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IN AUTOMATION
Supervised By:
Er. Rohit Kaushal Er. Rajveer
Submitted By:
Rajinder singh 90180517484 Electrical Engineering
1.
BASIC SYMBOLS USED IN AUTOMATION AND PLC 1.1 Contact Normally Open
Contacts are used in association with coils in contact relays. They can be normally open (NO) or normally closed (NC). These two types characterize the electrical behavior of contacts when they are not activated, i.e. when the coil to which they are associated is not activated. As soon as the coil has a current going through it, contacts to which it is associated change their status. Normally open (NO) contacts close, and normally closed (NC) contacts open. These two contacts work as opposites. A normally open (NO) contact blocks the passage of current in a circuit when not activated. Once activated, the contacts allow the passage of electrical current. On the other hand, a normally close (NC) contact allows the passage of electrical current when not activated and blocks it when activated. When the coil is under voltage, the contacts to which it is associated change their status instantly. For this reason, they are sometimes called instant contacts to differentiate them from delay contacts.
1.2 Contact Normally Close Contacts are used in association with coils in the electrical behavior of contacts when they are not activated, i.e. when the coil to which they are associated is not activated. As soon as the coil has a current going through it, contacts to which it is associated change their status. Normally open (NO) contacts close, and normally closed (NC) contacts open. These two contacts work as opposites. A normally open (NO) contact blocks the passage of current in a circuit when not activated. Once activated, the contacts allow the passage of electrical current. On the other hand, a normally close (NC) contact allows the passage of electrical current when not activated and blocks it when activated. When the coil is under voltage, the contacts to which it is associated change their status instantly. For this reason, they are sometimes called instant contacts to differentiate them from delay contacts.
1.5 Coil
A coil is made of a rolled up copper wire. When the coil has current going through it, an electromagnetic force is generated in its core. The coil is used in many electrical applications, in contact relays for example. In contact relays, the electro-magnetic force generated by the passage of the current in the coil opens or closes the contacts of the relay that are associated with the coil. Three types of coils are available in the Electrical control workshop, they are the coil, and the coil latch and the coil unlatch. When a coil in under voltage, the normally open contacts associated with it close whereas the normally closed contacts associated with it open. When the coil is no longer under voltage, the contacts take back their initial status. The coil latch works as the coil except that the contacts that are associated with it stay in their activated status even if the coil latch is no longer under voltage. That way, when the coil latch is under voltage, the normally open contacts close and the normally closed contacts open. The coil unlatch allows the contacts that were activated by a coil latch to take back their initial status. When the coil unlatches is activated, the normally open contacts become open again and the normally closed contacts become closed again. The contacts will remain in that status even if the coil unlatches is no longer under voltage. In Automation Studio, the coil has to have the same tag names than the contacts to which it is associated.
LEDs relies on an important characteristic of electronics. It uses a special p-n junction that emits light when it is under direct current (when the anode-cathode voltage is positive).
1.9 LED
The LED is used to see the logical state of the digital circuit where the LED is connected. The logical state can be either 0 or 1. The component color undergoes a change according to the logical state of its input signal.
1.10 Fuse
A fuse is a protection device. It can shut down a circuit in which the current going through is too high (for example, in a short circuit situation). The fuse is calibrated to support a maximum intensity for the circuit. As long as the intensity does not go over the set intensity value, the fuse acts as a wire and does not influence the circuit. If the intensity of the current goes over the set value, the internal element of the fuse melts rapidly, opening the circuit. All the voltage goes to the terminals of the fuse and no current can circulate in the circuit. Fuses are usually made of a zinc or silver filament enclosed in a glass, ceramic or fiber tube. The heat generated from the current going through the circuit provokes, if it goes over the maximum intensity set for the fuse, the melting of the filament and consequently, the opening of the circuit. Fuses are often used in control circuits of motors.
1.12Power Supply L2
A power supply line is characterized by its voltage and supplies the electrical power to circuits and motors. For example, a triple-phase motor supply needs three power lines, one for each of the phases. In industrial and domestic electrical installations, power supply is available from the local power company. The electrical company supplies many types of power sources, mainly a triple-phase 600 Volts system with three lines and a triple-phase 208/120 Volts system with four lines. The 600 Volts supply with three lines is used in industrial installations as a motive force for the drive of triple-phase motors. The 208/120 Volts supply system with four lines supplies three power lines with 208 Volts line-to-line and a neutral. A line to neutral connection is used to supply a 120 Volts single-phase voltage. All three lines can be used to supply 208 Volts line-toline triple-phase motors. Each 208 Volts line-to-line bus can be combined with the neutral to supply 120 Volts lighting circuits. In triple-phase power circuits, the line to neutral voltage is equal to the line-to-line voltage divided by 1,73. For example, from a line-to-line 208 Volts
triple-phase supply it is possible to obtain a 208/1,73 = 120 Volts line-to-line single-phase supply.
1.14 Neutral
The neutral is used in electrical power circuits as a reference for the voltage on a single-phase or triple-phase line. It is also used in triple-phase supply circuits to supply a smaller voltage than the line to line voltage. In triple-phase power circuits, the combination of a power line with a neutral allows the supply of a smaller voltage than the line to line voltage. For example, the combination of a 208 Volts triple-phase line to line power line with the neutral, has an output supply of 120 Volts line to neutral. In triple-phase circuits, the line to neutral voltage is equal to
the line to line voltage divided by 1,73. For example, with a triple-phase supply of 208 Volts line to line, it is possible to obtain a single-phase supply of 208/1,73 = 120 Volts line to neutral. Sockets for ordinary domestic current are composed of two terminals. One terminal is connected to the single-phase 120 or 240 Volts line (depending on the country) and the other terminal is connected to the neutral.
1.15 Ground The ground is equal to 0 Volts. It represents the reference by which the voltages are measured. The term ground is used because one of the wires of a supply cord in electrical installations is always linked to the ground by a low resistance wire. In reality, in the case of commercial and residential buildings, this connection is done by the water supply pipe located at the entrance of the building. In certain cases, the ground is also called the common. In electrical installations, the main objective of the ground is to reduce the danger of electrical shocks. Domestic electrical appliances with a metallic casing are required to have a ground wire on their casing. Such is the case for electric stoves, and water heaters for example. In that type of appliance, the plug socket, has a third terminal used to connect the casing to the ground. In industrial installations, the ground is usually achieved through a grid stuck in the ground. All motors and machines in factories are fitted with a ground.
1.17Common (0 Volts)
The common component is the equivalent to the Ground component but it is for circuits in DC current.
switches need to have the same tag name that the mechanical position sensors to which they are associated. Mechanical position sensors are components from other workshops.
Once the position sensor is no longer activated, the mobile contact of the limit switch takes back its initial position, under the action of a return spring. The switch takes back its rest status. Limit switches need to have the same tag name that the mechanical position sensors to which they are associated. Mechanical position sensors are components from other workshops.
1.25Position Switch
The 3 position switches make it possible to connect the line 1 or the line 2. Initially, the switch is in the neutral position 3. The change of state is triggered by a click on the pushbutton. The arrow of the symbol indicates the current conducting line or the neutral position.
2.2 Output:
OUT SET RST Output coil Latch (ON Clear the contacts or the registers
94 95
ORP ORF
2.8 Other:
NOP P I 98 INV No operation Pointer Interrupt program marker Inverting operation
PLC Exercises
1) Devise a circuit that can be used to start a motor and then after a delay of 10 sec start a pump. When the motor is switched off there should be delay of 10 sec before the pump is off. 2) Device a circuit in which When X1 is pressed Y0 gets ON, Y1,Y2 get off, When X1 is pressed again Y1 gets ON and Y0, Y2 get OFF When X1 is pressed again Y2 gets ON and Y0, Y1 get OFF (Interlocking mechanism)
Study and use the following commands: MOV, INC, DEC, MUL, ADD, SUB, ZCMP
3) Switch on a Lamp after 5 sec, now using mov command change the timer to 10 second and change back to 5 sec. You have 1 maintained button and 2 push buttons only. Maintained button to switch on/off the lamp. Other two push button for changing the time from 5 to 10 sec and vice-versa 4) Device a circuit in which Y0 is on only when X1 is pressed in 10 sec. just after start of the machine(X0). Otherwise if X1 is pressed after 10 sec. Nothing should happen. 5) Device a circuit in which if X1 does not get pressed just after 5 second after output Y0 is on by pressing X0, alarm (Y1) is ON and blinking with frequency of 2Hz. 6) Device a circuit, in which if X0 is pressed once Y0 should ON and when X0 is pressed again Y0 should turn off. 7) Device a circuit, in which When X1+X2+X3 > Y0 ON FOR 5 SEC THEN OFF X4+X2+X1 > Y1 ON FOR 6 SEC THEN OFF X4+X5+X6 -> Y2 ON FOR 7 SEC THEN OFF Cycle should repeat 8) Use one push button (X1) turn ON Y0 in following sequence: Y0 on for 2 sec. then off for 2 sec. then on for 3 sec. then off for 3 sec then on for 4 sec. then continuously off. 9) When you press X0 Y0 and Y1 should blink after a delay of 2 sec continuously and when you press X1 Y0 and Y1 should blink after a delay of 3 sec. 10) Start a bulb as soon as PLC run and stop the bulb as soon as PLC stops.
11) You have 5 outputs Y0, Y1, Y2, Y3, Y4 When M0 is pressed All five should ON When M1 is pressed Y1, Y2, Y3 should OFF When M2 is pressed Y4 should off and Y1 should ON When M3 is pressed Y2, Y3 gets ON and Y0 goes OFF and Y4 goes ON again (take M0~M3 as maintained button and dont use set-reset commands) 12) I have a constant K10 in D0 Multiply it with 100 Add 56 to it Subtract 14 from it Finally store it in D10 13) Design electrical circuit to start 220 V motor with 24 PLC output. 14) Automatic Cold Drink making machine: Use X0 Main selector switch to ON/OFF the machine Use X1 & X2 as push buttons for selecting small/large cup Make a small beep (Y3)of 2 sec when cup is filled Blink an LED when cup is filling Make an arrangement to change (increment or decrement) the timing of timers for both small and large cups (Assume small cup gets filled in 5 sec and big cups filled in 10 sec.)
PLC Exercise -2
1) A toggle start switch and a limit switch (LS1) on a safety gate must both be on before a motor is energized. 2) While the motor is energized, it must remain energized until a limit switch (LS2) is activated. This second limit switch indicates the turn off of motor. 3) A cycle counter should also be included to allow counts of parts produced. When this value exceeds 5 the machine should shut down and a light lit up. 4) A safety check should be included. If the solenoid has been on for more than 5 seconds, it suggests that the cylinder is jammed or the machine has a fault. If this is the case, the machine should be shut down and maintenance light turned on. 5) Write ladder logic for a motor starter that has a start and stop button that uses latches .Write the same ladder logic without latches. 6) Design ladder logic that uses a timer and counter to measure a time of 50.0 days 7) Develop the ladder logic that will turn on an output (light), 15 seconds after switch (A) has been turned on 8) Develop the ladder logic that will turn on a output (light), after a switch (A) has been closed 10 times. Push button (B) will reset the counters 9) Develop a program that will latch on an output (B), 20 seconds after input (A) has been turned on. The timer will continue to cycle up to 20 seconds, and reset itself, until A has been turned off. After the third time the timer has timed to 20 seconds, B will be unlatched 10) A motor will be connected to a PLC and controlled by two switches. The GO switch will start the motor, and the STOP switch will stop it. If the motor is going, and the GO switch is thrown, this will also stop the motor. If the TOP switch was used to stop the motor, the GO switch must be thrown twice to start the motor. When the motor is running, a light should be turned on (a small lamp will be provided). 11) In dangerous processes it is common to use two palm buttons that require a operator to use both hands to start a process (this keeps hands out of presses, etc.). To develop this
there are two inputs that must be turned on within 0.25s of each other before a machine cycle may begin. 12) Write a ladder logic program that does what is described below. - When button A is pushed, a light will flash for 5 seconds. - The flashing light will be on for 0.25 sec and off for 0.75 sec. - If button A has been pushed 5 times the light will not flash until the system is reset. - The system can be reset by pressing button B 13) Write a program that will turn on a flashing light for the first 15 seconds and then off. Dont use start stop button 14) Write a program that only uses one timer. When an input A is turned on a light will be on for 10 seconds. After that it will be off for two seconds and then again on for 5 seconds. After that the light will not turn on again until the input A is turned off