Government of Karnataka

Department of Technical Education

Board of Technical Examinations, Bengaluru

Course Title: Programmable Logic Controller Lab Course Code: 15MC55P

Mode (L:T:P) : 0:2:4 Credits :3 Core/ Elective: Core
Type of course: Tutorials and Practical’s Total Contact Hours: 78
CIE- 25 Marks SEE- 50 Marks

Prerequisites: Knowledge of BEEE, PLC Programming, Digital Electronics, Fluid Pneumatics.

Course Objectives: understand ladder programming, interface and develop PLC program for
broadly defined engineering applications.

Course Outcomes: At the end of the course, students should be able to

1. Develop and execute ladder programs for given Engineering applications.

2. Interface PLC with hardware for given Engineering applications.

Cognitive Linked Teaching

Course Outcome
Level with PO Hours
Develop and execute ladder programs
CO1 A 2,3,4 60
for given applications
Interface PLC with hardware for given
CO2 A 2,3,4 18
applications
Total sessions 78
Legend: R; Remember, U: Understand A: Application

Mapping of Course Outcomes with Program Outcomes

Course Programme Outcomes

1 2 3 4 5 6 7 8 9 10
Programmable Logic Controller
- 3 3 3 - - - - - -
Lab

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 Contents
1. Develop a PLC ladder diagram to construct an alarm system which operates as follows
. If one input is ON nothing happens
. If any two inputs are ON, a red light goes ON
. If any three inputs are ON, an alarm sirens sound
. If all are ON, the fire department is notified.
2. Develop a PLC program using ladder diagram for start-stop jog.

3. Develop a PLC program using ladder diagram for Forward-reverse-stop with mutual
interlocks

4. Develop PLC ladder diagram to realize the following logic gates.

AND, OR, NOT, NAND, NOR, EX-OR.

5. Develop the following Boolean expressions in to ladder diagram and realize

I) [(P+ Q +R).(U+V). W .X]+(S+T).Y=Z.


II) B.(C.( D  E  C )  F .C ) = A.

6. In certain process control application a fan is to run only when all of the following conditions
are met

. Input A is OFF

. Input B is ON or i/p C is ON, or both B &C are ON

. Inputs D &E both are ON

. One or more of inputs F, G, or H is ON

Develop Gate logic, equivalent Boolean expression & realize the same using PLC ladder
diagram

7. Develop a PLC ladder diagram to realize the following Timer operation. Write timing
diagrams.

i) One shot operation

ii) Limited ON time

8. There are 3 mixing devices on a processing line A,B ,C. After the process begin mixer-A is to
start after 7 seconds elapse, next mixer-B is to start 3.6 second after A. Mixer-C is to start 5

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seconds after B. All then remain ON until a master enable switch is turned off. Develop PLC
ladder diagram, timing diagram and realize the same.

9. An indicating light is to go ON when a count reaches 23.The light is then go off when a count
of 31 is reached. Develop, construct, and test PLC circuits for this process.

10. In certain process control application when the count reaches 25, a paint spray is to run for 40
seconds. Develop, construct, and test PLC circuits for this process.

11. Develop a Ladder diagram for the forward and reverse moment of a piston in pneumatic
cylinder. The Ladder diagram should consist of 2 input Push button switches I1 and I2 .The
output O1 and O2 of PLC are connected to Forward and retract Coil of the Pneumatic Cylinder.

12. In bottling plant of cool drinks the bottles are kept on the conveyor. Some bottles are capless,
so these bottles are to be removed from the conveyor. I1 are I2 are two toggle switches
connected to input unit of PLC. I1 is used to operate (ON) the conveyor and I2 is used to stop
(OFF) the conveyor at any time. O1 is the output used to operate the conveyor. S2 is the
Proximity Switch which predicts that metal cap is not present on the bottle top. Use I3 switch to
operate the conveyor after the removal of capless bottle from the conveyor. Develop the Ladder
diagram to achieve the above Industrial Scenario.

13. There are 4 cars parking spaces .Car is to detected and allowed to enter into the parking space
if space is available. I1 is the proximity switch at the gate for detecting the presence of Car. I2,
I3, I4, I5 are proximity switches which are installed at suitable places in 4 parking spaces. When
the car is parked in a parking place , presence of Car is indicated by corresponding output
O2,O3,O4,O5 (by glowing the Output) .If space is vacant the corresponding light will not glow
and the car owner will have to go in that parking place. Develop the Ladder diagram to achieve
the above Scenario.

14. Develop and Interface a PLC program for the following real time applications

i) Traffic light controlling

ii) Water level controlling

References

1. “Programmable Logic Controllers Principles & Applications” by John W. Webb –

Ronald A. Reis. , 5th Edition, Published by PHI Publication.

2. Exploring Programmable Logic-Controllers with Applications by Pradeep Kumar Srivastava, BPB

PUBLICATIONS.

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 Contents linked with CO and PO

Sl No Contents CO PO

1 Develop a PLC ladder diagram to construct an alarm system which 1 2,3,4

operates as follows
. If one input is ON nothing happens
. If any two inputs are ON, a red light goes ON
. If any three inputs are ON, an alarm sirens sound
. If all are ON, the fire department is notified

2 Develop a PLC program using ladder diagram for start-stop jog. 1 2,3,4
3 Develop a PLC program using ladder diagram for Forward-reverse- 1 2,3,4
stop with mutual interlocks
4 Develop PLC ladder diagram to realize the following logic gates. 1 2,3,4
AND, OR, NOT, NAND, NOR, EX-OR.
5 Develop the following Boolean expressions in to ladder diagram and 1 2,3,4
realize
I) [(P+ Q +R).(U+V). W .X]+(S+T).Y=Z.

II) B.(C.( D  E  C )  F .C ) = A.
6 In certain process control application a fan is to run only when all of 1 2,3,4
the following conditions are met
. Input A is OFF
. Input B is ON or i/p C is ON, or both B &C are ON
. Inputs D &E both are ON
. One or more of inputs F, G, or H is ON
Develop Gate logic, equivalent Boolean expression & realize the
same using PLC ladder diagram.
7 Develop a PLC ladder diagram to realize the following Timer 1 2,3,4
operation. Write timing diagrams.
i) One shot operation
ii) Limited ON time
8 There are 3 mixing devices on a processing line A,B,C. After the 1 2,3,4
process begin mixer-A is to start after 7 seconds elapse, next mixer-B
is to start 3.6 second after A. Mixer-C is to start 5 seconds after B.
All then remain ON until a master enable switch is turned off.
Develop PLC ladder diagram, timing diagram and realize the same.
9 An indicating light is to go ON when a count reaches 23.The light is 1 2,3,4
then go off when a count of 31 is reached. Develop, construct, and
test PLC circuits for this process.
10 In certain process control application when the count reaches 25, a 1 2,3,4
paint spray is to run for 40 seconds. Develop, construct, and test PLC
circuits for this process.
11 Develop a Ladder diagram for the forward and reverse moment of a 1 2,3,4

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 piston in pneumatic cylinder. The Ladder diagram should consist of 2
input Push button switches I1 and I2 .The output O1 and O2 of PLC
are connected to Forward and retract Coil of the Pneumatic Cylinder.
12 In bottling plant of cool drinks the bottles are kept on the conveyor. 1 2,3,4
Some bottles are capless ,so these bottles are to be removed from the
conveyor. I1 are I2 are two toggle switches connected to input unit of
PLC. I1 is used to operate (ON) the conveyor and I2 is used to stop
(OFF) the conveyor at any time. O1 is the output used to operate the
conveyor. S2 is the Proximity Switch which predicts that metal cap is
not present on the bottle top. Use I3 switch to operate the conveyor
after the removal of capless bottle from the conveyor. Develop the
Ladder diagram to achieve the above Industrial Scenario.
13 There are 4 cars parking spaces .Car is to detected and allowed to 1 2,3,4
enter into the parking space if space is available. I1 is the proximity
switch at the gate for detecting the presence of Car. I2, I3, I4, I5 are
proximity switches which are installed at suitable places in 4 parking
spaces. When the car is parked in a parking place , presence of Car is
indicated by corresponding output O2,O3,O4,O5 (by glowing the
Output) .If space is vacant the corresponding light will not glow and
the car owner will have to go in that parking place. Develop the
Ladder diagram to achieve the above Scenario.

14 Develop and Interface a PLC program for the following real time 2 2,3,4
applications
i) Traffic light controlling
ii) Water level controlling

Scheme of valuation for SEE

S Performance Max. Marks
l. No.
1 Writing two Ladder diagrams. 10.
2 Entering two programs in computer system 10.
3 Simulation\Execution 10.
4 Result 10
5 Viva - Voce 10
Total 50

Student Activity

Activity No. Description of Student Activity

1 Prepare the hand written report on various sensors, actuators, transducers
used in industrial automation.
2 Students can make models of Programmable Logic Controller applications
beyond the curriculum.

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Note:
1. Group of max four students should do any one of the above activity or any other similar
activity related to the course COs and get it approved from concerned Teacher and HOD.
2. No group should have activity repeated or similar
3. Teacher should ensure activities by different groups must cover all Cos.

4. Teacher should asses every student by using suitable Rubrics approved by HOD

Sample Rubrics

Dimension
Exemplary Accomplished Developing Beginning Roll No. of the Student

5/4 3 2 1 1 2 3 4 5
Organization Information Information in Difficult to Cannot Ex:
presented in logical follow understand 2
logical, sequence presentation-- presentation--
interesting student jumps no sequence
sequence around of
information
Subject Demonstrates At ease with Uncomfortable Does not 3
Knowledge full expected with have a grasp
knowledge by answers to information of the
answering all questions but and is able to information.
class does not answer only Cannot
questions with elaborate rudimentary answer
explanations questions questions
and about subject
elaborations
Graphics Explain and Relate to text Occasionally Uses 4
reinforce and uses graphics superfluous
screen text presentation that rarely graphics or
and support text no graphics
presentation and
presentation
Oral Maintains eye Maintains eye Occasionally Reads with 5
Presentation contact and contact most of uses eye no eye
pronounces all the time and contact, mostly contact and
terms pronounces reading incorrectly
precisely. All most words presentation, pronounces
audience correctly. Most and incorrectly terms. Speaks
members can audience pronounces too quietly
hear members can terms.
hear Audience
presentation members have
difficulty
hearing
Total Score=(2+3+4+5)=14/4=3.5=4

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 Course Assessment Pattern

Particulars Max Evidence Course

Marks outcomes

Direct Assessment CIE Two tests 10 Blue books 1 &2

(Average of
Two tests)

Practical 10 Practical 1 &2

record record

Student 05 Student 1 &2

Activity Activity
Sheets

SEE End of the 50 Answer scripts 1 &2

course at BTE

Indirect Assessment Student Middle of the Feedback 1 &2

Feedback course forms
on course
End of the Feedback 1 &2
course forms

*CIE – Continuous Internal Evaluation *SEE – Semester End Examination

Note:
1. I.A. test shall be conducted as per SEE scheme of valuation. However obtained marks
shall be reduced to 10 marks. Average marks of two tests shall be rounded off to the next
higher digit.
2. Rubrics to be devised appropriately by the concerned faculty to assess Student activities.

List of Equipments
1. PLC Trainer Kits with interfacing facility

2. Interfacing modules.
2.1 Traffic light controller
2.2 Water level controller

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