AUTOMATIOM IN PLC

ACKNOWLEDGEMENT

I would like to extend my gratitude & my sincere thanks to our guide Er.SANJEEV

BADIWAL, Department of Electrical and Electronics Engineering for his valuable

guidance, constant encouragement and kind help at different stages for the execution of

this dissertation work. I would also like to thank the staff at EXCELLENCE

TECHNOLOGY Chandigarh .for allowing us to carry out our project work in the lab.

We also express our sincere gratitude to Er.SANJEEV, BADIWAL Head of the

Department,Electrical and Electronics Engineering, for providing us with this project and

valuable departmental facilities.

I would like to thank my teachers and friends for their cooperation in carrying out the project.

UR NAME XXXX (reg no xxxxxx)

Er.XXXXXXX Sir (HoD)

B-tech (EE)

Name Of College, (faridkot ).

 AUTOMATIOM IN PLC

CONTENTS

TOPIC

1. Abstract

2. Introduction to Programmable Logic Controllers

3. WORK DONE IN TRAINING

4. DIFFERENCE BETWEEN PLC & RELAY

5. PROGRAMMABLE LOGIC CONTROLLER (PLC)

6. WHAT IS INSIDE A PLC

7. PROGRAMMING LANGUAGE USED A PLC

8. CIRCUIT ISOLATION IN PLC

9. SINKING AND SOURCING

10. RELATION OF LADDER LOGIC TO X-OR LOGIC

11. LOGIC GATES

12. TIMERS AND COUNTERS

13. SCADA:-Supervisory Control And Data Acquisition

14. SCADA ARCHITECTURES

15. History of SCADA

16. SCADA System Concept

17. Application of SCADA

18. RELAY

19. BIBLIOGRAPHY
 AUTOMATIOM IN PLC

ABSTRACT

This project work is divided into two parts. The first part deals with the history and
development of Programmable Logic Controllers and its subsequent applications in different
industries. In The second part PLC was implemented to control 3 different processes namely
lift car controller, Liquid level controller, Temperature controller.

Automation of many different processes, such as controlling machines or factory assembly

lines, 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.

Before, a programmable logic controller would have been programmed in ladder logic, which
is similar to a schematic of relay logic. 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. The program is stored in the programmable logic controller in non-volatile
memory.

The programmable logic controller has made a significant contribution to factory automation.
Earlier automation systems had to use thousands of individual relays and cam timers, but all
of the relays and timers within a factory system can often be replaced with a single
programmable logic controller. Today, programmable logic controllers deliver a wide range
of functionality, including basic relay control, motion control, process control, and complex
networking, as well as being used in Distributed Control Systems.

There are several different types of interfaces that are used when people need to interact with
the programmable logic controller to configure it or work with it. This may take the form of
simple lights or switches or text displays, or for more complex systems, a computer of Web
interface on a computer running a Supervisory Control and Data Acquisition (SCADA)
system.

Programmable logic controllers were first created to serve the automobile industry, and the
first programmable logic controller project was developed in 1968 for General Motors to
replace hard-wired relay systems with an electronic controller.

The lift controller controls the movement of the lift. The program is designed to make the lift
car move to the correct floor based on floor request. The temperature controller controls the
temperature of the fluid based on a set point. The level controller controls the level of a liquid
in a tank.
 AUTOMATIOM IN PLC

CHAPTER-1
A- INTRODUCTION

Industrial automation is the use of control systems, such as computers or robots, and
information technologies for handling different processes and machineries in an industry to
replace a human being. It is the second step beyond mechanization in the scope of
industrialization.
Automation or automatic control is the use of various control systems for operating
equipment such as machinery, processes in factories, boilers and heat treating ovens,
switching in telephone networks, steering and stabilization of ships, aircraft and other
applications with minimal or reduced human intervention. Some processes have been
completely automated. The biggest benefit of automation is that it saves labor; however, it is
also used to save energy and materials and to improve quality, accuracy and precision.
Automation has been achieved by various means including mechanical, hydraulic, pneumatic,
electrical, electronics and computers, usually in combination. Complicated systems, such as
modern factories, airplanes and ships typically use all these combined techniques.

Figure- A.1
 AUTOMATIOM IN PLC

1.1.Advantages and disadvantages –

The main advantages of automation are:

 Increased throughput or productivity.

 Improved quality or increased predictability of quality.

 Improved robustness (consistency), of processes or product.

 Reduced direct human labor costs and expenses.

 Install automation in operations to reduce cycle time.

 Install automation where a high degree of accuracy is required.

 Replacing human operators in tasks that involve hard physical or monotonous work.

 Replacing humans in tasks done in dangerous environments (i.e. fire, space, nuclear
facilities, underwater, etc.)

 Performing tasks that are beyond human capabilities of size, weight, speed, etc.

 Economic improvement: Automation may improve in economy of enterprises, society

or most of humanity.

 Reduces operation time and work handling time significantly.

 Frees up workers to take on other roles.

 Provides higher level jobs in the development, deployment, maintenance and running
of the automated processes.

 Real time operation.

The main disadvantages of automation are:

 Causing unemployment and poverty by replacing human labor.

 AUTOMATIOM IN PLC

 Security Threats/Vulnerability: An automated system may have a limited level of

intelligence, and is therefore more susceptible to committing errors outside of its
immediate scope of knowledge.

 Unpredictable/excessive development costs: The research and development cost of

automating a process may exceed the cost saved by the automation itself.

 High initial cost: The automation of a new product or plant typically requires a very
large initial investment in comparison with the unit cost of the product, although the
cost of automation may be spread among many products and over time.

 In manufacturing, the purpose of automation has shifted to issues broader than

productivity, cost, and time.

 Technology limits. Current technology is unable to automate all the desired tasks.

 Environment. The costs of automation to the environment are different depending on

the technology, product or engine automated. There are automated engines that
consume more energy resources from the Earth in comparison with previous engines
and those that do the opposite too.

Figure- A.2

1.2.The main applications of automation are:

 Automated manufacturing

 Home automation

 Automated retail
 AUTOMATIOM IN PLC

 Automated video surveillance

 Automated highway systems

 Automated waste management

 Industrial automation

 Agriculture

 Food &Beverage

Different control systems used in Automation?

 PID Controller based control system
 PLC based control system
 CNC based control system
 DCS based Control system
 PC Based automation system

History of Automation

1) Manual Control
2) Pneumatic Control
3) Hard wired logic Control
4) Electronic Control using Logic Gates
5) Programmable Logic Controller

I) Manual Control
All the actions related to process control are taken by the operators
Drawbacks
1) Likely human errors and consequently its effect on quality of final product
2) The production, safety, energy consumption and usage of raw material are all subject to
the correctness and accuracy of human action.
II) Pneumatic Control
1) Industrial automation, with its machine and process control, had its origin in the 1920s
 AUTOMATIOM IN PLC

with the advent of "Pneumatic Controllers".

2) Actions were controlled by a simple manipulation of pneumatic valves, which in turn were
controlled by relays and switches.
Drawbacks
1.Bulky and Complex System
2.Involves lot of rework to implement control logic
3.Longer project time
III) Hard wired logic control
1.The Relays and Contactor together with hardware timers and counters were used in
achieving the desired level of automation
Drawbacks
1.Bulky panels
2.Complex wiring
3.Longer project time
4. Difficult maintenance and troubleshooting
IV) Electronic Control using Logic Gates
1.In 1960s with the advent of electronics, the logic gates started replacing the relays and
auxiliary contactors in the control circuits.
2. The hardware timers & counters were replaced by electronic timers & counters.
Advantages
1.Reduced space requirements
2.Energy saving
3.Less maintenance & greater reliability
Drawbacks
1.Changes in control logic not possible
2.More project time

V) Programmable Logic Controllers (PLC’s)

1.In 1970s with the coming of microprocessors and associated peripheral chips, the whole
process of control and automation underwent a radical change.
2. Instead of achieving the desired control or automation through physical wiring of control
devices, in PLC it is achieved through a program or say software.
 AUTOMATIOM IN PLC

CHAPTER-2
B -WORK DONE IN TRAINING

2.1.DIFFERENCE BETWEEN PLC & RELAY

RELAY PLC

1. Logic is made from wiring only 1. Logic is made from programming

2. The System is very complex & 2. The System is very simple & much
complicated cleaner

3. Contact Failure rate is very high 3. Contact Failure rate is very low

4. Speed of operation is very slow 4. Speed of operation is very fast

5. Maintenance cost is high 5. Reduces the Maintenance cost

6. A Relay cannot accept a new module 6. A PLC can easily accept a new
It is required to build another panel module in a slot or get an expansion
base.
7. It is required to build another panel
to increase inputs & output. 7. In PLC, It's so much easierUser can
easily modify the logic to add
8. Any change or troubleshooting on a
number of input outputs
relay system means the system might
have to go offline. 8. Changes in a PLC can often be made
online with no downtime.
9. Panel size is large because use of
many relays. 9. PLC is a real space saver & reduces
panel size.
10. Data collection difficult
10. Data collection easy
11. Opting to use relays only in
applications where different voltages 11. PLC output could not handle the
were being switched (Input or current requirements of the
 AUTOMATIOM IN PLC

Output) application.

12. Rewiring and/or 12. Rewiring and/or troubleshooting is

troubleshootingsome pretty not complicated because of
complicated relay control panels
13. PLC has the ability to simulate I/O.
13. Relay didn’t have the ability to
simulate I/O.
14. The input output instructions in PLC
14. All the symbols in the relay logic ladder logic represent only data
represent actual components and values stored in the PLC memory.
contacts present in the system

2.2HISTORY OF PLC’S
The first Programmable Logic Controllers were designed and developed by Modicon as a
relay re-placer for GM and Landis. These controllers eliminated the need for rewiring and
adding additional hardware for each new configuration of logic. The new system drastically
increased the functionality of the controls while reducing the cabinet space that housed the
logic. The first PLC, model 084, was invented by Dick Morley in 1969. The first commercial
successful PLC, the 184, was introduced in 1973 and was designed by Michael Greenberg.

2.3.PROGRAMMABLE LOGIC CONTROLLER (PLC)

A programmable logic controller (PLC) is an industrial computer control system that
continuously monitors the state of input devices and makes decisions based upon a custom
program to control the state of output devices.
Almost any production line, machine function, or process can be greatly enhanced using this
type of control system. However, the biggest benefit in using a PLC is the ability to change
and replicate the operation or process while collecting and communicating vital information.
Another advantage of a PLC system is that it is modular. That is, you can mix and match the
types of Input and Output devices to best suit your application.
 AUTOMATIOM IN PLC

Figure- B.1

USE OF PLC

 Increased throughput or productivity.

 Improved quality or increased predictability of quality.

 Improved robustness (consistency), of processes or product.

 Increased consistency of output.

 Reduced direct human labor costs and expenses.

 Install automation in operations to reduce cycle time.

 Install automation where a high degree of accuracy is required.

 Reduces operation time and work handling time significantly.

 Frees up workers to take on other roles.

 Replacing human operators in tasks that involve hard physical or monotonous work.
 AUTOMATIOM IN PLC

 The following methods are often employed to improve productivity, quality, or

robustness.

 Performing tasks that are beyond human capabilities of size, weight, speed,
endurance, etc.

 Economic improvement: Automation may improve in economy of enterprises, society

or most of humanity.

 Provides higher level jobs in the development, deployment, maintenance and running
of the automated processes.

 Replacing humans in tasks done in dangerous environments (i.e. fire, space,

volcanoes, nuclear facilities, underwater, etc.

Selection of PLC

Choosing the most effective controller for your application depends on a number of factors.
To begin the selection process, a drawing of the machine or process is a good start. This can
help identify field devices and physical requirements for hardware locations. From the
drawing, you can determine how many analog and/or discrete devices you will have. Once
the field device requirements and hardware locations are defined, you can review controllers
that will meet your requirements. See the Controller Selection Worksheet in this section that
will help you work through the considerations for determining the type of controller you will
need, regardless of which manufacturers you are evaluating.

PLC selection criteria consist of:

* System (task) requirements.

* Application requirements.
* What input/output capacity is required?
* What type of inputs/outputs are required?
* What size of memory is required?
* What speed is required of the CPU?
* Electrical requirements.
 AUTOMATIOM IN PLC

* Speed of operation.
* Communication requirements.
* Software.
* Operator interface.
* Physical environments.

PLC Brands:-

1. Allen Bradley

2. Siemens

3. Delta

4. Schneider Electric

5. ABB

6. Honeywell

7. Omron

8. GE Fanuc

9. General Electric

10. Modicon

11. Mitsubishi

12. Toshiba

13. LG

14. Yokogawa

15. Messung

Requirement of PLC
 AUTOMATIOM IN PLC

Continuous demand for efficient manufacturing necessitates high quality and reliable Control
systems. Programmable Logic controller (PLC) is a digital device used for automating
electromechanical processes, such as control of machinery on factory assembly lines. PLC is
called 'The Work Horse' and represents a key driver in automation, production & process
planning in the manufacturing industry. The PLC is a Powerful Automation tool and its role
is of paramount importance as the production process goes through a fixed repetitive
sequence of operations that involve logical steps and decisions. Thus PLCs offer a system
with flexibility that is suited to withstand harsh industrial environment, reduced machine
down‐time and also easily maintainable.

2.4.WHAT IS INSIDE A PLC

O
Central U
I Processing T
N Unit P
P + U
U Memory T
T

Figure- B.2.4
The Central Processing Unit, the CPU, contains an internal program that tells the PLC how to
perform the following functions:
Execute the Control Instructions contained in the User's Programs. This program is stored in
"nonvolatile" memory, meaning that the program will not be lost if power is removed
Communicate with other devices, which can include I/O Devices, Programming Devices,
Networks, and even other PLC’s.
Perform Housekeeping activities such as Communications, Internal Diagnostics, etc.
The CPU is the brain of a PLC system. It consists of the microprocessor, memory integrated
circuits, and circuits necessary to store and retrieve information from memory. It also
includes communications ports to other peripherals, other PLC's or programming terminals.
Today's processors vary widely in their capabilities to control real world devices. Some
control as few as 6 inputs and 4 outputs (I/O) and others 40,000 or more. One processor can
control more than one process or manufacturing line. Processors are often linked together in
 AUTOMATIOM IN PLC

order to provided continuity throughout the process. The number of inputs and outputs PLC’s
can control are limited by the overall capacity of the PLC system hardware and memory
capabilities. The job of the processor is to monitor status or state of input devices, scan and
solve the logic of a user program, and control on or off state of output devices.

RAM or Random Access Memory is a volatile memory that would lose it's information if
power were removed. This is why some processor units incorporate a battery back up. The
type of RAM normally used is CMOS or Complementary Metal Oxide Semiconductor.
CMOS RAM is used for storage of the user's program (ladder logic diagrams) and storage
memory.

ROM or Read Only Memory is a non-volatile type of memory. This means you don't need an
external power source to keep information. In this type of memory, information can be read,
but not changed. For this reason the manufacture sometimes calls this firmware. It is placed
there for the internal use and operation of processor units.

EEPROM or Electrically Erasable Programmable Read Only Memory is usually an add-on

memory module that is used to back up the main program in CMOS RAM of the processor.
In many cases, the processor can be programmed to load the EEPROM's program to RAM if
RAM is lost or corrupted.

Input Module

There are many types of input modules to choose from. The type of input module used is
dependent upon what real world input to the PLC is desired. Some examples of inputs are
limit switches, electric eyes, and pushbuttons. DC inputs, such as thumbwheel switches, can
be used to enter integer values to be manipulated by the PLC. DC input cards are used for this
application. Since most industrial power systems are inherently noisy, electrical isolation is
provided between the input and the processor. Electromagnetic interference (EMI) and Radio
Frequency Interference (RFI) can cause severe problems in most solid state control systems.
The component used most often to provide electrical isolation within I/O cards is called an
optical isolator or optocoupler. The wiring of an input is not complex. The object is to get a
voltage at a particular point on the card. Typically there are 8 to 32 input points on any one
input module. Each point will be assigned a unique address by the processor. Analog input
 AUTOMATIOM IN PLC

modules are special input cards that use analog to digital conversion (A to D) to sense
variables such as temperature, speed, pressure, and position. The external device normally is
connected to a controller (transducer) producing an electrical signal the analog input card can
interpret. This signal is usually 4 to 20 ma or a 0 to 10 volt signal.

Output Module

Output modules can be for used for ac or dc devices such as solenoids, relays, contractors,
pilot lamps, and LED readouts. Output cards usually have from 6 to 32 output points on a
single module. The output device within the card provides the Connection from the user
power supply to the load. Usually silicon controlled rectifiers (SCR), triac, or dry contact
relays are use for this purpose. Individual outputs are rated most often at 2 to 3 amperes.
Output cards, like input cards have electrical isolation between the load being connected and
the PLC. Analog output cards are a special type of output modules that use digital to analog
conversion (D to A). The analog output module can take a value stored in a 12 bit file and
convert it to an analog signal. Normally this signal is 0 -10 volts dc or 4 to 20 ma. This
analog signal is often used in equipment such as motor operated valves and pneumatic
position control devices.

OPERATION OF PLC
A PLC operates by continually scanning the program and acting upon the instructions, one at
a time, to switch on or off the various outputs. In order to do this the PLC first "looks" at all
the inputs and remembers their states (i.e. "1" or "0" / on or off) this information is then
stored in memory. The PLC then scans the program instructions and decides if an output
should be on or off and this is important to remember, the physical output is NOT turned on
immediately. When the PLC has finished scanning the programmed instructions it will,
finally, turn on the required outputs. This is called updating the process output image. At this
point the PLC then checks its own operating system and if everything is ok it then goes and
checks the states of the inputs and starts all over again. This is program scanning and the
delay is called the program scan time. From the above statement it should be seen that there is
a delay from when an input is turned on; the program scanned and then a physical output
being turned on or off. As the delay is only ms it is not usually a problem unless you are
 AUTOMATIOM IN PLC

using the PLC in a high speed process. However it should be remembered that in a PLC with
many thousand I/O an input could turn on and then off before the PLC has finished scanning
the programmed instructions. This could result in an output coming on for one or two scans
when in fact it should be off.

PLC SCAN CYCLE

In case of PLC, before any output devices can be turned ON or OFF, the processor has to
scan the entire program that is in user memory

Input scan :- In input scan, the states of inputs are scanned and input status table is updated
accordingly.

Program scan : In this scan, data input table is applied to used created program, program is
executed and output table is updated accordingly.

Output scan :- In this scan, the states of outputs are generated as per the data associated
with output status table.

Figure- B.3

2.5.PROGRAMMING LANGUAGE USED A PLC

While Ladder Logic is the most commonly used PLC programming language, it is not the
only one. The following table lists of some of languages that are used to program a PLC.
Ladder Diagram (LD) Traditional ladder logic is graphical programming language. Initially
programmed with simple contacts that simulated the opening and closing of relays, Ladder
Logic programming has been expanded to include such functions as counters, timers, shift
registers, and math operations.
 AUTOMATIOM IN PLC

Figure- B.4
Function Block Diagram (FBD) - A graphical language for depicting signal and data flows
through re-usable function blocks. FBD is very useful for expressing the interconnection of
control system algorithms and logic.

Figure- B.5
Structured Text (ST) – A high level text language that encourages structured programming. It
has a language structure (syntax) that strongly resembles PASCAL and supports a wide range
of standard functions and operators. For example;
If Speed1 > 100.0 then
Flow_Rate: = 50.0 + Offset_A1;
Else
Flow_Rate: = 100.0; Steam: = ON
End_If;

Instruction List (IL): A low level “assembler like” language that is based on similar
instructions list languages found in a wide range of today’s PLCs.
LD R1
MPC RESET
 AUTOMATIOM IN PLC

LD PRESS_1
ST MAX_PRESS
RESET: LD 0
ST A_X43

Sequential Function Chart (SFC) A method of programming complex control systems at a

more highly structured level. A SFC program is an overview of the control system, in which
the basic building blocks are entire program files. Each program file is created using one of
the other types of programming languages. The SFC approach coordinates large, complicated
programming tasks into smaller, more manageable tasks.

Figure- 2.6
CIRCUIT ISOLATION IN PLC
When logic high signal comes from the processor the LED is on & light strike to
phototransistor. Which become in conduction region & give a triggering pulse to at the gate
of triac. The triac conducts-and load lamp is energized through it as clear from fig.
The interfacing is providing by opto-coupler (LED, Phototransistor) as in the input module.

Figure- B.7 Isolator Circuit Diagram

 AUTOMATIOM IN PLC

SINKING AND SOURCING

PLC input and output terminals are wired based upon the concepts of sinking and sourcing. In
sinking the direction of current flow is inward to PLC I/O module and sourcing, the direction
of current from is outward from PLC I/O module.

Figure- 2.8

Figure- 2.9
 AUTOMATIOM IN PLC

Figure- B.10

Figure- B.11
 AUTOMATIOM IN PLC

CHAPTER-3
PROJECT WORK DONE

3.1.PROGRAMMING
Ladder Logic or Ladder Diagrams is the most common programming language used to
program a PLC. Ladder logic was one of the first programming approaches used in PLCs
because it borrowed heavily from the Relay Diagrams that plant electricians already knew.
The symbol used in Relay Ladder Logic consists of a power rail to the left, a second power
rail to the right, and individual circuits that connect the left power rail to the right. The logic
of each circuit (or rung) is solved from left to right. The symbols of these diagrams look like
a ladder with two side rails and circuits that resemble rungs on a ladder.

Figure- C.1
The picture above has a single circuit or "rung" of ladder. If Input1 is ON (or true) - power
(logic) completes the circuit from the left rail to the right rail – and Output1 turns ON (or
true).
If Output1 is OFF (or false) - then the circuit is not completed and logic does not flow to the
right - and Output 1 is OFF. There are many logic symbols available in Ladder Logic -
including Timers, Counters, Math, and Data Moves- such that any logical condition or
control loop can be represented in Ladder Logic. With just a handful of basic symbols - a
Normally Open Contact, Normally Closed Contact, Normally Open Coil, Normally Closed
Coil, Timer, Counter - most logical conditions can be represented.
 AUTOMATIOM IN PLC

3.2.COMMUNICATION SOFTWARE

Figure- C.2
STEPS TO OPEN SOFTWARE

Figure- C.4STEPS TO OPEN SOFTWARE

 AUTOMATIOM IN PLC

Figure- C.5

Figure- C.6
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PROGRAMMING SOFTWARE

Figure- C.7PROGRAMMING SOFTWARE

STEPS TO OPEN SOFTWARE

Figure- C.8STEPS TO OPEN SOFTWARE

 AUTOMATIOM IN PLC

Figure- C.9

Figure- C.10
 AUTOMATIOM IN PLC

Figure- C.11

Figure- C.12
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Figure- C.13
Data Files
Data table files contain the stratus information associated with external I/O and all
other instruction you use in your main and subroutine ladder program files. In addition these
files store information concerning controller operation.
SLC controllers support up to 256 (0-255) data files. The first eight data files have default file
types. Micrologix-1000 controller allows you eight default data files as defined below.
O0(output)
I1(Input)
S3(Status)
B3(Binary)
T4(Timer)
C5(Counter)
R6(Control)
N7(Integer)
F8(Floating)

Output:- This files stores the state of output terminal for the controller.
Input:- This files stores the state of input terminal for the controller.
Status:- This file store the controller information useful for troubleshooting controller and
program operation.
Binary:- This file store internal relay logic.
Timer:- This file store the timer accumulator and preset values and status bits.
Counter:- This file store the counter accumulator and preset.
 AUTOMATIOM IN PLC

Control:- This file the length pointer position and status bits for specific instruction such as
shift register and sequencers.
Integer:- This file issued to store numeric values or bit information.
Floating Points:- This file stores with a range of -1.1754944e-38 to 3.40282341e+38.(SLC
only not for ML1000)

Figure- C.14

Figure- C.15
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Figure- C.16

Figure- C.17

3.3.INSTRUCTIONS

Ladder logic Instructions in Allen Bradley PLC

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In Allen Bradley PLC Software different instruction are used we are discuss in briefly here,
in Allen Bradley PLC Seven types instruction are available, Just see below.

1. Bit logic Instruction (Relay type instruction)

2. Timer/Counter Instruction

3. Compare Instruction

4. Compute/Math Instruction

5. Move/Logical Instruction

6. Program Control Instruction

7. Scaling Instruction (Analog valve processing )

Figure- C.18

3.4.Bit Logic Instruction

XIC :- Examine If Close

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XIO :- Examine If Open

OTE :- Output Energize
OTL :- Output Latch
OTU :- Output Unlatch

Symbols:-

XIC:This instruction (also called " Examine on" Or "Normally open") function as an input or
Storage bit, if the corresponding memory bit is a "1"(ON) this information will allow
rung continuity and output will be energized.
If the corresponding memory but is a "0" (OFF) this instruction will not allow rung continuity
(It assumes it's normally open states) and output on the rung will be de-energized (Other
factor can influence rung continuity)
XIO:This instruction (also called "Examine off" Or "Normally Closed" ) function as an input
or storage bit, if the corresponding memory bit is a "1" (ON) this information will not allow
rung continuity and output on it's rung will be de-energized. it the corresponding memory bit
is a "0" (OFF) this instruction will assume it's normal status and allow rung continuity and
output on the rang will be energized.
 AUTOMATIOM IN PLC

OTE: This Instruction sets the specified bit when rung continuity is achieved (Rung goes
true) under normal operating conditions if the set bit corresponds to an output device the
output device will be energized when the rung goes true.

OTL:This instruction functions much the same as the OTE with the exception that once a bit
is set with an OTL, it is "Latched" on, once an OTL bit has been set "ON" (1 in Memory) it
will remain "ON" even if the rung condition goes false the bit be reset with an OTU
instruction. Latch and unlatch instruction must be assigned the same address in your logic
program.

OTU:Use this output instruction to unlatch (Reset) a latched (Set) bit which was set by an
OTL instruction. The OTU address be identical to the OTL address which originally set the
bit.

RELATION OF LADDER LOGIC TO X-OR LOGIC:

Figure- C.19

BOOLEAN ALGEBRA
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In 1847 George Boole (1815–1864), an English mathematician, published one of the works
that founded symbolic logic. His combination of ideas from classical logic and algebra
resulted in what is called Boolean algebra.
Using variables and symbols, Boole designed a language for describing and manipulating
logical statements and determining if they are true or not. The variables stand for statements
that are either true or false. The symbols (+) (*) (-) represent and, or, and not and are
equivalent to the symbols [.logicaland], [.logicalor], and − used in the truth tables in logic.
Although truth tables use T and F (for true and false respectively) to indicate the state of the
sentence, Boolean algebra uses 1 and 0.
The relationship between Boolean algebra, set algebra, logic, and binary arithmetic has given
Boolean algebra a central role in the development of electronic digital computers.

Boolean algebra Truth Tables

As well as a standard Boolean Expression, the input and output information of any Logic
Gate or circuit can be plotted into a standard table to give a visual representation of the
switching function of the system. The table used to represent the Boolean expression of a
logic gate function is commonly called a Truth Table. A logic gate truth table shows each
possible input combination to the gate or circuit with the resultant output depending upon the
combination of these input(s).

LOGIC GATES

Gates - OR/AND/NOR/NAND/XOR/XNOR
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Figure- C.20

AND Gate:-

OR Gate:-
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NOT Gate:-

NAND Gate:-

NOR Gate:-

EX-OR Gate:-
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START-STOP:-

Figure- C.21

When we press the start push button NO type output side motor on, we put parallel input
contact but address is output side so when input is discharge because input is momentary
types but output motor is on.
When we press stop push button NC type output side motor off. This is simple Start-Stop
Logic.
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3.5.TIMERS AND COUNTERS

Many times we will want to take action in a control program based on more than the
states of discrete inputs and outputs. Sometimes, we will want to turn something on after a
delay, or count the number of times a switch is hit. To do these simple tasks, we will need
Timers & Counters.

Timer
A timer is simply a control block that takes an input and changes an output based on time.
There are two basic timer types we will deal with initially (there are other advanced
timers, but we will start with the basics first) - On-Delay Timer and the Off-Delay Timer.

On-Delay Timer
- this timer takes an input, waits a specific amount of time, then turns ON an output (or
allows logic to flow after the delay).

Off-Delay Timer
- this timer takes turns ON an output (or allows logic to flow) and keeps that output ON
until the set amount of time has passed, then turns it OFF (hence off-delay)

Counter
A counter simply counts the number of events that occur on an input. There are two basic
types of counters
- Up counter and a Down counter.

Up Counter
- As its name implies, whenever a triggering event occurs, an up counter
increments the counter.

Down Counter
- Whenever a triggering event occurs, a down counter decrements the counter.
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TIMER

Figure- C.22
COUNTER

Figure- C.23
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NEGATIVE EDGE AND POSITIVE EDGE:-

Figure- C.24
Decision/action flow diagrams
These are flow charts which show the sequence of action steps and questions to be considered
in complex tasks which involve decision-making. Decision/Action Flow Diagrams are similar
to the flow charts used in computer program development. Both charts are based on binary
choice decisions and intervening operations. In general, the binary decision logic in
Decision/Action charts expedites communications through the use of simple conventions and
provides for easy translation of Decision/Action charts into logic flow charts for
computerized sections of the system.
Decision/Action charts can be learned easily and workers usually find them useful in
formulating for the analyst their mental plans which may involve decision-making, time-
sharing, or complex conditions and contingencies. Decision/Action charts have only a single
level of task description, and when complex tasks are analyzed the diagrams become
unwieldy and difficult to follow. Also, it is possible to lose sight of the main objectives of the
task. To this extent, HTA is more appropriate because the task can be represented in varying
degrees of detail and the analyst can get a useful overview of the main objectives to be
achieved during the performance of the task.
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Although little training is required to learn the technique, Decision/Action charts should be
verified by different operators to ensure that a representative view of the decision task is
obtained.

Advantages of flow diagrams

• Decision/Action charts can be used to represent tasks which involve decision-making, time-
sharing, or complex conditions and contingencies.
• Workers find it easy to express their work methods in terms of flow diagrams. This
representation can then provide input to other Task Analysis methods.
• They can be used to identify critical checks that the workers have to carry out to complete a
process control task.
• For fault-diagnostic tasks, they can help the analyst to identify whether new staff members
make effective use of plant information.

Some Uses of the Process Chart

It can be seen from the foregoing discussions that the process chart has some useful purposes
in the manufacturing industry. One of the primary uses is for documenting and filing the
procedures for processing new and existing products. Most companies have in their
possessions similar documents filed for documentation and for training new employees who
may not be familiar with the procedures for fabricating the product. It is also a good source of
reference material for companies to use during programs.
The time element of the process chart is an invaluable piece of information that is often used
in product cost estimation. When an order is received by a job shop, cost estimation is usually
generated so that the customer will know how much it will cost the company to fabricate the
parts contained in the order. The wooden stool’s seat, for example, would cost about $45.5 in
labor cost to fabricate if it took 186 minutes to fabricate and the operator charged $15 per
hour to do the job. The material and overhead costs are also added to this estimate to generate
the final cost to the customer.
The process chart also helps in the preparation of route sheets. Route sheets are instruction
papers that are attached to parts lots as they make their way around a plant during processing.
They contain instructions, specifying which workstation to route the parts to and which
comes next, until the parts are completed. The process chart makes the task of preparing the
route sheet a simple one in that the route sheet is a simplified version of the process chart.
 AUTOMATIOM IN PLC

The route sheet does not contain all the other details like processing time and set up of
machines.
One of the most important uses of the process chart is for improving manufacturing
processes. The chart helps to reveal unnecessary and time-wasting processes, which can be
eliminated, combined or modified. In today’s highly competitive manufacturing industry,
engineers use such charts to help them get a better picture of how their existing
manufacturing systems look like compared to their target. In advanced manufacturing, this
type of analysis helps in developing ideal facility layout and placement of machines for
efficient operation. Often, this also helps in the preparation of tooling and purchase of ideal
equipment needed for production.

3.6.How to make the flow graph of given task?

Flowcharts
A flow chart is a graphical or symbolic representation of a process. Each step in the process is
represented by a different symbol and contains a short description of the process step. The
flow chart symbols are linked together with arrows showing the process flow
direction. Flowcharts describe a sequence of operations. All flowcharts use the same
symbols, linked with arrows to show the direction of the flow.

Different flow chart symbols have different meanings. The most common flow chart symbols
are:
 Terminator: An oval flow chart shape indicating the start or end of the process.
 Process: A rectangular flow chart shape indicating a normal process flow step.
 Decision: A diamond flow chart shape indication a branch in the process flow.
 Connector: A small, labeled, circular flow chart shape used to indicate a jump in the
process flow.
 Data: A parallelogram that indicates data input or output (I/O) for a process.
 Document: used to indicate a document or report
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Figure- C.25
The flow chart below shows the system for making a cup of tea. Note the shape of the boxes
the start and finish are rectangular with rounded corners, the process boxes are rectangular
with square corners, the decision box is a diamond and all boxes are joined by arrows
showing the direction of flow.

Figure- C.26
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Some Examples of Automation:-

Bottle filling:-

Figure- C.27

Figure- C.28
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Sequencing:-

Figure- C.29
Packing & Counting:-

Figure- C.30
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CHAPTER-4
SCADA

4.1Supervisory Control And Data Acquisition

SCADA stands for supervisory control and data acquisition. It generally refers to an
industrial control system a computer system monitoring and controlling a process.

Leading of SCADA companies are:-

Invensys Wonderware: In touch

Siemens: WinCC
Allen Bradley: RS View 32 works

Figure- D.1
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Industrial process includes those of manufacturing production, power generation, fabrication,

and refining, and may run in continuous, batch, repetitive, or discrete modes.
Infrastructure processes may be public or private, and include water treatment and
distribution, wastewater collection and treatment, oil and gas pipelines, electrical power
transmission and distribution, and large communication system.
Facility processes occur both in public facilities and private ones, including building, airports,
ships, and space stations.

4.2.SCADA SYSTEM USUALLY CONSISTS OF THE FOLLOWING SUBSYSTEMS

Human Machine interface or HMI is the apparatus which presents process data to a human
operator and through this, the human operator, monitors and controls the process. A
supervisory system gathering data on the process and sending commands to the process.
Remote terminal units (RTU’s) are connecting to sensors in the process, converting sensors
signal to digital data and sending digital data to the supervisory system.
Programmable Logic Controller (PLCs) used as field devices because they are more
economical, versatile, flexible, and configurable than special purpose RTUs.
Supervisory (computer) system
It gathers data on the process and sending commands (or control) to the process.
Communication infrastructure
It provides connectivity to the supervisory system to the Remote Terminal Units.

SCADA ARCHITECTURES:
SCADA systems have evolved through four generations as follows:
First generation: "Monolithic"
Early SCADA system computing was done by large minicomputers. Common network
services did not exist at the time SCADA was developed. Thus SCADA systems were
independent systems with no connectivity to other systems. The communication protocols
used were strictly proprietary at that time. The first-generation SCADA system redundancy
was achieved using a back-up mainframe system connected to all the Remote Terminal
Unit sites and was used in the event of failure of the primary mainframe system. Some first
generation SCADA systems were developed as "turn key" operations that ran on
minicomputers such as the PDP-11 series made by the Digital Equipment Corporation
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Second generation: "Distributed"

SCADA information and command processing was distributed across multiple stations which
were connected through a LAN. Information was shared in near real time. Each station was
responsible for a particular task thus making the size and cost of each station less than the one
used in First Generation. The network protocols used were still not standardized. Since the
protocols were proprietary, very few people beyond the developers knew enough to
determine how secure a SCADA installation was. Security of the SCADA installation was
usually overlooked.

Third generation: "Networked"

Similar to a distributed architecture, any complex SCADA can be reduced to simplest
components and connected through communication protocols. In the case of a networked
design, the system may be spread across more than one LAN network called a process control
network (PCN) and separated geographically. Several distributed architecture SCADAs
running in parallel, with a single supervisor and historian, could be considered a network
architecture. This allows for a more cost effective solution in very large scale systems.

Fourth generation: "Internet of Things"

With the commercial availability of cloud computing, SCADA systems have increasingly
adopted Internet of Things technology to significantly reduce infrastructure costs and
increase ease of maintenance and integration. As a result SCADA systems can now report
state in near real-time and use the horizontal scale available in cloud environments to
implement more complex control algorithms than are practically feasible to implement on
traditional programmable logic controllers. Further, the use of open network protocols such
as TLS inherent in the Internet of Things technology provides a more readily comprehensible
and manageable security boundary than the heterogeneous mix of proprietary network
protocols typical of many decentralized SCADA implementations.

4.3.History of SCADA:

Supervisory control first evolved in electric utility systems when a need to operate remote
substation equipment without sending in personnel or line crew at the remote site was felt. In
1940s, a pair of wires for every equipment was used between sites. The potential of
 AUTOMATIOM IN PLC

multiplexing on one pair of lines was soon put to use taking ideas from the Magnetic
Stepping Switch developed by telephone companies in the 30s. Security being an issue, a
select-check-operate procedure was adopted where the operator waited for acknowledgement
from device before finally operating it. Taking further cues from the telephone relay systems
and its coding schemes, Westinghouse and North Electric Company developed the Viscose
supervisory control.

General Electric and Control Corporation too developed their own independent supervisory
control programs. These were used in pipelines, gas companies and even airports for runway
landing lights. These systems became popular during 1950 and 1965. By that time, i.e. in
1960s Telemetry was developed for monitoring purposes. Before 1970’s equipment was
generally hard wired as solid state devices were in birth and infancy stages. But with the
advent of low cost computer technology, software and computers enabled the performing of
the functions previously done by technicians and operators sitting besides panel instruments
and tone telemetry.

The first push was given by the 8 and 16 bit computers called minicomputers. The second
was the microprocessors, several years later. Computers offered flexibility in programming
and communicating with field data acquisition units that was previously being done by hard
wired equipments. This was the dawn of SCADA. Many organizations have been involved
with the standardization of SCADA systems since then, including the IEEE, American
National Standards Institute, Electric Power Research Institute, International Electro
technical Commission, DNP3 Users group etc.

SCADA SystemConcept

The term SCADA usually refers to centralized systems which monitor and control entire
sites, or complexes of systems spread out over large areas (anything between an industrial
plant and a country).
Most control actions are performed automatically by Remote Terminal Units (RTUs) or
by programmable logic controllers (PLCs).
Host control functions are usually restricted to basic overriding or supervisory level
intervention. For example, a PLC may control the flow of cooling water through part of an
industrial process, but the SCADA system may allow operators to change the set points
 AUTOMATIOM IN PLC

for the flow, and enable alarm conditions, such as loss of flow and high temperature, to be
displayed and recorded.
The feedback control loop passes through the RTU or PLC, while the SCADA system
monitors the overall performance of the loop.

Figure- D.2
A simple SCADA system with single computer

Figure- D.3
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SCADA for Supervisory Control And Data Acquisition. It generally refers to an industrial
control system: a computer system monitoring and controlling a process. The process can be
industrial, infrastructure or facility based as described below:

Industrial processes include those of manufacturing, production, power generation,

fabrication, and refining, and may run in continuous, batch, repetitive, or discrete modes.
Infrastructure processes may be public or private, and include water treatment and
distribution, wastewater collection and treatment, oil and gas pipelines, electrical power
transmission and distribution, and large communication systems.
Facility processes occur both in public facilities and private ones, including buildings,
airports, ships, and space stations. They monitor and control HVAC, access, and energy
consumption.
A SCADA System usually consists of the following subsystems:
A Human-Machine Interface or HMI is the apparatus which presents process data to a human
operator, and through this, the human operator, monitors and controls the process.
Remote Terminal Units (RTUs) connecting to sensors in the process, converting sensor
signals to digital data and sending digital data to the supervisory system.
Communication infrastructure connects the supervisory system to the Remote Terminal
Units.

4.12.Use of SCADA systems in industry

SCADA (supervisory control and data acquisition) is an industrial control system at the core
of many modern industries such as manufacturing, energy, water, power, transportation and
many more. SCADA systems deploy multiple technologies that allow organizations to
monitor, gather, and process data as well as send commands to those points that are
transmitting data. Virtually anywhere we look in today's world, we will find some version of
a SCADA system running, whether it's at our local supermarket, refinery, waste water
treatment plant, or even our own home.

Manufacturing
In manufacturing environments, SCADA is used to make sure that productivity targets are
met and all systems run smoothly. The SCADA system in place on a production line tracks
 AUTOMATIOM IN PLC

how many units have been produced and how many are in various stages of completion.
Analog values like temperature at various production stages are also measured. Imagine how
important it is to know the temperature of molten metal that must be formed into usable
products.
FoodProduction
Very similar to manufacturing, food production is a major SCADA application. If
temperature is important for equipment manufacturing, it is absolutely critical for the mass
production of delicate foods. If temperature varies more than a few degrees, entire batches
can fall out of acceptable specifications. This generates a lot of wasteful expense, which
makes deployment of a SCADA system absolutely critical. The movement of liquid and solid
ingredients and mixtures through the production process is also tracked by SCADA.

Electric and Gas Utilities

Utility companies, particularly gas utilities, suffer the combined headaches of manufacturing
and telecom companies. They have to move a physical product (electricity isn't considered
very physical, but it creates many more concerns than data transmission) through their
systems, and they are spread out across gigantic territories. This makes utility environments a
natural application for SCADA devices. They need to control the movement of electricity and
gas through the distribution chain and also keep the supporting telecom infrastructure online.

Wastewater Treatment
The conversion of wastewater back into potable drinking water can really be thought of as
another type of manufacturing process that delivers the world's most critical commodity.
Flow rate sensors are extremely common in wastewater processing centers, as are
contaminant sensors.

Telecom and Information Technology (IT)

Although not generally known as "SCADA" in telecommunications environments, a large
number of professional do use this term to describe remote monitoring and control systems in
these industries. Realistically, telecom is simply a near-instantaneous production
environment, with bits of data instead of parts or food products. Monitoring temperature of
servers and other delicate equipment is common when SCADA is used in this particular
application. Monitoring the dedicated alarm contact closures of various equipments is also
 AUTOMATIOM IN PLC

CHAPTER-6
Relay
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Terminal Descriptions
 COIL- This the is the COIL terminal. These are the terminals
where you apply voltage to in order to give power to the coils
(which then will close the switch). Polarity does not matter. One
side gets positive voltage and the other side gets negative
voltage. It doesn't matter which order. Polarity only matters if a
diode is used.
 NO- This is Normally Open switch. This is the terminal where you
connect the device that you want the relay to power, when the
 AUTOMATIOM IN PLC

relay is powered, meaning when the COIL receives sufficient

voltage. The device connected to NO will be off when the relay
has no power and will turn on when the relay receives power.
 NC- This is the Normally Closed Switch. This is the terminal
where you connect the device that you want powered when the
relay receives no power. The device connected to NC will be on
when the relay has no power and will turn off when the relay
receives power.
 COM- This is the common of the relay. If the relay is powered and
the switch is closed, COM and NO have continuity. If the relay
isn't powered and the switch is open, COM and NC have
continuity. This is the terminal of the relay where you connect the
first part of your circuit to.
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CHAPTER-6
BIBLIOGRAPHY

 Dane E.Gilkey, (2011, April 6), EET 331 Programmable Logic Controllers,”LogixPro
Relay Logic Introductory Lab.”
 Engineeringtalk, Initials (2008,June 12). The Future for programmable logic
controllers. Retrieved from http://www.engineeringtalk.com/news/arb/arb201.html.
 TextBook by FrankD. Pentruzzella,”Programmable Logic Controllers”, 4th Edition,
Published by McGraw-Hill, 200
 http://en.wikipedia.org/wiki/Automation

 http://industrialautomation-info.blogspot.in/2010/05/history-of-automation_28.html

 http://www.amci.com/tutorials/tutorials-what-is-programmable-logic-controller.asp
 http://www.plcs.net/chapters/howworks4.htm

 http://www.amci.com/tutorials/tutorials-what-is-programmable-logic-controller.asp
 http://www.daenotes.com/electronics/industrial-electronics/PLC-programable-logic-
control