CTIEMT/ECE/100220414148

Acknowledgement

I am heartily thankful to my training teachers …………. and ………….. whose

encouragement ,guidance and support from the initial to the final level enabled me to develop an

understanding of the subject.

First of all, I would like to say thanks to GOD for giving me the strength

and health to do this report work until it done .Not forgotten to my family for providing everything

such as money to buy anything that are related to this project work and their advise which is most

needed for this project.

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Table of Content

Topics Page No.

Overview of the project

Introduction to automation system

Switches and Logic Gates

Number System used for PLC

Introduction to PLC

Programming in PLC

Project

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Automatic Railway Gate Control

A level crossing occurs where a railway line is intersected

by a road or path on one level, without recourse to a bridge or
tunnel. It is a type of at-grade intersection.
The term also applies when a light rail line with separate right-of-
way or reserved track crosses a road in the same fashion. Other
names include railway crossing, railroad crossing, and road
through railroad, train crossing or grade crossing.
Overview
Early level crossings had a flagman in a nearby booth that would,
on the approach of a train, wave a red flag or lantern to stop all
traffic and clear the tracks. Manual or electrical closable gates that
barricaded the roadway were later introduced. The gates were
intended to be a complete barrier against intrusion of any road
traffic onto the railway. In the early days of the railways much
road traffic was horse drawn or included livestock. It was thus
necessary to provide a real barrier. Thus, crossing gates, when
closed to road traffic, crossed the entire width of the road. When
opened to allow road users to cross the line, the gates were swung
across the width of the railway, preventing any pedestrians or
animals getting onto the line.
With the appearance of motor vehicles, this barrier became less
effective and the need for a barrier to livestock diminished
dramatically. Many countries therefore substituted the gated

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crossings with weaker but more highly visible barriers and relied
upon road users following the associated warning signals to stop.

In many countries, level crossings on less important roads and

railway lines are often "open" or "uncontrolled", sometimes with
warning lights or bells to warn of approaching trains. Ungated
crossings represent a safety concern; many accidents have
occurred due to failure to notice or obey the warning.
Level crossings present a significant risk of collisions between
trains and road vehicles. Level crossings in India, China, Thailand,
and Malaysia are still largely manually-operated, where the
barriers are lowered using a manual switch when trains
approach.

Block Diagram:

Automatic Railway Gate Control

Advantages:

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 No manpower used.
 Better Output.
 High efficiency.
 Low cost.
 Automatic control system.
 No accident chance.

Block Diagram

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Chapter1:- Introduction to automation systems

1.1 Automation :- To analyze and control all the process parameters in the plant by the help of

automation devices.

1.2 Automation systems:- The technique, method, or system of operating or controlling a

process by highly automatic means, as by electronic devices, reducing human intervention to a

minimum.

Figure 1.1

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1.3 Automation device:- Automation device is a system,which on the basis of information fed

in it , performs pre defined action with the bearing on its environment.

1.4 Examples of automation devices components:-

1). Sensors:- Device that detects changes in the ambitient conditions or in the state of another

device and a system and conveys or record this infor mation in a certain manner.

Figure 1.2

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2).Power control:- To provide the power necessary for the motor and act as a intermediary with

the data processing system,specific devices are necessary. These are power control systems.

Figure 1.3

1.5 Techniques used before Automation:-

1) Manual control

2) Hardwired control

3) Electronic control

4) Automtion(PLC) control

Figure 1.4

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1) Manual control :- In this system work is done with the help of man power.

Disadvantages:-

1) It is very expensive.

2) Result is not too much correct.

Figure 1.5

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2) Hardwired control:- In this system work is done with the help of electrical circuit.

Disadvantages:-

1) It is expensive.

2) Heat losses are too much.

3) Result is not too much correct.

Figure 1.6

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3) Electronic control:- In this system work is done with the help of microcontroller.

Disadvantages:-

1) Its memory is upto 1MB.

2) Heat sensible.

3) Voltage Current fluctuation.

Figure 1.7

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4): Automation control:- In this system work is done with the help of PLC.

Advantages:-

1). Inputs and Outputs are 64000

2). Memory can be extended.

3). Voltage current fluctuation.

Figure 1.8

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Chapter2:- Switches and Logic Gates

2.1 Switch:

An electrical switch is any device used to interrupt the flow of electrons in a circuit. Switches are

essentially binary devices: they are either completely on ("closed") or completely off ("open").

2.2 Types of switches:

 Toggle switch

 Pushbutton switch

 Selector switch

 Limit switch

 Proximity switch

 Pressure switch

 Level switch

 Photo-electric sensors

 Ultrasonic sensors

 RADAR

1)Toggle switch:

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Toggle switches are actuated by a lever angled in one of two or more positions. The common light

switch used in household wiring is an example of a toggle switch. Most toggle switches will come

to rest in any of their lever positions, while others have an internal spring mechanism returning the

lever to a certain normal position, allowing for what is called "momentary" operation

Figure 2.1

2) Pushbutton switch:

A switch that is open when unactuated is called normally-open. A switch that is closed when

unactuated is called normally-closed. Sometimes the terms "normally-open" and "normally-closed"

are abbreviated N.O. and N.C., respectively

Figure 2.2

3)Selector switch:

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Selector switches are actuated with a rotary knob or lever of some sort to select one of two or more

positions. Like the toggle switch, selector switches can either rest in any of their positions or

contain spring-return mechanisms for momentary operation.

Figure 2.3

4)Limit switch:

Some switches are specifically designed to be operated by the motion of a machine rather than by

the hand of a human operator. These motion-operated switches are commonly called limit switches

Figure 2.4

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5)Proximity switch:

Proximity switches sense the approach of a metallic machine part either by a magnetic or high-

frequency electromagnetic field. Simple proximity switches use a permanent magnet to actuate a

sealed switch mechanism whenever the machine part gets close (typically 1 inch or less).

Figure 2.5

6)Pressure switch:

Gas or liquid pressure can be used to actuate a switch mechanism if that pressure is applied to a

piston, diaphragm, or bellows, which converts pressure to mechanical force.

Figure 2.6

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7)Level switch:

A floating object can be used to actuate a switch mechanism when the liquid level in an tank rises

past a certain point.

Figure 2.7

8)Photo-electric sensors:

A photoelectric sensor, or photo eye, is a device used to detect the distance, absence, or presence

of an object by using a light transmitter, often infrared, and a photoelectric receiver. They are used

extensively in industrial manufacturing.

There are three different functional types: opposed , retro reflective, and proximity-sensing.

 An opposed (through beam) arrangement consists of a receiver located within the line-of-sight

of the transmitter. In this mode, an object is detected when the light beam is blocked from

getting to the receiver from the transmitter.

 A retro reflective arrangement places the transmitter and receiver at the same location and uses

a reflector to bounce the light beam back from the transmitter to the receiver. An object is

sensed when the beam is interrupted and fails to reach the receiver.

 A proximity-sensing (diffused) arrangement is one in which the transmitted radiation must

reflect off the object in order to reach the receiver. In this mode, an object is detected when the

receiver sees the transmitted source rather than when it fails to see it.

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9)Ultrasonic sensors:

Ultrasonic sensors (also known as transducers when they both send and receive) work on a

principle similar to radar which evaluate attributes of a target by interpreting the echoes from radio

or sound waves respectively. Ultrasonic sensors generate high frequency sound waves and evaluate

the echo which is received back by the sensor. Sensors calculate the time interval between sending

the signal and receiving the echo to determine the distance to an object.

10)RADAR:

Radar is an object detection system that uses electromagnetic waves to identify the range, altitude,

direction, or speed of both moving and fixed objects such as aircraft, ships, motor vehicles,

weather formations, and terrain. The term RADAR was coined in 1941 as an acronym for radio

detection and ranging.

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2.3 LOGIC GATES

Gate’s name

Sr. and its Circuit Diagram Ladder Diagram Truth Table

symbol

I1 I1

I1 I2 Or

Or Gate I2 Q1 0 0 0
I/P O/P

1. 0 1 1
I2
1 0 1

1 1 1

I1 I2 And
And Gate I1 I2 0 0 0

2. I/P O/P I1 I2 0 1 0
Q1
1 0 0

1 1 1

Not Gate I1 Not

3. I 1
0 1

I/P
I1
O/P
1 0
Q1

I1 I2 Nand
Nand Gate 0 0 1
I/P O/P Q1
I1
4. 0 1 1
I1
1 0 1

I2 1 1 0

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I2

I1 I2 Nor
Nor Gate I1 I2 0 0 1
I/P O/P
5. I1 0 1 0
Q1
1 0 0

1 1 0
I2

I1 I2
I1 I2 Xor
Q1
Xor Gate 0 0 0

6. I/P O/P 0 1 1
I1 I2

1 0 1

1 1 0

I2 I1

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Chapter 3:- Number system used for PLC

3.1 Number System used for PLC:

Number system is ordered set of digits, which are used to perform the arithmetic operations. There

are different types of number systems:

S.no. Number Base Symbols Used

System Examples

1. Binary 2 0&1 1101.01

2. Octal 8 0,1,2,3,4,5,6 &7 3761.62

3. Decimal 10 0,1,2,3,4,5,6,7,8&9 9540.57

4. Hexadecimal 16 0,1,2,3,4,5,6,7,8,9,A,B,C,D,E&F 3F6A.F9

1) Binary system: Binary means 2. So binary system is string/group of 0’s and 1’s.

Bit: Bit is an abbreviation of binary digit.

B: from binary.

It is from digit

Example: binary number 10101 has 5 bits.

LSB 1*2 raise to power 0=1

0*2 raise to power 1=0

1*2 raise to power 2=4

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0*2 raise to power 3=0

1*2 raise to power 4=16

Total=21

So weight of 10101 is 21.

Nibble: group of 4 bits.

Byte: group of 8 bits.

Word: group of 16 bits.

Double Word: group of 32 bits.

Floating word: is used for real numbers.

2) Decimal system: This system is most commonly used number system with base/radix 10.

For any number system there is one MSB (most significant bit) & LSB (least significant bit). The

extreme left is MSB & the right one is LSB.

Example: decimal number 4351.

Here in the above decimal number:

1 is LSB

4 is MSB

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There is weight of each bit; it is base raise to power of index. The index starts from 0 for LSB and

keep on increment by 1 towards MSB. In the above example 4351 is the decimal no: with base 10.

So LSB-1*10 raise to power 0=1

5*10 raise to power 1=50

3*10 raise to power 2=300

4*10 raise to power 3=4000

Total=4351

3) Hexadecimal System:

The base/index of hexadecimal number is 16.which uses the 16 digits to represent the number.

These digits r :0,1,2,3,4,5,6,7,8,9,A,B,C,D,E,F

e.g:14FA

Here LSB A*16 raise to power0=10

F*16 raise to power 1=240

4*16 raise to power 2=1024

1*16 raise to power 3=4096

Total=5370

Hence its weight is 5370

4) BCD (binary coded decimal): In this code, decimal digits 0 through 9 represented by their

natural binary equivalents using four bits and each decimal digit of a decimal number is

represented by this four bit code individually. Example: 23 in decimal is represented by 0010 0011

in BCD system

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Chapter4:- Introduction to PLC

4.1 Basic definition

PLC is a solid state device designed to perform the logic functions previously accomplished by

components such as electromechanical relays, drum switches, mechanical timers/counters etc. for

the control and operation of manufacturing process equipment and machinery. Even though the

electromechanical relay have served well for many generation, often under adverse conditions, the

ever increasing sophistication and complexity of modern processing equipment requires faster

acting, more reliable control functions that electromechanical relays or timing devices cannot offer.

PLC is user friendly, microprocessor based specialized computer that carries out control functions

of many types and at many levels of complexity. Its purpose is to monitor crucial process

parameters and adjust process parameters accordingly. It can be programmed, controlled and

operated by a person unskilled in operating computers.

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4.2 What is PLC?

 PLC Stands For :Programmable Logic Controllers

 A Programmable Logic Controller (PLC) is an industrial computer that accepts inputs from

switches and sensors, evaluates these in accordance with a stored program, and generates

outputs to control machines and processes.

 A programmable controller is a solid state device that uses soft wired logic contained in the

controller’s memory to duplicate the functions of relays and hardwired solid state control

devices. In operation, the memory unit sequentially scans inputs( sensors, limit switches, push

buttons, photocells) in cyclic fashion to determine which outputs( contacts, motor starters,

solenoids, pilot lights, converters, etc.) should be turned on or off.

4.3Advantages of PLC:

1. Flexibility: In the past, each different electronically controlled production machine required its

own controller; 15 machines might require 15 different controllers. Now it is possible to use just 1

model of PLC to run any one of the 15 machines. Furthermore, you would probably need fewer

than 15 controllers, because one PLC can easily run many machines. Each of 15 machines under

PLC control would have its own distinct program.

2. Implementing Changes and Correcting Errors: With a wired relay type panel, any

program alterations require time for rewiring of panels and devices. When a PLC program circuit

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or sequence design change is made, the PLC program can be changed from a keyboard sequence in

a matter of minutes. No rewiring is required for a PLC- controlled system. Programming error can

also be corrected in a PLC control ladder diagram by typing a change quickly.

3. Large Quantity of Contacts: The PLC has a large number of contacts for each coil available

in its programming. Suppose that a panel wired relay has four contacts and all are in use when a

design change requiring three more contacts is made. Time would have to be taken to procure and

install a new relay or relay control block. Using a PLC, however, only three more contacts would

be typed in. The three contacts would be automatically available in the PLC. Indeed, a hundred

contacts can be used from one relay-if sufficient computer memory is available.

4. Lower Cost: Increased technology makes it possible to condense more functions into smaller

and less expensive packages. Now you can purchase a PLC with numerous relays, timers, counters,

a sequencer and functions at low price.

5. Pilot Running: A PLC programmed circuit can be pre-run and evaluated in the office or lab.

The program can be typed in, tested, observed and modified if needed, saving valuable factory

time. In contrast, conventional relay systems have been tested on the factory floor, which can be

very time consuming.

6. Visual Observation: A PLC circuit operation can be seen during operation directly on a CRT

screen. The operation and miss operation of a circuit can be observed as it happens. Logic paths

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CTIEMT/ECE/100220414148

light up on the screen as they are energized. Troubleshooting can be done more quickly during

visual observation.

7. Speed of Operation: Relays can take an unacceptable amount of time to actuate. The

operational speed for the PLC program is very fast. The speed for the PLC logic operation is

determined by scan time, which is a matter of milliseconds.

8. Ladder or Boolean Programming Method: An electrician or technician can accomplish

the PLC programming in the ladder mode. Alternatively, a PLC programmer who works in digital

or Boolean control systems can also easily perform PLC programming.

9. Reliability and Maintainability: Solid-state devices are more reliable than mechanical

systems or relays and timers. The PLC is made of solid-state components with very high reliability

rates. Consequently, the control system maintenance costs are low and downtime is minimal.

10. Documentation: An immediate printout of the true PLC circuit is available in minutes.

There is no need to look at the blue prints of the circuit in remote files. The PLC prints out the

actual circuit in operation at a given moment. Often the file prints for relay panels are not properly

kept up to date. A PLC printout is the circuit at the present time; no wire tracing is needed for

verification.

11. Security: A PLC program change cannot be made unless the PLC is properly unlocked and

programmed. Relay panels tend to undergo undocumented changes. People on late shifts do not

always record panel alterations made when the office area is locked up for the night.

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12. Ease of Changes by Reprogramming: The PLC can be reprogrammed quickly; mixed

production processing can be accomplished. For example, if part B comes down the assembly line

while part A is still being processed, a program for part B’s processing can be reprogrammed into

the production machinery in a matter of seconds.

4.4 Disadvantages of PLC:

1. Newer technology: It is difficult to change the thinking of some personnel from ladders and

relays to the PLC computer concept. Although today with pervasive use of computers not only at

home and in office but on the factory floor acceptance of the computer as a powerful and reliable

productivity enhancing tool is almost so. Electricians and technicians have to take the trainings on

PLC’s for job security and advancement.

2. Fixed program applications: Some applications are single function applications. It does not

pay to use a PLC that includes multiple programming capabilities if they are not needed.

3. Environmental considerations: Certain process environments, such as high heat and

vibration, interface with the electronic devices in PLC’s, which limit their use.

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4. Fixed circuit operation: If the circuit in operation is never altered, a fixed control system

(such as mechanical drum) might be less costly than a PLC. The PLC is most effective when

periodic changes in operation are made.

5. Fail-Safe Operation: In relay systems, the stop button electrically disconnects the circuit; if

the power system fails, the system stops. Furthermore, the relay system does not automatically

restart when power is restored. This, of course, can be programmed into the PLC; however in some

PLC programs, you may have to apply an input voltage to cause a device to stop. These systems

are not fail-safe.

This disadvantage can be overcome by adding safety relays to a PLC system.

Block Diagram of PLC:

Comp
uter

Communicat
Bus
ion module

Sens
Power ors

Supply Processor I/O Actuato

Memory Interfa rs

Figure 4.1

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CTIEMT/ECE/100220414148

4.5 Components of PLC:

Central Processing Unit or Processor

It is the brain of the system. The CPU, or processor, constitutes the motor or the “master of

ceremonies” of the Controller. It is the CPU that:

 Reads the sensors value

 Executes the program with the data contained in memory

 Writes the output connected to the actuators

The processor unit houses the microprocessor, memory and communication circuitry necessary for

the processor to operate and communicate with the input/output and other peripheral equipment.

The DC power required for the processor is provided either by a power supply that is the integral

part of the processor unit or by a separate power supply unit. Processor or “brain” of the PLC is a

decision maker that controls the operation of the equipment to which it is connected. It also

controls the operation of the input devices and the program that has been entered into the memory.

Processors controls as few as 8 or as many as 40,000 real word inputs and outputs. The larger the

number of input and output devices that are required for the process, the more powerful the

processor must be properly control the number of input/output that will be connected.

The processor may be self contained unit or may be modular in design. Processor scan does the

following:

 Determines the status of input devices

 Interpret the logic of program (read and solve logic)

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 Update (turn ON/OFF output device.

 Communication with connected devices & housekeeping (updating internal timers, counters &

registers)

Normally, before any output devices can be turned ON or OFF, the processor has to scan the entire

program that is in user memory. The program may be only of few rungs or of hundred pages in

length, depending on the equipment that being controlled. Some input devices operate so fast that

by the time the user program can be read and solved the outputs updated, the input device may

have changed the positions more that once since the processor originally determined its status at

the start of the scan. It may be true for an output device that may be updated sooner than a regular

scan will allow. To solve this problem, many PLC’s have special program instructions that allow

critical or high speed input and output devices to be updated sooner that would be possible under

normal scan conditions. Special instructions actually interrupt the scan when it is reading the

program and allow I/O devices to be updated immediately.

Memory

The controller memory contains the program to be executed, but also the data used by the program

(timer values, mono-stable values, counter values, etc.) This is where all the data contained in the

Controller is stored. The Controller cannot operate without memory.

Memory section of the processor consists of hundreds or thousands of locations where information

is stored. It is divided into two parts, user and storage. The user memory is for storage of the user

program, which contains the ladder logic, or instructions that control the driven equipment. The

storage memory is used to store information such as input/output status, timer or preset/

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accumulated values and internal control relays etc that are necessary for the processor to control

equipment.

The memory chips used in the processor can be separated into two distinct groups:

 Volatile: That losses its stored information when power is removed.

 Non-volatile: It has the ability to retain stored information when power is removed,

accidentally or intentionally.

Back-up batteries included in the processor power supply protect volatile memory. The battery

may be D sized dry cells re-chargeable nickel cadmium or non-rechargeable alkaline, lithium

types.

Memory types:

i. Random Access Memory (RAM): Information can be written into or read from a RAM chip
and is often referred to as read/write memory. Information stored in the memory can be retrieved

or read. Random access refers to the ability of any location (address) in the memory to be

accessed or used. It is used for both user memory and storage memory in many PLC’s. Since

RAM is volatile, it must have battery back-up to retain or protect the stored program.

ii. Read Only Memory (ROM): It is common non-volatile memory do not require battery back-
up & retains information or program when power is lost. Read only indicates that information

stored in memory can be read only and cannot be changed. Information in ROM is place by the

manufacturer for the internal use and operation of the PLC & the manufacturer do not want the

information changed or altered.

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iii. Programmable Read Only Memory (PROM): PROM allows initial and/or additional

information to be written into the chip. PROM may be written into only once after being received

from the PLC manufacturer. This type of memory is used to prevent unauthorized program

changes.

iv. UVPROM-EPROM: Ultra violet programmable read only memory is ideally suited when

program storage is to be semi-permanent or additional security is needed to prevent unauthorized

program changes. UVPROM chip is also referred to as EPROM (Erasable programmable read

only memory). EPROM has quartz window over a silicon material that contains electronic IC’s.

This window is normally covered by an opaque material but when opaque material is removed

and the circuitry exposed to ultraviolet light, the memory content can be erased. Once erased, the

EPROM chip can be re-programmed using a special programmer.

Figure 4.2

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CTIEMT/ECE/100220414148

I/O Modules: The input module has terminals into which outside process electric signals,

generated by sensors or transducers, are entered. The output module has terminals to which

output signals are sent to activate relays, solenoids, various solid-state switching devices, motors,

and displays. An electronic system for connecting I/O modules to remote locations can be added

if needed. The actual operating process under PLC control can be thousands of feet from the

CPU and its I/O modules.

Power Supply:

The electrical supply that convert alternating current (AC) line voltage to various operational DC

values to ensure proper computer operation

Bus:

It enables all parts to communicate with each other. It is the internal dialogue tool of the

programmable controller.

Communication Module:

This transfers the data from computer to controller or controller to computer.

Controller Cycle:

As soon as we launch the execution of the program, the controller will carry out three phases

cyclically:

Phase 1: snapshot of the status of its inputs

Phase 2: program execution

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Phase 3: output activation or deactivation

At the end of the phase 3, the controller returns to phase 1, and so on.

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CTIEMT/ECE/100220414148

Chapter5:- Programming in PLC

5.1 Different Types Of Languages:-

1) Functional Block Diagram language:- In this language program is written in terms of

blocks. A function block diagram (FBD) is a block diagram that describes a function between input

variables and output variables. A function is described as a set of elementary blocks. Input and

output variables are connected to blocks by connection lines.

Figure 5.1

36
CTIEMT/ECE/100220414148

Inputs and outputs of the blocks are wired together with connection lines, or links.

Disadvantage:

Difficult to write a program.

2) Instruction List Language:- Instruction list (IL) programming is defined as part of the IEC

61131 standard. It uses very simple instructions similar to the original mnemonic programming

languages developed for PLCs.

Figure 5.2

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CTIEMT/ECE/100220414148

Disadvantage:-

Difficult to write a program in it.

3) Sequential Functional Chart Language:- SFC programming offers a graphical method of

organizing the program. The three main components of an SFC are steps, actions and transitions.

Steps are merely chunks of logic, i.e., a unit of programming logic that accomplishes a particular

control task. Actions are the individual aspects of that task. Transitions are the mechanisms used to

move from one task to another. Control logic for each Step, Action and Transition is programmed

in one of the other languages such as Ladder Diagram or Structured Text.

Figure 5.3

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CTIEMT/ECE/100220414148

Disadvantage:-

Difficult to write a Program in it.

4) Structured text language:- Structured Text uses operators such as logical branching,

multiple branching, and loops.

Figure 5.4

Disadvantage:-

Difficult to write a program in it.

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5) LADDER Language:-

Ladder Language:

With LADDER programming language, two alternative types of symbol can be used:

 LADDER symbols.

 Electrical symbols.

“Free input” mode also allows the creation of mnemonics and notes associated with each line of

the program. Instant switching from one input mode to the other is possible at any time, by simply

clicking the mouse. Up to 120 control scheme lines can be programmed, with 5 contacts and 1 coil

per program line.

Figure 5.5

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CTIEMT/ECE/100220414148

Programming Devices (Programmers)

A programming device is needed to enter, modify and troubleshoot the PLC program, or

to check the condition of the processor. Once the program has been and the PLC is

running, the programming device may be disconnected. Three types of programmers are

generally used:

1) Hand held (smaller, cheaper, portable but limited display capability & few functions)

2)Dedicated desktop (user-friendly, designed for industrial use, portable but costly,

limited PLCs can be programmed, limited documentation and limited graphics

capability).

3)Personal computer: With software available for all major brands of PLCs, the PC

today is the most common programming device. It can store program on floppy disk /

hard disk. If for some reason the program is lost the restoration of the program is

simple. When the s/w is updated by the manufacturer to provide additional features,

the update is easily accomplished by loading the new s/w program onto the PC hard

disk by way of the floppy disk drive.

Program input & control instructions

1) Normally open contact: When this contact closes, the function carries out some kind

of action.

2)Normally closed contact: When this contact opens, the function carries out some

kind of action.

4)Latch/ unlatch system: Actuating the latch input turns the function on or causes it to

change state. The function then stays on even if the latch is turned off. To turn the

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function off, another input, unlatch, is turned on, which turns the function off. If

function remains off.

5)Differentiation up, or rising-edge actuation: This involves turning the function on

for one scan time at the leading edge of an input signal pattern.

6) Differentiation down, or falling-edge actuation: This involves turning the function

on for one scan time at the trailing edge of a signal pattern.

7) Jump & label instruction: are used in combination, these two instructions allow for

skipping over portions of the program to save program scan time. If there is a portion

of the program that is not operational during certain portions of the process, the

portion that is not used or needed can be jumped over or bypassed until it is needed

again. By jumping over parts of the program, the scan time is decreased and more

scans can be completed in a given period of time.

BASIC INSTRUCTIONS

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Steps for installation/commissioning of PLC

1) Understand the machine or process.

2) Decide the (inputs & outputs) + 10%

3) Choose the controller.

4) Prepare the input/output list.

5) Wiring diagram of PLC/control/power.

6) Write down sequence of operation

7) Prepare the application software on paper using pencil and rubber.

8) Write the application software in computer.

9) Test the wiring with continuity tester/multimeter without powering the panel (4-5 times). Never

use bulb and holder. Check specially no high voltage sharing is there.

Check the supply to PLC & PLC inputs/outputs is in the specified range.

10) Before power up of main MCB, switch off all internal MCBs.Disconnect the output of the

transformer before checking.

11) Switch on all required MCBs turn by turn prior checking its Inputs.

12) Don’t switch ON the MCB of the common to outputs. Disconnect it.

13) Check the inputs/outputs with loop testing as per input/output list.

14) Download the software.

15) Simulate the manual cycle first and then auto.

16) Switch the MCB of the output common till keeping one person (Hand) on main supply control.

17) Check the cycle of machine.

18) Handover to the person and watch for 5-6 cycles.

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USAGE OF VARIOUS LADDER ELEMENTS AS CONTACTS

Normally Normally
Ladder Function in N. O. Function in N. C.
Sr. Open ( N. Closed ( N.
Elements Mode Mode
O.) Mode C.) Mode

If the input is If the input is

Discrete supplied, the contact supplied, the contact is

1. I- i-
Inputs is said to be said to be non-

conducting. conducting.

Contact will not

Discrete Contact conducts
2. Q- q- conduct when
Outputs when powered.
powered.

If powered the contact

Auxiliary If powered the contact
3. M- m- will be non
Relays will be conducting.
conducting.

Contact will not

Contact conducts
4. ZX Keys Z- z- conduct when
when powered.
powered.

Contact is conducting Contact is conducting

when current counter as long as current

5. Counters C- c-
value = preset value counter value has not

in TO mode (up- reached the preset

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count mode) or = 0 in value in TO mode

FROM mode (down- (up-count mode) or ≠

count mode) 0 in FROM mode

(down-count mode)

Contact is conducting Contact is conducting

Counter
6. V- when the condition is v- when the condition is
Comparator
verified. not verified.

Contact is conducting Contact is conducting

7. Clocks or H- when the clock is in a or h- when the clock is not

validity period. in a validity period.

If the output is active, If the output is active,

8. Timer T- the contact is said to t- the contact is said to

be conducting. be non-conducting.

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5.2 PROGRAM TO RUN THE MOTOR IN FORWARD AND REVERSE DIRECTION

STEP1:- I/O LIST

INPUT OUTPUT

I1 STOP PUSH BUTTON Q1 FORWARD MOTOR

I2 START (P.B.) FWD. Q2 REVERSE MOTOR

I3 START (P.B.) REV.

STEP2:- SEQUENCE OF OPERATION

S.NO. CONDITION ACTION

1. I2 ON Q1 ON

2. I1 ON + Q1 ON Q1 OFF

3. I3 ON Q2 ON

4. I1 ON + Q2 ON Q2 OFF

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LADDER DIAGRAM

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Chapter 6 :- Project

Name of Project:- Railway crossing system

Hardware Discription:-

DC gear moter

Specifications:

Voltage:12V

Small Push Buttons:-

Power Supply

Specification:-

24 V DC

Proximately sensors

Specification:-

24 V D

Battery

Specification:-

9V

PLC

Specifications:-

Having 12 inputs and 8 Outputs

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Power Supply is the essential part of every electronics circuit. Power supply circuit
consists of +24 V DC to drive PLC and other sensors.

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DC Gear Motors are used to provide the motion to conveyor. As we have dc power
supply so we use the DC motor instead of AC motors.

PLC is the heart of this system we are using zileo based PLC, which has 12 inputs
and 8 outputs.

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Figure 6.1

Program :-

Figure 6.2

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Figure 6.3

Figure 6.4

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Figure 6.5

Figure 6.6

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Figure 6.7

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Figure 6.8

Figure 6.9

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