DJM 40082 – PROGRAMMABLE LOGIC CONTROLLER PRACTICAL 3

[Pick the date]

PRACTICAL 3 (3 HOURS)
PLC APPLICATION IN THE INDUSTRY 2
(WATER LEVEL AND MIXER CONTROL)

CLO3 : Adapt a PLC for an automated application.

PLO3 : Design / development of solution: Design solutions for well-defined technical problems and assist
with the design of systems, components or processes to meet specified needs with appropriate
consideration for public health and safety, cultural, societal, and environmental considerations
(DK5)
: Adaptation – Skills are well developed and the individual can modify movement patterns to fit
P6
special requirements

1. AIM
i. To solve a PLC based system design programming.

2. OUTCOMES
At the end of the session, the student will be able to;
i. Integrate the PLC instructions to suit the design requirements.
ii. Solve the well-defined technical problems with the design of systems.

3. EQUIPMENTS/MATERIALS
PLC Trainer – OMRON

4. THEORY

Programmable Logic Controllers was designed as a replacement for automatic control systems that used
hard wired relays and timer to create a controlled sequencer. PLCs can be programmed to perform a variety
of tasks; from starting and stopping motors to mathematical computing operations. With the processing
power, data storage, and communication capabilities of today’s modern computers, PLCs provide
intelligent (act as miniature computers) that can deliver reliable operation in various challenging
environments, such as extreme temperatures, electrical noise, vibration, and shock.

By interfacing with everything from sensors and machine guards to motion control and advanced
identification devices, PLCs ensure operations run smoothly and flexible; manufacturers can manage
multiple machines at once and achieving a higher level of integration thus improving production quality
and cost of operation.

PRACTICAL 3: PLC APPLICATION IN THE INDUSTRY 2 1

 DJM 40082 – PROGRAMMABLE LOGIC CONTROLLER PRACTICAL 3
[Pick the date]
5. PROCEDURES
i. Solve the Practical 3A technical problems by providing design solutions (I/O assignments, ladder
diagram and mnemonic code)
ii. Revises the solution (RUN the program and verify the answer).

PRACTICAL 3A: WATER LEVEL AND MIXER CONTROL

Condition : Figure 3.1 shows a water level and mixer control system. When the start
pushbutton is press to “ON”, the solenoid A will be OPEN and the water in the
tank will rise from the empty sensor switch level to the level where the full
sensor switch is located. When the full sensor switch is ‘ON’, solenoid A will
CLOSE and the motor will be ON to start a mixing process. The mixing process
will be continuing for 10 seconds before the mixer motor is OFF and solenoid B
is OPEN to empty the tank. When the water reaches the level where the empty
sensor switch is located, the solenoid B will be CLOSING and the process is finish.
The start pushbutton needs to be press to start the process again. The stop push
button is an emergency stop button that is used to stop the machinery quickly
when there is a risk of injury or the workflow requires stopping.

Figure 3.1: Water Level and Mixer Control

PRACTICAL 3: PLC APPLICATION IN THE INDUSTRY 2 2