Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
INDUSTRIAL TRAINING
At
PUNE
Submitted by:
ROHIT RAJ
Reg no.: 070921206
DEPT. OF INSRUMENTATION AND CONTROL ENGINEERING
CONTENTS
1. Company profile
2. Certificate
3. PLC(Introduction)
4. PLC programming
5. Timers
6. Counters
7. Special PLCs in market( Allen Bradley, Mitsubishi, Siemens, Messung)
8. HMI/MMI
9. SCADA
10. AC Drives
11. Conclusion
COMPANY PROFILE
ACS thinks and conducts business internationally. ACSs experience and established
company tradition are the basis for innovation and success. The skills, knowledge,
dedication and motivation of our employees ensure the quality of our products.
Excellence in performance and a satisfied client are our goals. Learning is a vital part of
our organization. Our commitment to technical advances guarantees our future and
continued success. ACS continues to be a leader in the manufacturing industries
serving a multitude of industries in a variety of disciplines. Industries using our products
and services include:
Automation and Control in the industry are witnessing dramatic value addition through
newer and latest Technology. It is the key to enhance productivity and increase
profitability. We at ACS are in touch with the latest Technology and have the expertise
and knowledge to smoothly integrate new technology solutions with your existing
infrastructure
At ACS we have executed large projects involving various brands of Field
Instrumentation, PLCs, AC Drives and SCADA
Services Provided
We are in the field of providing Industrial Automation to various industries like Food,
Power Process, Automobile, Pharmaceutical, Packaging etc. We are geared to provide
total turnkey support from the stage of requirement analysis, system engineering,
software development, installation and commissioning and on site training to maintain
the above products.
Our Expertise
* Control System Configuration
* Startup & commissioning Assistance
* Application Software Development
* PLC and SCADA Programming
* Operator, Maintenance
* Engineering Training
ACC cements
Apollo Tyres
Gas Authority of India Ltd.
Ashok Leyland
Bajaj Auto Ltd
Bharat Forge Ltd
Bharat Gear
Bharat Petroleum Corporation Ltd.
BHEL - Bangalore
Birla Copper
Crompton Greaves
DLF Power Ltd
E. I. Dupont (India) Ltd.
.
Hero Honda
Hindustan Lever Ltd.
Indian Aluminium Ltd.
Indian Osalate Ltd
Indian Petrochemicals Corp Ltd.
Kinetic Engineering Ltd.
Moser Baer Ltd.
Precision Gears Ltd
LG Electronics
RANBAXY Ltd
LML Ltd.
G M Motors
Maruti Udyog Ltd.
PLC
Definition:
PLCs are defined as miniature industrial computers that contain hardware and software
used to perform control functions.
A PLC consists of two basic components :- the CPU and the I/O interface system. The
CPU which controls all the PLC activity can be further classified into :- the processor
and the memory system.
The I/O system is physically connected to the field devices (e.g- switches, sensors,
motor, bulb) and provides the interface between the CPU and the information providers
(input) and the controllable devices (output).
PLC Operation:
To operate the CPU reads input data from the connected field devices through the use
of its input interfaces and then executes or performs the control program that has been
stored in its memory system. Programs are typically created in ladder logic, a language
that closely resembles a relay based wiring schematic and are entered into the CPU
memory prior to operation. Finally based on the program the PLC writes or updates
output devices via the output interfaces. This process also known as scanning typically
continues in the same sequence without interruption and changes only when a change
is made to the control program.
Scan Cycle
The scanning takes place continuously once the program is run. The scan cycle
consists of three phases :- input scan, logic scan( creation of ladder logic), output scan.
output devices
Push button
Mechanical valves
Selector switch
Solenoid valves
Alarm
Limit switch
Motor or fan
Level switch
AC drives
Proximity switch
Relay
Thumbwell switch
Actuator
PLC vs PC
PLC is basically a type of PC. The differences are:PLC has no keyboard. For i/p we use an input module which is basically a little box with
a row of screws infront of it.
We wire up a bunch of push buttons, sensors, switches to the little screws this serves
as an input device for our PLC computer.
PLC has no monitor. For o/p we use an output module which is basically another little
box with a row of screws infront of it.
We wire up a bunch of solenoid valves, indicator lamps, motor starters to the little
screws this serves as an output device for our PLC computer.
Advantages
Economic ( much cheaper than PC, hence can be used in a versatile manner)
Very accurate( performance degradation is very less even after years of functioning.
ladder logic is binary in nature hence almost no error in execution of correct code)
Non stop functioning( i.e. the scan cycle runs continuously for the entire lifetime
once PLC is installed)
Types Of PLCs
There are basically 3 types of PLCs
1. Micro PLC- has 64 i/o ports
HMI integrated in the PLC. We can see the row of screws for input/output.
3. Rack (modular) PLC has 4096 i/o ports.
There are various slots for different cards e.g. input cards, output cards, CPU card,
power card, special cards (for communication, HS pulse etc.)
This type of PLC is scalable i.e. we can attach another i/o PLC module. The female
connector of the primary PLC is connected to the male connector of the extension PLC
(DB-9).
Each PLC requires a power card but the CPU card is present only in the primary PLC.
On the CPU card (intelligent module) we have DB9 connectors for communication
with HMI or PC.
PLC Programming
Based on ladder logic. Each ladder has switches or flags as inputs and a single coil or a
single flag as an output.
1. Switch- push button and toggle switch
Push button gives high input only during the time it is kept pressed in on condition.
(i.e. goes to off state on releasing)
Two types:- normally open(NO) and normally closed(NC)
Toggle switch gives high input once the switch is pressed on.(i.e. does not go off
even when released)
2. Coil : the output is taken across the coil. Symbol for coil is
I1
output
I1
output
I1
output
examples
Q1) Suppose we have 2 push buttons red and green. When the green button is pressed
bulb is turned ON and remains ON even after releasing the switch. Whenever the red
button is pressed the bulb is turned OFF and remains OFF(after releasing) till the green
button is pushed again. Give the ladder logic for the given situation.
Assume %ix0.0 as the green button and %ix0.1 as the red button. %qx0.0 is the bulb.
set-reset
NOTE: As we can see that using set reset we got an alternative solution for the previous
question assuming i0 as the green and i1 as the red button.
Pulse/ trigger
Two types- rising edge and falling edge
Q2)
Consider the case:- on either side of the gate there are 2 sensors. Sensor 1detects the
head of the bus and opens gate. The gate remains open till the bus passes completely
and is closed after the tail of the bus passes sensor 2. Assume only one way traffic and
give the logic ladder.
Rising edge at sensor1 sets the gate o/p and opens it. Falling edge at the sensor2
resets the gate o/p therefore, the gate is closed.
Memory flag
Used to decrease the number of output ports used in the ladder. The intermediate logic
results can be stored in flags which can be used in subsequent rung or scan cycle.
Q3)Design a push button switch which when pressed turns a bulb on continuously. The
next time the switch is pressed the bulb turns off . Again if the switch is pressed the bulb
turns on and the pattern follows.
M1 is a flag set on rising edge for a pulse interval each time the switch i0 is pressed.
Xor with previous output state gives the new output state, Next State which is the toggle
value of Present State.
Q4) write a program for rising and falling edge triggers using NO, NC contacts only.
Q5) suppose we have a push button i0 and 2 bulbs q0 and q1. Generate the following
cyclic pattern
I0
Q0
Q1
1st time
2nd time
3rd time
Timers
There are 4 types of timers. They are TON,TOFF,TP,RTC. The most basic is TON ,
other timers can be derived from this timer.
1)Time delay on timer(TON)= output is turned on after the preset time value( eg 5 secs)
from the time when a continuous power supply input is given
Note:- the output of timer is high(after 5 secs) only if the input supply is still available.
2)Time delay off timer(TOFF)= the output is high the instant the switch is on(power
supply) and the output goes to low after preset time value(eg 5 secs) from the time
supply is cut.
3)Pluse timer(TP)= for a pulse input at positive edge the timer starts and the output is
high for the time timer runs.
4)RTC(real time clock)= used for real time applications and is internet controlled for
remote work site eg:- gas pipelines( rate of flow and valve function)
While timer is running run bit=1 done bit=0 and current value(22)<preset value(50)
timer has expired run bit=0 done bit=1 and current value(50)=preset value(50)
Q5)design a ladder logic for the given specification. I0 is switched onq0 on for 10
secafter 10 secsq0 off and q1 on for 8 secafter 8 sec q1 off and q2 on for 15 sec.
repeat the cycle continuously.
Counter
Three types:- CTU,CTD,CTUD
CTU(Up counter)= counts the number of input pulses. If current no. of i/p pulses
(accumulator) = preset value then o/p=high
Eg- if preset value is 5, then after 5 i/p pulses the o/p goes from low to high. (high even
if supply is removed, here supply i/p is pulse)
A pulse given to reset sets accumulator=0 and o/p to low
CTD(Count down)= initially o/p=high and accumulator=0
When the first pulse is applied to load (like reset in CU)accumulator=preset value, and
o/p low
When subsequent I/P pulses are applied to enable ACC is decremented and when
accumulator=0 o/p is high.
CTUD(Counter up/down)= only one accumulator value which can be either incremented
by giving a pulse CU and decremented by giving a pulse to CD port.
RST=to reset in CU
LOAD=to load PV in CD
Q6)Assume a car garage. we have an entry and an exit door. We have 4 sensors
arranged as shown in diagram. A maximum of 5 cars can be accommodated in the
garage at a time. When the garage is full the entry door should not open when a new
car is detected waiting at the door. Draw a ladder logic for the problem.
Sensor 0 detects the incoming car(head) at rising edge and opens entry gate.
Sensor 1 detects the incoming car(rear) at falling edge when the car is fully inside the
garage and closes entry gate.
Sensor 0 detects the outgoing car(head) at rising edge and opens exit gate.
Sensor 1 detects the outgoing car(rear) at falling edge when the car is fully outside the
garage and closes exit gate.
software
country
mitsubishi
ACPU,FXCPU
GX Devloper
Japan
allen bradley
Micrologix
RSlogix
US
siemens
S7300CPU
S7 Microwin
Germany
messung
Nexgen 2000
Codesys
India
MITSUBISHI
Produced in Japan.
Product name=MELSEC
Hardware series=>
Rack type
FX SERIES=FX3U(latest),FXOS,FXON,FX1N,FX2N
A MODE=ACPU,QCPU,QnCPU(all are old)
Q MODE= Q CPU
MOTION CPU( for servo drives,robots)
Micro plc
FXCPU
For slave:-
When master goes down the slave takes charge and performs all 3 scans.
The software is used to create the ladder logic which is downloaded into th PLC
hardware.
e.g. FX GPWIN is a special software used to create download the ladder logic for the
specific hardware FXCPU.
GX Developer is an advanced feature software. Can be used for all CPUs. It has the
special feature of simulation online edit(download the program in run mode and part of
the program can be edited even while running on the plc)
Programming notations=>
Input address= X_
Output address=Y_
Memory address=M_
T0 K50= Timer no.(t0) and time set(k50=5secs)
There are 255 number of counters(CU). Bydefault CTD and CTUD are not present
Press f4(convert) and then run the program(ladder).
Where y3 y4 and y6 are red yellow and green lights respectively.x0 is the i/p
Allen Bradley
Manufactured in united states.
Hardware series=>
Modular PLC
FLEX LOGIX
SLC
CONTRO LOGIX(latest)
Micro PLC
MICRO LOGIX- 1000,1500,2000
Software series=>
RSLOGIX 500,5000
Communication software=>
RSLINX(Separate communication software only for allen Bradley)
Programming notations=>
Input= i:0/0 to i:0/15
Output=o:0/0 to o:0/15
Memory flag=b3:0/0 to b3:0/15
Timer =t4:0 to t4:255
Counter=c5:0 to c5:255
rising trigger
falling trigger
latch=set
unlatch=reset
Siemens
Manufactured in Germany.
Product name= SIMETIC
Hardware series=>
Mini PLC
LOGO
S5 CPU
Micro PLC
S7200 CPU
Rack PLC
S7300 CPU
S7400 CPU
Software series=>
Step 5 microwin
Step 6 microwin 3.2 or 4.0
Step 7 microwin 5.3
Simulation software=>
SIMETIC manager
Programming notations=>
Input address= i0._
Output address=o0._
Memory address=m0._
Timer=t37(time base of 100 ms)
MESSUNG
Made in India
Hardware series=>
NEXGEN 2000
NEXGEN 5000 CPU
NEXGEN 2K PLUS
All are modular(rack) PLCs
Softwares=>
DOXMINI(DOS based) for hardware xmp8(outdated)
CODESYS=simulation software, has visualization(in built SCADA feature)
Programming notations=>
Input= %ix0.0 to %ix0.7 (%ix_._)
Output= %ox0.0 to %ox0.7 (%ox_._)
Memory=%mx0.0 to %mx0.7 (%mx_._)
Has 255 timers and counters. Has all types of timers and counters.
Has visualization(inbuilt SCADA)
Force input is used for testing (input given to a switch from pc rather than the attached
sensors while the program is running on plc).
HMI(TERMINALS)
SOFTWARE
Messung
SOFT line
Mitsubishi
GOT
GT Designer(GT Simulator)
Allen Bradley
Panel view
Panel builder
Siemens
TP,OP
TP,OP designers
hardwareE100
Jump to block 1
Timer
F2
Jump to block 2
Timer preset
F3
Jump to block 3
Timer accumulator
F4
Jump to block 4
motor
F2
F3
F4
Timer
Timer preset
Timer accumulator
motor
6)similarly do this for timer, timer preset, timer acc and motor subblocks making
necessary changes in the menu screen.
7)for timer preset
9)motor:
F1
Jump to block0
Main
F2
Jump to block1
Timer
F3
i/o momentarily x0
Start
F4
i/o momentarily x1
Stop
For F3 and F4
Select i/o instead of jump to block
i/o=x0
i/o=x1
Monitor mode= run on PLC(should be in write mode when transfer setup to HMI)
To set a value from PC use the steps1)right click on coil T0(timer)
2)select device test
3)device:D0(preset value)
Setting value:50(50 secs)
Set(press enter)
PLC
ELLIPSE
Mitsubishi
RS VIEW 32
Allen Bradley
WIN CC
Siemens
TAGS
M50
Start
M51
Stop(reset)
Y0
Alarm(motor)
T0
Timer accumulator
D0
Timer preset
C0
Counter accumulator
C0
Alarm(digital)
D1
Counter preset
PROCESS
1)PLC program
2)download program to PLC
3)make a list of PLC devices
4)open SCADA software
5)make SCADA graphics
Plc software dhould be in offline mode when running the SCADA software
N1=DEVICE
N2=DEVICE number
device
Component
X INPUT
Y OUTPUT
M MEMORY
N1
N2
M50
50
Y0
X0
D0
17
T0
C0
12
MIMIC development
AC DRIVES
AC Drives used in PLC are controlled on PWM(pulse width modulation)
Main manufacturers of ac drives are Allen Bradley and ABB
AC DRIVE SCHEMATIC
C000main frequency
C001acceleration time
C002deacceleration time
C0120(digital operator)
1(PLC interface)
2(other communication interface)
C0128reset and restore=>08(to activate factory setting)
C0130(frequency set by digital operator)
1(frequency set by potentiometer)
C012MULTISPEED( press F4)
Note:-Interlock is provided in the PLC program such that both forward and reverse
rotation orders at a single instance are not issued.
CONCLUSION
Finally I would like to conclude with the brief synopsis of all that we learnt in the training
tenure at ACS, pune.
Finally the training of 3 weeks was completed with a final presentation of various
applications and versatile use of PLCS in various fields and practical examples of
various concepts(HMI, SCADA, AC Drives) that we had studied during the lecture
hours.