Ladder logic example for beginners –

Over head water tank automatic level

control

This is a PLC program to control water level in an overhead tank and this will be a
useful guide for people who are interested in learning PLC Ladder logic
programming.
Control Description:
Let us consider one overhead tank installed on top of a building of which water level
needs to be controlled. There are two modes of operation involved, manual mode
and Auto mode as explained below

Manual Mode
In this mode water pump can be started or stopped manually.

Auto Mode
In this mode when the water level of the overhead tank reaches the low level, the
water pump should start and it should run until water level in the overhead tank
reaches high level. When high level of overhead tank reaches, then the water pump
should stop.

This water pumps inlet line is connected to a well and discharge line is connected to
the overhead tank. Whenever well water level is low, the water pump should not be
allowed to start in both Manual and Auto Mode.

Control Diagram:
Overhead Water tank level control diagram
Control Solution:
 To detect high and low levels of overhead tank, two level switches are placed,
one at the bottom of overhead tank and other one at the top of the overhead
tank, which gives output in digital terms that is when corresponding levels are
detected.
 To detect low level of the well, a level switch is used at the bottom of the well
which provides output in digital terms as well.
 When these inputs are received in PLC, output to the motor which is connected
to the water pump needs to be powered ON/OFF in such a way that overhead
tank water level can be maintained as mentioned in control description.
 Master Start/Stop has also been included to start the process when mode is in
manual.
PLC Program:
Below shown is the PLC program in Ladder logic to Control water Level of an
Overhead tank, along with program explanation and run time test cases.

List of Inputs and Outputs with its abbreviations

1. Overhead tank High Level Switch (Input) – OT H L SW
The NC contact of this switch is used in logic, whenever the overhead tank level
reaches high limit the limit switch contact opens and gives “FALSE” value and in
normal condition the limit switch contact will remain closed and give “TRUE” value.

2. Overhead tank Low Level Switch (Input) – OT L L SW

The NC contact pulse of this switch is used in logic, whenever overhead tank level is
more than low limit the limit switch contact opens and gives “FALSE” value and
whenever overhead tank level drops below low limit the limit switch contact closes
and gives a momentary pulse of “TRUE” value.

3. Well Low Level Switch (Input)- W L L SW

The NO contact of this switch is used in logic, whenever well level is more than low
limit the limit switch contact closes and gives “TRUE” value and whenever well level
drops below low limit the limit switch contact opens and gives “FALSE” value.

4. Auto/Manual switch (Input) – A/M SW

The NC contact of Auto/Manual switch is used for Manual mode.

The NO contact of Auto/Manual switch is used for Auto mode.

When the switch value is “FALSE” the contact will be in close state and Manual mode
will be selected.

When the switch value is “TRUE” the contact will be in open state and Auto mode will
be selected

5. Start switch (Input) – STRT SW

A positive pulse NO contact is used for the Start switch, when this switch is activated
a short pulse of “TRUE” value is received and drops back to low.

6. Stop switch (Input) – STOP SW

The NC contact of the Stop switch is used in logic, when the switch is activated the
contact opens and stops the motor from running.

7. Motor Coil (Output) – MTR COIL

When all the conditions for starting the motor are healthy, the motor coil will become
high and send a signal to start the motor.

When the stop condition is met, the motor coil will become low and will send a signal
to stop the motor.

Ladder Diagram for this process using online PLC simulator

Overhead Water tank level control ladder logic

Ladder Logic Description
Manual mode Rung with branch