Exp. no.

Date:

PLC - EXPERIMENTS

Introduction to PLC:
Programmable logic control or PLC is the most commonly used
industrial automation technique in the world. It is universally
applied for factory automation, process control and manufacturing
systems. Programmable logic control originated from the creation
of computerized versions of relay control systems used to control
manufacturing and chemical process systems. The programming
is done using a special technique called ladder logic, which allows
sequences of logical actions to be set up, inter-linked and timed. A
standard task in logic control is batch control and sequencing in a
process system. PLC allows as controlling an automated process.
Automation helps a manufacturing facility to1. Gain complete control of manufacturing process.
2. Achieve consistency in manufacturing
3. Improve quality & accuracy
4. Work in difficult or hazardous environments
5. Increase productivity
6. Shorten the time to market
7. Lower the cost of quality, scrap & rework
8. Offer greater product variety
9. Quality charge over from one product to another
10. Control inventory
1

A PLC is a user friendly, microprocessor specialized computer that

carries out control functions of many types and levels of
complexity. Its purpose is to monitor crucial process parameters
and adjust process operations accordingly. It can be programmed,
controlled and operated by a person unskilled in operating
computers. Essentially, a PLC's operator draws the lines and
devices of ladder diagrams with a keyboard onto a display screen.
The resulting drawing is converted into computer machine
language and run as a user program.

Architecture of PLC:

Basic Structure of PLC

PLC scan cycle :
A PLC works by continually scanning a program. We can think of
this scan cycle as consisting of 3 important steps. There are
typically more than 3 but we can focus on the important parts and
2

not worry about the others. Typically the others are checking the
system and updating the current internal counter and timer
values.

PLC operation

Advantage of PLC:
Programmable Logic Controllers have been gaining popularity on
the factory floor and will probably remain predominant for some
time to come. Most of this is because of the advantages they
offer. With the growth in technology PLCs are now capable of
advanced data manipulations, communications and process
controls. Benefits of using PLC in industries are
1. The PLC is a hardened industrial computer designed to
withstand the harsh
factory environment.
2. PLSs is reusable they contain a changeable program that
eliminators extensive
and component changes.
3

3. PLCs offer easy troubleshooting

4. PLCs feature easy installation and small size .

Some of the used Instructions:

Examine if Closed (XIC)

Use the XIC instruction in your ladder to determine if a bit is on.

When the instruction is executed, if the bit addressed is on (1),
then the instruction is evaluated as true. When the instruction is
executed, if the bit addressed off (0),
then the instruction is evaluated as false.

Examine if Open (XIO)

Use an XIO instruction in your ladder program to determine if a bit

is off. When the instruction is executed, if the bit addressed is off
(0), then the instruction is evaluated as true. When the instruction
is evaluated as false.

Timer On-Delay (TON)

Use the TON instruction to turn an output on or off after the timer
has been on for a preset time interval. The TON instruction begins
to count time base intervals when rung conditions become true.
As long as rung conditions remain true, the timer adjusts its
accumulated value (ACC) each evaluation until it reaches the
preset value (PRE). The accumulated value is reset when rung
conditions go false, regardless of whether the timer has timed
out.
4

Exp No:

Aim:

BATCH PROCESS REACTOR USING

PROGRAMMABLE LOGIC CONTROLLER

Date:

To control the batch process reactor (VPAT 05) using

programmable logic controller.
Apparatus required:
1. Batch process trainer kit
2. PLC (Allen Bradley Micrologix 1500 LRP series C)
3. PC with Versapro Software
4. RS232 cable
5. Patch chords

Procedure:
1.
2.
3.
4.
5.
6.
7.
8.
9.

Load the Versapro software to the PC

Open the Versapro software
Switch On the PLC trainer and lift controls system
Connect PLC with Batch process control kit.
Open the New folder and draw the ladder logic program
Select the correct hardware configuration.
Store the Program to PLC
Run the program
Verify the performance to the Batch process control

Process description:
Batch process reactor is a blending process, where two liquids are
mixed together to get the output mixture. The programmable
logic controller is used to control the whole process. The process
tanks 1 & 2 consist of two liquids, which are blended in process
tank 3. The process tank 1 & 2 consists of a low liquid level sensor
and a high liquid level sensor. The liquids are pumped to the
process tanks using respective pumps.
5

The two liquids are mixed in the process tank 3 using a stirrer.
Heater is used to heat the mixture. The solenoid valves provide
the liquids to the process tank 3 when the mixture level is low.
Solenoid valve 3 is connected to the output of the process tank 3,
which feeds mixed liquid to a vessel when it is sensed by the
vessel proximity sensor. The container is fed through a conveyor
belt run by stepper motor. Two solenoid valves 1 & 2 control the
flow of two liquids to the tank 3. The level sensors sense the level
in the process tanks 1,2&3. The level sensor is a magnetic sensor
and when the liquid level is above the high level sensor a HL (high
level) signal is send to the PLC. When the liquid level goes down
the low level sensor LL (low level) signal is send to the PLC. The
PLC checks the signals send by these sensors through its input
port and give the
proper signals through its output port as per the ladder logic
program.

Diagram:

Result:
The Batch process reactor was set up and controlled by using PLC
ladder logic program.