2 is made.

Increment Counter C1

Index Part

When Drill head is up ( Limit X2 is made ) , activate Y3 to rotate

table 90°.

Step 1 . Create an Input / Output List

I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 10
 Elevator Control
This is a 2 level elevator control. There are Pushbuttons on the outside to call the elevator. On the inside there are
level numbers and level lamps indicating the current level. There are 2 sensors to sense at which level the elevator is
at. There are2 door limits and 1 door closed limit. There is a door open and a door close relay, as well as an elevator
up and down relay.

This Elevator control is only for teaching purposes and does not comply to legal requirements of
an Elevator control
 Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 11
 Process Control #2
This application involves the control of a surface grinder. The cycle runs in a loop until the cycle is stopped via X5
(Cycle top PB). Please refer to the Process flow diagram on the next page for the sequence and timing of the
machine.

Process Flow

Start Grinder Motor

Push PB X2 to activate Relay Y0

 Start the Cycle

Push PB X4 to start cycle .Cycle Lamp Y3 on

Move Table Right

Activate Valve Y2 until limit X1 is reached

 Table Right Dwell

When table is at the right ( Limit X1 made )

Dwell at the right for 1 sec

Move Table Left

Activate Valve Y1 until limit X0 is reached

Table Left Dwell

When table is at the left ( Limit X0 made )

Dwell at the left for 1 sec
 Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 12
 Automatic Changeover Control
In this application a PLC is used to switch 2 ACB between Utility and a generator Supply. Refer to the process flow
diagram to see the sequence of operation in the event of a power failure, as well as power restoration. Study signal
interface on the next page.

Signal Interface
 Process Flow

Power Loss Power Restoration

 Phase Failure Monitor Phase Failure Monitor

On Loss of Power signal X3 is lost On Power restoration signal X3 sent to PLC

Open Utility Air Circuit Breaker Open Generator Air Circuit Breaker

Turn OFF output Y1 Turn OFF output Y2

Start Generator Stop Generator

Activate output Y0 Turn OFF output Y0

Wait for generator at Frequency signal Switch Utility ACB on

Wait for signal X0 from generator before Check Generator ACB is OFF ( X2 off )
switching Air Circuit Breaker Activate output Y1
 Switch Generator ACB on

Check Utility ACB is OFF ( X1 off )

Activate output Y2
 Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 13
 PLC Control of an AC Drive
In this application a PLC is used to control an AC Drive. The objective is to familiarise the student with the various
interface signals between the PLC and Drive
 Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
 Exercise 14

Star Delta Starter

Push the start button and the motor must run in Star and change over to Delta 2 seconds later. Push either the
emergency stop or the normal stop button and the motor must stop. In the event of the overload tripping the motor
must stop and a light must come on.

In the event of physically wiring this circuit to the PLC, Please ensure there are hardwired
interlocks between the Star and Delta contactors. Do not rely on software interlocks due to
response time of equipment.
Convert this old relay logic STAR- DELTA STARTER to be controlled by a
PLC.
 Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 15
 Slip Ring Starter
Push the start button and contactor KM1 is energized and timer T1 is activated. The Motor will run. Timer T1 will
switch KM2 and KM2 will start timer T2. Timer T2 will switch KM3 and KM3 will start timer T3. . Timer T3 will switch
KM4. As each contactor is switched each resistance bank is shorted out causing a change in speed of the motor.
Convert this old relay logic SLIP RING starter to be controlled by a PLC.
Step 1 . Create an Input / Output List
I/P Description
X0
X1
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 1
 Direct Online Starter
Push the start button and the motor must run. Push either the emergency stop or the normal stop button and the
motor must stop. In the event of the overload tripping the motor must stop and a light must come on.
Convert this old relay logic DOL starter to be controlled by a PLC.

Step 1 . Create an Input / Output List

I/P Description
X0 Emergency Stop PB [S1]
X1 Stop PB [S2]
X2 Start PB [S3]
X3 Overload [F2]
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0 Contactor KM1
Y1 Lamp H1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 2
 Fwd-Rev Starter
Push the FWD start button and the motor must run clockwise. Push the REV start button and the motor must run
anticlockwise Push either the emergency stop or the normal stop button and the motor must stop. In the event of the
overload tripping the motor must stop and a light must come on.
Convert this old relay logic FWD-REV starter to be controlled by a PLC.

Step 1 . Create an Input / Output List

 I/P Description
X0 Emergency Stop PB [S1]
X1 Stop PB [S2]
X2 Start PB Forward [S3]
X3 Overload [F2]
X4 Start PB Reverse [S4]
X5
X6
X7
X10
X11
X12

O/P Description
Y0 Contactor KM1 [ Forward]
Y1 Contactor KM2 [ Reverse]
Y2 Lamp H1
Y3
Y4
Y5
Y6
Y7
 Step 2 . Wire up
PLC
Step 3 . Write Program ( ladder Logic )
Exercise 3
 Sequence Starting #1
A common application for sequence starting is in a series of conveyors where the 1st conveyor needs to start before
the 2nd and so on to prevent a “Pile up” of material. In this exercise Motor 1 must start before Motor 2. In the event of
Motor 1 stopping, Motor2 must also stop. In the event of either motor tripping on overload the trip light must come on.
Convert this old relay logic SEQUENCE STARTING to be controlled by a
PLC.
 Step 1 . Create an Input / Output List

I/P Description
X0 Emergency Stop PB [S1]
X1 Stop PB Motor 2 [S2]
X2 Start PB Motor 1 [S3]
X3 Overload Motor 1 [F2]
X4 Start PB Motor 2 [S4]
X5 Overload Motor 2 [F3]
X6 Stop PB Motor 1 [S5]
X7
X10
X11
X12

O/P Description
Y0 Contactor KM1 [ Motor 1 ]
Y1 Contactor KM2 [ Motor 2 ]
Y2 Lamp H1
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 4
 Sequence Starting #2
A common application for sequence starting is in a series of conveyors where the 1st conveyor needs to start before
the 2nd and so on to prevent a “Pile up” of material. In this exercise Motor 2 must start 20 seconds after Motor 1. In
the event of Motor 1 stopping Motor2 must also stop. In the event of either motor tripping on overload the trip light
must come on. Help is given on the Timer function of the PLC
Convert this old relay logic SEQUENCE STARTING to be controlled by a
PLC.
 Step 1 . Create an Input / Output List

I/P Description
X0 Emergency Stop PB [S1]
X1 Stop PB Motor 2 [S2]
X2 Start PB Motor 1 [S3]
X3 Overload Motor 1 [F2]
X4 Start PB Motor 2 [S4]
X5 Overload Motor 2 [F3]
X6 Stop PB Motor 1 [S5]
X7
X10
X11
X12

O/P Description
Y0 Contactor KM1 [ Motor 1 ]
Y1 Contactor KM2 [ Motor 2 ]
Y2 Lamp H1
Y3
Y4
Y5
Y6
Y7
 Step 2 . Wire up
PLC
Step 3 . Write Program ( ladder Logic )
Exercise 5
 PLC Counter
In this exercise we have a machine with a cam assembly. 10 revolution of the cam indicates a finished component
and the valve for the ejector arm needs to be activated. The function of the electronic counter is now been replaced
by the PLC. Two wiring diagrams are given one for the original counter and the second for the PLC. You can skip the
PLC wiring diagram it is given just as an aid. Also Help is given on the Counter function of the PLC
 Step 1 . Create an Input / Output List
I/P Description
X0 Reset Push Button
X1 Count Sensor
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0 Contactor KM1
Y1
Y2
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 6 [ Solution ]
 Tank Level Control
In this application the pump is used to maintain a minimum level at X1 and a maximum level at X0. Sensor X1
initiates the pump and Sensor X0 stops it.

Step 1 . Create an Input / Output List

I/P Description
X0 High Level Sensor
X1 Low Level Sensor
X2
X3
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0 Pump Contactor KM1
Y1
Y2
Y3
Y4
Y5
Y6
Y7
 Step 2 . Wire up
PLC

Step 3 . Write Program ( ladder Logic )

 Exercise 7 [ Solution ]

Electro Hydraulic Control

Press Push Button X3 to initiate the cycle and Push Button X4 to stop the cycle. The cycle starts with the cylinder in
the back position and sensor X0 is activated, the cylinder then extends until sensor X1 is made. Its then dwells in the
extended position for 2 sec and then retracts until X0 is made. The cycle then stops. The cycle can now be restarted
again. If the Cycle is stopped via Push Button X4 then the cylinder will stop at any position.

Process Flow
Start the Cycle
 Push PB X3

Start Hydraulic Motor

Activate Output Y2

Sensor X0 Made

If cylinder is not in the back position ie. Sensor X0

is not made. Activate valve Y1 until cylinder is back

Move cylinder forward

Activate valve Y0 until cylinder is fully forward ie.

Sensor X1 is made.
 Dwell @ Forward Position for 2 sec

When cylinder is fully extended , wait for 2 secs

Retract cylinder

Activate valve Y1 until cylinder is back

End the cycle

When the cylinder is fully retracted ie. Sensor X0 is

made end the cycle.

Step 1 . Create an Input / Output List

I/P Description
X0 Cylinder Back Sensor
X1 Cylinder Forward Sensor
X2 Overload
X3 Cycle Start PB
X4 Cycle Stop PB
X5
X6
X7
X10
X11
X12
O/P Description
Y0 Cylinder Forward Valve
Y1 Cylinder Back Valve
Y2 Pump Motor Contactor
Y3
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 8 [ Solution ]
 Traffic Intersection
This is a typical traffic intersection. Please refer to the process flow diagram on the next page to get the correct
sequence and timing.

Process Flow
 Step 1 . Create an Output List

O/P Description
Y0 R1 Red 1
Y1 A1 Amber 1
Y2 G1 Green 1
Y3 R2 Red 2
Y4 A2 Amber 2
Y5 G2 Green 2
Y6
Y7
Step 2 . Wire up PLC
Step 3 . Write Program ( ladder Logic )
 Exercise 9 [ Solution ]

Process Control #1
This application involves the control of a drilling jig. Please refer to the Process flow diagram on the next page for the
sequence and timing of the machine.

Process Flow
Start Drill Motor Interlocks
 Push PB X5 to activate Relay Y0 Limit X2 to be made
before Index Y3

Sensor X0 to be made
before Drill Down Y2

Start the Cycle

Push PB X3 to start cycle...Cycle Lamp Y4 on

Reset Holes Drilled Counter

Reset internal Counter C1 to 0

 Move Drill Head Down

Activate valve Y2 until Drilling head is fully Down i.e. Limit X1

is made.
 Dwell @ Down Position for 1 sec End the cycle

Turn Off internal Cycle

Busy Relay and cycle
When Drilling head is fully down , wait for 1 sec lamp Y4
 Move Drill Head Up

Activate valve Y1 until Drill Head is fully Up i.e. X2 is made.

Increment Counter C1

Index Part

When Drill head is up ( Limit X2 is made ) , activate Y3 to rotate

table 90°.

Step 1 . Create an Input / Output List

I/P Description
X0 Index Counter Sensor
X1 Drill Down Limit
X2 Drill Up Limit
X3 Cycle Start Push Button
X4 Cycle Stop Push Button
X5 Drill Motor Start Push Button
X6 Drill Motor Start Push Button
X7
X10
X11
X12

/P Description
Y0 Drill Motor Relay
Y1 Drill Up Soleniod
Y2 Drill Down Soleniod
Y3 Index Table ( 90° ) Soleniod
Y4 Cycle Busy Lamp
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
 Exercise 10 [ Solution ]

Elevator Control
This is a 2 level elevator control. There are Pushbuttons on the outside to call the elevator. On the inside there are
level numbers and level lamps indicating the current level. There are 2 sensors to sense at which level the elevator
is at. There are2 door limits and 1 door closed limit. There is a door open and a door close relay, as well as an
elevator up and down relay.
This Elevator control is only for teaching purposes and does not comply to legal requirements of
an Elevator control

Step 1 . Create an Input / Output List

I/P Description
st
X0 1 Floor Push Button
X1 2nd Floor Push Button
X2 Up Push button
X3 Down Push Button
X4 Lift at 1st Floor sensor
X5 Lift at 2nd Floor sensor
X6 Door Open Limit
X7 Door Close Limit
X10 Door Close limit Safety Sensor
X11
X12

O/P Description
Y0 1st Floor Lamp
Y1 2nd Floor Lamp
Y2 Door Open Relay
Y3 Door Close Relay
Y4 Elevator Up Relay
Y5 Elevator Down Relay
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 11 [ Solution ]
 Process Control #2
This application involves the control of a surface grinder. The cycle runs in a loop until the cycle is stopped via X5
(Cycle top PB). Please refer to the Process flow diagram on the next page for the sequence and timing of the
machine.

Process Flow

Start Grinder Motor

Push PB X2 to activate Relay Y0

 Start the Cycle

Push PB X4 to start cycle .Cycle Lamp Y3 on

Move Table Right

Activate Valve Y2 until limit X1 is reached

 Table Right Dwell

When table is at the right ( Limit X1 made )

Dwell at the right for 1 sec

Move Table Left

Activate Valve Y1 until limit X0 is reached

Table Left Dwell

When table is at the left ( Limit X0 made )

Dwell at the left for 1 sec
 Step 1 . Create an Input / Output List
I/P Description
X0 Table Left Limit
X1 Table Right Limit
X2 Grinding Wheel Start Push Button
X3 Grindind Wheel Stop Push Button
X4 Cycle Start Push Button
X5 Cycle Stop Push button
X6
X7
X10
X11
X12

O/P Description
Y0 Grinding Wheel Motor Relay
Y1 Table Left Solenoid
Y2 Table Right Solenoid
Y3 Cycle Light
Y4
Y5
Y6
Y7
Step 2 . Wire up PLC
Step 3 . Write Program ( ladder Logic )
 Exercise 12 [ Solution ]

Automatic Changeover Control

In this application a PLC is used to switch 2 ACB between Utility and a generator Supply. Refer to the process flow
diagram to see the sequence of operation in the event of a power failure, as well as power restoration. Study signal
interface on the next page.

Signal Interface
 Process Flow

Power Loss Power Restoration

 Phase Failure Monitor Phase Failure Monitor

On Loss of Power signal X3 is sent to PLC On Power restoration signal X3 is OFF

Open Utility Air Circuit Breaker Open Generator Air Circuit Breaker

Turn OFF output Y1 Turn OFF output Y2

Start Generator Stop Generator

Activate output Y0 Turn OFF output Y0

Wait for generator at Frequency signal Switch Utility ACB on

Wait for signal X0 from generator before Check Generator ACB is OFF ( X2 off )
switching Air Circuit Breaker Activate output Y1
 Switch Generator ACB on

Check Utility ACB is OFF ( X1 off )

Activate output Y2
 Step 1 . Create an Input / Output List
I/P Description
X0 Generator at Frequency Signal
X1 Utility Supply Breaker Closed Signal
X2 Generator Breaker Closed Signal
X3 Power Loss Signal
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0 Start Generator
Y1 Close Utility Supply Air Circuit Breaker
Y2 Close Generator Air Circuit Breaker
Y3
Y4
Y5
Y6
Y7
 Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )

 Exercise 13 [ Solution ]

PLC Control of an AC Drive

In this application a PLC is used to control an AC Drive. The objective is to familiarise the student with the various
interface signals between the PLC and Drive
 Step 1 . Create an Input / Output List

I/P Description
X0 Stop Push Button
X1 Run Forward Push Button
X2 Run Reverse Push Button
X3 Drive Rest Push Button
X4 Drive Tripped Signal
X5
X6
X7
X10
X11
X12

O/P Description
Y0 Run Forward Command [R1]
Y1 Run Reverse Command [R2]
Y2 Drive reset Command [R3]
Y3
Y4
Y5
Y6
Y7
Step 2 . Wire up PLC
Step 3 . Write Program ( ladder Logic )
 Exercise 14 [ Solution ]

Star Delta Starter

Push the start button and the motor must run in Star and change over to Delta 2 seconds later. Push either the
emergency stop or the normal stop button and the motor must stop. In the event of the overload tripping the motor
must stop and a light must come on.

In the event of physically wiring this circuit to the PLC. Please ensure there are hardwired
interlocks between the Star and Delta contactors. Do not rely on software interlocks due to
response time of equipment.
Convert this old relay logic STAR- DELTA STARTER to be controlled by a
PLC.
 Step 1 . Create an Input / Output List
I/P Description
X0 Emergency Stop PB [S1]
X1 Stop PB [S5]
X2 Start PB [S3]
X3 Overload [F2]
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0 Main Contactor [ KMM ]
Y1 Star Contactor [ Star ]
Y2 Delta Contactor [ Delta ]
Y3 Lamp [ H1 ]
Y4
Y5
Y6
Y7

Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )
Exercise 15 [ Solution ]
 Slip Ring Starter
Push the start button and contactor KM1 is energized and timer T1 is activated. The Motor will run. Timer T1 will
switch KM2 and KM2 will start timer T2. Timer T2 will switch KM3 and KM3 will start timer T3. . Timer T3 will switch
KM4. As each contactor is switched each resistance bank is shorted out causing a change in speed of the motor.
Convert this old relay logic SLIP RING starter to be controlled by a PLC.
Step 1 . Create an Input / Output List
I/P Description
X0 Emergency Stop PB [S1]
X1 Stop PB [S2]
X2 Start PB [S3]
X3 Overload [F2]
X4
X5
X6
X7
X10
X11
X12

O/P Description
Y0 Contactor [KM1]
Y1 Contactor [KM2]
Y2 Contactor [KM3]
Y3 Contactor [KM4]
Y4
Y5
Y6
Y7
 Step 2 . Wire up PLC

Step 3 . Write Program ( ladder Logic )

Blank