1.

Company Profile

Softwizz is a software development company providing solutions in the field of education,

construction, publishing and many more. Our specialists are truly sensitive and responsive to the
needs of our clients due to their unwavering dedication and unequaled professionalism, which
help our company to deliver wide-ranging and proficient custom web design services.

Softwizz Pvt. Ltd. is leading software development and training group in various domains across
the industry like CSE IT, Non IT (ECE, ME, ETC, EEE) and Management based programs. We
are in software development industry, corporate training as well as individual training program to
meet our market segments.

Softwizz Pvt. Ltd. customized program is to provide the training Software industry with project
ready candidates by filling the gap between theoretical knowledge and industry requirement.

Vision:

To be the most admired and respected Technology company providing “Best value” software
solution and education system.

Mission:

To achieve the leadership position in our focus domains and to become a reason for smile for
everyone related with the organization in the form of staff, clients and trainees by providing the
best services with all the commitment and dedication of our work.

Core Value:

Clients first- We exist because of our clients.

Reliability and transparency- committed to be ethical, transparent and reliable in all our
operation.

1
2.Automation

Automation is the use of control systems and information technologies to reduce the need for
human work in the production of goods and services. In the scope of industrialization,
automation is a step beyond mechanization. Whereas mechanization provided human operators
with machinery to assist them with the muscular requirements of work, automation greatly
decreases the need for human sensory and mental requirements as well. Automation plays an
increasingly important role in the world economy and in daily experience.

Consider the examples of automation:

1. Automated video surveillance

2. Automated highway systems

3. Automated manufacturing

4. Home automation

5. Industrial automation

6. Agent-assisted Automation

2.1 Advantages of Automation:

1. Replacing human operators in tasks that involve hard physical or monotonous work.
2. Replacing humans in tasks done in dangerous environments (i.e. fire, space, volcanoes,
nuclear facilities, underwater, etc.)
3. Performing tasks that are beyond human capabilities of size, weight, speed, endurance,
etc.
4. Economy improvement: Automation may improve in economy of enterprises, society or
most of humanity. For example, when an enterprise invests in automation, technology
recovers its investment; or when a state or country increases its income due to automation
like Germany or Japan in the 20th Century.

2
`2.2 Disadvantages of Automation:

1. Unemployment rate increases due to machines replacing humans and putting those
humans out of their jobs.
2. Technical Limitation: Current technology is unable to automate all the desired tasks.
3. Security Threats/Vulnerability: An automated system may have limited level of
intelligence; hence it is most likely susceptible to commit error.
4. Unpredictable development costs: The research and development cost of automating a
process may exceed the cost saved by the automation itself.
5. High initial cost: The automation of a new product or plant requires a huge initial
investment in comparison with the unit cost of the product, although the cost of
automation is spread in many product batches of things.

3
3. ENGINEERING TOOLS

3.1 PLC (Programmable Logic Controller):

A programmable logic controller (PLC) or programmable controller is a digital computer

used for automation of electromechanical processes, such as control of machinery on factory
assembly lines, amusement rides, or light fixtures. PLCs are used in many industries and
machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact

3.2 SCADA (Supervisory Control And Data Acquisition)

SCADA (supervisory control and data acquisition) is a category of software application program
for process control, the gathering of data in real time from remote locations in order to control
equipment and conditions. SCADA is used in power plants as well as in oil and gas refining,
telecommunications, transportation, and water and waste control.

SCADA systems include hardware and software components. The hardware gathers and feeds
data into a computer that has SCADA software installed. The computer then processes this data
and presents it in a timely manner. SCADA also records and logs all events into a file stored on a
hard disk or sends them to a printer. SCADA warns when conditions become hazardous by
sounding alarms.

3.3 HMI (Human Machine Interface)

A Human-Machine Interface or HMI is the apparatus which presents process data to a human
operator, and through which the human operator controls the process.

An HMI is usually linked to the SCADA system's databases and software programs, to provide
trending, diagnostic data, and management information such as scheduled maintenance
procedures, logistic information, detailed schematics for a particular sensor or machine, and
expert-system troubleshooting guides.

The HMI system usually presents the information to the operating personnel graphically, in the
form of a mimic diagram. This means that the operator can see a schematic representation of the
plant being controlled.

4
3.4 Distributed Control System

A type of automated control system that is distributed throughout a machine to provide

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

3.5 Drives

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

5
4.RELAY AND CONTACTOR

4.1 RELAY:

A relay is a simple electromechanical switch made up of an electromagnet and a set of contacts.

Current flowing through the coil of the relay creates a magnetic field which attracts a lever and
changes the switch contacts. It is used for double through (changeover).

Fig 1.1 relay

The relay's switch connections are usually labeled COM, NC and NO:

 COM = Common, always connect to this, it is the moving part of the switch.
 NC = Normally Closed, COM is connected to this when the relay coil is off.
 NO = Normally Open, COM is connected to this when the relay coil is on.

4.1.1 Advantages of relays:

 Relays can switch AC and DC.

 Relays can switch higher voltages.
 Relays are often a better choice for switching large currents (> 5A).
 Relays can switch many contacts at once.
 Relay can be rated for very high voltage.

4.1.2 Disadvantages of relays:

 Relays are bulkier than transistors for switching small currents.

 Relays cannot switch rapidly (except reed relays), transistors can switch many times per
second.
 Relays use more power due to the current flowing through their coil.
 Relays require more current than many ICs can provide, so a low power transistor may be
needed to switch the current for the relay's coil.

6
4.2 CONTACTOR:

4.2.1 What is contactor?

Contactors are used to switch relatively large outputs and currents.

Contactors work on the same basic principle as relays.

The typical features of contactor are:

 double- break ( 2 break points per contact),

 positive-action contacts and
 closed arcing chambers (spark arresting chambers).

Fig.1.2 Symbol of contactor

4.2.2 Advantages of contactor:

 Easy to changeover.
 Durable.
 Easy to test.
 Basically used for high current ratings.

7
4.2.3 Disadvantages of contactor:

 Required more power

 Contacts wear

4.3 COMPARISON BETWEEN RELAY AND CONTACTOR:

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

Relays are used to switch Contactors are used to switch

relatively small outputs and relatively large outputs and
currents. currents.

8
5. PLC (Programmable Logic Controller)

5.1 INTRODUCTION

Control engineering has evolved over time. In the past humans were the main methods for
controlling a system. More recently electricity has been used for control and early electrical
control was based on relays. These relays allow power to be switched on and off without a
mechanical switch. It is common to use relays to make simple logical control decisions. The
development of low cost computer has brought the most recent revolution, the Programmable
Logic Controller (PLC). The advent of the PLC began in the 1970s, and has become the most
common choice for manufacturing controls. PLCs have been gaining popularity on the factory
floor and will probably remain predominant for some time to come. Most of this is because of
the advantages they offer.

• Cost effective for controlling complex systems.

• Flexible and can be reapplied to control other systems quickly and easily.

• Computational abilities allow more sophisticated control.

• Trouble shooting aids make programming easier and reduce downtime.

• Reliable components make these likely to operate for years before failure.

The term SCADA stands for Supervisory Control and Data Acquisition. A SCADA system is a
common process automation system which is used to gather data from sensors and instruments
located at remote sites and to transmit and display this data at a central site for either control or
monitoring purposes. The collected data is usually viewed on one or more SCADA Host
computers located at the central or master site.
A real world SCADA system can monitor and control hundreds to hundreds of thousands of I/O
points. A typical Water SCADA application would be to monitor water levels at various water
sources like reservoirs and tanks and when the water level exceeds a preset threshold, activate
the system of pumps to move water to tanks with low tank levels.
Common analog signals that SCADA systems monitor and control are levels, temperatures,

9
pressures, flow rate and motor speed. Typical digital signals to monitor and control are level
switches, pressure switches, generator status, relays & motors.Automation of many different
processes, such as controlling machines, basic relay control, motion control, process control is
done through the use of small computers called a programmable logic controller (PLC). This is
actually a control device that consists of a programmable microprocessor, and is programmed
using a specialized computer language. A programmable logic controller (PLC) or
programmable controller is a digital computer used for automation of electromechanical
processes, such as control of machinery on factory assembly lines, amusement rides, or lighting
fixtures. PLC’s are used in many industries and machines, such as packaging and semiconductor
machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output
arrangements, extended temperature ranges, immunity to electrical noise, and resistance to
vibration and impact. Programs to control machine operation are typically stored in battery-
backed or non-volatile memory. A PLC is an example of a real time system since output results
must be produced in response to input conditions within a bounded time, otherwise unintended
operation will result.

A modern programmable logic controller is usually programmed in any one of several languages,
ranging from ladder logic to Basic or C. Typically, the program is written in a development
environment on a personal computer (PC), and then is downloaded onto the programmable logic
controller directly through a cable connection. Programmable logic controllers contain a variable
number of Input/output (I/O) ports the programmable logic controller circuitry monitors the
status of multiple sensor inputs, which control output.

Fig .Programmable logic controller (PLC)

10
5.2 HISTORY

5.2.1 Origin

The PLC was invented in response to the needs of the American automotive manufacturing
industry. Programmable controllers were initially adopted by the automotive industry where
software revision replaced the re-wiring of hard-wired control panels when production models
changed.Before the PLC, control, sequencing, and safety interlock logic for manufacturing
automobiles was accomplished using hundreds or thousands of relays, cam timers, and drum
sequencers and dedicated closed-loop controllers. The process for updating such facilities for the
yearly model change-over was very time consuming and expensive, as the relay systems needed
to be rewired by skilled electricians.In 1968 GM Hydramatic (the automatic transmission
division of General Motors) issued a request for proposal for an electronic replacement for hard-
wired relay systems.The winning proposal came from Bedford Associates of Bedford,
Massachusetts. The first PLC, designated the 084 because it was Bedford Associates' eighty-
fourth project, was the result. Bedford Associates started a new company dedicated to
developing, manufacturing, selling, and servicing this new product: Modicon, which stood for
Modular Digital Controller. One of the people who worked on that project was Dick Morley,
who is considered to be the "father" of the PLC. The Modicon brand was sold in 1977 to Gould
Electronics, and later acquired by German Company AEG and then by French Schneider
Electric, the current owner.One of the very first 084 models built is now on display at Modicon's
headquarters in North Andover, Massachusetts. It was presented to Modicon by GM, when the
unit was retired after nearly twenty years of uninterrupted service. Modicon used the 84 moniker
at the end of its product range until the 984 made its appearance.

5.2.2 Programming

Early PLCs, up to the mid-1980s, were programmed using proprietary programming panels or
special-purpose programming terminals, which often had dedicated function keys representing
the various logical elements of PLC programs. Programs were stored on cassette tape cartridges.
Facilities for printing and documentation were very minimal due to lack of memory capacity.
The very oldest PLCs used non-volatile magnetic core memory.

11
5.2.3 Functionality

The functionality of the PLC has evolved over the years to include sequential relay control,
motion control, process control, distributed control systems and networking. The data handling,
storage, processing power and communication capabilities of some modern PLCs are
approximately equivalent to desktop computers. PLC-like programming combined with remote
I/O hardware, allow a general-purpose desktop computer to overlap some PLCs in certain
application.

5.3 ARCHITECTURE OF PLC

ARCHITECTURE OF PLC

12
5.3.1 PARTS OF PLC

 POWER SUPPLY: PLC requires 24V switch mode power supply for its operation.
 MCU: Its full form is microcontroller unit. It is the processor of PLC. It is basically the
brain of PLC. It performs various control operations of PLC.
 INPUTS AND OUTPUTS: PLC has a set of isolated inputs and isolated outputs.
Different PLC’s have different number and different type of inputs and outputs.Like in
Micrologix 1000 we have total number of 6 inputs and 4 outputs whereas in Micrologix
1100 we have 10 inputs and 6 outputs.
 EXPANSION PORT: In PLC there is an expansion port which is used for the addition
of any other equipment with PLC. For example analog cards.
 MEMORY MODULE: The memory module in PLC is used for the storage of
program in PLC for future use.
 COMMUNICATION PORT: The communication ports are used in PLC to
communicate with the computer. In PLC there are two types of communication
ports i.e. RS 232 comport and Ethernet port.
 This display screen is used as human machine interface i.e. it provides good visualization
of operation running.

5.3.2 PLC PIN DIAGRAM

Fig . Pin Diagram

13
5.4 INPUTS AND OUTPUTS OF PLC

PLC programs are made up of a combination of the "gates" together with inputs, outputs, timers,
counters, internal memory bits, analog inputs, analog outputs, mathematical calculations,
comparators etc.

5.4.1 INPUTS

These are the physical connections from the real world to the PLC. They can be limit switches,
push buttons, and sensors, anything that can "switch" a signal on or off. The voltages of these
devices are usually, but not always, 24 Volt DC. Manufacturers make inputs that can accept a
wide range of voltages both ac and dc. It should be remembered that an input will be ON, "status
1", when the voltage is present at the input connection and OFF, "status 0", when the voltage is
no longer present at the input connection.

TYPES OF INPUTS OF PLC

USER TYPE: These are the inputs and outputs that are physically present and are
practical to the inputs and outputs of the PLC.

BIT TYPE: These are the inputs and outputs that are not physically present and are
functional in the PLC only. These inputs/outputs are basically used to drive each other
in the ladder logic programming.

XIC (Examine if closed):

I/P O/P

0 0

1 1

I/P O/P

14
 XIO (Examine if open): 0 1

1 0

5.4.2 OUTPUTS

These are the connections from the PLC to the real world. They are used to switch solenoids,
lamps, contactors etc on and off. Again they are usually 24 Volt DC, either relay or transistor,
but can also be 115/220 Volt AC.

TYPES OF PLC OUTPUTS

 Relay type output

 Transistor type output

 TRIAC type output

5.5 PLC MANUFACTURES

SIEMENS

ALLEN BRADLEY

GENERAL ELECTRICAL

MITSUBISHI

SCHENIDER

ABB

15
6. PROGRAMMING OF PLC

PLC programs are typically written in a special application on a personal computer, then
downloaded by a direct-connection cable or over a network to the PLC. The program is stored in
the PLC either in battery-backed-up RAM or some other non-volatile flash memory. Often, a
single PLC can be programmed to replace thousands of relays. Under the IEC 61131-3 standard,
PLCs can be programmed using standards-based programming languages. A graphical
programming notation called Sequential Function Charts is available on certain programmable
controllers. Recently, the International standard IEC 61131-3 has become popular. IEC 61131-3
currently defines five programming languages for programmable control systems: FBD
(Function block diagram), LD (Ladder diagram), ST (Structured text, similar to the Pascal
programming language), IL (Instruction list, similar to assembly language) and SFC (Sequential
function chart). These techniques emphasize logical organization of operations.While the
fundamental concepts of PLC programming are common to all manufacturers, differences in I/O
addressing, memory organization and instruction sets mean that PLC programs are never
perfectly interchangeable between different makers. Even within the same product line of a
single manufacturer, different models may not be directly compatible.

In Allen Bradley PLC’s the logic used for the programming is ladder logic. Ladder logic is a
programming language that represents a program by a graphical diagram based on the circuit
diagrams of relay-based logic hardware. It is primarily used to develop software for
Programmable Logic Controllers (PLCs) used in industrial control applications. The name is
based on the observation that programs in this language resemble ladders, with two vertical rails
and a series of horizontal rungs between them. An argument that aided the initial adoption of
ladder logic was that a wide variety of engineers and technicians would be able to understand
and use it without much additional training, because of the resemblance to familiar hardware
systems. This argument has become less relevant given that most ladder logic programmers have
a software background in more conventional programming languages, and in practice
implementations of ladder logic have characteristics—such as sequential execution and support
for control flow features—that make the analogy to hardware somewhat imprecise.Ladder logic

16
is widely used to program PLCs, where sequential control of a process or manufacturing
operation is required. Ladder logic is useful for simple but critical control systems, or for
reworking old hardwired relay circuits. As programmable logic controllers became more
sophisticated it has also been used in very complex automation systems.

Fig . Simple ladder logic

The language itself can be seen as a set of connections between logical checkers (contacts) and
actuators (coils). If a path can be traced between the left side of the rung and the output, through
asserted (true or "closed") contacts, the rung is true and the output coil storage bit is asserted (1)
or true. If no path can be traced, then the output is false (0) and the "coil" by analogy to
electromechanical relays is considered "de-energized". The analogy between logical propositions
and relay contact status is due to Claude Shannon.
Ladder logic has contacts that make or break circuits to control coils. Each coil or contact
corresponds to the status of a single bit in the programmable controller's memory. Unlike
electromechanical relays, a ladder program can refer any number of times to the status of a single
bit, equivalent to a relay with an indefinitely large number of contacts.
So-called "contacts" may refer to physical ("hard") inputs to the programmable controller from
physical devices such as pushbuttons and limit switches via an integrated or external input
module, or may represent the status of internal storage bits which may be generated elsewhere in
the program.
Each rung of ladder language typically has one coil at the far right. Some manufacturers may
allow more than one output coil on a rung.
--( )-- a regular coil, energized whenever its rung is closed

17
--(\)-- a "not" coil, energized whenever its rung is open
--[ ]-- A regular contact, closed whenever its corresponding coil is energized
--[\]-- A "not" contact, open whenever its corresponding coil is energized
The "coil" (output of a rung) may represent a physical output which operates some device
connected to the programmable controller, or may represent an internal storage bit for use
elsewhere in the program.

Fig 2.8.PLC Trainer Kit

The above figure shows the view of PLC trainer kit. On this kit various operations are
performed. It has following components mounted:

1 .PLC MicroLogix1000 2 .SMPS (220V AC-24V DC)

3. A Contactor Relay 4. An Electromechanical Relay

5. Normally open Switch (4) 6. Normally closed Switch (4)

7. Output LED’s (4) 8. RS 232 Comport for communication with PC

18
 Fig2. 9.Trainer Board of micrologix1100 PLC

The above fig shows the trainer board of micrologix 1100 PLC. It has following components:

1.PLCmicrologix 1100 2. SMPS (220V ac to 24V dc)

3. Analog I/O card 4. A Contactor Relay
5. An Electromechanical Relay 6. Normally open Switch (4)
7. Normally closed Switch (4) 8. Output LED’s (4)
9.RS 232 Comport for communication with PC

PLC INSTRUCTIONS

There are various instructions which are useful for making ladder logic for PLC programming.
These are as follows:

XIC (Examine if closed):

19
Use the XIC instruction in your ladder program to determine if a bit is ON. When the instruction
is executed, if the bit addressed is on (1), then the instruction is evaluated as true. When the
instruction is executed, if the bit addressed is off (0), then the instruction is evaluated as false.

XIC (Examine if closed):

I/P O/P

0 0

1 1

Examples of devices that turn on or off include:

 A push button wired to an input (addressed as I:0/4).

 An output wired to a pilot light (addressed as O:0/2).
 A timer controlling a light (addressed as T4:3/DN).

XIO (Examine if open):

Use the XIO instruction in your ladder program to determine if a bit is OFF. When the
instruction is executed, if the bit addressed is off (0), then the instruction is evaluated as true.
When the instruction is executed, if the bit addressed is on (1), then the instruction is evaluated
as false.

I/P O/P

0 1

1 0

Examples of devices that turn on or off include:

• Motor overload normally closed (N.C.) wired to an input (I:0/10).

• An output wired to a pilot light (addressed as O:0/4).

20
• A timer controlling a light (addressed as T4:3/DN).

Output Energize (OTE):

Use the OTE instruction in your ladder program to turn on a bit when rung conditions are
evaluated as true. An example of a device that turns on or off is an output wired to a pilot light
(addressed as O:0/4).

Output Latch (OTL) and Output Unlatch (OTU):

OTL and OTU are retentive output instructions. OTL can only turn on a bit, while OTU can only
turn off a bit. These instructions are usually used in pairs, with both instructions addressing the
same bit. Your program can examine a bit controlled by OTL and OTU instructions as often as
necessary.

Latch output and Unlatch output

21
7. TIMERS AND COUNTERS

7.1 TIMER

Timers are used to perform the timing operations. Time base is the minimum value of time in
second that can be taken by the timer. Preset value is the total number of the seconds for which
the timing operation has to be done Accumulator starts increasing the time in secondsupto the
preset value. Upto the preset value of the accumulator the enable bit of timer is high & the timer
runs. When accumulator reaches the preset value then the timer stops and the done bit of the
timer becomes high.

The timer has following bits and these bits are useful in the operation of timer:

 EN- Enable- This bit will high when the input is given to the timer
 TT - Timer timing bit - This bit will be high during the timing process. It remains
high till accumulator value becomes equal to preset value
 DN – Done – This bit will be high when the timing process is ended. It set to high
when the accumulator value becomes equal to preset value.
In Micrologix 1000 and 1100 PLC there are three types of timers i.e.

TON Timer

T-OFF Timer

Retentive timer ON (RTO)

TONTimer:Use the TON instruction to turn an output on or off after the timer has been on for a
preset time interval. The TON instruction begins to count time-base intervals when rung
conditions become true. As long as rung conditions remain true, the timer adjusts its accumulated
value (ACC) each evaluation until it reaches the preset value (PRE). The accumulated value is
reset when rung conditions go false, regardless of whether the timer has timed out

22
 Fig .TON timer

T-OFF Timer:Use the TOF instruction to turn an output on or off after its rung has been off for
a preset time interval. The TOF instruction begins to count time base intervals when the rung
makes a true-to-false transition. As long as rung conditions remain false, the timer increments its
accumulated value (ACC) based on the time base for each scan until it reaches the preset value
(PRE). The accumulated value is reset when rung conditions go true regardless of whether the
timer has timed out.

Fig.T-OFF timer

Retentive Timer (RTO):Use the RTO instruction to turn an output on or off after its timer has
been on for a preset time interval. The RTO instruction is a retentive instruction that begins to
count timebase intervals when rung conditions become true.

The RTO instruction retains its accumulated value when any of the following occurs:

Fig.Retentive Timer (RTO)

23
7.2 COUNTERS:

Counters are used to count the number of operations. Its function is same as the timer accepts
that the timer counts the number of seconds and the counter counts the number of operations or
pulses. At each operation the value of the accumulator increases and when the value of the
accumulator comes to the preset value of the counter then the counter stops.

Counter bits:

 TT - Timer timing bit - This bit will be high during the counting process. It remains high
till accumulator value becomes equal to preset value
 DN – Done – This bit will be high when the counting process is ended. It set to high
when the accumulator value becomes equal to preset value.

Counter UP (CTU):The CTU is an instruction that counts false-to-true rung transitions. Rung
transitions can be caused by events occurring in the program (from internal logic or by external
field devices) such as parts traveling past a detector or actuating a limit switch. When rung
conditions for a CTU instruction have made a false-to-true transition, the accumulated value is
incremented by one count, provided that the rung containing the CTU instruction is evaluated
between these transitions. The ability of the counter to detect false-to-true transitions depends on
the speed (frequency) of the incoming signal. The accumulated value is retained when the rung
conditions again become false. The accumulated count is retained until cleared by a reset (RES)
instruction that has the same address as the counter reset.

Fig.Counter UP (CTU)

24
Counter Down (CTD):The CTD is an instruction that counts false-to-true rung transitions.
Rung transitions can be caused by events occurring in the program such as parts traveling past a
detector or actuating a limit switch. When rung conditions for a CTD instruction have made a
false-to-true transition, the accumulated value is decremented by one count, provided that the
rung containing the CTD instruction is evaluated between these transitions. The accumulated
counts are retained when the rung conditions again become false. The accumulated count is
retained until cleared by a reset (RES) instruction that has the same address as the counter reset.

Fig.Counter Down (CTU)

EQU (equal to)

Fig.Equal to

This input instruction is true when source A becomes equal to source B. The EQU instruction
compares two user specified values if values are equal, it allows rung continuity. The rung goes
true and output energies.

25
GEQ (greater than equal to)

This instruction compares two values and will be high when the counted value becomes equal to
or greater than the fixed value and will energize everything that is connected next to it.

Fig.Greater than Equal to

LEQ(less than equal to

Fig.Less than Equal to

This instruction compares two values and will be high when the counted value becomes equal to
or less than the fixed value and will energize everything that is connected next to it.

GRT (greater than)

Fig.Greater Than

26
Use of the GRT instruction to test whether one value (source A) is greater than another (source
B). If the value at source A is greater than the value at source B, the instruction is logically true.
If the value at source A is less than or equal to the value at source B, the instruction is logically
false. Source A must be an address. Source B can either be a program constant or an address.
Negative integers are stored in two’s complement form.

LES (less than)

Use of the LES instruction is to test whether one value (source A) is less than another (source B).
If source A is less than the value at source B, the instruction is logically true. If the value at
source A is greater than or equal to the value at source B, the instruction is logically false. Source
A must be an address. Source B can either be a program constant or an address. Negative
integers are stored in two’s complement form.

Fig. Less than

LIM (Limit):

Fig.Limit

Use the LIM instruction to test for values within or outside a specified range, depending on how
you set the limits.

27
RES (Reset):

Fig.Reset

Use a RES instruction to reset a timer or counter. When the RES instruction is enabled, it resets
the Timer ON Delay (TON), Retentive Timer (RTO), Count UP (CTU), or Count Down (CTD)
instruction having the same address as the RES instruction.When resetting a counter, if the RES
instruction is enabled and the counter rung is enabled, the CU or CD bit is reset. If the counter
preset value is negative, the RES instruction sets the accumulated value to zero. This in turn
causes the done bit to be set by a count down or count up instruction.

28
8. PLC PROGRAMS

8.1 Program no. 1:

Switching on/off the Lamp whether they are at the bottom or the top of the staircase.

Sol:

If the states of the bottom switch and the top switch are the same, both ON or OFF, the
light will be ON. If different, one is ON and the other is OFF, the light will be OFF

When the light is OFF, users can turn on the light by changing the state of either top
switch at the bottom switch of the stairs. Likewise, when the light is ON, users can turn off the
light by changing the state of one of the two switches.

29
30
 8.2 Program no. 2:

Starting 3 Motors Sequentially with delay i.e. starting the oil pump motor immediately when
START is pressed. The main motor will be started after a 10 sec delay and then the auxiliary
motor after a 5 sec delay. In addition, stopping all motors immediately when STOP is pressed.

Sol:

When START is pressed, the NO contact X0 will be activated, which makes Y0 to be ON and
latched. The oil pump motor will start the lube system. At the same time, [TMR T0 K100]
instruction will be executed. When T0 reaches its set value of 10 sec, the NO contact T0 will be
ON.

· When the NO contact T0 is ON, Y1 will be ON and latched, which starts the main motor and
stops timer T0. At the same time, [TMR T1 K50] is executed, and the NO contact T1 will be ON
when timer T1 reaches its set value.

· When the NO contact T1 is ON, Y2 will be ON and latched, which starts the auxiliary motor
and stops T1.

· When STOP is pressed, the NC contact X1 will be activated, which makes Y0, Y1 and Y2
OFF. The oil pump motor, main motor and auxiliary motor will stop working.

31
32
9.REFERENCE and BIBLIOGRAPHY

1. <http://plc-scada-dcs.blogspot.com>

2. <http://www.wikipedia .com>

3. <http://www.kirloskarpumps.com>

4. <http://www.engineersgarage.com>

Books Recommended Websites

William Bottom for PLC www.plcs.net

Keller,William L Jr.Graft www.rockwellautomation.com

MikroElektronika

33