SIX MONTH INDUSTRIAL TRAINING FINAL REPORT

(DEC – May 2015)

Submitted in the partial fulfillment of the requirements

for the 8th semester curriculum of degree of

Bachelor of Technology
in
ELECTRICAL ENGINEERING
of
PUNJAB TECHNICAL UNIVERSITY, JALANDHAR

Under the guidance of: Submitted

By:
(Name of the Teachers/ Industry Instructor) Name:
Inst Roll No:
Uni. Regd. No:

Department of Electrical Engineering

GURU TEG BAHADUR KHALSA INSTITUTE OF ENGINEERING &
TECHNOLOGY
CHHAPIAN WALI (MALOUT)
 Certificate

Certified that this project/training report entitled “six weeks industrial training” submitted
by Ramandeep singh (120935279527) , student of Electrical engineering , MMB Poly
college, Fatta Maloka , in the partial fulfillment of the requirement for the award of
Bachelors of Technology electrical engineering, degree of PSEBIT Chandigarh, is a record
of students own study carried under my supervision & guidance.

This report has not been submitted to any other university or institution for the award of
any degree.

Training In-charge:
Sumanpreet kaur

ii
 ACKNOWLEDGMENT

I am highly grateful to the Er Jasvir singh , HOD EE, for providing this opportunity to
carry out the six week industrial training at Wind Tech Pvt. Ltd. ,Chandigarh.

I would like to expresses my gratitude to other faculty members of Electronics and

communication engineering department of MMB Poly College, Fatta Maloka for
providing academic inputs, guidance & encouragement throughout the training period.

The author would like to express a deep sense of gratitude and thank
Deepak Kaushal Director/CEO of Company, without whose permission, wise counsel and
able guidance, it would have not been possible to pursue my training in this manner.

The help rendered by Mr Naveen Jha Supervisor for experimentation is greatly

acknowledged.

Finally, I express my indebtedness to all who have directly or indirectly contributed to the
successful completion of my industrial training.

iii
 ABSTRACT

The programmable logic controller represents a key factor in industrial Automation. Its use
permits flexible adaptation to varying processes as well as rapid fault finding and error
elimination.

This report explains the design of a programmable logic controller and its interaction with
peripherals with the detail of programming function and programming language.

One of the main focal points of the report deal with the practical of RELAYS,
PROGRAMMABLE LOGIC CONTROLLER.

Relay is an electromechanical switch which is used to isolate one electrical circuit from
another.
It allows a low current control circuit to make or break an electrically isolated high
current circuit path.

PLC is a multipurpose clock driven memory based electronic device which is also known
as specialized industrial computer which deals with different level of complexity and
control system.
A programmable logic controller (PLC) or programmable controller is a digital
computer used for automation of electromechanical processes, such as control of machinery
on factory assembly lines, amusement rides, or light fixtures. PLCs are used in many
industries and machines. Unlike general-purpose computers, the PLC is designed for
multiple inputs and output arrangements, extended temperature ranges, immunity to
electrical noise, and resistance to vibration and impact

iv
v
CONTENTS

Page No.
Candidate’s Declaration ii
Certificate iii
Acknowledgement iv
Abstract v
Contents vi
List of Figures vii
List of Tables viii

1 .Instrumentation
1.1 Automation
1.2 Engineering tools
1.3 Relays concepts
1.4 Contactor concepts

2. Programmable logic controller

2.1 Architecture of PLC
2.2 Inputs and Outputs of PLC
2.3 Catalog number
2.4 Source and sink concept
2.5 PLC wiring
2.6 Panel wiring
2.7 Software introduction
2.8 XIC-XIO concepts
2.9 Introduction to PLC memory
2.10 Introduction to Data files and Program Files.
2.11 Start Stop logic
2.12 Logic gates
2.13 OSR bit
2.14 Concept for Latch, Unlatch
2.15 Timer

6
 2.16 Counter
2.18 Compare function
2.19 Compute math

3. Project Based on Bottle Filling

3.1 Introduction
3.2 Features
3.3 Block Diagram
3.4 Discription of block diagram
4. References

LIST OF FIGURES

7
Figure No: Name of Figure Page No.

1.1 Relay 19

1.2 Symbol of contactor 20

2.1 Programmable logic controller (PLC) 22

2.2 architecture of PLC 24

2.3 Pin Diagram 25

2.6 Micrologix 1000 28

2.7 Micrologix 1100 with Analog Card 30

2.8 PLC Trainer Kit 33

2.9 Trainer Board of micrologix1100 PLC 34

2.10 RS Linx classic window 35

2.11 RS Logix 500 window 36

2.12a. TON timer 39

2.12b. TOFF timer 39

2.12c. Retentive Timer (RTO) 39

2.12d Counter UP (CTU) 40

2.12e Counter Down (CTU) 41

2.12f Equal to 41

2.12g Greater than Equal to 41

2.12h Less than Equal to 42

2.12i Greater Than 42

8
 2.12j Less than 43

2.12k Limit 43

2.12l Reset 43

Figure No. Name of Figure Page No.

4.1 Block diagram of bottle filling project 42

4.2 Power supply 12 volt. 42

4.3 IR sensor 43

4.4 Programmable logic controller (PLC) 44

4.5 Conveyer 44

4.6 Moter 45

4.7 Model of Project 45

Chapter 1:

9
Instrumentation

Automation

Automation is the use of control systems and information technologies to reduce the need for
human work in the production of goods and services. In the scope of industrialization, automation
is a step beyond mechanization. Whereas mechanization provided human operators with
machinery to assist them with the muscular requirements of work, automation greatly decreases
the need for human sensory and mental requirements as well. Automation plays an increasingly
important role in the world economy and in daily experience.
Consider the examples of automation:
1. Automated video surveillance

2. Automated highway systems

3. Automated manufacturing

4. Home automation

5. Industrial automation

6. Agent-assisted Automation

1.1 Advantages of Automation:

1. Replacing human operators in tasks that involve hard physical or monotonous work.
2. Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes,
nuclear facilities, underwater, etc.)
3. Performing tasks that are beyond human capabilities of size, weight, speed, endurance,
etc.
4. Economy improvement: Automation may improve in economy of enterprises, society or
most of humanity. For example, when an enterprise invests in automation, technology

10
 recovers its investment; or when a state or country increases its income due to automation
like Germany or Japan in the 20th Century.

`1.2 Disadvantages of Automation:

1. Unemployment rate increases due to machines replacing humans and putting those
humans out of their jobs.
2. Technical Limitation: Current technology is unable to automate all the desired tasks.
3. Security Threats/Vulnerability: An automated system may have limited level of
intelligence; hence it is most likely susceptible to commit error.
4. Unpredictable development costs: The research and development cost of automating a
process may exceed the cost saved by the automation itself.
5. High initial cost: The automation of a new product or plant requires a huge initial
investment in comparison with the unit cost of the product, although the cost of
automation is spread in many product batches of things.

1.1. ENGINEERING TOOLS

1.1.1 PLC (Programmable Logic Controller):

A programmable logic controller (PLC) or programmable controller is a digital computer
used for automation of electromechanical processes, such as control of machinery on factory
assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and
machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact
1.1.2 SCADA (Supervisory Control And Data Acquisition)

SCADA (supervisory control and data acquisition) is a category of software application program
for process control, the gathering of data in real time from remote locations in order to control
equipment and conditions. SCADA is used in power plants as well as in oil and gas refining,
telecommunications, transportation, and water and waste control.

11
 SCADA systems include hardware and software components. The hardware gathers and feeds
data into a computer that has SCADA software installed. The computer then processes this data
and presents it in a timely manner. SCADA also records and logs all events into a file stored on
a hard disk or sends them to a printer. SCADA warns when conditions become hazardous by
sounding alarms.

1.1.3 HMI (Human Machine Interface)

A Human-Machine Interface or HMI is the apparatus which presents process data to a human
operator, and through which the human operator controls the process.

An HMI is usually linked to the SCADA system's databases and software programs, to provide
trending, diagnostic data, and management information such as scheduled maintenance
procedures, logistic information, detailed schematics for a particular sensor or machine, and
expert-system troubleshooting guides.

The HMI system usually presents the information to the operating personnel graphically, in the
form of a mimic diagram. This means that the operator can see a schematic representation of the
plant being controlled

1.2.RELAY AND CONTACTOR

1.2.1 RELAY:
A relay is a simple electromechanical switch made up of an electromagnet and a set of contacts.
Current flowing through the coil of the relay creates a magnetic field which attracts a lever and
changes the switch contacts. It is used for double through (changeover).

12
 Fig 1.1 relay

The relay's switch connections are usually labeled COM, NC and NO:

 COM = Common, always connect to this, it is the moving part of the switch.
 NC = Normally Closed, COM is connected to this when the relay coil is off.
 NO = Normally Open, COM is connected to this when the relay coil is on.

1.2.2Advantages of relays:

 Relays can switch AC and DC.

 Relays can switch higher voltages.
 Relays are often a better choice for switching large currents (> 5A).
 Relays can switch many contacts at once.
 Relay can be rated for very high voltage.

1.2.3 Disadvantages of relays:

 Relays are bulkier than transistors for switching small currents.

 Relays cannot switch rapidly (except reed relays), transistors can switch many times per
second.
 Relays use more power due to the current flowing through their coil.
 Relays require more current than many ICs can provide, so a low power transistor may be
needed to switch the current for the relay's coil.

1.3 CONTACTOR:
1.3.1What is contactor?
Contactors are used to switch relatively large outputs and currents.

13
Contactors work on the same basic principle as relays.
The typical features of contactor are:
 double- break ( 2 break points per contact),
 positive-action contacts and
 closed arcing chambers (spark arresting chambers).

Fig.1.2 Symbol of contactor

1.3.2Advantages of contactor:
 Easy to changeover.
 Durable.
 Easy to test.
 Basically used for high current ratings.

1.3.3 Disadvantages of contactor:

 Required more power
 Contacts wear

14
1.4 COMPARISON BETWEEN RELAY AND CONTACTOR:

Relay Contactor
Relays possess a clapper-type
armature and are characterized by
Contactors possess a lifting
single contact separation
armature and are characterized by
double contact separation.

Relays are used to switch Contactors are used to switch

relatively small outputs and relatively large outputs and
currents. currents.

15
Chapter 2

PLC (Programmable Logic Controller)

2.1INTRODUCTION
Control engineering has evolved over time. In the past humans were the main methods for
controlling a system. More recently electricity has been used for control and early electrical control
was based on relays. These relays allow power to be switched on and off without a mechanical
switch. It is common to use relays to make simple logical control decisions. The development of
low cost computer has brought the most recent revolution, the Programmable Logic Controller
(PLC). The advent of the PLC began in the 1970s, and has become the most common choice for
manufacturing controls. PLCs have been gaining popularity on the factory floor and will probably
remain predominant for some time to come. Most of this is because of the advantages they offer.
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other systems quickly and easily.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce downtime.
• Reliable components make these likely to operate for years before failure.
The term SCADA stands for Supervisory Control and Data Acquisition. A SCADA system is a
common process automation system which is used to gather data from sensors and instruments
located at remote sites and to transmit and display this data at a central site for either control or
monitoring purposes. The collected data is usually viewed on one or more SCADA Host computers
located at the central or master site.
A real world SCADA system can monitor and control hundreds to hundreds of thousands of I/O
points. A typical Water SCADA application would be to monitor water levels at various water
sources like reservoirs and tanks and when the water level exceeds a preset threshold, activate the
system of pumps to move water to tanks with low tank levels.
Common analog signals that SCADA systems monitor and control are levels, temperatures,
pressures, flow rate and motor speed. Typical digital signals to monitor and control are level

16
switches, pressure switches, generator status, relays & motors.Automation of many different
processes, such as controlling machines, basic relay control, motion control, process control is
done through the use of small computers called a programmable logic controller (PLC). This is
actually a control device that consists of a programmable microprocessor, and is programmed
using a specialized computer language. A programmable logic controller (PLC) or
programmable controller is a digital computer used for automation of electromechanical
processes, such as control of machinery on factory assembly lines, amusement rides, or lighting
fixtures. PLC’s are used in many industries and machines, such as packaging and semiconductor
machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact. Programs to control machine operation are typically stored in battery-backed
or non-volatile memory. A PLC is an example of a real time system since output results must be
produced in response to input conditions within a bounded time, otherwise unintended operation
will result.A modern programmable logic controller is usually programmed in any one of several
languages, ranging from ladder logic to Basic or C. Typically, the program is written in a
development environment on a personal computer (PC), and then is downloaded onto the
programmable logic controller directly through a cable connection. Programmable logic
controllers contain a variable number of Input/output (I/O) ports the programmable logic controller
circuitry monitors the status of multiple sensor inputs, which control output.

Fig 2.1.Programmable logic controller (PLC)

HISTORY

17
2.2.1 Origin

The PLC was invented in response to the needs of the American automotive manufacturing
industry. Programmable controllers were initially adopted by the automotive industry where
software revision replaced the re-wiring of hard-wired control panels when production models
changed.Before the PLC, control, sequencing, and safety interlock logic for manufacturing
automobiles was accomplished using hundreds or thousands of relays, cam timers, and drum
sequencers and dedicated closed-loop controllers. The process for updating such facilities for the
yearly model change-over was very time consuming and expensive, as the relay systems needed
to be rewired by skilled electricians.In 1968 GM Hydramatic (the automatic transmission division
of General Motors) issued a request for proposal for an electronic replacement for hard-wired relay
systems.The winning proposal came from Bedford Associates of Bedford, Massachusetts. The first
PLC, designated the 084 because it was Bedford Associates' eighty-fourth project, was the result.
Bedford Associates started a new company dedicated to developing, manufacturing, selling, and
servicing this new product: Modicon, which stood for Modular Digital Controller. One of the
people who worked on that project was Dick Morley, who is considered to be the "father" of the
PLC. The Modicon brand was sold in 1977 to Gould Electronics, and later acquired by German
Company AEG and then by French Schneider Electric, the current owner.One of the very first 084
models built is now on display at Modicon's headquarters in North Andover, Massachusetts. It was
presented to Modicon by GM, when the unit was retired after nearly twenty years of uninterrupted
service. Modicon used the 84 moniker at the end of its product range until the 984 made its
appearance.

2.1.2 Programming

Early PLCs, up to the mid-1980s, were programmed using proprietary programming panels or
special-purpose programming terminals, which often had dedicated function keys representing the
various logical elements of PLC programs. Programs were stored on cassette tape cartridges.
Facilities for printing and documentation were very minimal due to lack of memory capacity. The
very oldest PLCs used non-volatile magnetic core memory.

18
2.1.3 Functionality

The functionality of the PLC has evolved over the years to include sequential relay control, motion
control, process control, distributed control systems and networking. The data handling, storage,
processing power and communication capabilities of some modern PLCs are approximately
equivalent to desktop computers. PLC-like programming combined with remote I/O hardware,
allow a general-purpose desktop computer to overlap some PLCs in certain application.

2.2. ARCHITECTURE OF PLC

2.2 ARCHITECTURE OF PLC

19
2. 2.1 PARTS OF PLC

2. 2.1 .1 POWER SUPPLY: PLC requires 24V switch mode power supply for its operation.

2.2.1 .2 MCU: Its full form is microcontroller unit. It is the processor of PLC. It is basically
the brain of PLC. It performs various control operations of PLC.

2.2.1 .3 INPUTS AND OUTPUTS: PLC has a set of isolated inputs and isolated outputs.
Different PLC’s have different number and different type of inputs and outputs.Like in
Micrologix 1000 we have total number of 6 inputs and 4 outputs whereas in Micrologix 1100 we
have 10 inputs and 6 outputs.

2. 2.1 4 EXPANSION PORT: In PLC there is an expansion port which is used for the addition
of any other equipment with PLC. For example analog cards.

2.2.1.5 MEMORY MODULE: The memory module in PLC is used for the storage of program
in PLC for future use.

2.2.1.6 COMMUNICATION PORT: The communication ports are used in PLC to

communicate with the computer. In PLC there are two types of communication ports i.e. RS
232 comport and Ethernet port.

2.2.1.7 MONITOR: This display screen is used as human machine interface i.e. it provides good
visualization of operation running

2.3.PLC PIN DIAGRAM

20
 Fig 2.3 .Pin Diagram

2.4 INPUTS AND OUTPUTS OF PLC

PLC programs are made up of a combination of the "gates" together with inputs, outputs, timers,
counters, internal memory bits, analog inputs, analog outputs, mathematical calculations,
comparators etc.
2.4.1 INPUTS
These are the physical connections from the real world to the PLC. They can be limit switches,
push buttons, and sensors, anything that can "switch" a signal on or off. The voltages of these
devices are usually, but not always, 24 Volt DC. Manufacturers make inputs that can accept a wide

21
range of voltages both ac and dc. It should be remembered that an input will be ON, "status 1",
when the voltage is present at the input connection and OFF, "status 0", when the voltage is no
longer present at the input connection.

2.4.2 TYPES OF INPUTS OF PLC

USER TYPE: These are the inputs and outputs that are physically present and are
practical to the inputs and outputs of the PLC.

BIT TYPE: These are the inputs and outputs that are not physically present and are
functional in the PLC only. These inputs/outputs are basically used to drive each other in
the ladder logic programming.

XIC (Examine if closed):

I/P O/P

0 0

1 1

XIO (Examine if open):

I/P O/P

0 1

1 0

22
2.4.3 OUTPUTS

These are the connections from the PLC to the real world. They are used to switch solenoids,
lamps, contactors etc on and off. Again they are usually 24 Volt DC, either relay or transistor, but
can also be 115/220 Volt AC.

2.4.3.1 TYPES OF PLC OUTPUTS

 Relay type output

 Transistor type output

 TRIAC type output

2.5 PLC MANUFACTURES

SIEMENS

ALLEN BRADLEY

GENERAL ELECTRICAL

MITSUBISHI

SCHENIDER

ABB

Here we have done programming of two PLC’s of Allen Bradley i.e. Micrologix 1000 and
Micrologix 1100.

23
2.5 .1 Micrologix 1000 Controllers 1761
Micrologix 1000 brings high speed, powerful instructions and flexible communications to
applications that demand compact, cost-effective solutions.TheMicrologix 1000 programmable
controller is available in 10-point, 16-point or 32-point digital I/O versions. Analog versions are
also available with 20 digital I/O points, with 4 analog inputs (two voltages and two current) and
1 analog output (configurable for either voltage or current).This little powerhouse is both
inexpensive and compact, with footprints as small as 120mm x 80 mm x 40 mm (4.72" x 3.15" x
1.57"). The analog I/O circuitry is embedded into the base controller, not accomplished through
add-on modules, providing compact and cost-effective analog performance.

2.5 .2 Features of Micrologix 1000

 Preconfigured 1K programming and data memory — help ease configuration (bit,

integer, timers, counters, etc)
 Fast processing — allows for typical throughput time of 1.5 ms for a 500-instruction
program
 Built-in EEPROM memory — retains all of your ladder logic and data if the
controller loses power, eliminating the need for battery back-up or separate memory
module
 RS-232 communication channel — allows for simple connectivity to a personal
computer for program upload, download and monitoring using multiple protocols,
including DF1 Full Duplex
 RTU slave protocol support — use DF1 Half-Duplex Slave, which allows up to 254
notes to communicate with a single master using radio modems, leased-line modems
or satellite uplinks

The Micrologix 1000 family provides small, economical programmable controllers. They are
available in configurations of 10 digital I/O (6 inputs and 4 outputs), 16 digital I/O (10 inputs and
6 outputs), 25 I/O (12 digital inputs, 4 analog inputs, 8 digital outputs, and 1 analog output), or 32

24
digital I/O (20 inputs and 12 outputs) in multiple electrical configurations of digital I/O. The I/O
options and electrical configurations make them ideal for many applications.

Fig 2.6.Micrologix 1000

2.5.3 Benefits

 Compact design—Lets the MicroLogix 1000 controller thrive in limited panel space.
 Choice of communication networks—An RS-232-C communication port is configurable
for: DF1 protocol for direct connection to a programming device or operator interface; DH-
485 networking through a 1761-NET-AIC converter; Device Net networking through a
1761-NET-DNI interface; Ethernet/IP networking through a 1761-NET-ENI interface; or
for half-duplex slave protocol in SCADA applications.
 Simple programming with your choice of programming device—You can program
these controllers in familiar ladder logic with MicroLogix 1000 A.I. Series Software®, PLC
500 A. I. Series Programming Software, RSLogix 500™ Windows Programming
Software, or the MicroLogix Hand-Held Programmer (1761-HHP-B30). This symbolic
programming language is based on relay ladder wiring diagrams that simplify the creation
and troubleshooting of your control program.

25
  Comprehensive instruction set—Over 65 instructions including simple bit, timer, and
counter instructions, as well as instructions for powerful applications like sequencers, high-
speed counter, and shift registers.
 Fast—Execution time for a typical 500-instruction program is only 1.56 ms.
 Choice of languages—Software and documentation are available in 5 languages. The
hand-held programmer has 6 languages built in.

2.5.4Features
The MicroLogix 1100 has 10 digital inputs, 2 analog inputs and 6 digital outputs, and supports
expansion I/O. Up to four 1762 I/O modules (also used on the MicroLogix 1200) may be added to
the embedded I/O, providing application flexibility and support of up to 80 digital I/O.

 One embedded 20 kHz high-speed counter (on controllers with DC inputs)—The built-
in independent high-speed counter uses 32-bit integers for extended range, features 8
modes of operation, and supports direct control of outputs independent of program scan.
 Two 20 kHz high-speed PTO/PWM outputs (on controllers with DC outputs).
 Digital trim potentiometers—Allow quick and easy adjustments of timers, counters, set
points, and more.
 Program data security—Data file download protection lets a program be reloaded into
the controller without overwriting protected data.
 Floating Point Data Files—You can create data files that can contain up to 256 IEEE-754
floating point values.
 Memory modules—Memory backup provides protection and transportability for
programs and data.

 Four interrupt inputs—Interrupt inputs let the controller scan a specific program file
(subroutine) when an input condition is detected from a sensor or field device.
 Real-Time Clock—embedded in every controller.

26
 Fig 2.7.Micrologix 1100 with Analog Card

2.5.5 Benefits

 Online Editing—modifications can be made to a program while it is running, making fine

tuning of an operating control system possible, including PID loops. Not only does this feature
reduce development time, but it aids in troubleshooting.
 Built-in LCD—lets you monitor data within the controller, optionally modify that data and
interact with the control program. The LCD displays status for embedded digital I/O and
controller functions, and acts as a pair of digital trim pots to allow a user to tweak and tune a
program.
 Ethernet/IP Port—for peer-to-peer messaging offers users high-speed connectivity between
controllers and the ability to access, monitor and program from the factory floor to anywhere
an Ethernet connection is available.
 Isolated RS-232/RS-485 combo port—provides a host of different point-to-point and
network protocols.
 Embedded Web Server—lets you custom configure data from the controller to be displayed
as a web page

2.6. PROGRAMMING OF PLC

PLC programs are typically written in a special application on a personal computer, then
downloaded by a direct-connection cable or over a network to the PLC. The program is stored in

27
the PLC either in battery-backed-up RAM or some other non-volatile flash memory. Often, a
single PLC can be programmed to replace thousands of relays. Under the IEC 61131-3 standard,
PLCs can be programmed using standards-based programming languages. A graphical
programming notation called Sequential Function Charts is available on certain programmable
controllers. Recently, the International standard IEC 61131-3 has become popular. IEC 61131-3
currently defines five programming languages for programmable control systems: FBD (Function
block diagram), LD (Ladder diagram), ST (Structured text, similar to the Pascal programming
language), IL (Instruction list, similar to assembly language) and SFC (Sequential function chart).
These techniques emphasize logical organization of operations.While the fundamental concepts of
PLC programming are common to all manufacturers, differences in I/O addressing, memory
organization and instruction sets mean that PLC programs are never perfectly interchangeable
between different makers. Even within the same product line of a single manufacturer, different
models may not be directly compatible.

In Allen Bradley PLC’s the logic used for the programming is ladder logic. Ladder logic is a
programming language that represents a program by a graphical diagram based on the circuit
diagrams of relay-based logic hardware. It is primarily used to develop software for Programmable
Logic Controllers (PLCs) used in industrial control applications. The name is based on the
observation that programs in this language resemble ladders, with two vertical rails and a series of
horizontal rungs between them. An argument that aided the initial adoption of ladder logic was
that a wide variety of engineers and technicians would be able to understand and use it without
much additional training, because of the resemblance to familiar hardware systems. This argument
has become less relevant given that most ladder logic programmers have a software background
in more conventional programming languages, and in practice implementations of ladder logic
have characteristics—such as sequential execution and support for control flow features—that
make the analogy to hardware somewhat imprecise.Ladder logic is widely used to program PLCs,
where sequential control of a process or manufacturing operation is required. Ladder logic is useful
for simple but critical control systems, or for reworking old hardwired relay circuits. As
programmable logic controllers became more sophisticated it has also been used in very complex
automation systems.

28
 Fig 7. Simple ladder logic

The language itself can be seen as a set of connections between logical checkers (contacts) and
actuators (coils). If a path can be traced between the left side of the rung and the output, through
asserted (true or "closed") contacts, the rung is true and the output coil storage bit is asserted (1)
or true. If no path can be traced, then the output is false (0) and the "coil" by analogy to
electromechanical relays is considered "de-energized". The analogy between logical propositions
and relay contact status is due to Claude Shannon.
Ladder logic has contacts that make or break circuits to control coils. Each coil or contact
corresponds to the status of a single bit in the programmable controller's memory. Unlike
electromechanical relays, a ladder program can refer any number of times to the status of a single
bit, equivalent to a relay with an indefinitely large number of contacts.
So-called "contacts" may refer to physical ("hard") inputs to the programmable controller from
physical devices such as pushbuttons and limit switches via an integrated or external input module,
or may represent the status of internal storage bits which may be generated elsewhere in the
program.
Each rung of ladder language typically has one coil at the far right. Some manufacturers may allow
more than one output coil on a rung.
--( )-- a regular coil, energized whenever its rung is closed
--(\)-- a "not" coil, energized whenever its rung is open
--[ ]-- A regular contact, closed whenever its corresponding coil is energized
--[\]-- A "not" contact, open whenever its corresponding coil is energized

29
The "coil" (output of a rung) may represent a physical output which operates some device
connected to the programmable controller, or may represent an internal storage bit for use
elsewhere in the program.

Fig 2.8.PLC Trainer Kit

The above figure shows the view of PLC trainer kit. On this kit various operations are performed.
It has following components mounted:

1 .PLC MicroLogix1000 2 .SMPS (220V AC-24V DC)

3. A Contactor Relay 4. An Electromechanical Relay

5. Normally open Switch (4) 6. Normally closed Switch (4)

7. Output LED’s (4) 8. RS 232 Comport for communication with PC

30
 Fig2. 9.Trainer Board of micrologix1100 PLC

The above fig shows the trainer board of micrologix 1100 PLC. It has following components:

1.PLCmicrologix 1100 2. SMPS (220V ac to 24V dc)

3. Analog I/O card 4. A Contactor Relay
5. An Electromechanical Relay 6. Normally open Switch (4)
7. Normally closed Switch (4) 8. Output LED’s (4)
9.RS 232 Comport for communication with PC

2.6.1 COMMUNICATION OF PLC WITH PC

To make communication of PLC with PC following steps are noted down:

Connect PC and PLC via RS232 comport or Ethernet.

Then click on RS Linx icon, a window will appear as shown in fig below

31
 Fig2. 10.RS Linx classic window

In this window add drivers i.e. whether it is RS232 comport or Ethernet and configure the drivers
and closes the window

Then click on icon RS who on the RS Linx classic window, another window will appear as shown
in fig
After opening the RS who window click on AB DF1-1 DH-485, the PLC is running is shown on
the window. Then close this window and double click on RS Logix 500 starter.

When we double click on RS Logix 500 starter a window will appear as shown in fig.

32
 Fig 2.11. RS Logix 500 window

2.6.2 PLC INSTRUCTIONS

There are various instructions which are useful for making ladder logic for PLC programming.
These are as follows:

9.2.1 XIC (Examine if closed):

Use the XIC instruction in your ladder program to determine if a bit is ON. When the instruction
is executed, if the bit addressed is on (1), then the instruction is evaluated as true. When the
instruction is executed, if the bit addressed is off (0), then the instruction is evaluated as false.

XIC (Examine if closed):

I/P O/P

0 0

1 1

Examples of devices that turn on or off include:

33
  A push button wired to an input (addressed as I:0/4).
 An output wired to a pilot light (addressed as O:0/2).
 A timer controlling a light (addressed as T4:3/DN).
2.6.2.2 XIO (Examine if open):
Use the XIO instruction in your ladder program to determine if a bit is OFF. When the instruction
is executed, if the bit addressed is off (0), then the instruction is evaluated as true. When the
instruction is executed, if the bit addressed is on (1), then the instruction is evaluated as false.

I/P O/P

0 1

1 0

Examples of devices that turn on or off include:

• Motor overload normally closed (N.C.) wired to an input (I:0/10).
• An output wired to a pilot light (addressed as O:0/4).
• A timer controlling a light (addressed as T4:3/DN).
2.6.2.3 Output Energize (OTE):
Use the OTE instruction in your ladder program to turn on a bit when rung conditions are evaluated
as true. An example of a device that turns on or off is an output wired to a pilot light (addressed as
O:0/4).

2.6.2.4Output Latch (OTL) and Output Unlatch (OTU):

OTL and OTU are retentive output instructions. OTL can only turn on a bit, while OTU can only
turn off a bit. These instructions are usually used in pairs, with both instructions addressing the
same bit. Your program can examine a bit controlled by OTL and OTU instructions as often as
necessary.

34
 Latch output and Unlatch output

2.7. TIMERS AND COUNTERS

2.7.1 TIMER
Timers are used to perform the timing operations. Time base is the minimum value of time in
second that can be taken by the timer. Preset value is the total number of the seconds for which the
timing operation has to be done Accumulator starts increasing the time in secondsupto the preset
value. Upto the preset value of the accumulator the enable bit of timer is high & the timer runs.
When accumulator reaches the preset value then the timer stops and the done bit of the timer
becomes high.
The timer has following bits and these bits are useful in the operation of timer:
 EN- Enable- This bit will high when the input is given to the timer
 TT - Timer timing bit - This bit will be high during the timing process. It remains
high till accumulator value becomes equal to preset value
 DN – Done – This bit will be high when the timing process is ended. It set to high
when the accumulator value becomes equal to preset value.
In Micrologix 1000 and 1100 PLC there are three types of timers i.e.
TON Timer
T-OFF Timer
Retentive timer ON (RTO)
2.7.1.1 TON Timer: Use the TON instruction to turn an output on or off after the timer has
been on for a preset time interval. The TON instruction begins to count time-base intervals when
rung conditions become true. As long as rung conditions remain true, the timer adjusts its

35
accumulated value (ACC) each evaluation until it reaches the preset value (PRE). The accumulated
value is reset when rung conditions go false, regardless of whether the timer has timed out

Fig 2.12a.TON timer

2.7.1.2 T-OFF Timer :Use the TOF instruction to turn an output on or off after its rung has
been off for a preset time interval. The TOF instruction begins to count time base intervals when
the rung makes a true-to-false transition. As long as rung conditions remain false, the timer
increments its accumulated value (ACC) based on the time base for each scan until it reaches the
preset value (PRE). The accumulated value is reset when rung conditions go true regardless of
whether the timer has timed out.

Fig 2.12b.T-OFF timer

2.7.1.3 Retentive Timer (RTO):Use the RTO instruction to turn an output on or off after
its timer has been on for a preset time interval. The RTO instruction is a retentive instruction that
begins to count timebase intervals when rung conditions become true.
The RTO instruction retains its accumulated value when any of the following occurs:

36
 Fig 2.12c.Retentive Timer (RTO)

2.7.2 Counters:
Counters are used to count the number of operations. Its function is same as the timer accepts
that the timer counts the number of seconds and the counter counts the number of operations or
pulses. At each operation the value of the accumulator increases and when the value of the
accumulator comes to the preset value of the counter then the counter stops.
Counter bits:
 TT - Timer timing bit - This bit will be high during the counting process. It remains high
till accumulator value becomes equal to preset value
 DN – Done – This bit will be high when the counting process is ended. It set to high
when the accumulator value becomes equal to preset value.
2.7.2.1 Counter UP (CTU):The CTU is an instruction that counts false-to-true rung
transitions. Rung transitions can be caused by events occurring in the program (from internal
logic or by external field devices) such as parts traveling past a detector or actuating a limit
switch. When rung conditions for a CTU instruction have made a false-to-true transition, the
accumulated value is incremented by one count, provided that the rung containing the CTU
instruction is evaluated between these transitions. The ability of the counter to detect false-to-
true transitions depends on the speed (frequency) of the incoming signal. The accumulated value
is retained when the rung conditions again become false. The accumulated count is retained until
cleared by a reset (RES) instruction that has the same address as the counter reset.

37
 Fig 2.12d.Counter UP (CTU)
2.7.2.1 Counter Down (CTD):The CTD is an instruction that counts false-to-true rung
transitions. Rung transitions can be caused by events occurring in the program such as parts
traveling past a detector or actuating a limit switch. When rung conditions for a CTD instruction
have made a false-to-true transition, the accumulated value is decremented by one count,
provided that the rung containing the CTD instruction is evaluated between these transitions. The
accumulated counts are retained when the rung conditions again become false. The accumulated
count is retained until cleared by a reset (RES) instruction that has the same address as the
counter reset.

Fig 2.12e.Counter Down (CTU)

2.7.2.3 EQU (equal to)

Fig 2.12f.Equal to
This input instruction is true when source A becomes equal to source B. The EQU instruction
compares two user specified values if values are equal, it allows rung continuity. The rung goes
true and output energies.
2.7.2.4 GEQ (greater than equal to)
This instruction compares two values and will be high when the counted value becomes equal to

38
or greater than the fixed value and will energize everything that is connected next to it.

Fig 2.12g.Greater than Equal to

2.7.2.5 LEQ(less than equal to)

Fig 2.12h.Less than Equal to

This instruction compares two values and will be high when the counted value becomes equal to
or less than the fixed value and will energize everything that is connected next to it.
2.7.2.6 GRT (greater than)

Fig 2. 12i.Greater Than

Use of the GRT instruction to test whether one value (source A) is greater than another (source
B). If the value at source A is greater than the value at source B, the instruction is logically true. If
the value at source A is less than or equal to the value at source B, the instruction is logically false.
Source A must be an address. Source B can either be a program constant or an address. Negative

39
integers are stored in two’s complement form.
2.7.2.7 LES (less than)
Use of the LES instruction is to test whether one value (source A) is less than another (source B).
If source A is less than the value at source B, the instruction is logically true. If the value at source
A is greater than or equal to the value at source B, the instruction is logically false. Source A must
be an address. Source B can either be a program constant or an address. Negative integers are
stored in two’s complement form.

Fig 2.12j. Less than

2.7.2.8 LIM (Limit):

Fig 2.12k.Limit
Use the LIM instruction to test for values within or outside a specified range, depending on how
you set the limits.
2.7.2.9 RES (Reset):

Fig2. 12l.Reset
Use a RES instruction to reset a timer or counter. When the RES instruction is enabled, it resets
the Timer ON Delay (TON), Retentive Timer (RTO), Count UP (CTU), or Count Down (CTD)
instruction having the same address as the RES instruction.When resetting a counter, if the RES

40
instruction is enabled and the counter rung is enabled, the CU or CD bit is reset. If the counter
preset value is negative, the RES instruction sets the accumulated value to zero. This in turn causes
the done bit to be set by a count down or count up instruction.

2.8. PLC PROGRAMS

2.8.1 Program no. 1:
A bottle takes 7 sec to be completely filled, if the filling is interrupted then it should resume from
the same level. When the filling of one bottle is completed the motor should run for 2 sec for
changing the bottle.
Sol:
In this program we have used two inputs and two outputs of PLC i.e. I:0/0 & I:0/1 as inputs and
O:0/0 & O:0/1 as outputs. We have used a RTO as timer and compare instructions LEQ and LIM.
When input I:0/0 is ON the RTO will start and conveyor motor is started for 7 sec by using LEQ
instruction and after 7 sec conveyor motor is stopped and then the valve is operated for 2 sec using
LIM instruction. Then after 2 sec the conveyor motor again starts automatically.

41
When RTO and conveyor motor runs by pressing start push button

42
when the valve operates and conveyor motor stops

43
 after filling bottle the valve stops and conveyor starts again

2.8.2 Program no. 2:

When a momentary start push button is pressed, a lamp goes ON. If again same start push button
is pressed first lamp goes off and it remains off for the next 20 seconds. If start push button is
pressed again in between these 20 seconds, lamp should not go ON. It should go ON again on
pressing start push button only after completing 20 seconds.
Sol:In this program one input and one output of PLC is used. A Counter, Timer and a Greater than
instructions are used.

44
 Program of controlling lamp by timer and counter

When lamp glows by pressing push button

.When lamp goes off by pressing push button second time

45
Lamp will not glow even if we press push button. The lamp will glow after 20 sec by
pressing push button.

46
Chapter 4
PROJECT ON BOTTLE FILLING SYSTEM

4.1 INTRODUCTION:
Simplification of engineering and precise control of manufacturing process can result in significant
cost savings. The most cost-effective way, which can pay big dividends in the long run, is flexible
automation; a planned approach towards integrated control systems. It requires a conscious effort
on the part of plant managers to identify areas where automation can result in better
deployment/utilization of human resources and savings in man-hours, down time. Automation
need not be high ended and too sophisticated; it is the phased, step-by-step effort to automate,
employing control systems tailored to one’s specific requirements that achieves the most attractive
results. That is where Industrial electronics has been a breakthrough in the field of automation and
control techniques.
The aim of this project is to design a Plc (Programming Logic Controller) based automatic bottle
filling system that sense the presence of bottle and level of liquid in it and then fills it accordingly
up to a fixed level. In this project we developed proximity sensor using infrared sensor that detects
the presence of bottle.
Here we use Plc to control the filling of liquid in bottle. Plc provides the sample input to the
computer and with these Ladder Logic program generates control signal for solenoid tap and that
can be accessed by it through Plc.

4.2 FEATURES
 It’s very efficient
 Low cost
 Easy to build
 Reduce human efforts.
 Working is very fast.
 Performing tasks that are beyond human capabilities of size, weight, speed)
 Reliability and maintainability.
 Flexibility

47
4.3 BLOCK DIAGRAM OF BOTTLE FILLING PROJECT

Input IR
Switches Sensor

PLC
(programmable
logic controller)
Power
Supply

Power Conveyer Pump

Supply Motor

4.4 DISCRIPTION OF BLOCK DIAGRAM:

4.4.1 POWER SUPPLY:
A power supply unit (PSU) converts mains AC to low-voltage regulated DC power for the internal
components of a computer. Modern personal computers universally use a switched-mode power
supply. Some power supplies have a manual selector for input voltage, while others automatically
adapt to the supply voltage. In our project we are using 2 types of power supplies 12volt and 220
volts. Here is diagram of power supply in fig 1.1

48
 Fig 4.2.Power supply 12 volt.
4.4.2 I R sensor:

An infrared sensor is an electronic device that emits and/or detects infrared radiation in order to
sense some aspect of its surroundings. Infrared sensors can measure the heat of an object, as well
as detect motion. Many of these types of sensors only measure infrared radiation, rather than
emitting it, and thus are known as passive infrared (PIR) sensors. All objects emit some form of
thermal radiation, usually in the infrared spectrum. This radiation is invisible to our eyes, but can
be detected by an infrared sensor that accepts and interprets it. In a typical infrared sensor like a
motion detector, radiation enters the front and reaches the sensor itself at the center of the device.
This part may be composed of more than one individual sensor, each of them being made from
pyroelectric materials, whether natural or artificial. These are materials that generate an electrical
voltage when heated or cooled.Thesepyroelectric materials are integrated into a small circuit
board. They are wired in such a way so that when the sensor detects an increase in the heat of a
small part of its field of view, it will trigger the motion detector's alarm. It is very common for an
infrared sensor to be integrated into motion detectors like those used as part of a residential or
commercial security system.

In our project we are using IR sensor. Here is diagram of intruder sensor in fig18.

49
 Fig 4.3. IR sensor

4.4.3 PLC (Programmable Logic Controller):

Control engineering has evolved over time. In the past humans were the main methods for
controlling a system. More recently electricity has been used for control and early electrical control
was based on relays. These relays allow power to be switched on and off without a mechanical
switch. It is common to use relays to make simple logical control decisions. The development of
low cost computer has brought the most recent revolution, the Programmable Logic Controller
(PLC). The advent of the PLC began in the 1970s, and has become the most common choice for
manufacturing controls. PLCs have been gaining popularity on the factory floor and will probably
remain predominant for some time to come. The advantages they offer.
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other systems quickly and easily.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce downtime.

50
 Fig .4.4. Programmable logic controller (PLC)

4.4.3 Conveyer:

We offer bottle transfer chain conveyor that is used to transfer bottles of different diameters from
one place to another. Widely finding application in bottling and engineering industries, the chain
conveyor has railing for bottle support. The high speed motor runs when strapping process starts.

Fig 4.5. Conveyer

4.4.4 Motor :

An electric motor is an electric machine that converts electrical energy into mechanical energy.

In normal motoring mode, most electric motors operate through the interaction between an electric
motor's magnetic field and winding currents to generate force within the motor. In certain
applications, such as in the transportation industry with traction motors, electric motors can operate
in both motoring and generating or braking modes to also produce electrical energy from
mechanical energy.

Found in applications as diverse as industrial fans, blowers and pumps, machine tools, household
appliances, power tools, and disk drives, electric motors can be powered by direct current (DC)

51
sources, such as from batteries, motor vehicles or rectifiers, or by alternating current (AC) sources,
such as from the power grid, inverters or generators. Small motors may be found in electric
watches.

Here is diagram of motor shown below in fig 6.8.

Fig 4.6. Motor

Project diagram description & Working:

52
 Fig 4.7.Model of Project

PLC based bottle filling system.

The working of project is dividing in three modules:
1. PLC programming
2. SCADA animation.
3. Hardware wiring

These are three faces of our project on which the whole working of our project is depended. Now
first we will deeply study about these three module to understand the working of the project.
Bottle filling application animation:

53
54
55
56
57
58
59
 Hardware wiring:
That is the third phase of the project in which we will assemble our project. Here is the block
diagram of our project:
5V
-
+ Sensor
+

Relay

+24V -24V DC I:0 I:1 I:2

comm

O/P DC
I:3 I:4

PLC
P N VACD O:0 VACD O:1 VACD O:2
C C C

+
+
VALV
220V +
_ Motor -

+ -
12V

Fig 6.9 Wiring of PLC based bottle filling system.

60
Working:

1. press start button

Start button

2. Conveyer will start moving.

Bottle at initial position

61
3. When sensor detects the bottle it will stop below the Valve.

Bottle is stopped and valve is open for filling

4. After filling the bottle the conveyer will again move.

Bottle after filling

62
5. To end the process press stop button.

Stop button
That project include following circuits:
1. Sensor:

2. Power supply:

63
3 PLC

4 Relay

5 Conveyer

64
 6. Motor

REFERENCE

1. Manual of allenbraedlyRClogix500 .

2. Instruction manual of RSview 32

3. <http://www.wikipedia .com>

4. <http://www.kirloskarpumps.com>

5. <http://www.engineersgarage.com>

65
66