S.H.

JONDHALE POLYTECHNIC DOMBIVLI(WEST)

A PROJECT REPORT ON PLC, SCADA, E-PLAN

Submitted by
Chirantan Ahirrao

Under the guidance of

Swarup Uparkar

In partial fulfilment for the award of diploma

In

Electronics & Telecommunication Engineering

S.H.JONDHALE POLYTECHNIC DOMBIVLI (WEST)
MAHRASHTRA STATE BOARD OF TECHNICAL EDUCATION

2023-24
 Introduction to an Industrial Automation
Industrial automation refers to the use of technology and control systems to
streamline and automate industrial processes, increasing efficiency, productivity,
and safety in various manufacturing and production environments. It involves
the application of advanced hardware and software solutions to monitor,
control, and optimize industrial operations.

The primary goal of industrial automation is to minimize human intervention in

repetitive, time-consuming, and error-prone tasks, allowing machines and
systems to perform them with precision and consistency. Automation can be
applied to a wide range of industries, including manufacturing, automotive,
aerospace, pharmaceuticals, food and beverage, logistics, and many others.

Benefits of industrial automation include increased productivity, improved

product quality and consistency, reduced labor costs, enhanced safety for
workers, reduced waste and energy consumption, faster time to market, and the
ability to adapt to changing market demands quickly.
 Need of an Industrial Automation
Increased Productivity: Industrial automation allows for the optimization of
production processes, leading to higher productivity levels. Automated systems
can operate continuously and at faster speeds than manual labor, resulting in
increased output and reduced cycle times.

Improved Quality and Consistency: Automation reduces the likelihood of

human error and variability in manufacturing processes. By implementing
precise and standardized automated procedures, product quality and
consistency can be significantly enhanced, resulting in fewer defects and higher
customer satisfaction.

Cost Reduction: Industrial automation helps reduce labor costs by replacing

manual tasks with automated systems. This reduces the need for extensive
manual labor, lowers the risk of workplace accidents, and minimizes costs
associated with human resources, training, and employee benefits.

Enhanced Safety: Automation eliminates or minimizes the need for human

intervention in potentially hazardous or dangerous tasks. It reduces the risk of
workplace accidents, injuries, and exposure to harmful substances, creating a
safer working environment for employees.

Increased Efficiency: Automation enables efficient utilization of resources such

as materials, energy, and time. It optimizes production processes, reduces waste,
and enables better resource planning and utilization, leading to cost savings and
improved overall efficiency.

Flexibility and Adaptability: Industrial automation provides the ability to

quickly adapt to changing market demands and production requirements.
Automated systems can be reprogrammed and reconfigured to accommodate
new product designs, variations, and customization, allowing for greater
flexibility in manufacturing processes.

Data Collection and Analysis: Automation systems generate vast amounts of

data that can be collected and analyzed in real-time. This data provides valuable
insights into process performance, equipment health, and predictive
maintenance, enabling proactive decision-making and continuous improvement.

Competitive Advantage: Implementing industrial automation can give

companies a competitive edge by increasing production capacity, reducing
costs, improving product quality, and shortening time to market. It allows
businesses to meet customer demands more effectively, stay ahead of
competitors, and adapt to market trends.

Skilled Workforce Utilization: By automating repetitive and mundane tasks,

industrial automation allows skilled workers to focus on more complex and
value-added activities. This leads to a better utilization of human resources,
utilizing the skills and expertise of employees for tasks that require critical
thinking and problem-solving abilities.

Industrial Automation Hierarchy Levels

 Introduction to Programmable Logic
Controller
PLC stands for "Programmable Logic Controller." It is a specialized digital
computer used in industrial automation and control systems to automate
various processes. PLCs are widely employed in manufacturing plants, factories,
and other industrial settings due to their reliability, flexibility, and ease of
programming.

The primary purpose of a PLC is to monitor inputs from sensors and other
devices, process this information through a user-defined program, and then
control outputs to actuators and other devices accordingly. This process allows
PLCs to automate and control a wide range of tasks, such as managing
machinery, assembly lines, temperature control, motor control etc.

BASIC STRUCTURE OF PLC

 Basic Components of a PLC
Central Processing Unit (CPU): The CPU is the "brain" of the PLC and is
responsible for executing the control program stored in its memory. It reads
inputs from connected sensors, processes the logic according to the user
programmed instructions, and controls the outputs to connected actuators. The
CPU manages the overall operation of the PLC system.

Input Modules: Input modules are used to interface the PLC with various
input devices and sensors. These devices could include push buttons, limit
switches, temperature sensors, pressure transducers, and more. The input
modules convert the physical signals from these devices into digital signals that
the PLC's CPU can process.

Output Modules: Output modules interface the PLC with output devices
and actuators. These devices could include motors, solenoid valves, relays, lights,
and other components. The output modules receive digital signals from the CPU
and convert them into physical signals to control the connected output devices.

Memory: PLCs have different types of memory to store various data and
program information. The main types of memory in a PLC are:

 Program Memory: This memory holds the user-programmed instructions

(logic) that dictate the PLC's behavior. It includes the ladder logic, function
block diagrams, or other programming languages used by the PLC.

 Data Memory: This memory stores the values of variables used in the PLC
program. It includes input values, output values, timers, counters, and other
data necessary for the program's execution.

Power Supply: The power supply provides electrical power to all the
components of the PLC. It converts the available power from the main source
(AC or DC) to the required voltage levels used by the PLC components.
Communication Ports: PLCs often have communication ports that allow
them to connect to other devices or systems. These ports facilitate data
exchange between PLCs, human-machine interfaces (HMIs), supervisory control
and data acquisition (SCADA) systems, and other devices on the industrial
network.

Programming Device/Software: PLCs are programmed using

specialized programming software running on a programming device, typically
a computer. Engineers and technicians use this software to create the logic that
defines the system's behavior. Once the program is complete, it is downloaded
to the PLC for execution.

TYPES OF PLC
There are several types of PLCs (Programmable Logic Controllers) available, each
designed for specific applications and industries. The classification of PLCs is
based on various factors, such as the number of input/output points, processing
capabilities, communication capabilities, and intended use. Basic PLC types can
be classified based on their size, capabilities, and intended applications.

Common Basic PLC types:

A. Compact PLC
B. Compact Modular PLC
C. Modular PLC

Each type of PLC has its advantages and is optimized for specific use cases. When
choosing a PLC type, it's essential to consider factors such as the size and
complexity of the automation system, the required I/O points, the processing
capabilities, and any safety or additional functionalities needed for the
application.
 1) Compact PLC

A Compact PLC is a small sized programmable logic controller designed for

Simple control tasks and applications with limited input/output requirements.
These controllers are typically used in small-scale automation projects,
standalone machines, or applications where space is a constraint. Despite their
smaller size, compact PLCs offer essential functionalities and are cost-effective
solutions for basic automation needs. Compact PLCs are wellsuited for certain
applications Like Elevators and Escalators, they may not be suitable for largescale
or complex automation projects just because they have limited I/Os.
 2) Compact Modular

Controller Expansion Modules

A Compact Expandable PLC combines the Features of a Compact PLC with the
ability to Expand its input/output (I/Os) capabilities through the addition of
External Modules. It offers the advantages of a smaller form factor and basic
functionalities typical of compact PLCs, while also allowing users to Increase the
I/O points and adapt to more extensive automation requirements when needed.

Key Features of a Compact Expandable PLC

1. Compact Design
2. Limited Built-in I/O
3. I/O Expansion
4. Easy Configuration
 3) Modular PLC
COM port

Expansion
Modules
Ethernet Power
port

A Modular PLC, also known as a Rack-based PLC or Expandable PLC, is a type

of programmable logic controller that is composed of Individual Modules that
can be added or removed to customize the system's functionality based on
specific automation requirements. Unlike compact PLCs that have a fixed
number of built-in I/O points, Modular PLCs offer greater Flexibility, Scalability,
and Expandability to accommodate a wide range of applications, from small to
large-scale automation projects.

Key Features of Expandable PLC

1. Modular Structure
2. Expandability
3. Scalability
4. Hot Swapping of Modules in Running Condition
5. Compact form factor
 I/O Modules

DIGITAL I/O MODULES:

A Digital I/O (Input/Output) PLC module is a type of specialized module used in
a Programmable Logic Controller (PLC) to interface with digital devices and
signals. It provides the PLC with the ability to read digital inputs (Like ON/OFF)
from sensors or devices and control digital outputs to such as lamp, Relay coil,
etc

ANALOG I/O MODULES:

An Analog I/O PLC module is a specialized input/output module used in
programmable logic controllers (PLCs) to handle analog signals. Unlike digital
signals, which have discrete values (ON/OFF, 0/1), analog signals have
Continuous values and Represent a range of values within a specific range.
Analog I/O modules allow the PLC to interface with and process signals from
various analog sensors and actuators, making them valuable in applications that
require precise control of analog parameters such as temperature, pressure, flow
rate

SPECIAL PURPOSE MODULES:

A special purpose I/O module for PLCs is a specific type of input/output module
designed to handle unique or specialized functions in industrial automation.
These modules are used to interface the PLC with devices and sensors that
require customized signal processing, communication protocols, or safety
features. Special purpose I/O modules enhance the capabilities of the PLC and
enable it to perform specific tasks in various industrial applications.
 DATA ORGANISATION IN PLC
Data organization in a PLC (Programmable Logic Controller) is a critical aspect
of programming and managing information within the control system. In PLCs
bit, byte, and word are common units of data organization and storage.

Bit: A bit is the smallest unit of information in a PLC. It represents a binary value
and can have two states 0 or 1. In PLC programming, bits are often used to
represent discrete signals, such as the status of sensors, switches, or actuators.

Byte: A Byte is a group of 8 bits. It is used to store and process larger amounts
of data. example, a byte may be used to store a numeric value that combines
multiple bits for a specific purpose.

Word: A word is a unit of data that consists of multiple Bytes. The number of
bytes in a word can vary depending on the specific PLC model and configuration,
but it is commonly 2 or 4 bytes. Words are used to store and manipulate larger
data values, such as integers, floating-point numbers, or control parameters. PLC
instructions often operate on words to perform arithmetic calculations,
comparisons, or data transfers.
 PROGRAMMING LANGUAGES IN PLC
1) Ladder Diagram

Ladder Logic is the most

widely used programming
language in PLCs and is
designed to mimic the
traditional relay ladder
diagrams used in electrical
control
systems. It uses graphical
symbols to represent logic
functions
and control sequences. Ladder Logic is easy to understand for those familiar
with electrical schematics and is commonly used for simple to moderately
complex applications.

2) Functional Block Diagram

FBD is a graphical
programming language that
represents control functions
as interconnected blocks.
Each block performs specific
tasks or calculations. It is
well-suited for complex
control tasks and can be
more structured and
modular than Ladder Logic.
FBD is often used in
conjunction with Ladder Logic or as an alternative for certain applications.
3) Instruction List Diagram

Instruction List is a low-level

text-based programming language
that uses mnemonics to represent
individual machinelevel instructions. It is not
as commonly used as other programming
languages but can be helpful for experienced

operation.

programmers who need fine-grained

4)Sequential Function Diagram

SFC is a graphical language used to describe

the sequential behavior of a system. It is ideal
for representing complex control sequences or
state-based control logic. SFC is often used in
applications where precise control timing and sequencing are crucial.
5) Structural Text Diagram

Structured Text is a high-level

textbased programming language similar to
programming languages used in software
development, such as C or Pascal. It allows for
more sophisticated programming with
conditional statements, loops, and mathematical
operations. ST is suitable for complex control
algorithms and advanced calculations.

TYPES OF I/O FIELD

DEVICES
Digital Input Field Devices
Push Buttons and Switches: Push buttons and switches are
manually operated devices used to control machines or
processes.

Limit Switches: Limit switches are

electromechanical devices used to
detect the presence or absence of an
object at a specific position.

Proximity Sensors: Proximity sensors

use various technologies (inductive,
capacitive, ultrasonic, etc.) to detect
the presence of an object without
direct physical contact. They are often
used for object detection or position
sensing.

measuring distances. Photoelectric Sensors:

Photoelectric sensors emit a light beam and detect its reflection
off an object. They can be used for object detection, counting,
or even
 Digital Output Field Devices
Relays: Electromechanical relays are widely used as digital output field devices in
PLCs. They act as switches to control electrical circuits and devices. When the PLC
sends a signal to the relay, it either closes or opens the circuit, allowing or interrupting
the flow of current to the connected equipment.

Solenoid Valves: Solenoid valves are used to control the flow of liquids or gases in
industrial processes. When the PLC sends a signal to the solenoid valve, it activates an
electromagnetic coil that opens or closes the valve, allowing or blocking the flow.

Indicator Lights: These devices are simple LED or bulb-based lights used to provide
visual indication of the status of different processes or machines. The PLC can control
the lights to indicate whether a particular condition is met or an action is taking place.

Analog Input Field Devices

Temperature Sensors: Thermocouples and Resistance
Temperature Detectors (RTDs) are commonly used to
measure temperature in industrial processes. They
provide analog signals corresponding to the temperature
being monitored.

Pressure Transmitters: Pressure transmitters measure

fluid or gas pressure and provide analog output signals
representing the pressure values.

Flow meters: Flow meters measure the flow rate of liquids

or gases in pipelines and convert the data into analog
signals for the PLC.

Load Cells: Load cells measure force or weight and

provide analog output signals representing the measured
values.
 Analog Output Field Devices
Digital to Analog Converters (DAC): DAC modules are used
to convert digital values from the PLC into analog voltage
or current signals. They are versatile and can be used in
various applications.

Proportional Integral Derivative (PID) Controllers: These

devices are used for precise control of industrial processes,
such as temperature, pressure, or flow rate. The PLC sends
control signals to the PID controller, which adjusts the
analog output accordingly to maintain the desired set
point.

Analog Panel Meters: Analog panel meters are used to

display analog values to operators and maintenance
personnel. The PLC can control these meters to show
realtime measurements or process information.

Concept of Sinking And Sourcing

Sink and source wiring are two common configurations used for connecting
input and output devices to a PLC. These configurations refer to how the devices
are connected in relation to the PLC's input and output modules. The choice
between sink and source wiring depends on the type of devices being used and
the PLC's input/output module specifications.
Sink Wiring (NPN):
In a Sink configuration, the positive voltage supply is connected to the positive
terminal of the input or output device, while the negative terminal of the device
is connected to the PLC's input/output module

In this type, the field device is connected between the positive voltage supply
and the PLC's input/output module. When the output is activated by the PLC, it
sinks current from the load
Source Wiring (PNP):

"Source wiring" of a Programmable Logic Controller (PLC), the load or field

device is connected between the positive voltage supply and the PLC's
input/output module. When the output is activated by the PLC, it sources current
to the load. This type of wiring is also known as "sourcing output" or "sourcing
input.

In source wiring, the current flows from the PLC to the load/device (for input) or
from the positive voltage supply to the load/device through the PLC.

Basic Specifications of Micrologix Controller

I/Os MAPPING IN ALLEN BRADLEY PLC

00
Introduction of Timer and Counter
What is a PLC?
A Programmable Logic Controller (PLC) is an industrial digital
computer adapted for the control of manufacturing processes, such
as assembly lines, robotic devices, or any activity that requires
highreliability control and ease of programming and process fault
diagnosis.
Timers in PLCs
Timers are crucial in PLC programming, providing a way to control
events based on time. They are used to delay actions, measure time
intervals, or create repetitive cycles. There are three main types of
timers in PLCs:

1 ON-Delay Timer (TON):

• Function: Activates an output after a set time delay once the

input is activated.
• Usage Example: Turning on a conveyor belt after a machine

starts to allow time for warm-up.

2 OFF-Delay Timer (TOFF):
• Function: Deactivates an output after a set time delay once the

input is deactivated.
• Usage Example: Keeping a fan running for a certain period after

a motor stops to cool it down.

3 Retentive Timer (RTO):
• Function: Accumulates time even if the input is interrupted. It
retains the elapsed time and continues counting when re-
energized.
• Usage Example: Keeping track of the total running time of a
machine for maintenance purposes.
Counters in PLCs
Counters are used to count occurrences of input events. They are
essential for tasks that require keeping track of items or operations.
There are two main types of counters:
1. Up Counter (CTU):
o Function: Increases the count value with each input event.

o Usage Example: Counting products passing on a

conveyor belt.
2. Down Counter (CTD):
o Function: Decreases the count value with each input

event.
o Usage Example: Keeping track of remaining items to be

processed from a batch.

3. Up/Down Counter (CTUD):
o Function: Can increment or decrement the count value

based on different input events. o Usage Example:

Managing an inventory system where items are added and
removed.
Applications of Timers and Counters in PLCs

Timers and counters are used in a wide range of industrial

applications, including:
• Conveyor Systems: Controlling the start and stop times of
conveyors.
• Packaging Lines: Counting items to ensure the correct number
of products in each package.
• Machinery Control: Managing the operating times and
sequences of different machines.
• Batch Processing: Measuring time intervals for mixing, heating,
or cooling processes.
• Traffic Control Systems: Timing traffic lights to manage vehicle
flow
Introduction of compare in PLC
What is a PLC?
A Programmable Logic Controller (PLC) is an industrial digital
computer designed to control manufacturing processes such as
assembly lines, machinery, and robotic devices. PLCs are highly
reliable, easily programmable, and equipped with extensive
diagnostic capabilities.
Comparison Instructions in PLCs
Comparison instructions in PLCs are used to evaluate the
relationship between two values or conditions. These instructions
help make decisions within the control program based on the
comparison results. They are essential for controlling processes that
depend on specific conditions or thresholds.

Types of Comparison Instructions

The primary comparison instructions used in PLCs include:

1. Equal (EQU):
o Function: Checks if two values are equal.

o Usage Example: Ensuring a process only starts when a

sensor reading matches a predefined setpoint.

equal
Not Equal (NEQ):
• Function: Checks if two values are not equal.

• Usage Example: Triggering an alarm if a machine's speed

deviates from the expected value

Not Equal

Greater Than (GRT):

• Function: Checks if one value is greater than another.

• Usage Example: Activating a cooling system when the

temperature exceeds a safe limit.

greater
Less Than (LES):

• Function: Checks if one value is less than another.

• Usage Example: Stopping a conveyor belt if the number of
items falls below a minimum required amount.
Less

Greater Than or Equal To (GEQ):

• Function: Checks if one value is greater than or equal to

another.
• Usage Example: Starting a pump when the tank level is at or

above a certain threshold.

Greater than or equal

Less Than or Equal To (LEQ):
• Function: Checks if one value is less than or equal to another.

• Usage Example: Shutting down equipment if the pressure

drops to a critical level or below.

Less than or equal