108021192-Plc-Scada-Lab-Manual-Part-1.pdf

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TRINITY COLLEGE OF ENGINEERING AND RESEARCH, PUNE. Electrical Engineering Department PLC & SCADA Applications �� /�� .

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GUIDELINES FOR LABORATORY NOTEBOOK

The laboratory notebook is a record of all work pertaining to the experiment. This record should be sufficiently complete so that you or anyone else of similar technical background can duplicate the experiment and data by simply following your laboratory notebook. Record everything directly into the notebook during the experiment. Do not use scratch paper for recording data. Do not trust your memory to fill in the details at a later time. Organization in your notebook is important. Descriptive headings should be used to separate and identify the various parts of the experiment. Record data in chronological order. A neat, organized and complete record of an experiment is just as important as the experimental work.

1. Heading:

The experiment identification (number) should be at the top of each page. Your name and date should be at the top of the first page of each day's experimental work. 2.Object:

A brief but complete statement of what you intend to find out or verify in the experiment should be at the beginning of each experiment 3.Diagram:

A circuit diagram should be drawn and labeled so that the actual experiment circuitry could be easily duplicated at any time in the future. Be especially careful to record all circuit changes made during the experiment. 4.Equipment List:

List those items of equipment which have a direct effect on the accuracy of the data. It may be necessary later to locate specific items of equipment for rechecks if discrepancies develop in the results. 5.Procedure:

In general, lengthy explanations of procedures are unnecessary. Be brief. Short commentaries alongside the corresponding data may be used. Keep in mind the fact that the experiment must be reproducible from the information given in your notebook. 6.Data: Think carefully about what data is required and prepare suitable data tables. Record instrument readings directly. Do not use calculated results in place of direct data; however, calculated results may be recorded in the same table with the direct data. Data tables should be clearly identified and each data column labeled and headed by the proper units of measure. 7.Calculations:

Not always necessary but equations and sample calculations are often given to illustrate the treatment of the experimental data in obtaining the results. �

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8.Graphs:

Graphs are used to present large amounts of data in a concise visual form. Data to be presented in graphical form should be plotted in the laboratory so that any questionable data points can be checked while the experiment is still set up. The grid lines in the notebook can be used for most graphs. If special graph paper is required, affix the graph permanently into the notebook. Give all graphs a short descriptive title. Label and scale the axes. Use units of measure. Label each curve if more than one on a graph. 9.Results:

The results should be presented in a form which makes the interpretation easy. Large amounts of numerical results are generally presented in graphical form. Tables are generally used for small amounts of results. Theoretical and experimental results should be on the same graph or arrange in the same table in a way for easy correlation of these results. 10.Conclusion:

This is your interpretation of the results of the experiment as an engineer. Be brief and specific. Give reasons for important discrepancies. TROUBLE SHOOTING HINTS

1. Be Sure that the power is turned ON 2. Be sure the ground connections are common 3. Be sure the circuit you build is identical to your circuit diagram (Do a node by node check) 4. Be sure that the supply voltages are correct 5. Be sure that the equipment is set up correctly and you are measuring the correct parameters 6.

If steps 1 through 5 are correct then you probably have used a component with the wrong value or one that doesn’t work. It is also possible that the equipment does not work (although this is not probable0 or the protoboard you are using may have some unwanted paths between nodes. To find your problem you must trace through the voltages in your circuit node by node and compare the signal you expect to have. Then if they are different use your engineering judgment to decide what is causing the different or ask your lab assistant

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Experiment No. 1(A)

�� Interfacing of lamp and button with PLC for ON/OFF operation. ��

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EXPERIMENT NO. 1 (A) INTERFACING OF LAMP AND BUTTON WITH PLC FOR ON & OFF OPERATION TITLE : Interfacing of lamp and button with PLC for ON & OFF operation. AIM : To study interfacing of lamp and button with PLC for ON/OFF operation. APPARATUS: Sr./ No.

Equipment

Specification

Quantity

1.

Programmable Logic Controller

Allen Bradley- MicroLogix 1100, Series -B

1 no

PLC Trainer Kit

In the trainer kit : 1. A two way ON/OFF selector switch 2. A Lamp

1 no

2.

THEORY: Introduction To PLC:

Definition of PLC: PLC is a microprocessor based digital controller which performs and controls many functions of many types and level of complexity. Advantages of PLC: 1. 2.

Lower cost: It performs more functions in less expensive packages. Flexibility: In the past each electronically controlled power machine is required to control each device. Now it is possible to control many device by one PLC. 3. Speed of operation: Relay takes more time to operation .speed of operation of PLC is very fast i.e. scan time is very less. 4. Implementing changes and corrections: In PLC based system, program can be changed easily within less time. Disadvantages of PLC: 1. Environmental condition: Due to high temperature of environment at operating station damages PLC. 2. Less expandability. �

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3. Every technicians or labour must know about the PLC operation. MACHINE CONTROL COMPONENTS AND THEIR SYMBOLS IN LADDER DIAGRAM:

1. SWITCHES : There are two fundamental uses for switches. First, switches are used for operator input to send instructions to the control circuit. Second, switches may be installed on the moving parts of a machine to provide automatic feedback to the control system. 2. PUSH BUTTON : The most common switch is the push button. It is widely used in automotive and electronic equipment applications. There are two types of the push button-the momentary and maintained. The momentary push button switch is activated when the button is pressed and deactivated when the button is released. The deactivation is done using an internal spring. The maintained push button switch activates when pressed, but remains activated when it is released. To deactivate it, it must be pressed second time. For this reason, this type of switch is sometimes called a push-push switch. The ON/OFF switches on desktop computers and laboratory oscilloscopes are maintained push buttons. The contacts on switches can be of two types. These are normally open (N/O) and normally closed (N/C).whenever a switch is in its deactivated position, the N/O contacts will be open (non-conducting) and the N/C contacts will be closed (conducting).There are no internal electrical connection between different contact pairs on the same switch. 3. SELECTOR SWITCHES : A selector switch is also known as a rotary switch. An automobile ignition switch and an oscilloscopes vertical gain and horizontal time base switches are examples of selector switches. The top contacts are closed when the switch selector is turned to the left position and open when the switch selector is turned to the right. The bottom set of contacts works exactly opposite. There is no electrical connection between top and bottom pairs of contacts. In most cases, we label the selector positions same as the labeling on the panel where the switch is located. 4. LIMIT SWITCHES: Normally, limit switches are not operator accessible. They are activated by moving parts on the machine. They are usually mechanical switches but can also be light activated (such as the automatic door openers used by stores and supermarkets) or magnetically operated (such as the magnetic by stores and home security system that sense window has been opened). 5. INDICATOR LAMPS: All the control panels include indicator lamps. They tell the operator when power is applied to the machine and indicate the present operating status of the machine. The light bulbs used in indicators are generally incandescent (white), they are usually covered with colored lenses. The colors are 10

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usually red, green, or amber, but other colors are also available. Red lamps are reserved for safety critical indicators (power is on, the machine is running, an access panel is open, or that a fault has occurred).Green usually indicates safe condition (power to the motor is off, brakes are on, etc) . Amber indicates conditions that are important but not dangerous (fluid. getting low, machine paused. Machine warming up, etc).other colors indicate information not critical to the safe operation of the machine (time for preventive maintenance, etc).sometimes it is important to attract the operator's attention with a lamp. In these cases, we usually flash the lamp continuously on and off.

Statement: Draw a Ladder Diagram to operate a lamp with one push button for ON & OFF operation. Explanation: When input i.e. button (I:0/1) is ON or it is pressed, O/P Lamp (O:0/0) should become ON. When input i.e. button (I:0/1) is OFF or it is unpressed, O/P Lamps (O:0/0) should become OFF. .

Ladder Diagram:

CONCLUSION:

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Experiment No. 1(B)

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EXPERIMENT NO. 1 (B) PERFORM DELAYED OPERATION OF LAMP BY USING PUSH BUTTON. TITLE :

Perform Delayed Operation Of Lamp By Using Push Button. AIM :

To Perform Delayed Operation Of Lamp By Using Push Button.

APPARATUS: Sr./ No.

Equipment

1.


2.

PLC Trainer Kit

Specification

Quantity


1 no.

NO type ON/OFF Push Buttons

2 nos.

LED Lamp

1 no.

THEORY : On Delay Timer:

It is used to program a time delay before instruction becomes true. ON delay timer is used when an action is to begin the specified time after input becomes true. Eg. A certain steps in manufacturing process are to begin 30 second after input is received from limit switch. 30 second is nothing but preset value of ON delay timer. ADDRESSING MODES OF TIMER: : T4: 0.ACC - The sub element is in accumulator T4: 0.PRE - Sub element of timer 0 13 = DN (done) 14 = TT (timer timing bit) 15 = EN (enable bit) Statement: Draw a ladder diagram to operate lamp using push button after 5 sec delay.

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Explanation: When start input i.e. Push Button (I:0/1) is ON then Timer (T4:1) will become on which generates delay as per the PRESET value (10sec) .When the PRESET value of Timer i.e. the delay and accumulator value of the timer will become equal then Done bit (DN) of timer will set and Output i.e. Lamp (O:0/0) will on after the delay.

When the RESET Input (I:0/2) Push Button is pressed then the Timer (T4:1) will become Reset as well as the Output (O:0/0) should become OFF and when RESET I:0/2 is un-pressed then Timer (T4:1) will restart. Ladder Diagram:

CONCLUSION:

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Experiment No. 2(A)

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EXPERIMENT NO. 2(A)

�� AIM: To study multiple push button operation with delayed lamp for ON/OFF operation.

APPARATUS: Sr./ No.

Equipment

1.


2.

PLC Trainer Kit

Specification

Quantity


1 no.


3 nos.

LED Lamp

3 nos.

THEORY:

There are mainly three types of timers use in PLC programming as follows. i) ON Delay Timer. ii) OFF Delay Timer. iii) Retentive Timer. 1.ON Delay Timer :

It is used to program a time delay before instruction becomes true. ON delay timer is used when an action is to begin a specified time after i /p becomes true. For e.g.- Certain stages in manufacturing processes is expected to begin 30 sec after i/p is received from limit switch, here 30 sec is nothing but the present value of ON delay timer. 2.OFF Delay Timer: It is used to program a time to begin after the i/p goes false. For e.g. – external cooling fan or a motor which has to run all the time & it is expected to turn off the fan or motor after 5 min when i/p is sensed by them. The 5 min is nothing but off delay time. 3.Retentive timer: It is used to reset accumulated value through power loss, process change state or in rung from true to false. For e.g. RTO is used to true running time OR motor for maintenance. The time is used to track accumulated value time the motor has run. For e.g. motor need maintenance 8hrs (28800 sec). Each time the motor is turned off, the timer needs to remember motor's total elapse time, next time when the motor is turned ON the timer will increased accumulated running time where it left off. 1�

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When total accumulated running tine has been reached, maintenance reminder time will be off, same procedure repeats. RESET instruction is used to reset accumulated value of a timer. It is used only in retentive timer & not in 'ON' or 'OFF' delay timer • Timer element instruction: EN

TT

DD

Reserved bit

Word 0

Preset value

Word 1

Accumulated value

Word 2

• Addressing mode of timer:

1. T4: 0 - timer 0 in file no 4. 2. T4: 0 ACC -sub-element is accumulator. 3. T4: 0 PRE - sub-element is preset value. The ON-OFF operation of delayed lamp can be achieved with PLC programming. In this programming the ON delay timer is used to give an O/P. Also 'OR' logic for multiple inputs is used as shown in ladder diagram. To achieve the multiple push-button operation 'OR' logic configuration is must which is similar to parallel combination of electrical circuit. The function of OR logic is that whenever a logic '1' to any i/p either 1 or 2 as shown in fig, there is an o/p. when logic '0' to both inputs, there will not be no output. EXPLANATION :

When PB1 I:0/1 or I:0/2 or I:0/3 is pressed Timer T4:0 will become on which generate delay as per the set. When preset value of the timer i.e. set value of delay and accumulator value of the timer will become equal to ON (done) bit of the timer will set and O/P i.e. Lamp (O:0.6)(GREEN) will on after the delay. When I:0/1 PB1 and I:0/2 PB2 0r I:0/1 PB1 and I:0/3 PB3 or I:0/2 PB2 or I:0/3 PB3 is ON Timer T4:1will become ON which generate delay as per the set. When preset value of the timer i.e. set value of delay and accumulator value of the timer will become equal to DN (done) bit of the timer will set and O/P i.e. Lamp YELLOW (O:0/4) will ON after the delay. When input PB1 (I:0/1) PB2(I:0/2)

& PB3

(I:0/3) is ON

Timer T4:2 will become on which generate delay as per the set. When preset value of the timer i.e. set value of delay and accumulator value of the timer will become equal to DN (done) bit of the timer will set and O/P i.e. Lamp RED (O:0/5) will on after the delay. Latching is provided so that at a time only one lamp is ON eg.O:0/5 & O:0/4 is normally close in rung 1 & 2. 1�

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LADDER DIAGRAM:

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CONCLUSION :

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Experiment No. 2(B)

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EXPERIMENT NO. 2(B) COMBINATION OF COUNTER & TIMER FOR LAMP ON/OFF OPERATION AIM :

To study multiple push button operation with delayed lamp for ON/OFF operation APPARATUS: Sr./ No.

Equipment

1.


2.

PLC Trainer Kit

Specification

Quantity


1 no.


3 nos.

LED Lamp

2 nos.

THEORY:

There are mainly three types of timers use in PLC programming as follows. i. ON Delay Timer. ii. ON Delay Timer. Retentive Timer. iii. 1. ON Delay Timer: It is used to program a time delay before instruction becomes true. ON delay timer is used when an action is to begin a specified time after i/p becomes true. For e.g.- Certain stages in manufacturing processes is expected to begin 30 sec after i/p is received from limit switch, here 30 sec is nothing but the present value of ON delay timer. 2. OFF Delay Timer:

It is used to program a time to begin after the i/p goes false. For e.g. – external cooling fan or a motor which has to run all the time & it is expected to turn off the fan or motor after 5 min when i/p is sensed by them. The 5 min is nothing but off delay time. 3. Retentive timer: It is used to reset accumulated value through power loss, process change state or in rung from true to false. For e.g. RTO is used to true running time OR motor for maintenance. The time is used to track accumulated value time the motor has run. For e.g. motor need maintenance 8hrs (28800 sec). Each time the motor is turned off, the timer needs to remember motor's total elapse time, next time when the motor is turned ON the timer will increased accumulated running time where it left off. When total accumulated running time has been reached, maintenance reminder time will be off, same procedure repeats. RESET instruction is used to reset accumulated value of a timer. It is used only in retentive timer & not in 'ON' or 'OFF' delay timer. 21

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• Timer element instruction: CU

CD

DN

Reserved bits

Word 0

Preset value

Word 1

Accumulated value

Word 2

COUNTERS : Every PLC has counter instructions. If the counter count from 0 to 100 desired value & so on it is called as UP counter & if the counter counts from 100 to 0 it is called as DOWN counter. Counter instructions are as follows: •

Count Up:- It is used to count from 0 to desired value. Ex. Counting number of parts produced or rejects from the batch.

•

Count Down:- It is used to count from desired value to 0 . Ex.- An operator interface display shows operator the number of parts remaining to be matched for a lot of 100 parts ordered.

•

High Speed Counter:- Used to count pulses that are too fast separated from normal input points & modules Ex.- To count signals from incremental encoder.

•

Counter Reset:- To set a counter. Ex.- Used to reset a counter to 0 so another counting sequence can begin.

• Counter element instruction: ��

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Addressing mode of Timer

Addressing mode of Counter

1. T4: 0  Timer 0 in file no 4.

1. C5:0  Counter 0 in file No. 5

2. T4: 0.1  T4: 0.PRE - Sub-element is PRESET Value.

2. C5: 0.1  C5: 0.PRE - Sub-element is PRESET Value.

3. T4: 0.2  T4: 0.ACC - Sub-element is ACCUMULATOR Value.

3. C5: 0.2  C5: 0.ACC - Sub-element is ACCUMULATOR Value. 22

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STATEMENT:

Draw a ladder diagram to start the timer for 2 sec and after every 2 sec a lamp will ON and a counter will count the Timer discrete output upto 5 count & switch ON another lamp. EXPLANATION:

The ladder diagram where the timer (T4:0) will start with a NO Push Button (I:0/2) and Reset by another NO Push Button (I:0/1). The Preset Value of T4:0 is 2 sec. and after every 2 sec. Timer will be Reset manually by I:0/1. The Done Bit (T4:0/DN) of Timer will ON for each 2 sec. A Lamp i.e. Lamp-1 will ON by this Done Bit (T4:0/DN) and a Counter (C5:0) will count the number of Done Bits. The Preset Value of counter is 5. So after 5 count a Done Bit (C5:0/DN) of counter will be generated. Another Lamp i.e. Lamp-2 (O:0/1) will be ON by the Counter Done Bit (C5:0/DN). Counter will be Reset by pressing a Push Button (I:0/3). LADDER DIAGRAM:

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CONCLUSION:

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Experiment No. 3

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EXPERIMENT NO. 3 TO STUDY SET AND RESET OPERATION OF LAMP. AIM :

To Set and Reset lamp by using one push button for ON and one push button for OFF . APPARATUS: Sr./ No.

Equipment

1.


2.

PLC Trainer Kit

Specification

Quantity


1 no.


4 nos.

LED Lamp

2 nos.

THEORY:

An operation latching instruction is an operation instruction used to maintain or latch an operation ON even if status of input logic that caused the output to energise changes. When any logical path on the ladder rung containing the latching instruction has continuity the output referred to latching instruction turns on and remains on even if rung's logical continuity or PLC system power is lost. Since the latch instruction retains its state through a system power loss, the latching instruction is called a retentive instruction. Remember, the processor's battery must be in good condition for the latching status to be remembered in case of power failure. The latched instruction will remain in a latched ON condition until unlatch instruction with same reference address is energised. Latch and Unlatch instruction are always used in pairs, each instruction is located on separate rung. Analysis of Ladder Logic and rung operation

Figure shows ladder diagram rungs. First rung shows latch instruction while other contains unlatch instruction. When input I:0/1on first rung is energised, the output latch instruction, address O:0/0is energized. The output latch instruction will remain latched on and will be unaffected no matter how input I:0/1 changes. We must use output unlatch instruction. The unlatch instruction will turn off output O:0/0 these 2�

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particular example rungs have only one input each. Any valid input logic may be used as input to latch and unlatch instruction. The following rules pertain to most latch and unlatch instruction. •

Latch and unlatch instruction are used in pairs.

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Latch and unlatch pairs of instruction must have the same reference address.

•

The latch and unlatch ladder rungs do not need to be grouped together in ladder program.

•

Latching and unlatching instruction are retentive, provided your plc system battery is installed and in good condition.

EXPLANATION:

When input Push Button START_1 (I:0/1) is pressed, Output LAMP_1 (O:0/0) should become ON and Latched, means LAMP_1 will remains ON whereas START_1 become un-pressed. AND when Push Button STOP_1 (I:0/6) will be pressed and LAMP_1 should become OFF. Also when input Push Button START_2 (I:0/2) is pressed, Output LAMP_2 (O:0/1) should become ON and Latched, means LAMP_2 will remains ON whereas START_2 become un-pressed. And when Push Button STOP_2 (I:0/7) will be pressed then LAMP_2 should become Unlatched. LADDER DIAGRAM:

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CONCLUSION:

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Experiment No.4

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EXPERIMENT NO.4

DOL STARTER & STAR DELTA STARTER OPERATION BY USING PLC. AIM :

To study DOL Starter & Star Delta Starter operation by using PLC. APPARATUS :

i) PLC ( Micrologix 1100B series). ii) 3 Phase Induction Motor. THEORY :

A direct on line (DOL) or across the line starter applies the full line voltage to the motor terminals. This is the simplest type of motor starter. A DOL motor starter also contain protection devices, and in some cases, condition monitoring. Smaller sizes of direct on-line starters are manually operated; larger size's use an electromechanical contactor (relay) to switch the motor circuit. Solid-state direct on line starters also exist. A direct on line starter can be used if the high inrush current of the motor does not cause excessive voltage drop in the supply circuit. The maximum size of a motor allowed on a direct on line starter may be limited by the supply utility for this reason. For example, a utility may require rural customers to use reduced-voltage starters for motors larger than 10 kW. DOL starting is sometimes used to start small water pumps, compressors, fans and conveyor belts. In the case of an asynchronous motor, such as the 3-phase squirrel-cage motor, the motor will draw a high starting current until it has run up to full speed. This starting current is typically 6-7 times greater than the full load current. To reduce the inrush current, larger motors will have reducedvoltage starters or variable. speed drives in order to minimize voltage dips to the power supply. A reversing starter can connect the motor for rotation in either direction. Such a starter contains two DOL circuits-one for clockwise operation and the other for counter-clockwise operation, with mechanical and electrical interlocks to prevent simultaneous closure. For three phase motors, this is achieved by transposing any two phases. Single phase AC motors and direct-current motors require additional devices for reversing rotation. Star Delta Starter: In the star-delta starting method, the wiring connection from the power supply source to the motor is connected from star (wye) to the delta connection. The motor is started in star configuration and then it is transferred to the delta configuration, allowing the full voltage to be applied to the motor during its running so as to get the full torque output. This can be further �0

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explained that in a Star-Delta starter, the motor is started as star connection and when the motor starts running the connection is changed to delta. With star connection, the motor takes √3 times less voltage. However, as the torque is proportional to square of the voltage, the starting torque also reduces. DIAGRAM:

DOL Starter

STAR - DELTA Starter

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1. DOL Starter: EXPLANATION: DOL Starter: Whenever START Push Button (I:0/1) is pressed then an internal memory bit (B3:0/0) is Latched and Motor Output (O:0/1) becomes ON with this bit, i.e. Motor gets connected to Mains.

The Motor (O:0/1) remains ON even after START Push Button (I:0/1) is released. And Motor (O:0/1) will be stopped if STOP Push Button (I:0/6) is pressed. LADDER DIAGRAM:

2.STAR – DELTA Starter: EXPLANATION: STAR-DELTA Starter: Whenever START Push Button (I:0/1) is pressed then an internal memory bit (B3:0/0) is Latched and with the bit the MOTOR Contact (O:0/0) and the STAR Contact (O:0/1) are connected and Latched. And also with this bit a Timer (T4:0) will ON with its Preset Value 5sec.

When The Preset Value and Accumulator Value of the Timer (T4:0) become same then by the Timer’s Done Bit (T4:0/DN) the internal memory bit (B3:0/0) become unlatched and so that the STAR contact (O:0/1) become disconnected. At the same Timer’s Done Bit (T4:0/DN) also connect and latched the DELTA contact (O:0/2) and Timer (T4:0) become Reset. �2

108021192-Plc-Scada-Lab-Manual-Part-1.pdf

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