FACULTY OF CHEMICAL AND ENERGY ENGINEERING

SETG4771-02
PROCESS CONTROL LABORATORY

FINAL REPORT
PROGRAMMABLE LOGIC CONTROLLER

GROUP 4 MEMBERS:
RANJEET A/L V RAJAH
NUR AIDA ADRIANA BINTI HAIRUL NIZAM
NURUL ZULFA AINA BINTI ZULKIPLY
MUHAMMAD HAZIQ HAIQAL BIN HAMDAN
NUR AIN NABILA BINTI HARMEN

LECTURER’S NAME:
DR. IZNI MARIAH BINTI IBRAHIM

DATE OF SUBMISSION:
22 NOVEMBER 2023
 ABSTRACT

This experiment is carried out to learn and comprehend the coding and operation of a
Programmable Logic Controller (PLC) and a ladder logic diagram. This experiment also required
the creation of a set of codes and programs from a ladder logic diagram, which is accessible for
laboratory pilot equipment. The role of PLCs in factory automation may also be determined from
this. The fundamentals of PLC functioning have been discussed. The result is a coding was
determined following the requirement instruction to run the process designed which was allowing
water to enter the tanks one by one according to the arrangement of Tank 1, 2 and 3, and then enter
the mixer at the same time from all three tanks. The arrangement involved sequential tank filling
followed by concurrent mixer input. The crucial components of an industrial-control system are
examined as the analog input function by the coding for instructions given.
TABLE OF CONTENTS

No. Contents Page

1 Introduction
1.1 Background of Experiment 1
1.2 Objectives of Experiment
1.3 Scopes of Experiment

2 Theory / Working Principle 2

3 Methodology 4
3.1 Experimental Set-up
3.2 Procedures
3.3 Safety Procedures

4 Results and Discussion 6

5 Conclusion 11
6 References 12
1.0 INTRODUCTION

1.1 BACKGROUND OF EXPERIMENT

A Programmable Logic Controller, PLC, or programmable controller is a digital computer

used for automation of typically industrial electromechanical processes, such as control of
machinery on factory assembly lines, amusement rides, or light fixtures. PLCs are used to control
a wide range of applications, from simple lighting operations to environmental systems and
chemical processing plants. These systems execute a wide range of operations, including analog
and digital input and output interfaces, signal processing, data conversion, and several
communication protocols. The controller, which is programmed for a specific purpose, lies at the
heart of all of the PLC's components and operations. There are five crucial elements of a PLC
which are power supply, processor unit, inputs, outputs, and communication interface.

A PLC's primary function is to control machinery. A PLC program is essentially a set of

instructions for turning on and off outputs based on input conditions and the internal program. But
in PLC, instead of using gate logic, like any other digital devices, it uses ladder logic which is like
a group of switches. PLC is normally open, and the others are closed. Besides that, vertical lines
representing the switches are opened while a diagonal line between the parallel vertical lines is for
a closed switch. PLC recognizes logic by ladder, so the system must be converted to that type of
representation.

1.1 Objectives

1. 1. To study the concept and application of PLC systems.

2. 2. To perform the PLC diagram for the desired process

1.2 Scope of Experiment

1. Set up a set of coding and programs from a ladder logic diagram, which is feasible for the
pilot equipment in the laboratory.

2. Able to run the process same as the program from the ladder logic diagram applied.

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2.0 THEORY/WORKING PRINCIPLE

A PLC (Programmable Logic Controller) is an industrial computer that automates

electromechanical processes like lighting fixtures, amusement rides, and factory assembly lines.
In industrial settings that are dangerous to the very microelectronic components that give current
PLCs their exceptional flexibility and precision, PLCs are expected to function flawlessly for
years.

Many of these systems were handled using contactor or relay controllers before PLCs.
Hardwired control is another name for this. It was necessary to construct circuit diagrams, specify
and install electrical components, and prepare wire lists. The components required to complete a
certain task would then be wired by electricians. The wires needed to be correctly rejoined if an
error was made. Significant component alterations and rewiring were necessary due to a change in
function or system expansion.

Programmable Logic Controller (PLC) are widely used in batch process control to execute the
desired binary logic operation and to implement the desired sequencing. The inputs to the PLC are
a set of relay contacts representing various device states (for example, limit switches indicate
whether a valve is fully open or fully closed). Various operator inputs for example start/stop buttons
are also provided. The PLC output signal energises (actuate) a set of relays that turn pumps on or
off, actuate light on a display panel, operate solenoid or motor driven valves and so on. Batch
control systems involve binary logic and discrete event analysis applied to the sequential of
different process steps in the same vessel, usually requiring the application of PLC (Seborg et
al.,2011).

3.1 Ladder Diagram

A ladder diagram is a symbol used to show the control logic in a PLC's programming. Vertical
lines at the beginning and end of each step are called rails in ladder diagrams, which feature
horizontal lines of control logic called rungs. The term "ladder diagram" was coined because it
resembles a ladder exactly.

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 A ladder diagram and an electrical schematic differ primarily in two ways which are the
control logic in an electrical schematic is represented using components whereas in a ladder
diagram symbols are used and The control logic execution in an electrical schematic is as per the
operation of an electrical circuit whereas in a ladder diagram it relies on the methodical nature of
the PLC scan.

PLC logic expressions are graphically expressed using ladder diagrams. Expressions for
conditional variables, input, and output are represented by symbols. Ladder diagrams are employed
because they are simpler to write than text-based programming languages and are comparable to
relay control circuits.

3.2 Principle Operation

Similar to relay logic, ladder logic operates without the time-consuming relay control wiring.
In layman's terms, the ladder logic programme determines which outputs to activate based on the
status of the input signals and the field input and output devices that are connected directly to the
PLC.

Supply rails, relay coils, relay contacts, counters, timers, PID loop controllers, and many
other components are present in ladder logic. Relay logic differs in that logic expressions are
produced by relay control circuits. There could be a significant number of wiring and relays
involved. In contrast, using ladder logic, the PLC is programmed with the logic expressions.
Therefore, the input and output devices are the only ones that need wiring.

We need a fundamental understanding of how a PLC operates and how ladder logic is
implemented in a PLC in order to correctly read ladder logic. You see, the PLC executes according
to a specific method, and if that protocol is not followed, the ladder logic may be read improperly.

In basic terms, PLCs run ladder logic by reading all the input states and storing them in
memory before executing any logic. The second step is to go through and assess each rung of the
ladder logic, going from top to bottom and left to right. Last but not least, the outputs are written
to and the resulting logic is executed at the conclusion of the scan.

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3.0 METHODOLOGY
3.1 Experimental Set-Up

Figure 3: Programmable Logic Control (PLC) System

3.2 Experimental Procedures

3.2.1 Start Up
1. The main power supply was switched on. The computer and IA 130:PLC
Module were switched on.
2. The XSOFT-CODESYS-2 system was opened.
3. The program was written and set up.

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3.2.2 Run Program
1. The program was set up to allow water entering Tank 3, Tank 2 and Tank
1 respectively. The program was also set to drain water in Tank 1, Tank 2
and Tank 3 concurrently.
2. Valve 5 opened to allow water entering Tank 3.
3. Valve 3 was opened to allow water input into Tank 2.
4. Valve 1 was opened to allow water input into Tank 1.
5. The drainage valve of Tank 1, Tank 2 and Tank 3 were opened and water flow out from
the tanks into the mixer.
6. Valve 8 was opened to drain water from the mixer.

3.2.3 Shut Down

1. All running output devices were stopped.
2. Click ‘Online’, then click ‘Stop’.
3. Click ‘Online’, then click ‘Logout’.
4. The XSOFT-CODESYS-2 system was closed.
5. The computer and all power supply switches were turned off.
6. The main power supply was switched off.

3.3 Safety Procedures

1. Follow the correct procedures and guidelines for operating the PLC
system.
2. Ensure that all personnel involved in operating the PLC system are
adequately trained and qualified.

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4.0 RESULTS AND DISCUSSION

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 Figure 4.1: Ladder Diagram

5.1 Explanation of the Coding of the Process

Figure 5.1 displays the entire ladder design as well as the outcome of the experiment. Our
group has created a coding for the program, which is then translated into instructions for the system
to enable the pilot plant equipment to carry out the process operation in accordance with the plan.
The input of the system is shown on the left side of the ladder diagram, while its output is shown
on the right side. With the use of sensors that can detect and send signals to the system, the
Programme Logic Controller (PLC) system is used to establish the input of the system. The signal
generated will be followed by the output, which consists of valves and stirrer, to perform functions

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such as opening or closing the valve. To determine the water level in the tanks, the PLC system
uses level sensors with low, medium, and high levels.

The pilot equipment operated according to the plan we had established before beginning
the trail. Water was to be introduced into the three tanks one after another, starting from Tank 3,
and ending with Tank 1, in accordance with the planned process. When the high level sensor of
Tank 3 sensed the water level in the tank reached the highest level, the filling valve of Tank 2 will
open and allow the water to flow into Tank 2. Once Tank 2 has reached its maximum level, its high
level sensor will detect the water level and release the filling valve of Tank 1 to let water into the
tank.

The drainage valves of Tanks 1, 2, and 3 will then opened simultaneously, allowing water
to enter the mixer when the high level sensor in Tank 1 detects a high water level. The stirrer will
start when the low level sensor of mixer detects the water level. The drainage process of the mixer
began as soon as the water level hits it maximum level.

5.2 Explanation of Each Line of Ladder Diagram

Industrial automation uses the programming language Ladder Diagram to create graphical
and visual representations of control systems. Symbols are used to represent various components
and their interactions, including timers, actuators, sensors, and logic functions. It is based on the
graphical representation of relay logic circuits.

A set of horizontal lines that represent the logic’s left-to-right flow are used to create the
program in a Ladder Diagram. Contacts, which indicated input conditions, and coils, which
represent outputs or actions, make up these horizontal lines.

Figure 5.2: Line 1 of Ladder Diagram.

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 The first line of the ladder diagram in Figure 5.2 shows how the status of the SWITCH
(input) determine whether to activate or control VALVE5 (output). For instance, make a rung in
the ladder diagram where the normally open contact (which represents the switch) is in series with
the coil (which represents the VALVE5) to open the valve when the switch is closed. This indicates
that only the switch is closed will the coil become energized.

Figure 5.3: Line 2 of Ladder Diagram.

The second line of the ladder diagram as shown in Figure 5.3 indicates how VALVE3 will
be turned open when the maximum level sensor of water is achieved. The program extends the
control to a second tank based on the condition of the sensor and valve of the first tank. When the
Switch is activated, VALVE5 opens. Once it reaches its maximum level that is indicated by
SENSORMAX5, VALVE3 opens to fill Tank 2 with water.

Figure 5.4: Line 3 of Ladder Diagram.

In Figure 5.4, the third line of the ladder diagram shows the valve to Tank 1 will open up
when the maximum level sensor in Tank 2 detects any liquid. Expanding the control to a third
tank involves adding the sensor for the maximum level of Tank 2 and introducing VALVE1,
which operates Tank 1.

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 Figure 5.5: Line 4 of Ladder Diagram.

The fourth line of ladder diagram in Figure 5.5 shows that once the water level in Tank 1
has reached the maximum water level, the draining valves 2, 4, and 6 (for tanks 1, 2, and 3,
respectively) will open, allowing the controlled transfer of their contents into the mixing tank.

Figure 5.6: Line 5 of Ladder Diagram.

Figure 5.6 shows that when the water level in the mixing tank reaches the maximum level,
which was detected by MAXMIXTANK, the draining valve of mixing tank, VALVE8, will be
opened, draining all the content completely. In order to control the drain valve of mixing tank
based on the reading from the maximum level sensor, the ladder logic would have to take these
conditions and interlocking relationships into account.

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5.0 CONCLUSION

Based on the situation by the lab assistant, the process in this experiment is successfully
controlled using programmable logic control (PLC). The sequential tank filling and concurrent
mixer input process design illustrated the usefulness of PLCs in industrial automation. The
experiment also demonstrated the significance of analogue input functions for industrial control
systems. In summary, the practical exposure greatly enhanced the understanding of PLC principles
and their essential function in automated procedures.

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6.0 REFERENCES

1. Curtis D. Johnson, 2003, Process Control Instrumentation Technology (Seventh Edition),

New Jersey. p 10-15.

2. D.E. Seborg, T.F. Edgar and D.A Mellichamp, 2011. Process Dynamics and Control (
Third Edition), John Wiley & Sons, Inc. p. 2-5, 124-135, 271-282.

3. Frank Petruzella, 2010, Programmable Logic Controllers (Forth Edition), McGraw-Hill

Education.

4. Mohd Kamaruddin, Ahamad Kamal, Khairiyah Mohd Yusof, Mimi Haryani, 2005.
SKC5771 Process Control Laboratory Student’s Manual (Second Edition and Revised).

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