7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 153
Automatic mixing amp Filling bottle
Using
PLC
By
PULAGAM LEELA VEERENDRA
KUMAR
veerandrapulagam500gmailcom
Mobile no 9966108092
Project video has been upload to YouTube Link
httpsyoutubeib9D0KwAG6Y
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 253
ABSTRACT
Nowadays the application of PLC is widely known and use in this digital world
PLCrsquos application is obviously applied at the industrial sector Normally the PLCrsquos that have
been used at the industrial field is usually to control a mechanical movement either of the
machine or heavy machine in order to create an efficient production and accurate signal
processing In this project a discussion about PLC application will be explained in more
details and specified Whereby a machine that used to prepare automatic mixing and filling
into the bottle is fully controlled by the SIEMENS PLC S7-1200 which acts as the heart of the
system The system sequence of operation is designed by ladder diagram and the programming
of this project by using totally integrated automation portal software (V-105)several
electronics and electric devices that usually been controlled by the PLC are submersible motor
pump sensor conveyor belt solenoid valve push buttons relays and other devices
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 353
Veerandrapulagam500gmailcom
Chapter 1
11 INTRODUCTION
A programmable logic controller (PLC) is a solid state device designed to previously
accomplish by electromechanically relays PLC is a basically a controller not continuous but logic
state ie on-off controller Hence sequences of logic states are programmed All operation is to
control a process operation of manufacturing equipment and machinery PLCs are in the
computer family They are used in commercial and industrial applications
Initially the plc was used to replace relay logic but its ever-increasing range of function
means that it is found in the many and more complex applications As the structure of a plc is
based on the same principle as those employed in computer architecture it is capable of
performing not only relay switching tasks but also other applications such as counting calculating
comparing and the processing of analog signals
12 Basic principle of PLC
PLC was invented in the 6070rsquos for the automotive manufacturing industry Since this
time they have developed into one of the most versatile tools used for industrial automation A
working knowledge of PLCs and other microprocessor based control system are critical to
technical personal who are staying current with technology in industry
PROGRAMMABLE LOGIC CONTROLLER or PLC is the hub of many manufacturing
processes These micro processor based units are used in processes as simple as boxing machines
or bagging equipment to controlling and tacking sophisticated manufacturing processes They are
in virtually all new manufacturing processing and package equipment in one form or another
Because of their population in industry it becomes increasingly more important to learn skills
related to these devices Click on the buttons to learn more about industrial automation and this
invaluable tool
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 453
Veerandrapulagam500gmailcom
The microprocessor or processor module is the brain of a PLC system It consists of the
microprocessor memory integrated from memory It also includes communications ports to other
peripherals other PLCs or programming terminals
Todayrsquos processors vary widely in their capabilities to control real devices Some control as few
as 6 inputs and outputs and other 40000 or more One processor can control more than one
process of manufacturing line Processor are often linked together in order to provide continuity
throughout the process The number of inputs and outputs PLCs can control are limited by the
overall capacity of the PLC system hard ware 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 control on
or off state of output devices
13 Objectives
There are four objectives to be achieved in this project Below are the following
Objectives
To design appropriate model for automatic mixing amp filling bottle
To design program using PLC for automatic mixing amp filling bottle
To interface PLC module with the inputs and outputs component
To design a prototype system for automatic mixing amp filling bottle
14 Scope of the Project
To achieve the objectives and purpose of the project the scope of study and research can
be divided into following areas
Design and develop the prototype for the automatic mixing amp filling bottle by
using PLC as the controller to enhance the existing system
This project will develop the prototype which is respect to the actual system
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 553
Veerandrapulagam500gmailcom
1 5 The development of hardware and software
A Hardware
1) Literature study of the hardware including PLC and others components
2)
Programmable logic controller (PLC) will used the as the brain of the project
3) Dc supply 24V
4) Solenoid valve is a bottle filling component
5) Conveyor moves bottle
6) Submersible motors used pump the water and flavor into mixing container
7) Mixing motor for mix water and flavor motor
B Software
1) Totally integrated automation on portal v-105
2) Simatic s7-1200
3) Ladder diagram as the source code to the PLC
16 Conditions of the project
There are three containers first container contains water second container contains flavor
and middle container is mixing amp filling container Water and flavor container consists of two
submersible motors Mixing container contains a mixing fan and a solenoid valve is fixed to itConveyor system arranged below the filling container one end point of conveyor is starts from
below the solenoid valve exactly and photo electric sensor is below solenoid valve to sense the
bottle to fill it
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 653
Veerandrapulagam500gmailcom
Figure 11 Photo of project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 753
Veerandrapulagam500gmailcom
Chapter2
Programmable Logic Controller (PLC)
21 History of PLC
In the late 1960s PLCs were first introduced The primary reason for designing such a device was
eliminating the large cost involved in replacing the complicated relay based machine control systems
Bedford Associates (Bedford MA) proposed something called a Modular Digital Controller (MODICON)
to a major US car manufacturer Other companies at the time proposed computer based schemes one of
which was based upon the PDP-8 The MODICON 084 brought the worlds first PLC into commercial
production
When production requirements changed so did the control system This becomes very expensive
when the change is frequent Since relays are mechanical devices they also have a limited lifetime which
required strict adhesion to maintenance schedules Troubleshooting was also quite tedious when so many
relays are involved Now picture a machine control panel that included many possibly hundreds or
thousands of individual relays The size could be mind boggling How about the complicated initial
wiring of so many individual devices These relays would be individually wired together in a manner that
would yield the desired outcome As can be seen there were many problems with this relay based design
These new controllers also had to be easily programmed by maintenance and plant engineers
The lifetime had to be long and programming changes easily performed They also had to survive the
harsh industrial environment Thats a lot to ask The answers were to use a programming technique most
people were already familiar with and replace mechanical parts with solid-state ones
In the mid70s the dominant PLC technologies were sequencer state-machines and the bit-slice
based CPU The AMD 2901 and 2903 were quite popular in Modicon and A-B PLCs Conventional
microprocessors lacked the power to quickly solve PLC logic in all but the smallest PLCs Asconventional microprocessors evolved larger and larger PLCs were being based upon them However
even today some are still based upon the 2903 (Ref A-Bs PLC-3) Modicon has yet to build a faster PLC
than their 984ABX which was based upon the 29016 Communications abilities began to appear in
approximately 1973 The first such system was Modicons Modbus The PLC could now talk to other
PLCs and they could be far away from the actual machine they were controlling They could also now be
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 853
Veerandrapulagam500gmailcom
used to send and receive varying voltages to allow them to enter the analog world Unfortunately the lack
of standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks Still it was a great decade for the PLC
The 80s saw an attempt to standardize communications with General Motors manufacturing
automation protocol (MAP) It was also a time for reducing the size of the PLC and making them software
programmable through symbolic programming on personal computers instead of dedicated programming
terminals or handheld programmers Today the worlds smallest PLC is about the size of a single control
relay
The 90s have seen a gradual reduction in the introduction of new protocols and the modernization
of the physical layers of some of the more popular protocols that survived the 1980s The latest standard
(IEC 1131-3) has tried to merge plc programming languages under one international standard We now
have PLCs that are programmable in function block diagrams instruction lists C and structured text all at
the same time PCs are also being used to replace PLCs in some applications The original company who
commissioned the MODICON 084 has actually switched to a PC based control system
211 Advantages of PLC
Less wiring
Wiring between devices and relay contacts are done in the PLC program
Easier and faster to make changes
Trouble shooting aids make programming easier and reduce downtime
Reliable components make these likely to operate for years before failure
212 Disadvantages
PLC was designed for relay logic ladder and has difficulty with some smart devices
To maximize PLC performance and flexibility a number of option modulus must beadded
213 Applications of plc
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 953
Veerandrapulagam500gmailcom
It is used in process automation
It is used to optimize the process
It is used to integrate the different processing level s
By using PLCs quality of production is possible
System accuracy is increased by using PLCs
Automatic traffic control system is possible
It is used in twisting machines automatic suspension of rotary system
Numerous applications are possible by using PLCs in the industry
After wiring of relay panel if the event sequence is to be changed it is necessary to rewire
all or part of the panel
Many of the control relay of the ladder diagram can be replaced by software which means
less hardware failure
It is easy to make change in programmed sequence of events when it is only in software
22 Plc compared with other control system
PLCs are well adapted to a range of automation tasks These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation system
is high relative to the total cost of the automation and where changes to the system would be
expected during its operational life PLCs contain input and output devices compatible with
industrial pilot devices and controls little electrical design is required and the design problem
centres on expressing the desired sequence of operations PLC applications are typically highly
customized systems so the cost of a packaged PLC is low compared to the cost of a specific
custom-built controller design On the other hand in the case of mass-produced goods
customized control systems are economical This is due to the lower cost of the components
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 253
ABSTRACT
Nowadays the application of PLC is widely known and use in this digital world
PLCrsquos application is obviously applied at the industrial sector Normally the PLCrsquos that have
been used at the industrial field is usually to control a mechanical movement either of the
machine or heavy machine in order to create an efficient production and accurate signal
processing In this project a discussion about PLC application will be explained in more
details and specified Whereby a machine that used to prepare automatic mixing and filling
into the bottle is fully controlled by the SIEMENS PLC S7-1200 which acts as the heart of the
system The system sequence of operation is designed by ladder diagram and the programming
of this project by using totally integrated automation portal software (V-105)several
electronics and electric devices that usually been controlled by the PLC are submersible motor
pump sensor conveyor belt solenoid valve push buttons relays and other devices
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 353
Veerandrapulagam500gmailcom
Chapter 1
11 INTRODUCTION
A programmable logic controller (PLC) is a solid state device designed to previously
accomplish by electromechanically relays PLC is a basically a controller not continuous but logic
state ie on-off controller Hence sequences of logic states are programmed All operation is to
control a process operation of manufacturing equipment and machinery PLCs are in the
computer family They are used in commercial and industrial applications
Initially the plc was used to replace relay logic but its ever-increasing range of function
means that it is found in the many and more complex applications As the structure of a plc is
based on the same principle as those employed in computer architecture it is capable of
performing not only relay switching tasks but also other applications such as counting calculating
comparing and the processing of analog signals
12 Basic principle of PLC
PLC was invented in the 6070rsquos for the automotive manufacturing industry Since this
time they have developed into one of the most versatile tools used for industrial automation A
working knowledge of PLCs and other microprocessor based control system are critical to
technical personal who are staying current with technology in industry
PROGRAMMABLE LOGIC CONTROLLER or PLC is the hub of many manufacturing
processes These micro processor based units are used in processes as simple as boxing machines
or bagging equipment to controlling and tacking sophisticated manufacturing processes They are
in virtually all new manufacturing processing and package equipment in one form or another
Because of their population in industry it becomes increasingly more important to learn skills
related to these devices Click on the buttons to learn more about industrial automation and this
invaluable tool
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 453
Veerandrapulagam500gmailcom
The microprocessor or processor module is the brain of a PLC system It consists of the
microprocessor memory integrated from memory It also includes communications ports to other
peripherals other PLCs or programming terminals
Todayrsquos processors vary widely in their capabilities to control real devices Some control as few
as 6 inputs and outputs and other 40000 or more One processor can control more than one
process of manufacturing line Processor are often linked together in order to provide continuity
throughout the process The number of inputs and outputs PLCs can control are limited by the
overall capacity of the PLC system hard ware 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 control on
or off state of output devices
13 Objectives
There are four objectives to be achieved in this project Below are the following
Objectives
To design appropriate model for automatic mixing amp filling bottle
To design program using PLC for automatic mixing amp filling bottle
To interface PLC module with the inputs and outputs component
To design a prototype system for automatic mixing amp filling bottle
14 Scope of the Project
To achieve the objectives and purpose of the project the scope of study and research can
be divided into following areas
Design and develop the prototype for the automatic mixing amp filling bottle by
using PLC as the controller to enhance the existing system
This project will develop the prototype which is respect to the actual system
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 553
Veerandrapulagam500gmailcom
1 5 The development of hardware and software
A Hardware
1) Literature study of the hardware including PLC and others components
2)
Programmable logic controller (PLC) will used the as the brain of the project
3) Dc supply 24V
4) Solenoid valve is a bottle filling component
5) Conveyor moves bottle
6) Submersible motors used pump the water and flavor into mixing container
7) Mixing motor for mix water and flavor motor
B Software
1) Totally integrated automation on portal v-105
2) Simatic s7-1200
3) Ladder diagram as the source code to the PLC
16 Conditions of the project
There are three containers first container contains water second container contains flavor
and middle container is mixing amp filling container Water and flavor container consists of two
submersible motors Mixing container contains a mixing fan and a solenoid valve is fixed to itConveyor system arranged below the filling container one end point of conveyor is starts from
below the solenoid valve exactly and photo electric sensor is below solenoid valve to sense the
bottle to fill it
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 653
Veerandrapulagam500gmailcom
Figure 11 Photo of project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 753
Veerandrapulagam500gmailcom
Chapter2
Programmable Logic Controller (PLC)
21 History of PLC
In the late 1960s PLCs were first introduced The primary reason for designing such a device was
eliminating the large cost involved in replacing the complicated relay based machine control systems
Bedford Associates (Bedford MA) proposed something called a Modular Digital Controller (MODICON)
to a major US car manufacturer Other companies at the time proposed computer based schemes one of
which was based upon the PDP-8 The MODICON 084 brought the worlds first PLC into commercial
production
When production requirements changed so did the control system This becomes very expensive
when the change is frequent Since relays are mechanical devices they also have a limited lifetime which
required strict adhesion to maintenance schedules Troubleshooting was also quite tedious when so many
relays are involved Now picture a machine control panel that included many possibly hundreds or
thousands of individual relays The size could be mind boggling How about the complicated initial
wiring of so many individual devices These relays would be individually wired together in a manner that
would yield the desired outcome As can be seen there were many problems with this relay based design
These new controllers also had to be easily programmed by maintenance and plant engineers
The lifetime had to be long and programming changes easily performed They also had to survive the
harsh industrial environment Thats a lot to ask The answers were to use a programming technique most
people were already familiar with and replace mechanical parts with solid-state ones
In the mid70s the dominant PLC technologies were sequencer state-machines and the bit-slice
based CPU The AMD 2901 and 2903 were quite popular in Modicon and A-B PLCs Conventional
microprocessors lacked the power to quickly solve PLC logic in all but the smallest PLCs Asconventional microprocessors evolved larger and larger PLCs were being based upon them However
even today some are still based upon the 2903 (Ref A-Bs PLC-3) Modicon has yet to build a faster PLC
than their 984ABX which was based upon the 29016 Communications abilities began to appear in
approximately 1973 The first such system was Modicons Modbus The PLC could now talk to other
PLCs and they could be far away from the actual machine they were controlling They could also now be
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 853
Veerandrapulagam500gmailcom
used to send and receive varying voltages to allow them to enter the analog world Unfortunately the lack
of standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks Still it was a great decade for the PLC
The 80s saw an attempt to standardize communications with General Motors manufacturing
automation protocol (MAP) It was also a time for reducing the size of the PLC and making them software
programmable through symbolic programming on personal computers instead of dedicated programming
terminals or handheld programmers Today the worlds smallest PLC is about the size of a single control
relay
The 90s have seen a gradual reduction in the introduction of new protocols and the modernization
of the physical layers of some of the more popular protocols that survived the 1980s The latest standard
(IEC 1131-3) has tried to merge plc programming languages under one international standard We now
have PLCs that are programmable in function block diagrams instruction lists C and structured text all at
the same time PCs are also being used to replace PLCs in some applications The original company who
commissioned the MODICON 084 has actually switched to a PC based control system
211 Advantages of PLC
Less wiring
Wiring between devices and relay contacts are done in the PLC program
Easier and faster to make changes
Trouble shooting aids make programming easier and reduce downtime
Reliable components make these likely to operate for years before failure
212 Disadvantages
PLC was designed for relay logic ladder and has difficulty with some smart devices
To maximize PLC performance and flexibility a number of option modulus must beadded
213 Applications of plc
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 953
Veerandrapulagam500gmailcom
It is used in process automation
It is used to optimize the process
It is used to integrate the different processing level s
By using PLCs quality of production is possible
System accuracy is increased by using PLCs
Automatic traffic control system is possible
It is used in twisting machines automatic suspension of rotary system
Numerous applications are possible by using PLCs in the industry
After wiring of relay panel if the event sequence is to be changed it is necessary to rewire
all or part of the panel
Many of the control relay of the ladder diagram can be replaced by software which means
less hardware failure
It is easy to make change in programmed sequence of events when it is only in software
22 Plc compared with other control system
PLCs are well adapted to a range of automation tasks These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation system
is high relative to the total cost of the automation and where changes to the system would be
expected during its operational life PLCs contain input and output devices compatible with
industrial pilot devices and controls little electrical design is required and the design problem
centres on expressing the desired sequence of operations PLC applications are typically highly
customized systems so the cost of a packaged PLC is low compared to the cost of a specific
custom-built controller design On the other hand in the case of mass-produced goods
customized control systems are economical This is due to the lower cost of the components
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 353
Veerandrapulagam500gmailcom
Chapter 1
11 INTRODUCTION
A programmable logic controller (PLC) is a solid state device designed to previously
accomplish by electromechanically relays PLC is a basically a controller not continuous but logic
state ie on-off controller Hence sequences of logic states are programmed All operation is to
control a process operation of manufacturing equipment and machinery PLCs are in the
computer family They are used in commercial and industrial applications
Initially the plc was used to replace relay logic but its ever-increasing range of function
means that it is found in the many and more complex applications As the structure of a plc is
based on the same principle as those employed in computer architecture it is capable of
performing not only relay switching tasks but also other applications such as counting calculating
comparing and the processing of analog signals
12 Basic principle of PLC
PLC was invented in the 6070rsquos for the automotive manufacturing industry Since this
time they have developed into one of the most versatile tools used for industrial automation A
working knowledge of PLCs and other microprocessor based control system are critical to
technical personal who are staying current with technology in industry
PROGRAMMABLE LOGIC CONTROLLER or PLC is the hub of many manufacturing
processes These micro processor based units are used in processes as simple as boxing machines
or bagging equipment to controlling and tacking sophisticated manufacturing processes They are
in virtually all new manufacturing processing and package equipment in one form or another
Because of their population in industry it becomes increasingly more important to learn skills
related to these devices Click on the buttons to learn more about industrial automation and this
invaluable tool
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 453
Veerandrapulagam500gmailcom
The microprocessor or processor module is the brain of a PLC system It consists of the
microprocessor memory integrated from memory It also includes communications ports to other
peripherals other PLCs or programming terminals
Todayrsquos processors vary widely in their capabilities to control real devices Some control as few
as 6 inputs and outputs and other 40000 or more One processor can control more than one
process of manufacturing line Processor are often linked together in order to provide continuity
throughout the process The number of inputs and outputs PLCs can control are limited by the
overall capacity of the PLC system hard ware 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 control on
or off state of output devices
13 Objectives
There are four objectives to be achieved in this project Below are the following
Objectives
To design appropriate model for automatic mixing amp filling bottle
To design program using PLC for automatic mixing amp filling bottle
To interface PLC module with the inputs and outputs component
To design a prototype system for automatic mixing amp filling bottle
14 Scope of the Project
To achieve the objectives and purpose of the project the scope of study and research can
be divided into following areas
Design and develop the prototype for the automatic mixing amp filling bottle by
using PLC as the controller to enhance the existing system
This project will develop the prototype which is respect to the actual system
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 553
Veerandrapulagam500gmailcom
1 5 The development of hardware and software
A Hardware
1) Literature study of the hardware including PLC and others components
2)
Programmable logic controller (PLC) will used the as the brain of the project
3) Dc supply 24V
4) Solenoid valve is a bottle filling component
5) Conveyor moves bottle
6) Submersible motors used pump the water and flavor into mixing container
7) Mixing motor for mix water and flavor motor
B Software
1) Totally integrated automation on portal v-105
2) Simatic s7-1200
3) Ladder diagram as the source code to the PLC
16 Conditions of the project
There are three containers first container contains water second container contains flavor
and middle container is mixing amp filling container Water and flavor container consists of two
submersible motors Mixing container contains a mixing fan and a solenoid valve is fixed to itConveyor system arranged below the filling container one end point of conveyor is starts from
below the solenoid valve exactly and photo electric sensor is below solenoid valve to sense the
bottle to fill it
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 653
Veerandrapulagam500gmailcom
Figure 11 Photo of project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 753
Veerandrapulagam500gmailcom
Chapter2
Programmable Logic Controller (PLC)
21 History of PLC
In the late 1960s PLCs were first introduced The primary reason for designing such a device was
eliminating the large cost involved in replacing the complicated relay based machine control systems
Bedford Associates (Bedford MA) proposed something called a Modular Digital Controller (MODICON)
to a major US car manufacturer Other companies at the time proposed computer based schemes one of
which was based upon the PDP-8 The MODICON 084 brought the worlds first PLC into commercial
production
When production requirements changed so did the control system This becomes very expensive
when the change is frequent Since relays are mechanical devices they also have a limited lifetime which
required strict adhesion to maintenance schedules Troubleshooting was also quite tedious when so many
relays are involved Now picture a machine control panel that included many possibly hundreds or
thousands of individual relays The size could be mind boggling How about the complicated initial
wiring of so many individual devices These relays would be individually wired together in a manner that
would yield the desired outcome As can be seen there were many problems with this relay based design
These new controllers also had to be easily programmed by maintenance and plant engineers
The lifetime had to be long and programming changes easily performed They also had to survive the
harsh industrial environment Thats a lot to ask The answers were to use a programming technique most
people were already familiar with and replace mechanical parts with solid-state ones
In the mid70s the dominant PLC technologies were sequencer state-machines and the bit-slice
based CPU The AMD 2901 and 2903 were quite popular in Modicon and A-B PLCs Conventional
microprocessors lacked the power to quickly solve PLC logic in all but the smallest PLCs Asconventional microprocessors evolved larger and larger PLCs were being based upon them However
even today some are still based upon the 2903 (Ref A-Bs PLC-3) Modicon has yet to build a faster PLC
than their 984ABX which was based upon the 29016 Communications abilities began to appear in
approximately 1973 The first such system was Modicons Modbus The PLC could now talk to other
PLCs and they could be far away from the actual machine they were controlling They could also now be
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 853
Veerandrapulagam500gmailcom
used to send and receive varying voltages to allow them to enter the analog world Unfortunately the lack
of standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks Still it was a great decade for the PLC
The 80s saw an attempt to standardize communications with General Motors manufacturing
automation protocol (MAP) It was also a time for reducing the size of the PLC and making them software
programmable through symbolic programming on personal computers instead of dedicated programming
terminals or handheld programmers Today the worlds smallest PLC is about the size of a single control
relay
The 90s have seen a gradual reduction in the introduction of new protocols and the modernization
of the physical layers of some of the more popular protocols that survived the 1980s The latest standard
(IEC 1131-3) has tried to merge plc programming languages under one international standard We now
have PLCs that are programmable in function block diagrams instruction lists C and structured text all at
the same time PCs are also being used to replace PLCs in some applications The original company who
commissioned the MODICON 084 has actually switched to a PC based control system
211 Advantages of PLC
Less wiring
Wiring between devices and relay contacts are done in the PLC program
Easier and faster to make changes
Trouble shooting aids make programming easier and reduce downtime
Reliable components make these likely to operate for years before failure
212 Disadvantages
PLC was designed for relay logic ladder and has difficulty with some smart devices
To maximize PLC performance and flexibility a number of option modulus must beadded
213 Applications of plc
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 953
Veerandrapulagam500gmailcom
It is used in process automation
It is used to optimize the process
It is used to integrate the different processing level s
By using PLCs quality of production is possible
System accuracy is increased by using PLCs
Automatic traffic control system is possible
It is used in twisting machines automatic suspension of rotary system
Numerous applications are possible by using PLCs in the industry
After wiring of relay panel if the event sequence is to be changed it is necessary to rewire
all or part of the panel
Many of the control relay of the ladder diagram can be replaced by software which means
less hardware failure
It is easy to make change in programmed sequence of events when it is only in software
22 Plc compared with other control system
PLCs are well adapted to a range of automation tasks These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation system
is high relative to the total cost of the automation and where changes to the system would be
expected during its operational life PLCs contain input and output devices compatible with
industrial pilot devices and controls little electrical design is required and the design problem
centres on expressing the desired sequence of operations PLC applications are typically highly
customized systems so the cost of a packaged PLC is low compared to the cost of a specific
custom-built controller design On the other hand in the case of mass-produced goods
customized control systems are economical This is due to the lower cost of the components
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 453
Veerandrapulagam500gmailcom
The microprocessor or processor module is the brain of a PLC system It consists of the
microprocessor memory integrated from memory It also includes communications ports to other
peripherals other PLCs or programming terminals
Todayrsquos processors vary widely in their capabilities to control real devices Some control as few
as 6 inputs and outputs and other 40000 or more One processor can control more than one
process of manufacturing line Processor are often linked together in order to provide continuity
throughout the process The number of inputs and outputs PLCs can control are limited by the
overall capacity of the PLC system hard ware 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 control on
or off state of output devices
13 Objectives
There are four objectives to be achieved in this project Below are the following
Objectives
To design appropriate model for automatic mixing amp filling bottle
To design program using PLC for automatic mixing amp filling bottle
To interface PLC module with the inputs and outputs component
To design a prototype system for automatic mixing amp filling bottle
14 Scope of the Project
To achieve the objectives and purpose of the project the scope of study and research can
be divided into following areas
Design and develop the prototype for the automatic mixing amp filling bottle by
using PLC as the controller to enhance the existing system
This project will develop the prototype which is respect to the actual system
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 553
Veerandrapulagam500gmailcom
1 5 The development of hardware and software
A Hardware
1) Literature study of the hardware including PLC and others components
2)
Programmable logic controller (PLC) will used the as the brain of the project
3) Dc supply 24V
4) Solenoid valve is a bottle filling component
5) Conveyor moves bottle
6) Submersible motors used pump the water and flavor into mixing container
7) Mixing motor for mix water and flavor motor
B Software
1) Totally integrated automation on portal v-105
2) Simatic s7-1200
3) Ladder diagram as the source code to the PLC
16 Conditions of the project
There are three containers first container contains water second container contains flavor
and middle container is mixing amp filling container Water and flavor container consists of two
submersible motors Mixing container contains a mixing fan and a solenoid valve is fixed to itConveyor system arranged below the filling container one end point of conveyor is starts from
below the solenoid valve exactly and photo electric sensor is below solenoid valve to sense the
bottle to fill it
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 653
Veerandrapulagam500gmailcom
Figure 11 Photo of project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 753
Veerandrapulagam500gmailcom
Chapter2
Programmable Logic Controller (PLC)
21 History of PLC
In the late 1960s PLCs were first introduced The primary reason for designing such a device was
eliminating the large cost involved in replacing the complicated relay based machine control systems
Bedford Associates (Bedford MA) proposed something called a Modular Digital Controller (MODICON)
to a major US car manufacturer Other companies at the time proposed computer based schemes one of
which was based upon the PDP-8 The MODICON 084 brought the worlds first PLC into commercial
production
When production requirements changed so did the control system This becomes very expensive
when the change is frequent Since relays are mechanical devices they also have a limited lifetime which
required strict adhesion to maintenance schedules Troubleshooting was also quite tedious when so many
relays are involved Now picture a machine control panel that included many possibly hundreds or
thousands of individual relays The size could be mind boggling How about the complicated initial
wiring of so many individual devices These relays would be individually wired together in a manner that
would yield the desired outcome As can be seen there were many problems with this relay based design
These new controllers also had to be easily programmed by maintenance and plant engineers
The lifetime had to be long and programming changes easily performed They also had to survive the
harsh industrial environment Thats a lot to ask The answers were to use a programming technique most
people were already familiar with and replace mechanical parts with solid-state ones
In the mid70s the dominant PLC technologies were sequencer state-machines and the bit-slice
based CPU The AMD 2901 and 2903 were quite popular in Modicon and A-B PLCs Conventional
microprocessors lacked the power to quickly solve PLC logic in all but the smallest PLCs Asconventional microprocessors evolved larger and larger PLCs were being based upon them However
even today some are still based upon the 2903 (Ref A-Bs PLC-3) Modicon has yet to build a faster PLC
than their 984ABX which was based upon the 29016 Communications abilities began to appear in
approximately 1973 The first such system was Modicons Modbus The PLC could now talk to other
PLCs and they could be far away from the actual machine they were controlling They could also now be
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 853
Veerandrapulagam500gmailcom
used to send and receive varying voltages to allow them to enter the analog world Unfortunately the lack
of standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks Still it was a great decade for the PLC
The 80s saw an attempt to standardize communications with General Motors manufacturing
automation protocol (MAP) It was also a time for reducing the size of the PLC and making them software
programmable through symbolic programming on personal computers instead of dedicated programming
terminals or handheld programmers Today the worlds smallest PLC is about the size of a single control
relay
The 90s have seen a gradual reduction in the introduction of new protocols and the modernization
of the physical layers of some of the more popular protocols that survived the 1980s The latest standard
(IEC 1131-3) has tried to merge plc programming languages under one international standard We now
have PLCs that are programmable in function block diagrams instruction lists C and structured text all at
the same time PCs are also being used to replace PLCs in some applications The original company who
commissioned the MODICON 084 has actually switched to a PC based control system
211 Advantages of PLC
Less wiring
Wiring between devices and relay contacts are done in the PLC program
Easier and faster to make changes
Trouble shooting aids make programming easier and reduce downtime
Reliable components make these likely to operate for years before failure
212 Disadvantages
PLC was designed for relay logic ladder and has difficulty with some smart devices
To maximize PLC performance and flexibility a number of option modulus must beadded
213 Applications of plc
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 953
Veerandrapulagam500gmailcom
It is used in process automation
It is used to optimize the process
It is used to integrate the different processing level s
By using PLCs quality of production is possible
System accuracy is increased by using PLCs
Automatic traffic control system is possible
It is used in twisting machines automatic suspension of rotary system
Numerous applications are possible by using PLCs in the industry
After wiring of relay panel if the event sequence is to be changed it is necessary to rewire
all or part of the panel
Many of the control relay of the ladder diagram can be replaced by software which means
less hardware failure
It is easy to make change in programmed sequence of events when it is only in software
22 Plc compared with other control system
PLCs are well adapted to a range of automation tasks These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation system
is high relative to the total cost of the automation and where changes to the system would be
expected during its operational life PLCs contain input and output devices compatible with
industrial pilot devices and controls little electrical design is required and the design problem
centres on expressing the desired sequence of operations PLC applications are typically highly
customized systems so the cost of a packaged PLC is low compared to the cost of a specific
custom-built controller design On the other hand in the case of mass-produced goods
customized control systems are economical This is due to the lower cost of the components
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 553
Veerandrapulagam500gmailcom
1 5 The development of hardware and software
A Hardware
1) Literature study of the hardware including PLC and others components
2)
Programmable logic controller (PLC) will used the as the brain of the project
3) Dc supply 24V
4) Solenoid valve is a bottle filling component
5) Conveyor moves bottle
6) Submersible motors used pump the water and flavor into mixing container
7) Mixing motor for mix water and flavor motor
B Software
1) Totally integrated automation on portal v-105
2) Simatic s7-1200
3) Ladder diagram as the source code to the PLC
16 Conditions of the project
There are three containers first container contains water second container contains flavor
and middle container is mixing amp filling container Water and flavor container consists of two
submersible motors Mixing container contains a mixing fan and a solenoid valve is fixed to itConveyor system arranged below the filling container one end point of conveyor is starts from
below the solenoid valve exactly and photo electric sensor is below solenoid valve to sense the
bottle to fill it
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 653
Veerandrapulagam500gmailcom
Figure 11 Photo of project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 753
Veerandrapulagam500gmailcom
Chapter2
Programmable Logic Controller (PLC)
21 History of PLC
In the late 1960s PLCs were first introduced The primary reason for designing such a device was
eliminating the large cost involved in replacing the complicated relay based machine control systems
Bedford Associates (Bedford MA) proposed something called a Modular Digital Controller (MODICON)
to a major US car manufacturer Other companies at the time proposed computer based schemes one of
which was based upon the PDP-8 The MODICON 084 brought the worlds first PLC into commercial
production
When production requirements changed so did the control system This becomes very expensive
when the change is frequent Since relays are mechanical devices they also have a limited lifetime which
required strict adhesion to maintenance schedules Troubleshooting was also quite tedious when so many
relays are involved Now picture a machine control panel that included many possibly hundreds or
thousands of individual relays The size could be mind boggling How about the complicated initial
wiring of so many individual devices These relays would be individually wired together in a manner that
would yield the desired outcome As can be seen there were many problems with this relay based design
These new controllers also had to be easily programmed by maintenance and plant engineers
The lifetime had to be long and programming changes easily performed They also had to survive the
harsh industrial environment Thats a lot to ask The answers were to use a programming technique most
people were already familiar with and replace mechanical parts with solid-state ones
In the mid70s the dominant PLC technologies were sequencer state-machines and the bit-slice
based CPU The AMD 2901 and 2903 were quite popular in Modicon and A-B PLCs Conventional
microprocessors lacked the power to quickly solve PLC logic in all but the smallest PLCs Asconventional microprocessors evolved larger and larger PLCs were being based upon them However
even today some are still based upon the 2903 (Ref A-Bs PLC-3) Modicon has yet to build a faster PLC
than their 984ABX which was based upon the 29016 Communications abilities began to appear in
approximately 1973 The first such system was Modicons Modbus The PLC could now talk to other
PLCs and they could be far away from the actual machine they were controlling They could also now be
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 853
Veerandrapulagam500gmailcom
used to send and receive varying voltages to allow them to enter the analog world Unfortunately the lack
of standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks Still it was a great decade for the PLC
The 80s saw an attempt to standardize communications with General Motors manufacturing
automation protocol (MAP) It was also a time for reducing the size of the PLC and making them software
programmable through symbolic programming on personal computers instead of dedicated programming
terminals or handheld programmers Today the worlds smallest PLC is about the size of a single control
relay
The 90s have seen a gradual reduction in the introduction of new protocols and the modernization
of the physical layers of some of the more popular protocols that survived the 1980s The latest standard
(IEC 1131-3) has tried to merge plc programming languages under one international standard We now
have PLCs that are programmable in function block diagrams instruction lists C and structured text all at
the same time PCs are also being used to replace PLCs in some applications The original company who
commissioned the MODICON 084 has actually switched to a PC based control system
211 Advantages of PLC
Less wiring
Wiring between devices and relay contacts are done in the PLC program
Easier and faster to make changes
Trouble shooting aids make programming easier and reduce downtime
Reliable components make these likely to operate for years before failure
212 Disadvantages
PLC was designed for relay logic ladder and has difficulty with some smart devices
To maximize PLC performance and flexibility a number of option modulus must beadded
213 Applications of plc
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 953
Veerandrapulagam500gmailcom
It is used in process automation
It is used to optimize the process
It is used to integrate the different processing level s
By using PLCs quality of production is possible
System accuracy is increased by using PLCs
Automatic traffic control system is possible
It is used in twisting machines automatic suspension of rotary system
Numerous applications are possible by using PLCs in the industry
After wiring of relay panel if the event sequence is to be changed it is necessary to rewire
all or part of the panel
Many of the control relay of the ladder diagram can be replaced by software which means
less hardware failure
It is easy to make change in programmed sequence of events when it is only in software
22 Plc compared with other control system
PLCs are well adapted to a range of automation tasks These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation system
is high relative to the total cost of the automation and where changes to the system would be
expected during its operational life PLCs contain input and output devices compatible with
industrial pilot devices and controls little electrical design is required and the design problem
centres on expressing the desired sequence of operations PLC applications are typically highly
customized systems so the cost of a packaged PLC is low compared to the cost of a specific
custom-built controller design On the other hand in the case of mass-produced goods
customized control systems are economical This is due to the lower cost of the components
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 653
Veerandrapulagam500gmailcom
Figure 11 Photo of project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 753
Veerandrapulagam500gmailcom
Chapter2
Programmable Logic Controller (PLC)
21 History of PLC
In the late 1960s PLCs were first introduced The primary reason for designing such a device was
eliminating the large cost involved in replacing the complicated relay based machine control systems
Bedford Associates (Bedford MA) proposed something called a Modular Digital Controller (MODICON)
to a major US car manufacturer Other companies at the time proposed computer based schemes one of
which was based upon the PDP-8 The MODICON 084 brought the worlds first PLC into commercial
production
When production requirements changed so did the control system This becomes very expensive
when the change is frequent Since relays are mechanical devices they also have a limited lifetime which
required strict adhesion to maintenance schedules Troubleshooting was also quite tedious when so many
relays are involved Now picture a machine control panel that included many possibly hundreds or
thousands of individual relays The size could be mind boggling How about the complicated initial
wiring of so many individual devices These relays would be individually wired together in a manner that
would yield the desired outcome As can be seen there were many problems with this relay based design
These new controllers also had to be easily programmed by maintenance and plant engineers
The lifetime had to be long and programming changes easily performed They also had to survive the
harsh industrial environment Thats a lot to ask The answers were to use a programming technique most
people were already familiar with and replace mechanical parts with solid-state ones
In the mid70s the dominant PLC technologies were sequencer state-machines and the bit-slice
based CPU The AMD 2901 and 2903 were quite popular in Modicon and A-B PLCs Conventional
microprocessors lacked the power to quickly solve PLC logic in all but the smallest PLCs Asconventional microprocessors evolved larger and larger PLCs were being based upon them However
even today some are still based upon the 2903 (Ref A-Bs PLC-3) Modicon has yet to build a faster PLC
than their 984ABX which was based upon the 29016 Communications abilities began to appear in
approximately 1973 The first such system was Modicons Modbus The PLC could now talk to other
PLCs and they could be far away from the actual machine they were controlling They could also now be
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 853
Veerandrapulagam500gmailcom
used to send and receive varying voltages to allow them to enter the analog world Unfortunately the lack
of standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks Still it was a great decade for the PLC
The 80s saw an attempt to standardize communications with General Motors manufacturing
automation protocol (MAP) It was also a time for reducing the size of the PLC and making them software
programmable through symbolic programming on personal computers instead of dedicated programming
terminals or handheld programmers Today the worlds smallest PLC is about the size of a single control
relay
The 90s have seen a gradual reduction in the introduction of new protocols and the modernization
of the physical layers of some of the more popular protocols that survived the 1980s The latest standard
(IEC 1131-3) has tried to merge plc programming languages under one international standard We now
have PLCs that are programmable in function block diagrams instruction lists C and structured text all at
the same time PCs are also being used to replace PLCs in some applications The original company who
commissioned the MODICON 084 has actually switched to a PC based control system
211 Advantages of PLC
Less wiring
Wiring between devices and relay contacts are done in the PLC program
Easier and faster to make changes
Trouble shooting aids make programming easier and reduce downtime
Reliable components make these likely to operate for years before failure
212 Disadvantages
PLC was designed for relay logic ladder and has difficulty with some smart devices
To maximize PLC performance and flexibility a number of option modulus must beadded
213 Applications of plc
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 953
Veerandrapulagam500gmailcom
It is used in process automation
It is used to optimize the process
It is used to integrate the different processing level s
By using PLCs quality of production is possible
System accuracy is increased by using PLCs
Automatic traffic control system is possible
It is used in twisting machines automatic suspension of rotary system
Numerous applications are possible by using PLCs in the industry
After wiring of relay panel if the event sequence is to be changed it is necessary to rewire
all or part of the panel
Many of the control relay of the ladder diagram can be replaced by software which means
less hardware failure
It is easy to make change in programmed sequence of events when it is only in software
22 Plc compared with other control system
PLCs are well adapted to a range of automation tasks These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation system
is high relative to the total cost of the automation and where changes to the system would be
expected during its operational life PLCs contain input and output devices compatible with
industrial pilot devices and controls little electrical design is required and the design problem
centres on expressing the desired sequence of operations PLC applications are typically highly
customized systems so the cost of a packaged PLC is low compared to the cost of a specific
custom-built controller design On the other hand in the case of mass-produced goods
customized control systems are economical This is due to the lower cost of the components
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 753
Veerandrapulagam500gmailcom
Chapter2
Programmable Logic Controller (PLC)
21 History of PLC
In the late 1960s PLCs were first introduced The primary reason for designing such a device was
eliminating the large cost involved in replacing the complicated relay based machine control systems
Bedford Associates (Bedford MA) proposed something called a Modular Digital Controller (MODICON)
to a major US car manufacturer Other companies at the time proposed computer based schemes one of
which was based upon the PDP-8 The MODICON 084 brought the worlds first PLC into commercial
production
When production requirements changed so did the control system This becomes very expensive
when the change is frequent Since relays are mechanical devices they also have a limited lifetime which
required strict adhesion to maintenance schedules Troubleshooting was also quite tedious when so many
relays are involved Now picture a machine control panel that included many possibly hundreds or
thousands of individual relays The size could be mind boggling How about the complicated initial
wiring of so many individual devices These relays would be individually wired together in a manner that
would yield the desired outcome As can be seen there were many problems with this relay based design
These new controllers also had to be easily programmed by maintenance and plant engineers
The lifetime had to be long and programming changes easily performed They also had to survive the
harsh industrial environment Thats a lot to ask The answers were to use a programming technique most
people were already familiar with and replace mechanical parts with solid-state ones
In the mid70s the dominant PLC technologies were sequencer state-machines and the bit-slice
based CPU The AMD 2901 and 2903 were quite popular in Modicon and A-B PLCs Conventional
microprocessors lacked the power to quickly solve PLC logic in all but the smallest PLCs Asconventional microprocessors evolved larger and larger PLCs were being based upon them However
even today some are still based upon the 2903 (Ref A-Bs PLC-3) Modicon has yet to build a faster PLC
than their 984ABX which was based upon the 29016 Communications abilities began to appear in
approximately 1973 The first such system was Modicons Modbus The PLC could now talk to other
PLCs and they could be far away from the actual machine they were controlling They could also now be
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 853
Veerandrapulagam500gmailcom
used to send and receive varying voltages to allow them to enter the analog world Unfortunately the lack
of standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks Still it was a great decade for the PLC
The 80s saw an attempt to standardize communications with General Motors manufacturing
automation protocol (MAP) It was also a time for reducing the size of the PLC and making them software
programmable through symbolic programming on personal computers instead of dedicated programming
terminals or handheld programmers Today the worlds smallest PLC is about the size of a single control
relay
The 90s have seen a gradual reduction in the introduction of new protocols and the modernization
of the physical layers of some of the more popular protocols that survived the 1980s The latest standard
(IEC 1131-3) has tried to merge plc programming languages under one international standard We now
have PLCs that are programmable in function block diagrams instruction lists C and structured text all at
the same time PCs are also being used to replace PLCs in some applications The original company who
commissioned the MODICON 084 has actually switched to a PC based control system
211 Advantages of PLC
Less wiring
Wiring between devices and relay contacts are done in the PLC program
Easier and faster to make changes
Trouble shooting aids make programming easier and reduce downtime
Reliable components make these likely to operate for years before failure
212 Disadvantages
PLC was designed for relay logic ladder and has difficulty with some smart devices
To maximize PLC performance and flexibility a number of option modulus must beadded
213 Applications of plc
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 953
Veerandrapulagam500gmailcom
It is used in process automation
It is used to optimize the process
It is used to integrate the different processing level s
By using PLCs quality of production is possible
System accuracy is increased by using PLCs
Automatic traffic control system is possible
It is used in twisting machines automatic suspension of rotary system
Numerous applications are possible by using PLCs in the industry
After wiring of relay panel if the event sequence is to be changed it is necessary to rewire
all or part of the panel
Many of the control relay of the ladder diagram can be replaced by software which means
less hardware failure
It is easy to make change in programmed sequence of events when it is only in software
22 Plc compared with other control system
PLCs are well adapted to a range of automation tasks These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation system
is high relative to the total cost of the automation and where changes to the system would be
expected during its operational life PLCs contain input and output devices compatible with
industrial pilot devices and controls little electrical design is required and the design problem
centres on expressing the desired sequence of operations PLC applications are typically highly
customized systems so the cost of a packaged PLC is low compared to the cost of a specific
custom-built controller design On the other hand in the case of mass-produced goods
customized control systems are economical This is due to the lower cost of the components
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 853
Veerandrapulagam500gmailcom
used to send and receive varying voltages to allow them to enter the analog world Unfortunately the lack
of standardization coupled with continually changing technology has made PLC communications a
nightmare of incompatible protocols and physical networks Still it was a great decade for the PLC
The 80s saw an attempt to standardize communications with General Motors manufacturing
automation protocol (MAP) It was also a time for reducing the size of the PLC and making them software
programmable through symbolic programming on personal computers instead of dedicated programming
terminals or handheld programmers Today the worlds smallest PLC is about the size of a single control
relay
The 90s have seen a gradual reduction in the introduction of new protocols and the modernization
of the physical layers of some of the more popular protocols that survived the 1980s The latest standard
(IEC 1131-3) has tried to merge plc programming languages under one international standard We now
have PLCs that are programmable in function block diagrams instruction lists C and structured text all at
the same time PCs are also being used to replace PLCs in some applications The original company who
commissioned the MODICON 084 has actually switched to a PC based control system
211 Advantages of PLC
Less wiring
Wiring between devices and relay contacts are done in the PLC program
Easier and faster to make changes
Trouble shooting aids make programming easier and reduce downtime
Reliable components make these likely to operate for years before failure
212 Disadvantages
PLC was designed for relay logic ladder and has difficulty with some smart devices
To maximize PLC performance and flexibility a number of option modulus must beadded
213 Applications of plc
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 953
Veerandrapulagam500gmailcom
It is used in process automation
It is used to optimize the process
It is used to integrate the different processing level s
By using PLCs quality of production is possible
System accuracy is increased by using PLCs
Automatic traffic control system is possible
It is used in twisting machines automatic suspension of rotary system
Numerous applications are possible by using PLCs in the industry
After wiring of relay panel if the event sequence is to be changed it is necessary to rewire
all or part of the panel
Many of the control relay of the ladder diagram can be replaced by software which means
less hardware failure
It is easy to make change in programmed sequence of events when it is only in software
22 Plc compared with other control system
PLCs are well adapted to a range of automation tasks These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation system
is high relative to the total cost of the automation and where changes to the system would be
expected during its operational life PLCs contain input and output devices compatible with
industrial pilot devices and controls little electrical design is required and the design problem
centres on expressing the desired sequence of operations PLC applications are typically highly
customized systems so the cost of a packaged PLC is low compared to the cost of a specific
custom-built controller design On the other hand in the case of mass-produced goods
customized control systems are economical This is due to the lower cost of the components
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 953
Veerandrapulagam500gmailcom
It is used in process automation
It is used to optimize the process
It is used to integrate the different processing level s
By using PLCs quality of production is possible
System accuracy is increased by using PLCs
Automatic traffic control system is possible
It is used in twisting machines automatic suspension of rotary system
Numerous applications are possible by using PLCs in the industry
After wiring of relay panel if the event sequence is to be changed it is necessary to rewire
all or part of the panel
Many of the control relay of the ladder diagram can be replaced by software which means
less hardware failure
It is easy to make change in programmed sequence of events when it is only in software
22 Plc compared with other control system
PLCs are well adapted to a range of automation tasks These are typically industrial
processes in manufacturing where the cost of developing and maintaining the automation system
is high relative to the total cost of the automation and where changes to the system would be
expected during its operational life PLCs contain input and output devices compatible with
industrial pilot devices and controls little electrical design is required and the design problem
centres on expressing the desired sequence of operations PLC applications are typically highly
customized systems so the cost of a packaged PLC is low compared to the cost of a specific
custom-built controller design On the other hand in the case of mass-produced goods
customized control systems are economical This is due to the lower cost of the components
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1053
Veerandrapulagam500gmailcom
which can be optimally chosen instead of a generic solution and where the non-recurring
engineering charges are spread over thousands or millions of units
For high volume or very simple fixed automation tasks different techniques are used For
example a consumer dishwasher would be controlled by an electromechanical cam timer costingonly a few dollars in production quantities
A microcontroller- based design would be appropriate where hundreds or thousands of
units will be produced and so the development cost (design of power supplies inputoutput
hardware and necessary testing and certification) can be spread over many sales and where the
end-user would not need to alter the control Automotive applications are an example millions of
units are built each year and very few end-users alter the programming of these controllers
However some specialty vehicles such as transit buses economically use PLCs instead of custom-
designed controls because the volumes are low and the development cost would be
uneconomical
Very complex process control such as used in the chemical industry may require
algorithms and performance beyond the capability of even high-performance PLCs Very high-
speed or precision controls may also require customized solutions for example aircraft flight
controls Single-board computers using semi-customized or fully proprietary hardware may be
chosen for very demanding control applications where the high development and maintenance
cost can be supported Soft PLCs running on desktop-type computers can interface with
industrial IO hardware while executing programs within a version of commercial operating
systems adapted for process control needs
Programmable controllers are widely used in motion control positioning control and
torque control Some manufacturers produce motion control units to be integrated with PLC so
that G-code (involving a CNC machine) can be used to instruct machine movements
PLCs may include logic for single-variable feedback analog control loop a proportionalintegral derivative (PID) controller A PID loop could be used to control the temperature of a
manufacturing process for example Historically PLCs were usually configured with only a few
analog control loops where processes required hundreds or thousands of loops a distributed
control system (DCS) would instead be used As PLCs have become more powerful the boundary
between DCS and PLC applications has become less distinct
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1153
Veerandrapulagam500gmailcom
PLCs have similar functionality as remote terminal units (RTU) An RTU however usually does
not support control algorithms or control loops As hardware rapidly becomes more powerful and
cheaper RTUs PLCs and DCSs are increasingly beginning to overlap in responsibilities and
many vendors sell RTUs with PLC-like features and vice versa The industry has standardized on
the IEC 61131-3 functional block language for creating programs to run on RTUs and PLCs
although nearly all vendors also offer proprietary alternatives and associated development
environments
In recent years safety PLCs have started to become popular either as standalone models
or as functionality and safety-rated hardware added to existing controller architectures (Allen
Bradley Guard logic Siemens F-series etc) These differ from conventional PLC types as being
suitable for use in safety-critical applications for which PLCs have traditionally been
supplemented with hard-wired safety relays For example a safety PLC might be used to control
access to a robot cell with trapped-key access or perhaps to manage the shutdown response to an
emergency stop on a conveyor production line Such PLCs typically have a restricted regular
instruction set augmented with safety-specific instructions designed to interface with emergency
stops light screens and so forth The flexibility that such systems offer has resulted in rapid
growth of demand for these controllers
23 What constitutes a PLC
The PLC is programmed interface between the input field element and output field elements
24 PLC consists of
Input module
CPU (central process unit)
Program memory
Output module
Power supply
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1253
Veerandrapulagam500gmailcom
241 Input module
There are two types of input modules
a Digital inputs
b Analog inputs
A Digital inputs
These convert the external binary signal from the process to the internal digital signal
level of programmable controller
Digital Input devices
Push buttons
Switches
Limit switch
Proximity sensor
Photo sensor
B Analog inputs
fig 21 block diagram of PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1353
Veerandrapulagam500gmailcom
Analog inputs cards convertsrsquo continuous signal via a analog to digital converter into
discrete values for the PLC
Analog inputs devices
Pressure transmitter
Flow transmitter
Level transmitter
Load cell
Thermo couples
242 CPU (central processing unit)
The CPU is the brain of the system The CPU is a very microprocessor based system that
replaces control relays counter timers and sequencers A processor appears only once in a plc
and it can be either a one bit (or) a word logic operation PLCs with word processors are used
when processing text and numerical data calculations gauging controlling and recording as well
as the simple processing of signals in binary code are required The CPU accepts (reads) input
data from various sensing devices executes the stored user program from memory and sends
appropriate commands to control device A direct current (dc) source is required to produce the
flow level voltage used by the processor and the inputs and outputs modules
This power supply can be housed in the CPU unit (or) may be a separately mounted unit
depending on the PLC system manufacturer Most of the CPUs contain the backup batteries that
keep the operating program in storage in the event of a plant power failure
The processor memory module is a major part of the CPU housing Memory is where the
control plan or program is held or stored in the controller the information stored in the memory
relates to the way the input and output data should be processed The amount of memory required
is based on the complexity of the program Memory elements store individual pieces of
information called bits (for binary digits)
The main purpose of the CPU is ldquoscanningrdquo It performs the three main functions like
Read the inputs
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1453
Veerandrapulagam500gmailcom
Depends up on reading executes
Return to the values of the output
These three functions done simultaneously by the CPU called CPU scan cycle
The time required to complete the only one cycle is called ldquoCPU scan timerdquo The CPU scan time
depends upon our logic If the scan time is increase the plc speed decreases If the scan time is
decreases the plc speed increases
a
CHECK INPUT STATUS (read the inputs)
First the PLC takes a look at each input to determine if it is on or off In other words is
the sensor connected to the first input on Then the second input Then the third and so
onhellip It r ecords this data into its memory to be used during the next step
b EXECUTE PROGRAM (depends up on reading executes)
Next the PLC executes your program one instruction at a time Maybe the program says
that if the first input was on then it should turn on the first output Since it already knows which
inputs are onoff from the previous step it will be able to decide whether the first output
should be turned on based on the state of the first input It will store the execution results for use
later during the next step
c UPDATE OUTPUT STATUS (return to values of the output)
Finally the PLC updates the status of the outputs It updates the outputs based on which inputs
were on during the first step and the results of executing your program during the second step
Based on the example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is true After the
third step the PLC goes back to step one and repeats the steps continuously One scan time is
defined as the time it takes to execute the 3 steps listed above
The basic elements of a PLC include input modules or points a central processing unit
(CPU) output modules or points and a programming device The type of input modules
or points used by a PLC depends upon the types of input devices used Some input
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1553
Veerandrapulagam500gmailcom
modules or points respond to digital inputs also called discrete inputs which are either on or
off Other modules or inputs respond to analog signals These analog signals represent machine
or process conditions as a range of voltage or current values The primary function of a
PLCrsquos input circuitry is to convert the signals provided by these various switches and
sensors into logic signals that can be used by the CPU
The CPU evaluates the status of inputs outputs and other variables as it executes
a stored program The CPU then sends signals to update the status of outputs Output modules
convert control signals from the CPU into digital or analog values that can be used to control
various output devices The programming device is used to enter or change the PLCrsquos
program or to monitor or change stored values Once entered the program and associated
variables are stored in the CPU In addition to these basic elements a PLC system may also
incorporate an operator interface device to simplify monitoring of the machine or process
In our case the input module will be composed of an array of switches that help us
to input Logic ones or Logic zeros to the PLC the output module is made of LEDs to display
the status of the system our programming device is the SIEMENS provided STEP 7 MicroWin
and the operator interface is a WinCC based Human Machine Interface herein referred to HMI
243Output modules
There are two types of input modules
1 Digital outputs
2 Analog outputs
Digital outputs
These convert the internal signal level of the programmable controller into the binary
signal level required externally by the process
Digital outputs devices
Relays
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1653
Veerandrapulagam500gmailcom
Contractor
Values
Led
Solenoid value
Coilers
Analog outputs
Analog outputs cards convertsrsquo digital values in the PLC to converts continuous
signals via a digital to analog converts
Analog outputs devices
Flow control values
Pressure control values
Drive inputs
Values
Analog ports
244 Program memory
In program memory is classified into three types
I System memory
II Load memory
III Work memory
System memory
In system memory contain all hardware configuration details
Load memory
Each CPU has an internal load memory The size of this internal load memory depends on the
CPU used
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1753
Veerandrapulagam500gmailcom
This internal load memory can be replaced by using external memory cards If there is no
memory card inserted the CPU uses the internal load memory if a memory card is inserted
the CPU uses the memory card as load memory
The size of the usable external load memory cannot however be greater than the internal
load memory even if the inserted SD card has more free space
Work memory
Work memory is a non-retentive memory area for storing elements of the user program that
are relevant for program execution The user program is executed exclusively in work
memory and system memory
It divided into two
I Run mode
II
Stop mode
Is the working area of the PLC consisting of data regarding the status of input
and output mathematics calculations timer and counter values etc
245 Power supply
Here the power supply is separately mention because for plc to power up it requires only 24v dc
so to convert 230v ac to 24vdc one converter is used called SMPS(switch mode power supply )
25 PLC memory organization
Memory can be categorized into voltaic and non volatile and non volatile memory Volatile
memory will lose its stored information if all operating power is lost (or) removed Volatile
memory is easily altered and quite suitable for most applications when supported by battery
backup Non volatile memory can retain stored information when power is removed accidentally
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1853
Veerandrapulagam500gmailcom
or intentionally Plc makes use of many different types of volatile and non volatile memory
devices
Common memory types description
1 RAM Random access memory (RAM) is designed so that information can be
written into (or) read from the memory todayrsquos controllers use the CMOS-RAM
with battery support for user program memory RAM provides an excellent means
for easily creating and altering a problem
2 ROM Read- only memory (ROM) is designed so that information stored in
memory can be read and cannot be changed under ordinary circumstances
3 EPROM Erasable programmed read only memory (EPROM) is designed so that
it can be reprogrammed after being entirely erased with the use of an ultraviolet
light source
4 EEPROM Electrically erasable programmed read- only memory (EEPROM) is
a non volatile memory that offers the same programmed flexibility as does RAM
It provides permanent storage of the program but can be easily changed using
standard programming devices
26 Basic PLC architecture
CPU
Power supply
Memory
Input blocks
Output blocks
Communication
Expansion connections
27 Siemens Characteristics
271 SIMATIC S7-1200
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 1953
Veerandrapulagam500gmailcom
In the field of automation powerful components are a key factor to success But what really
gives us a unique advantage is all of them working together The new modular SIMATIC S7-1200
controller provides simple but highly precise Automation tasks
The SIMATIC S7-1200 controller is modular and compact versatile a secure investment and
is powerfully fit for a full range of applications It features an integrated PROFINET interface
powerful integrated technology functions and a highly scalable and flexible design a communication
interface that fulfills the highest standards of industrial communication and a full range of powerful
integrated technology functions make this controller an integral part of a complete and comprehensive
automation solution
272 Scalable and flexible design
The SIMATIC S7-1200 controller family was designed with maximum flexibility to fit any
individual machine requirements This allows us to custom design our controller system to meet the
requirements it also makes future system expansions quick and easy
273 Industrial communication
The SIMATIC S7-1200lsquos integrated PROFINET interface provides seamless communication
with the SIMATIC STEP 7 Basic engineering system for programming with SIMATIC HMI Basic
Panels for visualization with additional controllers for PLC-to-PLC communication and with third-
party devices for advanced integration options
274 Integrated technology
The name SIMATIC has been a reliable symbol in the field of automation for many years
They have integrated proven and innovative technology functions into the new controller ndash ranging
from counting and measuring speed position and duty cycle control to simple process control
functionality This wide variety of functionality guarantees the ability to solve a wide array of
applications based on technology that has proven its validity in the field for many years Up to 3
communication modules can be added to any of the SIMATIC S7-1200 CPUs The RS485 and RS232
communication modules provide the connection for performing point-to-point serial communication
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2053
Veerandrapulagam500gmailcom
275 High-speed inputs amp outputs
The new SIMATIC S7-1200 controller comes with 6 high-speed counters Three inputs at 30
kHz are integrated for counting and measuring Two high-speed pulse train outputs at 100 kHz areintegrated for controlling the speed and position of a stepper motor or a servo drive They can
alternatively be used as pulse-width-modulated outputs for controlling the speed of a motor position
276 Memory
Up to 50 KB of integrated work memory is provided with a floating boundary between the user
program and user data Up to 2 MB of integrated load memory and 2 KB of integrated retentive
memory are also provided The optional SIMATIC Memory Card provides an easy way to transfer programs to multiple CPUs This card can also be used for storing miscellaneous files or to update the
firmware of the controller system
2 77 Signal modules
Up to eight signal modules can be connected to the largest CPUs for the support of additional
digital and analog IOrsquos With the addition of a signal board you can increase the number of digital or
analog IOrsquos on the controller to custom-fit your needs without increasing the controllerlsquos footprint
The SIMATIC S7-1200 system comes in three different models CPU 1211C CPU 1212C and CPU
1214C that may each be expanded to exactly fit your machine requirements One signal board can be
added inside the front of any CPU to easily expand the digital or analog IOrsquos without affecting the
physical size of the controller Signal modules can be connected to the right side of the CPU to further
expand the digital or analog IO capacity CPU 1212C accepts two and CPU 1214C accepts eight
signal Modules CPU 1214C has a width measuring only 110 mm and both the CPU 1212C and CPU
1211C are only 90 mm wide Together with the small footprint of the communication modules and
signal modules this modular and compact system saves valuable space and offers you the highest
level efficiency and flexibility during the installation process
High-speed outputs for speed position or duty cycle control two high-speed outputs are integrated
into the SIMATIC S7-1200 controller for use as either pulse train outputs or pulse-width-modulated
outputs When configured as a PTO a 50 percent duty cycle pulse train is provided at a rate of up to
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2153
Veerandrapulagam500gmailcom
100 kHz for the open-loop speed and position control of stepper motors and servo drives Feedback for
the pulse train outputs is provided internally using two of the high-speed counters When configured as
a PWM output a fixed cycle time output with a variable duty cycle is provided for controlling the
speed of a motor position of a valve or duty cycle of a heating element
28 INTERFACING OF PLC WITH PC
A PLC user program can also be created using a personal or industrial to develop the user
ladder program a PLC ladder development software package is used The primary difference
between a personal computer and an industrial computer is that the industrial computer has been
hardened to withstand the factory environment
When the entire user ladder program has been developed entered and verified for correctness the
next step is to download the program into the processorrsquos memory Transferring the PLC program
from a personal computerrsquos memory to PLC memory is called downloading the program
Before downloading a user program the processor must be in program mode After downloading
the program if all input and output signals are wired to the correct screw terminals the processor
can be put in run mode In run mode the program will continuously run and solve the
programmed instructions Solving the programmed instructions are called solving the logic This
continual running of the program in a PLC is called scanning As part of the processorrsquos problem
solving routine the PLC will look at the incoming signals follow the preprogrammed output field
devices
281 Communication
PLCs have built in communications ports usually 9-pin RS-232 but optionally EIA-
485 or Ethernet Modbus BACnet or DF1 is usually included as one of the communications
protocols Other options include various fieldbuses such as Device Net or Profibus Other
communications protocols that may be used are listed in the List of automation protocols
Most modern PLCs can communicate over a network to some other system such as a
computer running a SCADA (Supervisory Control And Data Acquisition) system or web browser
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2253
Veerandrapulagam500gmailcom
PLCs used in larger IO systems may have peer-to-peer (P2P) communication between
processors This allows separate parts of a complex process to have individual control while
allowing the subsystems to co-ordinate over the communication link These communication links
are also often used for HMI devices such as keypads or PC-type workstations
Formerly some manufacturers offered dedicated communication modules as an add-on
function where the processor had no network connection built-in
282 Limitations of Ethernet
There are practical limits to
the size of our Ethernet network A
primary concern is the length of the
shared cable Electrical signals
propagate along a cable very quickly
but they weaken as they travel and
electrical interference from neighboring devices (fluorescent lights for example) can scramble the
signal A network cable must be short enough that devices at opposite ends can receive each
others signals clearly and with minimal delay This places a distance limitation on the maximum
separation between two devices on an Ethernet network Additionally since in CSMACD only a
single device can transmit at a given time there are practical limits to the number of devices that
can coexist in a single network Ethernet networks face congestion problems as they increased in
size If a large number of stations connected to the same segment and each generated a sizable
amount of traffic many stations may attempt to transmit whenever there was an opportunity
Under these circumstances collisions would become more frequent and could begin to choke out
Fig 22 Ethernet
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2353
Veerandrapulagam500gmailcom
successful transmissions which could take inordinately large amounts of time to complete One
way to reduce congestion would be to split a single segment into multiple segments thus creating
multiple collision domains This solution creates a different problem as now these now separate
segments are not able to share information with each other To alleviate these problems Ethernet
networks implemented bridges Bridges connect two or more network segments increasing the
network diameter as a repeater does but bridges also help regulate traffic They can send and
receive transmissions just like any other node but they do not function the same as a normal node
The bridge does not originate any traffic of its own like a repeater it only echoes what it hears
from other stations
Chapter 3
PLC PROGRAMMING WITH INSTRUCTIONS
31 Introduction
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2453
Veerandrapulagam500gmailcom
The programming language allows the user to communicate with programmable controller
(PC) via a programming device PC manufactures use several different programming languages
but they all convey to the system by means of instruction a basic control plan
The four must common types of languages encountered in programmable controller system design
are
I Ladder diagram
II Boolean mnemonics
III Function blocks and
IV The sequential function chart
These languages can be grouped into two major categories the first two ladder and
Boolean basic p c languages while function charting are considered high ndash level languages The
basic programmable controller languages consist of a set of instructions that will perform the most
primitive type of control functions the functions are relay replacement timing counting and
ONOFF control High level languages are used for analog control Data manipulation repeating
and other function that is not possible with the basic instruction sets The languages used in a pc
actually dictate the range of applications in which the controller can be applied Depending on the
size and capabilities of the controller on or more languages may be used typical combination of
languages are
a) Ladder diagrams only
b) Boolean only
c) Ladder diagrams and functional blocks
d) Ladder and sequential function chart
e) Ladder function blocks sequential function chart
32 Ladder language
The ladder language is a symbolic instruction set that is used to create a programmable controller
program It is composed of six categories of instruction that include relay-type timercounter data
manipulation arithmetic data transfer and program control The ladder instruction symbols can
be formatted to obtain control logic that is to entered into memory
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2553
Veerandrapulagam500gmailcom
The main function of the ladder diagram program is to control outputs based on the input
condition This control is accomplished through the use of what is referred to as a ladder rung
In general a rung consists of a set of input conditions represented by relay contact type instruction
and an output Instruction at end of the rung represented by the coil symbol Throughout the
section the contact instruction for a rung may be referred to as input conditions rung conditions or
control logic
Coils and contacts are the basic symbols of the ladder diagram instruction set The contact symbol
programmed in a given rung represents conditions to be evaluated in order to determine the
control of the output all
The format of the rung contacts is dependent on the desired control logic Contacts may be placed
in any configuration such as series parallel or series parallel that is required to control a given
output for an output to be activated or energized at least one left-to ndash right path of contacts must be
closed A complete closed path is referred to as having logic continuity When logic continuity
exists in at least one path it is said that the rang condition is TRUE The rung condition is
FALSE If no path has continuity
In the early year the standard ladder instruction set was limited to performing only relay
equivalent functions using the basic relay-type contact and coil symbols similar to those
illustrates in
A need for greater flexibility coupled with developments in technology led to extended ladder
diagram instructions that perform data manipulation arithmetic and program flow control
33 Bit logics
331 Normally open
Symbol ---| |---
Description
The activation of the normally open contact depends on the signal state of the associated
operand If the operand has signal state 1 the normally open contact is closed Power flows
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2653
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2753
Veerandrapulagam500gmailcom
Description
You can use the Output coil operation to set the bit of a specified operand When the
result of logic operation (RLO) at the input of the coil is 1 the specified operand is set to
signal state 1 When the signal state is 0 at the input of the coil the bit of the specified
operand is reset to 0
The operation does not influence the RLO The RLO at the input of the coil is sent
immediately to the output
Placement
The Output coil operation can be placed at any position in the network Using branches
several coils can be placed within each other
334 NOT operation
Symbol ---| NOT |---
Description
You can use the Invert result of logic operation operation to invert the signal state of the result of
logic operation (RLO) When the signal state is 1 at the input of the operation the output of the
operation provides the signal state 0 When the signal state is 0 at the input of the operation the
output of the operation provides the signal state 1
Placement
The Invert result of logic operation operation can be placed at any position in the network
34 TIMERS
Timers are used to ONampOFF the output with same delay Timers occupy one word
of memory By using timers the time delay will be 0milli seconds to 9990 seconds
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2853
Veerandrapulagam500gmailcom
Types of timers
1 ON delay timer
2 OFF delay timer
3
Pulse extent timer
Parameters of the timers
TV = timer interval
R= reset
S=set
Q= output
BI=balancing interval
BCD= blocking interval but it is in BCD form
341 TP Pulse generation timer
Symbol
Description
You can use the Generate pulse operation to set the Q output for a pre-programmed period of
time The operation is started when the result of logic operation (RLO) at the IN input changes
from 0 to 1 When the operation is started the time programmed for PT starts running
Output Q is set for the period of time PT regardless of the subsequent course of the input
signal Even when a new positive edge is detected the signal state at the Q output is not
affected as long as PT is running
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached The value at the ET
output can be queried as long as the PT timer is running and the input IN has signal state 1
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 2953
Veerandrapulagam500gmailcom
When inserting the Generate pulse operation an instance data block is created in which the
operation data is saved
Placement
The Generate pulse operation requires a preceding logic operation for
the edge evaluation It can placed within or at the end of the network
Pulse diagram
342 TON On delay timer
Symbol
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3053
Veerandrapulagam500gmailcom
Description
You can use the On delay operation to delay a rising edge by the time set at PT The On delay
operation is executed when the result of logic operation (RLO) changes from 0 to 1 at input
IN (rising edge) When the operation is started the time set for PT starts running When the PT
time expires output Q has signal state 1 Output Q remains set as long as the start input is still
1 If there is a signal change at the start input from 1 to 0 output Q is reset The timer
function is started again when a new positive edge is detected at the start input
The ET output supplies the time that has elapsed since the last rising edge at the IN input This
time starts at T0s and ends when the value set for the PT timer is reached The elapsed time can
be queried at output ET as long as input IN has signal state 1
When inserting the On delay operation an instance data block is created in which the operation
data is saved
Placement
The On delay operation requires a preceding logic operation for the edge evaluation It can place
within or at the end of the network
Pulse diagram
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3153
Veerandrapulagam500gmailcom
342 TOF Off delay
Symbol
Description
You can use the Off delay operation to delay a falling edge by the time set at
PT The Q output is set when the result of logic operation (RLO) at input IN changes from 0 to
1 When the signal state at the IN input switches back to 0 the time set at PT starts Output Q
remains set as long the time set at PT is running The Q output is reset when the PT time expires
If the signal state at the IN input changes to 1 before the time set at PT time expires the timer is
reset The signal state at the Q output will continue to be 1
It is possible to query how long the current timer function has been running at output ET This
time starts at T0s and ends when the value set for the PT timer is reached When the time set at
PT expires output ET remains set to the current value until input IN changes back to 1 If the IN
input switches to 1 before the PT time has expired the ET output is reset to the value T0
When inserting the OFF delay operation an instance data block is created in which the
operation data is saved
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3253
Veerandrapulagam500gmailcom
Placement
The Off delay operation requires a preceding logic operation for the edge evaluation It can
placed within or at the end of the network
Pulse diagram
Chapter 4
41 Relay
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3353
Veerandrapulagam500gmailcom
A relay is an electrically operated switch Many relay use an electromagnet to
operate a switching mechanism mechanically but other operating principle are also used
relays are used where it is necessary to control a circuit by a low-power signal (with
complete electrical isolation between control and controlled and circuit) or where several
circuits must be controlled by on signal
FIG 41 RELAY TERNMINALS
The relays 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
o Connect to COM and NO if you want the switched circuit to be on when the relay coil is
on
Connect to COM and NC if you want the switched circuit to be on when the relay coil is
off
42 Advantages of relays
Relays can switch AC and DC transistors can only switch DC
Relays can switch high voltages transistors cannot
Relays are a better choice for switching large currents (gt 5A)
Relays can switch many contacts at once
FIG 42 RELAY
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3453
Veerandrapulagam500gmailcom
43 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 chips can provide so a low power transistor
may be needed to switch the current for the relays coil
44 Specification of relay
Contact rating
Contact ratings 1A1C
Contact material AgCdO
Contact resistance 100MΩ(1A 6VDC)
Contact capacity 5A 250VAC 5A 30VDC
Specification
Insulation resistance 100M O 500VDC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3553
Veerandrapulagam500gmailcom
Dielectric strength BCC 1500V 1min
BOC 750v 1min
Operate time 10ms5ms
Terminal type PCB
Coil rating
Normal coil power 036W045W
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3653
Veerandrapulagam500gmailcom
Chapter 5
51 Solenoid valve
A solenoid valve is an electromechanical device used for controlling liquid or gas flow
The solenoid valve is controlled by electrical current which is run through a coil When the coil is
energized a magnetic field is created causing a plunger inside the coil to move Depending on the
design of the valve the plunger will either open or close the valve When electrical current is
removed from the coil the valve will return to its de-energized state
In direct-acting solenoid valves the plunger directly opens and closes an orifice inside the
valve In pilot-operated valves (also called the servo-type) the plunger opens and closes a pilot
orifice The inlet line pressure which is led through the pilot orifice opens and closes the valveseal
The most common solenoid valve has two ports an inlet port and an outlet port Advanced
design may have three or more ports Some designs utilize a manifold-type design
Solenoid valves make automation of fluid and gas control possible Modern solenoid
valves offer fast operation high reliability long service life and compact design
FIG 51 SOLENOID VALVE
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3753
Veerandrapulagam500gmailcom
52 Different parts of a solenoid valve
The illustration below depicts the basic components of a solenoid valve The valve shown in the
picture is a normally-closed direct-acting valve This type of solenoid valve has the most simple
and easy to understand principle of operation
1 Valve Body
2 Inlet port
3 Outlet port
4 Coilsolenoid
5
Coil windings
6 Lead wire
7 Plunger
8 Spring
9 orifice
53 How does a solenoid valve work
The media controlled by the solenoid valve enters the valve through the inlet (Part 2 in the
illustration above) The media must flow through the orifice (9) before continuing into the outlet
port (3) The orifice is closed and opened by the plunger (7)
The valve pictured above is a normally-closed solenoid valve Normally-closed valves use
a spring (8) which presses the plunger tip against the opening of the orifice The sealing material
at the tip of the plunger keeps the media from entering the orifice until the plunger is lifted up by
an electromagnetic field created by the coil
FIG 52 SOLENOID VALVE PARTS
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3853
Veerandrapulagam500gmailcom
54 SPECFICTIONS OF SOLENOID VALVE
Model no HT-SV-24
Supply power 24v
Pressure 0 ~07pa
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 3953
Veerandrapulagam500gmailcom
Chapter 6
61 Submersible pump
In either centrifugal or positive displacement pumps the materials used in the wet portions
of the pumps are critical to their safe use Whatever materials are used for these wetted parts they
should not contaminate the fluids being pumped nor should the fluids being pumped degrade the
materials used in the pump For the record stainless steel will eventually corrode in saltwater and
should be avoided when possible titanium is OK but expensive and brittle Most wetted parts of
the pumps we use are plastic or other non-metallic materials such as ceramics that are safe for
saltwater If you are pumping liquids other than saltwater (as in the case of trace element
replacement systems) make sure that the fluids you are pumping are safe with the materials used
in the pump (outfits such as Cole-Palmer and other chemical equipment houses normally provide
tables that indicate what materials are safe together)
As most centrifugal pumps operate via electric motors you also need some means of
isolating the motor from the wetted portions of the pump to prevent the pump fluids from
eventually damaging the motor while at the same time rotating the impeller in order for the pump
to work This connection between motor and wetted portions of the pumps used in aquariums is
most often accomplished by magnetically coupling the impeller
shaft to a rotating magnet attached to the motor The impeller
shaft has a second magnet attached to it (normally coated to
prevent contaminating the fluid being pumped) that is attracted
to the rotating motor magnet By relying on magnetic attraction
of the two magnet assemblies it is not necessary to have direct
physical contact between the impeller and motor thus the two
can be sealed from each other FIG 61 Submersible pumps
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4053
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4153
Veerandrapulagam500gmailcom
The second possible problem with submersible pumps is the greater danger of electrical shorting
to the tank Most submersible pumps are designed to prevent water from reaching any of the
electrical parts but wear andor damage to the pump may expose some of these electrical
connections causing dangerous shorts It is highly recommended that one use GFI (Ground Fault
Interrupters) outletsbreakers when using any electrical equipment around water such as pumps
but especially submersible pumps These GFI devices will detect when electrical shorts occur and
immediately shut off the offending pump or piece of equipment thus reducing the danger to both
you and your tank These two limitations of submersible pumps namely greater heat transfer and
danger of electrical shorting are likely why you do not often see larger capacity submersible
pumps (another potential disadvantage depending on your application requirements)
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4253
Veerandrapulagam500gmailcom
Chapter 7
71 Conveyor system
A conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt
conveyor) A belt conveyor system is one of many types of conveyor systems A belt conveyor
system consists of two or more pulleys (sometimes referred to as drums) with an endless loop of
carrying medium mdash the conveyor belt mdash that rotates about them One or both of the pulleys are
powered moving the belt and the material on the belt forward The powered pulley is called the
drive pulley while the unpowered pulley is called the idler pulley There are two main industrial
classes of belt conveyors Those in general material handling such as those moving boxes along
inside a factory and bulk material handling such as those used to transport large volumes of
resources and agricultural materials such as grain salt coal ore sand overburden and more
Today there are different types of conveyor belts that have been created for conveying different
kinds of material available in PVC and rubber materials
FIG 71 VIEW OF CONVEYOR BELT
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4353
Veerandrapulagam500gmailcom
FIG72 CONVEYOUR SYSTEM
The belt consists of one or more layers of material Many belts in general material handling have
two layers An under layer of material to provide linear strength and shape called a carcass and an
over layer called the cover The carcass is often a woven fabric having a warp amp weft The most
common carcass materials are polyester nylon and cotton The cover is often various rubber or
plastic compounds specified by use of the belt Covers can be made from more exotic materials
for unusual applications such as silicone for heat or gum rubber when traction is essential
72 Motor used for conveyor system
Gear motor
FIG 73 GEAR MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4453
Veerandrapulagam500gmailcom
Specifications motor
Supply voltage 12v
High torque
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4553
Veerandrapulagam500gmailcom
CHAPTER 8
81 Photoelectric Sensor
A photoelectric sensor is another type of position sensing device Photoelectric sensors use amodulated light beam that is either broken or reflected by the target The control consists of anemitter (light source) a receiver to detect the emitted light and associated electronics that
Evaluate and amplify the detected signal causing the photo electricrsquos output switch to change
state
82 Advantages
Senses all Kinds of Material s
Long Life
Longest Sensing Range
Very Fast Response Time
83 Disadvantages
Lens Subject to Contamination
Sensing Range Affected by Colour and Reflectivity of Target
84 Applications
Packaging Material Handling
Parts Detection
FIG 81 Photo of sensor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4653
Veerandrapulagam500gmailcom
85 Wiring of sensor
This sensor is PNP type it has three wires first wire vcc is connected to the DC 24v and
Enable wire is output of the sensor it is connected to the input of PLC and the third wire is
ground
FIG 82 Wiring connection of Sensor to PLC
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4753
Veerandrapulagam500gmailcom
Chapter 9
91 Wiring of the project
FIG 91 WIRING OF COMPONENTS WITH PLC KIT
Input addressing
I00- Main switch
I01- Starting switch
I02- Photo electric sensor
NOTE - Reaming are in use
Output addressing
Q00- water motor
Q01-flavour motor
Q02- mixing motor
Q03- solenoid valve
Q04-conveyor motor
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4853
Veerandrapulagam500gmailcom
Q05 ndash is not used
92CONNECTIONS OF SINGLE PHASE AC MOTOR WITH PLC
The output power of the plc is just 24V DC but we have to operate AC motor which requires
230V AC in order to supply it we are using the relays It operates at 24V DC the common of the
relay is connected to phase of supply and motor is connected to NO in series with neutral
When relay is energized then only motor runs
FIG 92 RELAY CONNECTIONS WITH AC MOTOR
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 4953
Veerandrapulagam500gmailcom
93 Ladder diagram for automatic mixing ampfilling bottle
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5053
Veerandrapulagam500gmailcom
The program was created and damped in the plc module as per our requirement In
our program first main switch is ON and then starting switch is ON to start the
submersible motors The program was designed to run water motor for 10seconds
and the flavor motor 7 seconds When the flavor motor stops the mixing motor
which is in the mixing and filling container mixes the water and flavor for 10seconds when the mixing motor stops and when the bottle is placed on the conveyor
and when the sensor senses the bottle the solenoid valve will be opened the bottle
below it will be filled for 15 seconds then filled bottle will move forward on
conveyor system for 3seconds
94 SPECIFICATIONS OF SIEMENS S7-1200 MODULE
No Of inputs - 08
External inputs - 08
No of outputs - 06
Input voltage of module 230VOLTS
CPU - 1212C
Software required Totally integrated automation on portal v-105
FIG 93 PLC module
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5153
Veerandrapulagam500gmailcom
FIG 94 Indication of each part of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5253
Veerandrapulagam500gmailcom
Chapter 10
101 Conclusion
The project lsquoAutomatic mixing and filling bottle using plcrdquo has been successfullydesigned and executed
Presence of every equipment has been reasoned out and placed carefully thus
contribution to the best working of the project
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual
7232019 plcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf
httpslidepdfcomreaderfullplcprojectsofbottelfillingveerendra-150603035921-lva1-app6892pdf 5353
Chapter 11
111BIBLIOGRAPHY
1111 Web Sites
wwwelprocuscom
wwwplc simulatornet
wwwautomationcom
wwwplcdocnet
wwwplcgoodscom
wwwmikroecom
wwwsiemenscom
1112 Books
Programmable logic controllers by JOHN WWEBB
Siemens s7 1200 manual