College Name:Aryans College Of Engineering(Banur)

FOUR MONTH HARDWARE TRAINING IN CNT TECHNOLOGIES PVT LTD. (CHANDIGARH)A TRAINING REPORT

ON

PLC & SCADA

PUNJAB TECHNICAL UNIVERSITY

JALANDHAR, PUNJAB, INDIA

SUBMITTED BY SUBMITTED TO

NAME OF CANDIDATE: HARDEEP SINGH MRS. MANVI

ROLL NUMBER: 1280088COURSE NAME: B-TECHMONTH YEAR: 5 / 2015

FOUR MONTH HARDWARE TRAINING IN CNT TECHNOLOGIES PVT LTD. (CHANDIGARH)ARYANS COLLEGE OF ENGINEERING

AND

TECHNOLOGY

PUNJAB TECHNICAL UNIVERSITYAryans College of Engineering and Technology

Village-Nepra,Chandigarh-Patiala Highway,

Chandigarh. Letter head of Aryans College of Engineering Date: 18/05/15

CANDIDATE'S DECLARATION

I hereby certify that the work which is being presented in the report entitled, PLC & $CADA, by Hardeep Singh (1280088 ) , B.TECH in EEE submitted at Aryans College of Engineering, is an authentic record of my own work carried out during a period from JUNUARY 2015 to MAY 2015 under the supervision of Ms. Meenakshi,Software Trainer,CNT Chd.

Signature of the Student

ACKNOWLEDGEMENT

I express my sincere gratitude to Aryans Group of Colleges for giving me the opportunity to work on the PLC & SCADA during my B.Tech. Training is an important aspect in the field of engineering.

Hardeep Singh)

1280088 FOUR MONTHS HARDWARE TRAINING

REPORT

Submitted for partial fulfillment of award of

BACHELOR OF ELECTRICAL & ELECTRONICS ENGINEERING

ARYANS COLLEGE OF ENGINEERING

BANUR (RAJPURA) CONTENTS1) Company profile2) Programmable logic controller (PLC) Architecture of PLC

Inputs and Outputs of PLC

Catalog number

Source and sink concept

PLC wiring

Panel wiring

Software introduction

XIC-XIO concepts

Introduction to PLC memory

Introduction to Data files and Program Files.

Start Stop logic

Logic gates

Concept for Latch, Unlatch

Timer

Counter

Compare function

Compute math

Move logic

Higher instruction (jmp, lbl, jsr, sbr, tnd, ret, mcr) 3) Supervisory Control and Data Acquisition (SCADA) Digital control

Start stop control

Digital programming

Analog control

SCADA interface to PLC

Digital control with plc and scada

Analog control with plc and scada

ACKNOWLEDGEMENT

First of all I would like to thank almighty GOD who has given this wonderful gift of life to us. He is the one who is guiding us in right direction to follow noble path of humanity. In my six months industrial training it is a wonderful experience to be a part of CNT TECHNOLOGIES where I have opportunity to work under brilliant minds. I owe my deep regards for the supporting and kind staff authorities who are helping me in my lean patches during these six months. The knowledge I am gaining throughout my studies have the practical implementation during this period. I am grateful to all the staff of CNT and for their timely support and sharing of their experience with me. I would like to express my heartiest concern for Miss. Meenakshi for her able guidance and for his inspiring attitude, praiseworthy attitude and honest support. Not to forget the pain staking efforts of our college training and placement cell and specially my training and placement officer Mrs.Manvi Mam Last but not the least I would express my utmost regards for the electrical department of our Institute.

COMPUTER SOFTWARE AND NETWORKING TECHNOLOGIES

CNT is one of the most acknowledged names in Software development and Network Training. Apart from providing Software Solutions to the various companies, CNT is also involved in imparting High-end project based training to students of MCA and B.Tech etc. The training professionals are basically Software Developers having Industry experience and exposure to live projects on various technologies like Java (With Advanced Java), VB.NET, ASP.NET, C Sharp, MCSE, CCNA, CCNP, LINUX and Oracle etc. CNT has trained thousands of the Engineering/MCA students of various institutes by providing Industrial training. Special emphasis is laid on exposure to Real Time Projects.

The Trainees are equipped with thorough knowledge of various modules from basic to advance in the software involved in their projects. With a right blend of interactive coaching, laboratory tutoring and a case study based approach; the skills of the trainees are sharpened to their best.

CNT has an excellent infrastructure with Air conditioned labs, and classrooms and fully equipped library. The lab facility extended to the trainees is unparalleled with every trainee having an independent system access for the entire training period.

In short, Computer Software and Network Technologies is guided by a dynamic management team that believes in integrity, quality, continuous learning and personal dedication

OBJECTIVESa) To provide world-class technology and Indian expertise globally in all fields of networking and information technology.

b) To sustain, expand and excel in its operations in software technologies.

c) To acquire latest technology on a continuing basis.

FUTURECNT core competence in the Networking and Software Project has enabled it to earn respect of clients all over the world. CNT is now using state-of-the-art technology in the areas of Information Technology Access Networks. All in order to continue providing better solutions through better understanding.

TRAININGThe business of CNT is characterized by Hi-tech mainly in the field of Network and IT, and technology in this area is advancing very fast and with the view to keep update with the latest technology. CNT undertakes training activities either through its own resources or through external agencies.

CNT has also organized a number of training programmes catering to specific requirements.IT SERVICES

Turnkey Solution to meet end-to-end customer requirements

Networking Solutions with total System Integration and Implementations

Project Consultancy services from concept to commissioning

IT Training

MISSION

To provide world class professional training and solutions in advance networking, Embedded systems design and career services for IT professionals as well as electronic system designers.

1. PLC AND SCADA (SUPERVISORY CONTROL AND DATA ACQUISITIN)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.

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

1.1.4 Distributed Control System

A type of automated control system that is distributed throughout a machine to provide instructions to different parts of the machine. Instead of having a centrally located device controlling all machines, each section of a machine has its own computer that controls the operation. For instance, there may be one machine with a section that controls dry elements of cake frosting and another section controlling the liquid elements, but each section is individually managed by a DCS. A DCS is commonly used in manufacturing equipment and utilizes input and output protocols to control the machine

1.1.5 Drives

The main power components of an AC drive, have to be able to supply the required level of current and voltage in a form the motor can use. The controls have to be able to provide the user with necessary adjustments such as minimum and maximum speed settings, so that the drive can be adapted to the user's process

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).

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.

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

1.4 COMPARISON BETWEEN RELAY AND CONTACTOR:RelayContactor

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

Relays are used to switch relatively small outputs and currents.Contactors are used to switch relatively large outputs and currents.

PLC (Programmable Logic Controller)

2.1INTRODUCTIONControl 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 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. PLCs 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

2.2.1 OriginThe 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 ProgrammingEarly 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.

2.1.3 FunctionalityThe 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

2. 2.1 PARTS OF PLC

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

2. 2.1 .2MCU: 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 .3INPUTS AND OUTPUTS: PLC has a set of isolated inputs and isolated outputs. Different PLCs 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 This display screen is used as human machine interface i.e. it provides good visualization of operation running

2.3.PLC PIN DIAGRAM

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 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/PO/P

00

11

I/PO/P

01

10

XIO (Examine if open):

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

ABBHere we have done programming of two PLCs of Allen Bradley i.e. Micrologix 1000 and Micrologix 1100.

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. The Micrologix 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 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 designLets the Micrologix 1000 controller thrive in limited panel space.

Choice of communication networksAn 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 deviceYou 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.

Comprehensive instruction setOver 65 instructions including simple bit, timer, and counter instructions, as well as instructions for powerful applications like sequencers, high-speed counter, and shift registers.

FastExecution time for a typical 500-instruction program is only 1.56 ms.

Choice of languagesSoftware 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 potentiometersAllow quick and easy adjustments of timers, counters, set points, and more.

Program data securityData file download protection lets a program be reloaded into the controller without overwriting protected data.

Floating Point Data FilesYou can create data files that can contain up to 256 IEEE-754 floating point values.

Memory modulesMemory backup provides protection and transportability for programs and data.

Four interrupt inputsInterrupt inputs let the controller scan a specific program file (subroutine) when an input condition is detected from a sensor or field device.

Real-Time Clockembedded in every controller.

Fig 2.7.Micrologix 1100 with Analog Card

2.5.5 Benefits

Online Editingmodifications 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 LCDlets 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 Portfor 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 portprovides a host of different point-to-point and network protocols.

Embedded Web Serverlets 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 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 PLCs 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 characteristicssuch as sequential execution and support for control flow featuresthat 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.

Fig 7. Simple ladder logicThe 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

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 LEDs (4) 8. RS 232 Comport for communication with PC

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 LEDs (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

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 windowThen 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.

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.

I/PO/P

00

11

XIC (Examine if closed):

Examples of devices that turn on or off include:

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/PO/P

01

10

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.

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 TONTimer: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 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 time base intervals when rung conditions become true.The RTO instruction retains its accumulated value when any of the following occurs:

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.

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 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 integers are stored in twos 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 twos 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 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 countdown 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.

When RTO and conveyor motor runs by pressing start push button

when the valve operates and conveyor motor stops

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.

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

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

SCADA

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 switches, pressure switches, generator status, relays & motors.

3.1 Features of SACDA:

Dynamic process Graphic

Alarm summery

Alarm history

Real time trend

Historical time trend

Security (Application Security)

Data base connectivity

Device connectivity

Scripts

Recipe management

3.2 Manufactures of SCADA:

Modicon (Telemecanique) Visual look

Allen Bradley : RS View

Siemens: win cc

Gefanc:

KPIT : ASTRA

Intelution : Aspic

Wonder ware : In touch

3.3 Working with project:

A project consists of a folder on your hard disk that contains, at minimum, the following items:

1. project file (.rsv)

2. tag folder

3. comprf (communications profile) folder

4. cache folder

3.3.1 Steps for creating a project:

3.3.2 Creating tag:

Tags and the tag database: In the tag database, you define the data you want RSView32 to monitor. Each entry in the database is called a tag. A tag is a logical name for a variable in a device or in local memory (RAM). For example, a tag can represent a process variable in a programmable controller

3.3.3 Naming tag:

Tag names can be up to 255 characters long. If you create a folder, the folder name becomes part of the tag name. The tag name can contain the following characters: A to Z

0 to 9

underscore (_) and dash (-)

3.3.4 Tag database

3.3.5 Creating graphic display:

A graphic display represents the operators view of plant activity. The display can show system or process data and provide operators with a way to write values to an external device such as a programmable controller. Operators can also print the display at runtime to create a visual record of tag values.The graphic display editor:

To open the Graphic Display editor:

In the Project Manager, open the Graphics folder.

Open the Graphic Display editor by doing one of the following:

doubleclick the Display icon

rightclick the Display icon and then click NewThe editor main components:

3.3.6 Setting up the display:

3.3.7 Animation:

About the Animation dialog box

The Animation dialog box is a floating dialog box, which means you can have it open all the time and can move it around the screen, select other objects, and open other dialog boxes.

Dialog box:

Animation on slider:

Horizontal position animation:

Visibility animation:

THANKS YOU

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