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Lecture-7

The document outlines the process of writing ladder logic programs based on narrative descriptions, providing examples of various control systems including a drilling process, an automatic garage door, and a continuous filling operation. It emphasizes the importance of defining processes, sketching systems, and considering safety measures. Additionally, it includes exercises for designing PLC programs for motor controls and temperature control systems.

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Lecture-7

The document outlines the process of writing ladder logic programs based on narrative descriptions, providing examples of various control systems including a drilling process, an automatic garage door, and a continuous filling operation. It emphasizes the importance of defining processes, sketching systems, and considering safety measures. Additionally, it includes exercises for designing PLC programs for motor controls and temperature control systems.

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تُحف العقول
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Systems

Lecture 7

Dr. Salim Al-Wasity


 Writing a Ladder Logic Program Directly
from a Narrative Description.
 Example-1
 Example-2
 Example-3
 Exercises
WRITING A LADDER LOGIC PROGRAM DIRECTLY FROM A
NARRATIVE DESCRIPTION

Some guide steps used in planning a program


 Define the process to be controlled.
 Draw a sketch of the process, including all sensors and manual controls needed to carry out the control sequence.
 List the sequence of operational steps in as much detail as possible.
 Write the ladder logic program to be used as a basis for the PLC program.
 Consider different scenarios where the process sequence may go astray and make adjustments as needed.
 Consider the safety of operating personnel and make adjustments as needed.
EXAMPLE-1

 The figure below shows the sketch of a drilling process


that requires the drill press to turn on only if there is a
part present and the operator has one hand on each of
the start switches.
 This precaution will ensure that the operator’s hands
are not in the way of the drill. The sequence of
operation requires that switches 1 and 2 and the part
sensor all be activated to make the drill motor operate.
 The ladder logic program required for the process
shown below.
EXAMPLE-2
▪ Normally closed door stop button for stopping the door.
A motorized overhead garage door is to be operated ▪ Red door ajar light to signal when the door is partially open.
automatically to preset open and closed positions. The field ▪ Green door open light to signal when the door is fully open.
devices include one of each of the following: ▪ Yellow door closed light to signal when the door is fully
closed.
 Reversing motor contactor for the up and down directions.
 Normally closed down limit switch to sense when the door The sequence of operation requires that:
is fully closed. ▪ When the up button is pushed, the up motor contactor
energizes and the door travels upward until the up limit
 Normally closed up limit switch to sense when the door is switch is actuated.
fully opened. ▪ When the down button is pushed, the down motor
 Normally open door up button for the up direction.
contactor energizes and the door travels down until the
down limit switch is actuated.
 Normally open door down button for the down direction. ▪ When the stop button is pushed, the motor stops. The
motor must be stopped before it can change direction.
EXAMPLE-2
EXAMPLE-3

The figure below shows the sketch of a continuous filling


operation. This process requires that boxes moving on a
conveyor be automatically positioned and filled.
The sequence of operation for the continuous filling
operation is as follows:
 Start the conveyor when the start button is
momentarily pressed.
 Stop the conveyor when the stop button is momentarily  Stop the conveyor when the right edge of the box is
pressed. first sensed by the photosensor.
 Energize the run status light when the process is  With the box in position and the conveyor stopped,
operating. open the solenoid valve and allow the box to fill. Filling
 Energize the standby status light when the process is should stop when the level sensor goes true.
stopped.  Energize the full light when the box is full. The full light
should remain energized until the box is moved clear of
the photosensor.
EXAMPLE-3
EXERCISES

Exercise-1:
Design a PLC program and prepare a typical I/O connection diagram and ladder logic program for the following motor control:
 A motor must be started and stopped from any one of three start/stop pushbutton stations.
 Each start/stop station contains one NO start pushbutton and one NC stop pushbutton.
 Motor OL contacts are to be hardwired.
Exercise-2:
Design a PLC program and prepare a typical I/O connection diagram and ladder logic program for the following motor control:
 Three starters are to be wired so that each starter is operated from its own start/stop pushbutton station.
 A master stop station is to be included that will trip out all starters when pushed.
 Overload relay contacts are to be programmed so that an overload on any one of the starters will automatically drop all of the
starters.
 All pushbuttons are to be wired using one set of NO contacts.
EXERCISES

Exercise-3:
A pump is to be used to fill two storage tanks. The pump is manually started by the operator from a start/stop station. When the
first tank is full, the control logic must be able to automatically stop flow to the first tank and direct flow to the second tank
through the use of sensors and electric solenoid valves. When the second tank is full, the pump must shut down automatically.
Indicator lamps are to be included to signal when each tank is full.
 Draw a sketch of the process.
 Prepare a typical PLC program for this control process.
EXERCISES

Exercise-4:
A temperature control system consists of four thermostats controlling three heating units. The thermostat contacts are set to
close at 50°, 60°, 70°, and 80°F, respectively. The PLC ladder logic program is to be designed so that at a temperature below 50°F,
three heaters are to be ON. Between 50° to 60°F, two heaters are to be ON. For 60° to 70°F, one heater is to be ON. Above 80°F,
there is a safety shutoff for all three heaters in case one stays on because of a malfunction. A master switch is to be used to turn
the system ON and OFF.
 Prepare a typical PLC program for this control process.

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