Experiment No.

:- 1 (a)

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.

PLC specification:- 1) PLC-AB Micrologix 1400B

2) I/O configuration.

Theory:-

Introduction To PLC:-

Definition of PLC :- PLC is a microprocessor based digital controller

which performs and controls many functions of many types and levels of
complexity.

Advantages of PLC :-

1) Lower cost :-It performs more functions in less expensive packages.

2) Flexibility :- In the past each electronically controlled power
machine is required to control each device. Now it is possible to
control many devices 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) Implementation changes and corrections:- In PLC based systems,
program can be changed easily within less time.

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Disadvantages of PLC :-

1) Environmental condition:- Due to high temperature of

environment at operating station damages PLC.
2) Every technicians or labor must know 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
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 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 the
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

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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 super markets) 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 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 usually
red, green, or amber, but other colors are also available. Red lamps are

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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.). Some time it is important to attract the
operators 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 and OFF operation.

Explanation:-

When input i.e. button (I:0/0) is ON or it is pressed , O/P lamp (O:0/0)

should become ON .

When input i.e. button (I:0/0) is OFF or it is pressed , O/P lamp (O:0/0)
should become OFF .

Ladder Diagram:-

Conclusion:-

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 EXPERIMENT NO. 1

Title: 1 b) Perform Delayed Operation Of Lamp By Using Push

Button

Aim: To Perform Delayed Operation Of Lamp By Using Push

Button

PLC Specifications: i) PLC AB Micrologix 1400 B

ii) I/O configuration

Theory:

ON DELAY TIMER: It is used to perform 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.

e.g. A certain steps in manufacturing processes are to begin after

input is received from limit switch. 30 sec is nothing but preset
value of ON delay timer.

ADDRESSING MODES OF TIMER:

T4:0/255 Timer 0 in file no. 4

T4:0/Acc The sub-element is in an accumulator

T4:0 PRE Sub element of timer 0

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Statement:- Draw a ladder diagram to operate lamp using push
button after 5 sec delay

Explanation: When input i.e. button (I:0/0) is ON timer T4 will

become ON which generates delay as per the set value. When
preset value of timer i.e. set value of delay and accumulator value
of the timer will become equal DN bit of timer will be set and
output i.e. lamp (O:0/0) will on after the delay. When input (I:0/0)
is off, output should be off.

Ladder Diagram:

Conclusion:

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 Experiment no. 2

Title: 2a) Multiple push button operation with delayed lamp for
ON/OFF operation

Aim: to study multiple push button operation with delayed lamp

for on/off operation.

PLC specifications: 1) PLC-AB Micrologix 1400 B

2) I/O configuration-

Theory:

There are mainly three types of timers use in PLC programming as

follows-

1) ON Delay Timer.

2) OFF Delay Timer

3) 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 eg.- Certain stages in manufacturing
processes is expected to begin 30sec. after i/p is received from

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limit switch, here 30sec is nothing but the present value of ON
delay timer.

2) OFF Delay Timer:

It is used to program a time to begin after i/p goes false. For eg.
external cooling fan or a motor which has to run all the time & it is
expected to turn off the fan or motor after 5min when i/p is sensed
by them. The 5 min is nothing but turn 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 eg:- 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 8 hr (28800 sec) Each time the motor is turned
off the timer need to remember motors 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.

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 Timer element instruction

EN TT DN 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.

COUNTERS

Every PLC has counter instruction. If the counter count from 0 to

100 desired value and so on it is called as UP Counter. If the
counter count from 100 to 0 desired value and so on 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 rejected from batches

Count DOWN: it is used to count from desired value to 0

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Ex. An operator interface display shows operator the number of
parts remaining to be matched for a lot of 100 parts order

High Speed Counter: Used to pulses that are too fast

separated from normal input points and modules.

Ex. To count signals from incremental encoder.

Counter RESET: To reset the counter

Ex. Used to reset a counter to 0 so another counting sequence can

begin

Statement: Draw a ladder diagram to start the timer for 5 sec and
after 5 sec start and counting operation upto 10 and switch on the
lamp

Explanation:

When PB1 (I:0/0) is on timer T4:0 is on. When reset value of timer
is reached count value of up counter will increase i.e. (C5:0.PRE)
and accumulated value counter (C5:0.ACC) become equal it will
set value the O/P lamp (O:0/0) become ON

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Ladder Diagram:

Conclusion:

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 Experiment no. 2 (b)

Title:- Multiple push button operation with delayed lamp for ON/OFF
operation

Aim:- To study multiple push button operation with delayed lamp for on/off
operation.

PLC Specifications:- 1) PLC-AB Micrologix 1400 B

2) I/O configuration-

Theory:

There are mainly three types of timers use in PLC programming as follows-

4) ON Delay Timer.
5) OFF Delay Timer
6) Retentive Timer

4) 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 eg.- Certain stages in manufacturing processes is expected to begin
30sec. after i/p is received from limit switch, here 30sec is nothing but the
present value of ON delay timer.

5) OFF Delay Timer:-

It is used to program a time to begin after i/p goes false. For eg. external
cooling fan or a motor which has to run all the time & it is expected to turn

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off the fan or motor after 5min when i/p is sensed by them. The 5 min is
nothing but turn off delay time.

6) Retentive timer:-

It is used to reset accumulated value through power loss, process change

state or in rung from true to false. For eg:- 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 8 hr (28800
sec) Each time the motor is turned off the timer need to remember motors
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.

Timer element instruction

EN TT DN Reserved bit Word 0

Preset value Word 1
Accumulated value Word 2

Addressing mode of timer:

4. T4: 0- Timer 0 in file NO. 4
5. T4: 0 ACC sub-element is accumulator.
6. T4: 0 PRE- Sub-element is preset value.

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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
output also OR logic for multiple input 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 input either 1 or 2 as
shown in fig, there is an output. When logic 0 to both inputs, there will not
be no output.

Explanation:-

When PB1 I:O/0 or I:O/1 or I:O/2 is pressed Timer T4:0 will become on
which generate delays as per the set. When present value of timer that is 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 (O:0.0)(GREEN) will
on after the delay.

When I:O/0 PB1 and I:O/1 PB2 or I:O/0 PB1 and I:O/2 PB3 or I:O/1 PB2 or
I:O@ PB3 is ON Timer T4:4 will become ON which generate delay as per
the set.

When present 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
is lamp YELLOW(O:0/1) will ON after the delay.

When input PB1(I:O/0) PB(I:O/0) &PB3(I:O/2) 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

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equal to DN(done) bit of the timer will be set and o/p i.e. lamp RED (O:0/2)
will on after the delay.

Ladder Diagram:

Conclusion:

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 Experiment No. : 3

Title:- 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.

PLC Configuration:- 1) PLC AB-Micrologix 1000.

2) I/o configuration.

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 energize changes.

When any logic path on the ladder rung containing the latching instruction
has continuity the output referred to latching instruction turns on and
remains on even if rungs 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
processors 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 energized. Latch and unlatch
instruction are always used in pairs, each instruction is located on separate
rung.

Analysis of Ladder logic and rung operation

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Figure shows ladder diagram rungs. First rung shows latch instruction while
other contains unlatch instruction.

When input I : 0/1 on first rung is energized , the output latch instruction ,
address O:0/0 is 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 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. The following rules
pertain to most latch and unlatch instruction.

Latch and unlatch instruction are used in pairs.

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 PB1 (I:0/0) is pressed , O/P lamp (O: 0/0) should become ON.

When input PB2 i.e. (i:0/1) is pressed , O/P lamp (O:0/0) should become
OFF.

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Ladder Diagram:

Conclusion:

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 Experiment No. 4

Title: DOL starter and star delta starter operation by using PLC.

Aim: To study the DOL starter and star delta starter operation by using PLC
apparatus

PLC Specification:- 1)PLC (Micrologix 1400 B series)

2) 3 phase induction motor.

Theory: Direct online (DOL) or across the line starter applies the full line
voltage to the motor terminal .This is the simplest type of motor starter. A
DOL motor starter also contain protection device and in some cases
condition monitoring. Smaller size of on-line starters is mutually operated
.Larger size use an electromechanical contractor (relay) to switch the motor
circuit. Solid state direct online starter also exists.

A direct on-line starter can be used if the high in rush current of the motor
does not cause excessive voltage drop in the supply circuit .The maximum
size of motor allowed on the direct online starter may be limited by the
supply utility for this reason. For example, utility may require rural customer
to use reduce the voltage starter for motors larger than 10 kw .

DOL starting is sometime used to start small water pumps, compressors,

fans and conveyor belts. In the case of an asynchronous motor, such as 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 in rush current, larger motors
will have reduce voltage starter on variable speed drives in order to
minimize voltage dips to the power supply.

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A receiving starter can connect the motor for rotation in either direction.
Such starters contain 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 motor, this is
achieved by transposing any two phases. Single phase AC motor and direct
current motors require additional device for receiving rotation.

Star Delta Starter: In the star delta starting method the wiring connection
come from the power supply source to the motor is connected from the star
(wye) to the delta connection. The motor is started in the 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 explained that in the star delta starter, the motor
is started as star connection and when the motor start running then the
connection is changed to the delta. With star connection, the motor takes 3
times less voltage. However as the torque is proportional to the square of the
voltage, the starting torque also reduced.

Diagram:

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Explanation:

1) DOL Starter : Whenever PB1 (I: 0/0) is pressed 3 phase motor gets
connected to the mains the motor (O:0/0) remains on the even after
push button is released
2) Star-Delta Starter: when the mains (I:0/0) is ON or 3 phase AC
supply is given that time the motor is connected to star connection i.e.
(O:0/0) ,so that the voltage across the motor is reduced 3 times then
after 5 seconds delay the delta connection is ON (O:0/0).

Conclusion:

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 Experiment No:6

Title: PLC based thermal ON/OFF control

Aim: To study PLC based thermal ON/OFF control

PLC Configuration :- i) PLC AB Micrologix 1400.

ii) I/O configuration

Theory/ Explanation:-

In this experiment I/P valve (0:0/0.5)i.e. (B3:10/5) is ON when temp is less

than or equal to 25 and level is than or equal to 10 at that time O/P
valve(0:0/0.6)i.e. (B3:10/6) is OFF

If level goes high i.e. greater than or equal to 75 but the temp is less then
O/P valve is ON but I/P valve is still ON it will become OFF when
temperature become greater or equal to 50.

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Ladder Diagram:

Conclusion:

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 Experiment No: 5

Title: plc based temperature sensing using RTD

Aim: To study plc based temperature sensing using RTD

PLC Configuration :-i) PLC AB-Micrologix 1400B

ii) I/o configuration:-

Theory/ Explanation:-

When the auto button (l: 0/0) is selected and set point is given from screen
which is stored in N7:0 Temp Sensed by RTD is given to i/p and it is stored
in F8:0 Here we compare both the Set point value and RTD value when
RTD value is greater the point heater (0:0/0) is automatically become off
and if temperature goes low heating automatically starts.

When manual button (l:0/1) is selected there is no need to set the set point
value and heater will turn ON and OFF with the help of manual button only .

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Ladder Diagram:

Conclusion:

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 Experiment No: 7

Title: PLC interface with SCADA and status read/command transfer

operation.

Aim: To study PLC interface with SCADA and status read/command

transfer operation.

PLC Configuration :- i) PLC AB-Micrologix 1400B.

ii) I/O configuration:-

iii) SCADA software wonderware touch

Theory/ Explanation:-

When the button for the input I: 0.0/4 is pressed status of the corresponding
I/P will change to green colour and command for the same i.e. I: 0.0/4 ON
is also visible.

If it is OFF status of the corresponding I/P will change to red colour and
command for the same I: 0.0/4 OFF is also visible.

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Ladder Diagram:

Conclusion:

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 Experiment No: 8

Title:- Parameter reading of PLC in SCADA

Aim:- Parameter reading of PLC in SCADA

PLC Configuration:- 1) PLC AB-Micrologix 1400B.

2) I/O configuration:-

3) SCADA Software- wonderware touch

Theory/explanation:-

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 Experiment No: 9

Title:- Alarm annunciation using SCADA

Aim:- To study alarm annunciation using SCADA

Configuration:- 1) PLC Micrologix (1400 series)

2) SCADA Wonderware software

Theory:-

One of the most important implementation of SCADA is Alarm. The alarm

has just two digital status points with values ALARM or NORMAL. When
the requirement of the Alarm is met they are activated .For example, when
the fuel tank is empty of car, the alarm is activated and light glows. The
attention of the SCADA operator is drawn to the system which requires
attention by the alarm to alert the SCADA operator along with the manager
text massages and emails are sent along with alarm activation.

When some of the variables in power station or sub-station are out of limit
operator gets corresponding alarm massages the operator receives the alarm
signal by virtue of past experience and human reasoning the control room
operator determine the cause of trouble and takes appropriate follow up
action insure system security .

The knowledge of single alarm by them self is often in sufficient and the
operator must able to draw conclusion from knowing the status and the
values of many other variable in the case of breaker status values the
operater are provided with one line display diagram have graphic indication
of breaker bus bar switches transformer etc. further the breaker position are

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shown so that a quick accurate assessment of a switching action can be
obtained by looking at the display.

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In this screen here we are able to read the parameter of PLC i.e. the value of
the analog input (:1.1).These analog inputs are scaled and the scaled values
are stored in N7:0and F8:0 which indicates the values of set point values &
Actual values.

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 Experiment No: 10

Title:- Reporting and trending in SCADA System.

Aim:- To study reporting and trending in SCADA system.

Configuration:- i) PLC (Micrologix 1400 series)

ii) SCADA Wonderware software.

Theory:-

Trend display is the distributed control system equivalent of chart records.

They are a profile of a value of a process variable showing changes that have
been taken place over a period of time.

The trend display information is valuable to the plant operator to observe the
resent pattern of operating history. It is valuable to the operator after an
upset has occurred, allowing him to determine which several interrelated
variable was the 1st to be affected by changing condition trends over larger
periods (over a week or more) can be saved on floppy disk, storage &
displayed when required. The figure show trend for the temperature set point
value & actual value sensed by the RTD when we touch on any of the
temperature indicator block then this trends window will pop up. In some
displays several trend graphs can be displayed at ones allowing comprising
of the history of several variables.

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Conclusion:

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 Experiment No: 11

Title:- Temperature sensing using SCADA

Aim:- To study temperature sensing using SCADA

PLC Configuration:-i) PLC AB-Micrologix 1400B

ii) I/O configuration.

Theory:-

When the auto button (1:0/0) is selected and set point is given from screen
which is stored in N7:0 temp. Sensed by RTD is given to I/P and it is stored
in F8:0. Here we compare the both set point value. When RTD value is
greater then set point heater (0:0/0) is automatically become OFF and if
temperature goes low heating automatically starts .

When manual button (1:0/0) is selected there is no need to set the set point
Value and heater will turn ON and OFF with the help of manual button only.

Conclusion:-

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