PLC Apps- By Eng.

Ahmed Mohamed Yasser

Helwan University at Helwan Engineering Faculty German Msc Program System Automation & Project Management

Programmable logic Controller Applications

By Eng. AHMED MOHAMED YASSER

Submitted To Prof. Dr. Moustafa Eissa
Jan.2012

Page 1

PLC Apps- By Eng. Ahmed Mohamed Yasser

List of contents
1- Motor On-Off. 2- Motor with heater sensor. 3- Motor right-left directly. 4- Motor right-left indirectly. 5- Motor right-left using Set-Reset. 6- Tank-Pump-2level sensors. 7- Two motors with timer (1st. method). 8- Two motors with timer (2nd method). 9- Three motors with Timers. 10111213141516Tank-3pumps-2level sensors-Mixers. OFF delay timer. Pump-Mixer-3Valves-2Sensors. Counter-Comparator. Markers. Garage Application-Only inlets. Garage Application-in-out.

Page 2

PLC Apps- By Eng. Ahmed Mohamed Yasser

1. Motor On-Off
I. Inputs/Outputs:
A motor with 2-inputs & 1-Outputs: Inputs I0.0 Start I0.1 Stop Outputs Q0.0 Motor

II. PLC Wiring:

III. Description:
We need to have On/Off motor using two pushbuttons.

IV. Ladder diagram:

Page 3

PLC Apps- By Eng. Ahmed Mohamed Yasser

2. Motor with heater sensor

I. Inputs/Outputs:
A motor with 3-Inputs & 1-Output: Inputs I0.0 Start I0.1 Stop I0.2 Heater sensor Outputs Q0.0 Motor

II. PLC Wiring:

III. Description:
We need to have On/Off motor using two pushbuttons; a heater sensor is inserted to stop the motor at certain temperature.

IV. Ladder diagram:

Page 4

PLC Apps- By Eng. Ahmed Mohamed Yasser

3. Motor right-left directly

I. Inputs/Outputs:
A motor with 3-inputs & 2-Outputs: Inputs I0.0 Rotate Right I0.1 Rotate Left I0.2 Stop Q0.0 Motor Right Outputs Q0.1 Motor Left

II. PLC Wiring:

III. Description:
We need to rotate the motor to right and left in a condition that: We stop the motor rotation in certain direction when its rotating in the other direction directly.

Page 5

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

Directly:

Page 6

PLC Apps- By Eng. Ahmed Mohamed Yasser

4. Motor right-left indirectly

I. Inputs/Outputs:
A motor with 3-inputs & 2-Outputs: Inputs I0.0 Rotate Right I0.1 Rotate Left I0.2 Stop Q0.0 Motor Right Outputs Q0.1 Motor Left

II. PLC Wiring:

III. Description:
We need to rotate the motor to right and left in a condition that: We stop the motor rotation in certain direction when its rotating in the other direction indirectly.

Page 7

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

Indirectly:

Note: The Indirect method is more accurate and safe.

Page 8

PLC Apps- By Eng. Ahmed Mohamed Yasser

5. Motor right-left using Set-Reset

I. Inputs/Outputs:
A motor with 3-inputs & 2-Outputs: Inputs I0.0 Rotate Right I0.1 Rotate Left I0.2 Stop Q0.0 Motor Right Outputs Q0.1 Motor Left

II. PLC Wiring:

III. Description:
We need to rotate the motor to right and left in a condition that: We stop the motor rotation in certain direction when its rotating in the other direction using Set/Reset.

Page 9

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

Page 10

PLC Apps- By Eng. Ahmed Mohamed Yasser

6. Tank-Pump-2level sensors
I. Inputs/Outputs:
A fluid tank with 2-inputs & 1-Output: Inputs I0.0 I0.1 Outputs Q0.0 Pump

Level sensor B1 Level sensor B2

II. PLC Wiring:

III. Description:
We have a tank with a pump at the top, drain at the bottom & two level sensors. When water level goes below sensor B2; pump is working. When water level is above sensor B1; pump stops.

Page 11

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

Page 12

PLC Apps- By Eng. Ahmed Mohamed Yasser

7. Two motors with timer (1st method)

I. Inputs/Outputs:
A motor with 2-inputs, 2-Outputs & 1 Timer: Inputs I0.0 Start I0.1 Stop Q0.0 Motor 1 Outputs Q0.1 Motor 2 Timer T0 Timer 0

II. PLC Wiring:

III. Description:
1st method: When we press start; motor 1 starts, 10 seconds later motor 2 starts rotation. When we press stop motor 1 & motor 2 are off.

Page 13

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

1st method:

Page 14

PLC Apps- By Eng. Ahmed Mohamed Yasser

8. Two motors with timer (2nd method)

I. Inputs/Outputs:
A motor with 2-inputs, 2-Outputs & 1 Timer: Inputs I0.0 Start I0.1 Stop Q0.0 Motor 1 Outputs Q0.1 Motor 2 Timer T0 Timer 0

II. PLC Wiring:

III. Description:
2nd method: When we press start; motor 1 starts, 10 seconds later motor 2 starts rotation & motor 1 is off. When we press stop motor 1 & motor 2 are off.

Page 15

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

2nd method:

Page 16

PLC Apps- By Eng. Ahmed Mohamed Yasser

9. Three motors with Timers

I. Inputs/Outputs:
A motor with 2-inputs, 3-Outputs & 3 Timer: Inputs I0.0 Start I0.1 Stop Q0.0 Motor 1 Timers T0 Timer 0 T1 Timer 1 T2 Timer 2 Outputs Q0.1 Motor 2 Q0.2 Motor 3

II. PLC Wiring:

III. Description:
Three motors with Timers such that when we press start Motor 1 is on for 10 seconds then off, then motor 2 is on for 20 seconds then off, then motor 3 is on for 30 seconds then off, then motor 1 is on and loop is repeated.

IV. Flowchart:
Start
M1 10 sec M2 20 sec M3 30 sec

Page 17

PLC Apps- By Eng. Ahmed Mohamed Yasser

V. Ladder Diagram:

Page 18

PLC Apps- By Eng. Ahmed Mohamed Yasser

Page 19

PLC Apps- By Eng. Ahmed Mohamed Yasser

10. Tank-3pumps-2level sensors-Mixer

I. Inputs/Outputs:
A motor with 4-inputs, 4-Outputs & 2 Timer: Inputs I0.0 Start PB. I0.1 Stop I0.2 I0.3 T0 Timer 0 Timers T1 Timer 1

High level sensor Low Level Sensor

Outputs Q0.0 Pump 1 Q0.1 Pump 2 Q0.2 Pump 3 Q0.3 Mixer

II. PLC Wiring:

III. Description:
when we press the start push button, pump 2 works for 5 seconds then stops, pump 1 works, pump 1 is stopped by high level sensor, at the same time mixer works for 10 seconds, when mixer is off pump 3 works, pump 3 is stopped by low level sensor, steps repeated.
Page 20

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Flow chart:

Start

P2 5 sec

P1
Stopped by

H.L.
Then

Mixer
Stoppe 10 sec dd later

P3 L.L.
Stopped by L.

Page 21

PLC Apps- By Eng. Ahmed Mohamed Yasser

V. Ladder Diagram:

Page 22

PLC Apps- By Eng. Ahmed Mohamed Yasser

Page 23

PLC Apps- By Eng. Ahmed Mohamed Yasser

11. OFF delay timer

I. Inputs/Outputs:
A motor with 2-inputs, 2-Outputs & 1 Timer: Inputs I0.0 Start I0.1 Stop Q0.0 Motor Outputs Q0.1 Lamp Timer T0 Timer 0

II. PLC Wiring:

III. Description:
When we press start Pb.; motor 1 starts & OFF delay timer is ON so lamp is ON. When we press stop Pb.; motor 1 is off & OFF delay timer waits for 5 more seconds then turns OFF and so do the Lamp.

Page 24

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

Page 25

PLC Apps- By Eng. Ahmed Mohamed Yasser

12. Pump-Mixer-3Valves-2Sensors
I. Inputs/Outputs:
A motor with 4-inputs, 5-Outputs & 2-Timer: Inputs I0.0 Start I0.1 Stop I0.2 I0.3 T0 Timer 0 Timers T1 Timer 1

Low level sensor (B1) High level sensor (B2)

Outputs Q0.0 Motor 2 Pump Q0.1 Motor 1 Mixer Q0.2 Y1 Valve 1 Q0.3 Y2 Valve 2 Q0.4 Y3 Valve 3

Page 26

PLC Apps- By Eng. Ahmed Mohamed Yasser

II. PLC Wiring:

III. Description:
1. When we press start Pb. ; Pump & (Y1) starts, When fluid reaches (B1) (Y1) is OFF & (Y2) is ON. 2. When fluid reaches (B2) (Y2) & Pump are OFF & Mixer is ON for 10 sec then OFF. 3. When Mixer is OFF (Y3) is ON till Fluid is below (B1) then turns OFF then cycle is repeated.

Page 27

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

Page 28

PLC Apps- By Eng. Ahmed Mohamed Yasser

Page 29

PLC Apps- By Eng. Ahmed Mohamed Yasser

13. Counter-Comparator
I. Inputs/Outputs:
A motor with 2-inputs, 2-Outputs & 1 counter & 1 comparator: Inputs I0.0 Sensor I0.1 Reset Q0.0 Lamp Outputs C0 Counter 0 Counter Q0.1 Motor Comparator Eq-I equal

II. PLC Wiring:

III. Description:
A counter is used to count the input to the sensor; output motor is ON only after 5 counts.

Page 30

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

Page 31

PLC Apps- By Eng. Ahmed Mohamed Yasser

14. Markers
I. Inputs/Outputs:
A motor with 1-Input, 1-Output & 1 Marker: Input I0.0 Start Output Q0.0 Motor Marker M0.0 marker

II. Description:
When we press start; Marker is ON Output ON

III. Ladder Diagram:

Page 32

PLC Apps- By Eng. Ahmed Mohamed Yasser

Page 33

PLC Apps- By Eng. Ahmed Mohamed Yasser

15. Garage Application-Only inlet

I. Inputs/Outputs:
A motor with 3-inputs, 3-Outputs, 2-Timers, 1-counter & 1-comparator: Inputs I0.0 Sensor 1 (S1) I0.1 I0.2 Q0.0 Outputs Q0.1 Q0.2 Alarm

Sensor 2 (S2) reset counter Motor up Motor down

Timers T0 Timer 0 T1 Timer 1

Comparator Eq-I Equal

Counter C0 Cars counter

II. PLC Wiring:

III. Description:
When the car enters the garage there are 2 sensors, when the 1st sensor (s1) is ON
Motor up for 10 sec. then motor down for 10 sec.

When both (S1) & (S2) are ON (C0) counts up.

Page 34

PLC Apps- By Eng. Ahmed Mohamed Yasser

When 5 cars are in the garage Alarm is ON & Motor Up-Down is deactivated.

IV. Ladder Diagram:

Page 35

PLC Apps- By Eng. Ahmed Mohamed Yasser

Page 36

PLC Apps- By Eng. Ahmed Mohamed Yasser

16. Garage Application-in-out

I. Inputs/Outputs:
A motor with 4-inputs, 3-Outputs, 2-Timers, 1-counter & 1-comparator: Inputs I0.0 Sensor 1 (S1) I0.1 I0.3 I0.2

Sensor 2 (S2) Sensor 3 (S3) reset counter

Timers T0 Timer 0 T1 Timer 1

Comparator Eq-I Equal

Counter C0 Cars counter Q0.0 Motor up

Outputs Q0.1 Q0.2

Motor down Alarm

Page 37

PLC Apps- By Eng. Ahmed Mohamed Yasser

II. PLC Wiring:

III. Description:
When the car enters the garage there are 2 sensors, when the 1st sensor (s1) is ON
Motor up for 10 sec. then motor down for 10 sec.

When both (S1) & (S2) are ON (C0) counts up. When (S3) at garage exit is ON it counts down (CO). When 5 cars are in the garage Alarm is ON & Motor Up-Down is deactivated.

Page 38

PLC Apps- By Eng. Ahmed Mohamed Yasser

IV. Ladder Diagram:

Page 39

PLC Apps- By Eng. Ahmed Mohamed Yasser

Page 40