PLC DIPLOMA

Exercise 1

Develop the automation of the basic process for sequential start and stop
forced from three three-phase motors, as described below:

A start button initiates the ignition of the first engine (see figure). Once
Once this is turned on, another button activates the ignition of the second engine, and a third
Button activates the operation of the third motor. No motor can be activated.
until the previous engine has been started.

To turn off the three engines, a similar sequence is followed, except that the
The shutdown order is carried out in reverse, that is, first the third one is turned off.
motor (with its respective stop button). Until it has not been turned off the
third, the second cannot be turned off, and so on, until the first engine is turned off.

Create the Ladder diagram and implement it in any of the PLCs.

industrial communications laboratory (NAIS, Allen Bradley or Siemens).

Note: The respective thermal protectors must be included in the Ladder for protection.
each engine.
Exercise 2

Objective

Design the circuit for controlling a flat material profiling machine.

Process graphs

Description of the process

A machine profiles flat materials. To this end, the material must be

manually introduced into the machine. The B1 sensor detects the correct position of the
part. A light barrier controls whether the operator has removed their hand from the
machine. If so, the machine is put into operation.
The material is processed according to the following sequences: once the operator
has removed your hand from the area controlled by the light barrier, lower the cylinder
A. Next, cylinders B and C move forward simultaneously. Upon reaching the end
of the race, those cylinders return to their initial position. Then A, also
recovers its initial position. Sensors B3 to B8 detect the position of the
cylinders A, B, and C.

It must be:

a) Create the sequential function chart or step diagram of the process.

b) Connection diagram of inputs and outputs to the PLC.
c) Implement the control program.

Entry distribution table

PLC input Function State

initial
X0 B1 = Sensor inductivo NA
X1 B2 = Photoelectric sensor NA
X2 B3 = End of race Cylinder A back NA
X3 B4 = End of race Cylinder A forward NA
X4 B5 = Final of race Cylinder B back NA
X5 B6 = End of travel Cylinder B front NA
X6 B7 = Final of race Cylinder C back NA
X7 B8 = End of race Cylinder C forward NA

Output distribution table

PLC output Function

Y0 Y1 = Electroválvula de avance Cilindro A
Y1 Y2 = Advance solenoid valve Cylinder B
Y2 Y3 = Advance solenoid valve Cylinder C
Y3 Y4 = Backflow solenoid valve Cylinder C

Exercise 3

Objective

Design a circuit for the control of filling a tank.

In a certain company, it is desired to control the filling of a tank with the following
characteristics:

When the tank is completely empty, a motor pump takes care of it.
to boost the fuel to carry out the filling until the limit sensor
superior indicates that this operation must be stopped.

The liquid outlet solenoid valve is independent of the process. However,

when it opens, sporadically, the tank begins to empty
again.

When the lower limit sensor detects that the tank is already at a point
low level critical, the pump must be turned on again to fill the
tank, until the upper level sensor sends the order again to
stop the filling process.

Schematic representation of the installation

Upper limit sensor

Lower limit sensor

Filling pump

Table of ticket distribution

PLC Entry Function Initial state

X1 Upper limit sensor Normally open
X2 Lower limit sensor Normally open
X3 Thermal relay motor pump Normally closed
X4 Emergency stop button of Normally closed
emergency

Output distribution table

PLC output Function

Y0 Motor pump
Y1 Pilot to indicate the limit
superior
Y2 Pilot to indicate the limit
inferior
Y3 Pilot to indicate a stop
emergency

Exercise 4

Objective

Design a circuit for the control of a sliding door.

This circuit is designed to control a sliding door using a
motor. The door opening movement is controlled by the contactor.
K3, and the door closing movement is controlled by the contactor K1.
The two contactors must be interlocked. The limit switch S3
operates when the door is completely open, and the limit switch S2
the race is activated when the door is completely closed.

The door opens when pressure is applied to a carpet using the switch.
S1 located in front of the door. If S1 is not activated, the door closes.
automatically after 5 seconds. If S1 is triggered, the contactor closes
K3 remains closed until it reaches the 'OPEN' position and the switch
On S3 at the end of the race, disconnect the contactor K3. In the "OPEN" position the
The limit switch also starts the 5-second timer after
from which the contactor K1 must be closed to close the door. K1 is held
closed until it is disconnected by the S2 end switch
race.

If the S1 contact of the mat is activated again while the door is open.
closing, the closing operation and the door must be interrupted immediately
The sliding door opens again through the contactor K3.

The H1 and H2 signaling lamps must indicate when it is closing or

opening the door.

Entry distribution table

PLC input Function Initial state

X1 S1 = Carpet button Normally open
X2 S2 = Limit switch (of the Normally open
sliding door closed
X3 S3 = Limit switch (of the Normally open
sliding door open

Output distribution table

PLC output Function

Y0 K1 = Contactor (cierre de la puerta corrediza)
Y1 K3 = Contactor (opening of the sliding door)
Y2 H1 = Sliding door closure indicator lamp
Y3 H2 = Indicator light for sliding door open

Exercise 5

Automate the signaling process of two traffic lights, pedestrian and vehicle.
as shown in the following figure.
The operating sequence is described by the following diagram of
times:

Note: The sequence begins with the pressing of a start button. And once
after the last 3 seconds have elapsed, the whole process must be repeated in
cyclical form.
Exercise 6

Objective

Design a circuit for a bottle filling installation.

On a conveyor belt driven by a three-phase motor with direct start,
Bottles that must be filled with a certain liquid are deposited.

A mechanical position switch detects the entry of the bottle into an area.
at which point the previous belt that transports the empty bottles stops.

At 0.5 seconds after the previous action, an electrov valve opens and the
bottle filling.

A photoelectric proximity sensor detects that the bottle is full, and when
After 0.5 seconds, the previous belt restarts.

The conveyor belt that carries the filled bottles will always be on brand during the
process.

Entry distribution table

PLC input Function Initial state

X1 Start button Normally open
X2 Stop button Normally closed
X3 Position switch Normally closed
mechanic
X4 Photoelectric detector Normally closed
X5 Thermal relay motor belt of Normally closed
full bottles
X6 Thermal relay for belt motor Normally closed
empty bottles

Output distribution table

PLC Output Function

Y0 Conveyor belt for empty bottles
Y1 Belt motor of filled bottles
Y2 Filling solenoid valve

Schematic representation of the installation

 MARCH
PARO Liquid

Switch
Filling valve
of mechanical position

Photoelectric sensor

IPM

Ribbon of empty bottles Tape of filled bottles

Work to be done:

1. Grafcet of the operation.

2. Ladder diagram of the control program.
3. Connection of inputs and outputs to the automaton.

Exercise 7

Objective
Automate the manufacturing process of a mixer so that it completes the cycle
that is described below.

Walking conditions

To start the cycle, the solenoid valves EV1, EV2, and EV3 must be present.
closed, P1 and P2 under pressure and therefore fluid.

Once everything is ready, the start button will be pressed.

Fluid A will enter and at the same time M1 will start to rotate.
2. After 5 minutes (5 seconds for the exercise), fluid B will enter.
3. After 8 minutes have passed (8 seconds for the exercise), the shaking is stopped for 4
minutes (4 s for the exercise) and EV1 and EV2 turn off.
4. The mixer is turned on again for 10 minutes (10 s for the
exercise).
5. After the previous time is completed, the tank is emptied.

6. After 1 minute of the emptying initiation (5 seconds for the exercise), it is considered

the process is completed and the cycle must be executed automatically 4 times again.

Table of ticket distribution

PLC input Function Initial state

I0 Start button Normally open
I1 Stop button Normally closed
I2 Pressure switch 1 Normally open
I3 Pressure switch 2 Usually open
I4 Thermal relay of M1 Normally closed

Output distribution table

PLC output Function

O0 Stirring motor (M1)
O1 Electro valve 1 (EV1)
O2 Electro valve 2 (EV2)
O3 Electro valve 3 (EV3)
Schematic representation of the installation
Work to be done:

1. Grafcet of operation.
2. Ladder diagram of the control program.
3. Connection of inputs and outputs to the automaton.

Exercise 8

Objective
Design the circuit for controlling a two-speed motor with reversal.
sense of rotation.

It is desired that the engine adheres to the following operating cycle:

1. Start at low speed (star connection) for 10 seconds to the left.

2. Pause for 2 seconds.
3. Turn right at low speed for 8 seconds.
2 seconds stop.
5. Right turn at high speed (triangle connection) for 15 seconds.
Stop at 2 s.
7. Turn left at high speed for 12 seconds.
8. 3-second pause.
9. Automatic repetition of the cycle.

Elaborate:

a) Power diagram.
b) Contact diagram.
c) List of input and output assignments.
d) Program.
e) Timeline diagram.
f) Connection diagram of sensors and actuators to the PLC.
g) Sequential flowchart.

Exercise 9

Objective
Design a circuit for a product mixing installation that is
composed and must function as follows:

Three silos S1, S2, and S3 that contain different products.

A conveyor belt T1 that is powered by a three-phase motor with
star-delta starter.
The star delta start time is 4 seconds.
A car C1 located at one end of the belt that receives the mixtures.
transported by the belt.
The mixtures to be made with the affected silos are as follows:

Mix1:S1+S2 Mix 2: S1 + S3 Mix3:S2+S3 Mix4:S1+S2+S3

The opening and closing of each gate of each silo is carried out with cylinders.
simple effect with spring return, each of them controlled by a
3/2 way solenoid valve.
The mixture selection will be carried out using 4 buttons (inputs X1,
X2, X3 and X4.
Once the cart is deposited at the end of the conveyor belt and its position is controlled.
(entry X5) the start-up of the belt can be carried out by
any of the buttons indicated for the mixtures, meaning that each
the button will select the corresponding mixture and start the
motor.
A push button (input X6) will be used as STOP, while a relay
The overload thermal (input X7) will protect the motor against overloads.
moderate.
The gate of each silo must remain open for a period of 15
seconds (use 5 s for laboratory practice), from the moment the order is given
through the corresponding button.
Once the silo gates are closed, the belt must remain on
operation for a period of 10 seconds (use 5 s for practice
in the laboratory), to evacuate the product to the cart.
If a power outage occurs, the entire system stops, and the product that
it can be found on top of the tape, or in the cart, it is removed manually,
having to start the cycle again.

Graphical representation of the installation

 Silo 1 Silo 2 Silo 3

1Y1 1Y2 1Y3

Car

Motor

Entry distribution table

PLC Input Function State

initial
X1 Mixing Button 1 NA
X2 Mix button 2 NA
X3 Mix button 3 NA
X4 Mixing button 4 NA
X5 Car position control NA
X6 Stop button NC
X7 Thermal relay NC

Output distribution table

PLC Output Function

Y1 Silo 1 Solenoid Valve
Y2 Silo 2 Solenoid Valve
Y3 Silo 3 Solenoid Valve
Y5 Star contactor belt motor
Y6 Triangle contactor motor belt

To carry out:

The sequential flow chart (Grafcet diagram) of the process.

The control program using Ladder Logic instructions.
The control program using normal instructions.
Power diagram.
Connection of inputs and outputs to the PLC.
Exercise 10
It is desired to control the level of a tank using three pumps, as follows
shown in the following figure.

The value of the level is provided by a transmitter, which delivers a signal of

4 mA for the 0% level and 20 mA for a 100% level.

The desired level value is to be maintained at 75% of its maximum capacity. The three
pumps are adjusted to operate when the level of the boiler falls below
below the value indicated in the MIN parameter. Any pump also has
that can be operated manually.

If the level in the tank exceeds 2.5% of the value adjusted as Set Point, it must
open the return valve to drain the water into tank 3. Tank 3
together with the 1, they provide the water to the boiler.

Note: When manual operation is selected for any of the pumps,

The automatic control for that pump must be canceled.

Ticket distribution table

 PLC Input Function State
initial
X1 Start pump button 1 - manual mode NA
X2 Stop pump button 1 - manual mode NC
X3 Switch pump 1 manual / automatic NA
X4 Start button pump 2 - manual mode NA
X5 Stop pump button 2 - manual mode NC
X6 Switch bomba 2 manual / automático NA
X7 Start pump button 3 - manual mode NA
X8 Stop pump button 3 – manual mode NC
X9 Switch pump 3 manual / automatic NA
XA Emergency button NC
DT0 Value word of the analog input
of the level.

Output distribution table

PLC output Function

Y1 Pump contractor 1
Y2 Pump Contactor 2
Y3 Pump Contactor 3
Y5 Return solenoid valve
DT2 Level control solenoid valve

Carry out:

The control program using scaling instructions and

comparison.
Power diagram.
Connection of inputs and outputs to the PLC.
Supervision and control system in Lookout for the entire system.

Exercise 11
It is desired to implement the control program for a plastic injector like the
shown in the figure on the next page. The conditions are as follows:

It must have the ability to operate in manual or automatic mode.

It must have an emergency stop button.
It must be able to operate for a certain number of cycles, depending on
of the programming desired by the operator.
The automatic cycle begins, as long as the temperature has been reached.
a value of 250ºC. Although the temperature control is not performed by the PLC,
this receives a signal from three series contacts of the controllers
temperature when the desired setpoint value is reached.

The process consists of the following:

Once the start button is pressed (automatically), the closure of the

mold (solenoid valve Y2) until the sensor S1 indicates that it has reached its end
race. At this moment, the approach of the injection unit begins.
(solenoid valve Y8), until the pressure switch S5 indicates that it has reached its limit.

Then the approach of the injection screw (solenoid valve Y5) begins,
which pushes the semi-melted plastic material into the cavity of the mold during a
Time T1. Once T1 ends, a process called Post-Pressing begins.
through the activation of the solenoid valve Y9 (not present in the diagram), during
a time T2. Once this time is completed, Y5 and Y9 are turned off, and it moves on to the
dosing process, which consists of rotating the injection screw
(solenoid valve Y4), for the loading of material, for the next cycle. The
dosage causes the screw to retract to the position indicated by S3.
Simultaneously with the dosing process, the time T3 also starts, which is
the cooling time that, as its name indicates, gives the necessary time
to cool the piece inside the cavity of the mold and solidify.

The activation of S3 also initiates the retraction of the injection screw.

(solenoid valve Y6), up to the limit switch S4. Now Y6 is turned off and starts the
retraction of the injection unit (electrovalve Y7), for a time T4. To
to complete T4, one waits until the cooling time (T3) is finished. When
finish T3, the mold opens (solenoid valve Y3), up to the limit switch S2 and is
it starts the expulsion process (solenoid valve Y1) until reaching the limit switch S6. A
Once S6 is activated, Y1 turns off causing the ejector to return to the limit.
S7 and the expulsion process repeats, as many times as it has been done.
programmed in the counter C1.

Once the expulsion process is complete, the machine waits for a pause time T5.
the end of which the entire process is repeated as many times as depending on the value of C2
(cycle counter).
 General Scheme - Plastic Injection Machine.

Entry distribution table

PLC Input Function State

initial
X1 Start button - automatic mode NA
X2 Manual / Automatic Selector NA
X3 Emergency stop button NC
X4 Final of the mold closure race (S1) NA
X5 Mold opening end of race NA
(S2)
X6 Final graduation of dosage (S3) NA
X7 Final of the screw's reverse stroke NA
injection (S4)
X8 Pressure switch for unit advancement NA
of injection (S5)
X9 End of the advance stroke of the expeller NA
(S6)
XA Final of the reverse journey of the NA
expeller (S7)
XB Temperature reached contact NA
 Output distribution table

PLC Output Function

Y1 Exhaust solenoid valve
Y2 Mold closing solenoid valve
Y3 Mold opening solenoid valve
Y4 Dosing solenoid valve (screw rotation)
Y5 Injection screw advance solenoid valve
Y6 Backflow solenoid valve of the injection screw
Y7 Back pressure solenoid valve of the injection unit
Y8 Advance solenoid valve of the injection unit
Y9 Post-pressure solenoid valve

Table of distribution of times and counters

PLC output Function

T1 Injection time
T2 Post-pressure time
T3 Cooling time
T4 Injection unit retraction time
T5 Break time
C1 Dismissal counter
C2 Cycle counter
Exercise 12

It is desired to implement the visualization and control interface for the activation of a
automatic ignition system for three pumps. The general sequence of
the system is as follows:

Once the start button is pressed, pumps 1 and 2 turn on.

for a time T1. After this time, pump 2 is turned off and enters
service the pump 3 for a time T2.

After completing T2, pump 1 is turned off and pump 2 comes into service.
for a time T3. Once T3 is completed, pump 3 is turned off and it enters again
pump 1 during T4.

•After T4 is completed, the three pumps are turned on for a time T5, after which
the cycle repeats.

The complete sequence can be stopped at any time by the

pressing a stop button.

For greater clarity, the time diagram is shown in the following graph.
corresponding to the entire sequence.

MARCH

B1

T3

B2
T2

T5
B3

T1 T4

Timing diagram of the pump activation sequence.

Additionally, it is required that the times and the activation sequence of the
bombs are fully configurable, through an operator interface or a
human-machine interface (HMI). That is, the sequence should not be subjected
not only exclusively to the diagram of the previous figure but it must also allow to be
changed at the worker's discretion.

For the development of this activity, transfer instructions should be used.

of registers, comparison instructions, and indirect addressing.
In addition, Intouch 9.5 will be used as the HMI for visualization and modification.
of parameters.

Assignment of records for the times and states of each stage.

DT0 DT1 DT2 DT3 DT4

PresetT1 PresetT2 PresetT3 PresetT4 PresetT5

DT10 DT11 DT12 DT13 DT14

State of the bombs State of the bombs State of the bombs State of the bombs State of the bombs
instage1instage2instage3instage4instage5

Note: The states of the 3 pumps are stored as integer values. Thus:
for a stage value = 3, pumps 1 and 2 will be on; for a value of
stage = 6 will have pumps 2 and 3 turned on; and so on.
Exercise 13

A block of 7 solenoid valves is connected to a module of 16 digital outputs.

of a PLC. This block controls the pressure in a production machine, which
works with a hydraulic system. The pressure values with which it works
the machine are stored in a data table in the PLC memory
integer values form (1 to 127; with 1 being the minimum value and 127 the maximum value)
applicable to the solenoid valve block.

An application for PLC must be developed that allows sending the first 5
pressure values stored in a data table to the block of
solenoid valves, so that the pressure behavior complies with the
next profile:

The equivalence table between the integer value of the PLC and the pressure value is the
next:

Integer value of the PLC register Hydraulic pressure (bar)

5 1
10 2
15 3
20 4
25 5

The sequence begins with the pressing of a start button.

Note: Keep in mind that the remaining 9 digital outputs of the PLC may be
connected to other actuators of the machine and therefore should not be seen
affected by the states of the 7 solenoid valves.

Create the corresponding Grafcet and Ladder.