Runnable simulator field guide
PLC sortation diverter scenario: test checklist
Direct answer
The learner can create one event per product, schedule one actuation, prevent double counts and recover tracking from stops or missing confirmation.
Written for pLC learners programming a conveyor diverter with classification input, product tracking and destination proof.

Scenario setup
Entry edge, product identity, class, conveyor state, travel delay, divert window, actuator feedback, destination sensor, counts and reject state.
I/O and state map
Sensor event through tracking record, time or position model, classification decision, output command, mechanism response and destination confirmation.
Normal run
Normal products and divert products each receiving one decision and one confirmed destination without duplicated counts.
Boundary run
Sensor chatter, back-to-back products, missing class, late response, failed confirmation, jam, stop during transit, restart and manual removal.
Injected fault
An event, identity, classification, tracking, timing, output, actuator, destination, count or recovery mismatch.
Target check
The model compared with measured conveyor travel, actuator response, sensor placement and safe recovery on target equipment.
How do I time a PLC conveyor diverter?
Measure or model travel from the identification sensor to the diverter, retain the product decision and command inside a window that includes speed and actuator-response tolerances.
Why does a sortation count drift?
Common causes include level-based counting instead of edges, sensor bounce, duplicated writers, missing destination proof, manual product removal and unreconciled restart state.