Process Automation Practical Connection Diagram

DIPLOMA IN MECHANICAL ENGINEERING Process Automation Practical 1. Direct operation of a motor using latching circuit.

CONNECTION DETAILS

Output motor connection: Input connection:

PLC

MOTOR

I1

---------------- ON !"i#c$ (%&-1)

Q5

----------------- coil – 1(Q5)

I2

---------------- O'' !"i#c$ (%&-2)

Q6

----------------- coil – 2(Q6)

Q7

----------------- coil – 3(Q7)

Q8

----------------- coil – 4(Q8)

PROCEDRE 1. Connect the Computer and PLC using usi ng RS232 serial cable 2. Open the S2client soft!are and open the "N "New ladder document #. #. $o! %ie! the program &indo! li'e LAD ()RS*O$ 3.2 then 'il* MEN +++, Open and bro!se the respecti%e folder in -our sa%ed location and double clic' or open the reuired program /e0pgm.gen and %ie! the ladder program page. 3. hen clic' the O+*,#io. the Li. co +o,# in the menu list 4then O+*,#io. M*./ ---0 it sho!s the Li. clic' the lin' com c om port4 one !indo! open it sho!s selecting c om -ou select the "default com port# in -our computer4 and mode is single mode selection onl-. then ensure after selecting the com port and mode selection correctl- clic' the lin' button in -our !indo!. if -our process is correct means it sho!s "connect successfull-#4 if it is !rong means "communication error#./chec' the communication serial cable if it connected or not O+*,#io. M*./ ---0select ---0select the &,i#* it &,i#* it sho!s the pop+up message li'e 5. hen clic' the O+*,#io. this "Old data will be lost, continue6# E% o, NO button. 7ou clic' "7es# button allo! to !rite the current data to the PLC. 8. hen clic' the O+*,#io. O+*,#io. M*./ ---0select ---0select the RN it RN it sho!s the pop+up message Li'e fro m module6# E% o, NO button. 7ou clic' "$O# it this "Do you want to read program from means a%oid to read the current program again. hen the PLC Read- to the R9$ mode. :. $o! the PLC is act as the !or'ing mode. Connections are connecting as per the connection diagram.

NOTE: - workin principles



*f -ou press the "S&+1#/*;1 push button then th e motor !ill be start to rotate continuousl-.



*f -ou press the "S&+2#/*;2 push button then th e motor !ill be stop the rotation.

2. Operation of a motor using
CONNECTION DETAILS Output motor connection: Input connection:

PLC

MOTOR

I1

----------------

!"i#c$ (%&-1)

Q5

----------------- coil – 1(Q5)

I2

----------------

!"i#c$ (%&-2)

Q6

----------------- coil – 2(Q6)

Q7

----------------- coil – 3(Q7)

Q8

----------------- coil – 4(Q8)

PROCEDRE 1. Connect the Computer and PLC using RS232 serial cable 2. Open the S2client soft!are and open the "New ladder document #. $o! %ie! the program &indo! li'e LAD ()RS*O$ 3.2 then 'il* MEN +++, Open and bro!se the respecti%e folder in -our sa%ed location and double clic' or open the reuired program /e0pgm.gen and %ie! the ladder program page. 3. hen clic' the O+*,#io. M*./ ---0 it sho!s the Li. co +o,# in the menu list4 then clic' the lin' com port4 one !indo! open it sho!s selecting c om -ou select the "default com port# in -our computer4 and mode is single mode selection onl-. then ensure after selecting the com port and mode selection correctl- clic' the lin' button in -our !indo!. if -our process is correct means it sho!s "connect successfull-#4 if it is !rong means "communication error#./chec' the communication serial cable if it connected or not 5. hen clic' the O+*,#io. M*./ ---0select the &,i#* it sho!s the pop+up message li'e this "Old data will be lost, continue6# E% o, NO button. 7ou clic' "7es# button allo! to !rite the current data to the PLC. 8. hen clic' the O+*,#io. M*./ ---0select the RN it sho!s the pop+up message Li'e this "Do you want to read program from module6# E% o, NO button. 7ou clic' "$O# it means a%oid to read the current program again. hen the PLC Read- to the R9$ mode. :. $o! the PLC is act as the !or'ing mode. Connections are connecting as per the connection diagram.

NOTE: - workin principles 

*n this program !or' the "A$D# ate operation. "A$D gate# logic truth table are follo!ing tabulation.



*f -ou press the both "S&+1# and "S&+2# push buttons then the motor !ill be start to rotate continuousl-. Other!ise the motor !ill be stop.

RH ALE I1

I2

O

0

0

0

0

1

0

1

0

0

1

1

1

3. Operation of a motor using
CONNECTION DETAILS Output motor connection: PLC

Input connection:

MOTOR

Q5

----------------- coil – 1(Q5)

I1

---------------- !"i#c$ (%&-1)

Q6

----------------- coil – 2(Q6)

I2

---------------- !"i#c$ (%&-2)

Q7

----------------- coil – 3(Q7)

Q8

----------------- coil – 4(Q8)

PROCEDRE 1. Connect the Computer and PLC using RS232 serial cable 2. Open the S2client soft!are and open the "New ladder document #. $o! %ie! the program &indo! li'e LAD ()RS*O$ 3.2 then 'il* MEN +++, Open and bro!se the respecti%e folder in -our sa%ed location and double clic' or open the reuired program /e0pgm.gen and %ie! the ladder program page. 3. hen clic' the O+*,#io. M*./ ---0 it sho!s the Li. co +o,# in the menu list4 then clic' the lin' com port4 one !indo! open it sho!s selecting c om -ou select the "default com port# in -our computer4 and mode is single mode selection onl-. then ensure after selecting the com port and mode selection correctl- clic' the lin' button in -our !indo!. if -our process is correct means it sho!s "connect successfull-#4 if it is !rong means "communication error#./chec' the communication serial cable if it connected or not 5. hen clic' the O+*,#io. M*./ ---0select the &,i#* it sho!s the pop+up message li'e this "Old data will be lost, continue6# E% o, NO button. 7ou clic' "7es# button allo! to !rite the current data to the PLC. 8. hen clic' the O+*,#io. M*./ ---0select the RN it sho!s the pop+up message Li'e this "Do you want to read program from module6# E% o, NO button. 7ou clic' "$O# it means a%oid to read the current program again. hen the PLC Read- to the R9$ mode. :. $o! the PLC is act as the !or'ing mode. Connections are connecting as per the connection diagram.

NOTE: - workin principles OR GAE - RH ALE I1

I2

O

0

0

0

0

1

1

1

0

1

1

1

1

 *n this program !or' the "OR# ate operation. "OR# gate logic truth table is

attaching the abo%e tabulation.  *f -ou press the "S&+1# or "S&+2# push buttons then the motor !ill be start. 

Similarl- if -ou press the both "S&+1# and "S&+2# push buttons also the motor !ill be start to rotate continuousl-.

5. On+Dela- control of a motor.


Input connection: I1

---------------- ON !"i#c$ (%&-1)

I2

---------------- O'' !"i#c$ (%&-2)

MOTOR

Q5

----------------- coil – 1(Q5)

Q6

----------------- coil – 2(Q6)

Q7

----------------- coil – 3(Q7)

Q8

----------------- coil – 4(Q8)

PROCEDRE 1. Connect the Computer and PLC using RS232 serial cable 2. Open the S2client soft!are and open the "New ladder document #. $o! %ie! the program &indo! li'e LAD ()RS*O$ 3.2 then 'il* MEN +++, Open and bro!se the respecti%e folder in -our sa%ed location and double clic' or open the reuired program /e0pgm.gen and %ie! the ladder program page. 3. hen clic' the O+*,#io. M*./ ---0 it sho!s the Li. co +o,# in the menu list 4then clic' the lin' com port4 one !indo! open it sho!s selecting c om -ou select the "default com port# in -our computer4 and mode is single mode selection onl-. then ensure after selecting the com port and mode selection correctl- clic' the lin' button in -our !indo!. if -our process is correct means it sho!s "connect successfull-#4 if it is !rong means "communication error#./chec' the communication serial cable if it connected or not 5. hen clic' the O+*,#io. M*./ ---0select the &,i#* it sho!s the pop+up message li'e this "Old data will be lost, continue6# E% o, NO button. 7ou clic' "7es# button allo! to !rite the current data to the PLC. 8. hen clic' the O+*,#io. M*./ ---0select the RN it sho!s the pop+up message Li'e this "Do you want to read program from module6# E% o, NO button. 7ou clic' "$O# it means a%oid to read the current program again. hen the PLC Read- to the R9$ mode. :. $o! the PLC is act as the !or'ing mode. Connections are connecting as per the connection diagram.

NOTE: - workin principles  



*n this program !or' the "O$# time dela- of the motor. *f -ou press the s!itch"S&+1 O$# condition the dela- time is running at a particular user defined time /the user can set the dela- time or can %arthe dela- time accordingl- using the program. Once the dela- time is o%er4 then the motor gets O$ continuousl-. *f -ou press the s!itch "S&+2# then the motor !ill be stop the rotation.

8. Off >Dela- control of a motor.



---------------- ON !"i#c$ (%&-1)

I2

---------------- O'' !"i#c$ (%&-2)

MOTOR

Q5

----------------- coil – 1(Q5)

Q6

----------------- coil – 2(Q6)

Q7

----------------- coil – 3(Q7)

Q8

----------------- coil – 4(Q8)



*n this program !or' the " O''# time dela- of the motor.



*f -ou press the s!itch "S&+1# then the motor !ill be start to rotate.



*f -ou press the s!itch"S&+2 O$# condition the off dela- time is running at a particular user defined time /the user can set the dela- time or can %ar- the dela- time accordingl- using the program. Once the dela- time is o%er4 then the motor gets O'' continuousl-.

:. Automatic operation of a Double acting c-linder+single c-cle.

CONNECTION DETAILS Output motor connection: Input connection: I1

---------------- ON !"i#c$ (%&-1)

I5

---------------- R* !"i#c$

PLC

D%ALE

Q1

----------------- coil – 1(%1)

Q2

----------------- coil – 2(%2)

PROCEDRE 1. Connect the Computer and PLC using RS232 serial cable 2. Open the S2client soft!are and open the "New ladder document #. $o! %ie! the program &indo! li'e LAD ()RS*O$ 3.2 then 'il* MEN +++, Open and bro!se the respecti%e folder in -our sa%ed location and double clic' or open the reuired program /e0pgm.gen and %ie! the ladder program page. 3. hen clic' the O+*,#io. M*./ ---0 it sho!s the Li. co +o,# in the menu list 4then clic' the lin' com port4 one !indo! open it sho!s selecting c om -ou select the "default com port# in -our computer4 and mode is single mode selection onl-. then ensure after selecting the com port and mode selection correctl- clic' the lin' button in -our !indo!. if -our process is correct means it sho!s "connect successfull-#4 if it is !rong means "communication error#./chec' the communication serial cable if it connected or not 5. hen clic' the O+*,#io. M*./ ---0select the &,i#* it sho!s the pop+up message li'e this "Old data will be lost, continue6# E% o, NO button. 7ou clic' "7es# button allo! to !rite the current data to the PLC. 8. hen clic' the O+*,#io. M*./ ---0select the RN it sho!s the pop+up message Li'e this "Do you want to read program from module6# E% o, NO button. 7ou clic' "$O# it means a%oid to read the current program again. hen the PLC Read- to the R9$ mode.

:. $o! the PLC is act as the !or'ing mode. Connections are connecting as per the connection diagram.


*n this e0ercises double acting c-linder is act as the single acting c-linder using PLC programming.



Connect the s!itch "!"-1# /I1 connector using cable and4 Reed s!itch"I5# connector also connect. hen the output side Q1 is connect the %1 rela- of the solenoid %al%e4 Q2 is connect the %2 rela- of the solenoid %al%e.



*nitiall- s!itch ON the


Suddenl- Reed s!itch <*;8= is sense and O$ the PLC input signal. So the PLC output ?2 is enable so c-linder is automaticall- return.

@. Automatic operation of a Double acting c-linder+single c-cle + for!ard4 time Dela-4 return.

Input connection:

Output motor connection: PLC

I1

---------------- ON !"i#c$ (%&-1)

I5

---------------- R* !"i#c$ (A1)

D%ALE

Q1

----------------- coil – 1(%1)

Q2

----------------- coil – 2(%2)




*n this e0ercises double acting c-linder is act as the single c-cle + for!ard4 time Dela-4 return.



Connect the s!itch "!"-1# /I1 connector using cable and4 Reed s!itch"I5# connector also connect. hen the output side Q1 is connect the %1 rela- of the solenoid %al%e4 Q2 is connect the %2 rela- of the solenoid %al%e.



*nitiall- s!itch ON the


Suddenl- Reed s!itch
time is running at a particular user defined time. &hen the dela- time is end PLC output Q2 is enable c-linder is automaticall- return.

. Automatic operation of Double acting c-linder+Bulti c-cle.


Output motor connection:

---------------- ON !"i#c$ (%&-1) PLC

I2

D%ALE

---------------- O'' !"i#c$ (%&-2) Q1

----------------- coil – 1(%1)

Q2

----------------- coil – 2(%2)

I4 ---------------- R* !"i#c$ (A) I5 ---------------- R* !"i#c$ (A1)




*n this e0ercises double acting c-linder is Automatic operation of +Bulti c-cle



Connect the s!itch "!"-1# /I14 "!"-2# /I24 /I44 /I5 connector are connect using cable. hen the output side Q1 is connect the %1 rela- of the solenoid %al%e4 Q2 is connect the %2 rela- of the solenoid %al%e.



S!itch ON the


*f -ou press the :I29 push button the PLC output signals are disable. And also solenoid %al%e rela-=s suppl- %oltage also off. So th e c-linder operations are off.

. Automatic operation of Double acting c-linder+$ c-cles /using counter function loc'


Output motor connection:

---------------- ON !"i#c$ (%&-1) PLC

I2

D%ALE

---------------- O'' !"i#c$ (%&-2) Q1

----------------- coil – 1(%1)

Q2

----------------- coil – 2(%2)

I4 ---------------- R* !"i#c$ (A) I5 ---------------- R* !"i#c$ (A1)




*n this e0ercises double acting c-linder is Automatic operation of $ c-cles /using counter function loc'



Connect the s!itch "!"-1# /I14 "!"-2# /I24 /I44 /I5 connector are connect using cable. hen the output side Q1 is connect the %1 rela- of the solenoid %al%e4 Q2 is connect the %2 rela- of the solenoid %al%e.



*n this program t!o counter functions are used4 input counter and output counter. /)0ample  input counter < 2 =4 output counter < : =



*f -ou press the push button :%"-19 s!itch no! input counter is read the first count4 again press the s!itch counter is read the second count. So the Q1 output is enable %1 rela- ON so the c-linder piston is mo%e to outside. hen the Reed s!itch is sense and signal is passed the PLC input terminal :I59. So the PLC output Q2 enable4 no! c-linder piston is mo%e to return to initial position. &hene%er the ?2 enables4 output counter !ill be increased.



PLC outputs !ill be stopped4 !hile the counter reaches <:=.

1;. Seuential operation of a Double Acting C-linder and a motor.

Output motor connection: Input connection:

PLC

D%ALE

Q1

----------------- coil – 1(%1)

I4 ---------------- R* !"i#c$ (A)

Q2

----------------- coil – 2(%2)

I5 ---------------- R* !"i#c$ (A1)

Q5

----------------- %M – 1(Q5)

Q6

----------------- %M – 2(Q6)

Q7

----------------- %M – 3(Q7)

Q8

----------------- %M – 4(Q8)

I1

---------------- ON !"i#c$ (%&-1)



*n this e0ercises Seuential operation of a Double Acting C-linder and a motor.



Connect the s!itch "%"-1# /I14 "%"-2# /I24 /I44 /I5 connector are connect using cable. hen the output ?1 is connect the %1 rela- of the solenoid %al%e4 Q2 is connect the %2 rela- of the solenoid %al%e. And also stepper motor connections are connecting using the connection diagram.



*n this program !or' the seuential input and output operation of the motor and c-linder.



&hen !ill be press the "S&+1# push button ?1 is O$ so the c-linder piston mo%e to outside4 in this same time stepper motor !ill be start to run. &hen the ?1 is enable time dela- is O$.



PLC output ?2 is O$ Botor !ill be stopped and also c-linder piston4 !hile the dela- time reaches.

11. Seuential operation of t!o Double Acting C-linders for the seuence AE4E4 +4 A+.


---------------- ON !"i#c$ (%&-1)

I3

---------------- ON !"i#c$ (%&-3)

I4 ---------------- R* !"i#c$ (A) I5 ---------------- R* !"i#c$ (A1) I6 ---------------- R* !"i#c$ () I7 ---------------- R* !"i#c$ (1)

Output motor connection: PLC

D%ALE

Q1

----------------- coil – 1(%1)

Q2

----------------- coil – 2(%2)

Q3

----------------- coil – 3(%3)

Q4

----------------- coil – 4(%4)



*n this e0ercises Seuential operation of t!o Double Acting C-linders for the seuence AE4E4 +4 A+.



Connect the s!itch "!"-1# /I14 "!"-3# /I34 /I44 /I54 /I64 /I74 connector is connecting using cable. hen the output side Q1 is connect the %1 rela- of the solenoid %al%e4 Q2 is connect the %2 rela- of the solenoid %al%e. Q3 is connecting %3 solenoid %al%e and also Q4 is connect the %4 solenoid %al%e.



*f -ou press the push button :%"-19 the seuential operation !ill start from Q3 then the c-linder A; !ill go outside.4 after this Q1 !ill be enabled then ; !ill go outside then Q2 !ill enable the - to mo%e inside and the Q4 !ill ma'e A- go inside.



After this full seuence the operation can be stopped b- pressing the :%&-29 push s!itch.

Process Automation Practical Connection Diagram

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