project report on p.l.c

8/3/2019 Project Report on p.l.c

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INDEXINDEXSr. No.Sr. No. CHAPTERSCHAPTERS Page No.Page No.

1.1. Project TitleProject Title

2.2. AcknowledgementAcknowledgement

3.3. Company introductionCompany introduction

4.4.

Project detailsProject details

(a)(a) Objectives of the ProjectObjectives of the Project

(b)(b) Introduction to the ProjectIntroduction to the Project

5.5. Overview of other selected Companies inOverview of other selected Companies in

the samplethe sample

8.8. ConclusionConclusion

6.6. AnalysisAnalysis

7.7. AnnexureAnnexure


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PROJECTPROJECT

REPORT ON P.L.CREPORT ON P.L.C


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COMPANY INTRODUCTIONCOMPANY INTRODUCTION


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ACKNOWLEDGEMENTACKNOWLEDGEMENT

Practical training during vacation provides us actual production scenario.Practical training during vacation provides us actual production scenario.

I in my report try to encompass everything that I have learnedI in my report try to encompass everything that I have learned

during my training in FMAL. Here everyone showed a supportiveduring my training in FMAL. Here everyone showed a supportive

and a helpful nature.and a helpful nature.

I am thankful to MR. YOGESH SINGH (HEAD OF MAINT. DEPTT.)I am thankful to MR. YOGESH SINGH (HEAD OF MAINT. DEPTT.)

Under the guidance of whom I completed my training project.Under the guidance of whom I completed my training project.

I express my gratitude to ER. VIPIN KUMAR and MR. RAJ KUMAR forI express my gratitude to ER. VIPIN KUMAR and MR. RAJ KUMAR for

their guidance, encouragement, incalculable help and support for thetheir guidance, encouragement, incalculable help and support for the

completion of training project.completion of training project.

Once again I thankful to all FMAL members, and specially MAINT.Once again I thankful to all FMAL members, and specially MAINT.DEPT. for the kind love and their right instructions every time .DEPT. for the kind love and their right instructions every time .

SHUBHAM NATANISHUBHAM NATANI


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ACKNOWLEDGEMENTACKNOWLEDGEMENT

Practical training during vacation provides us actual production scenario.Practical training during vacation provides us actual production scenario.

I in my report try to encompass everything that I have learnedI in my report try to encompass everything that I have learned

during my training in FMAL. Here everyone showed a supportiveduring my training in FMAL. Here everyone showed a supportive

and a helpful nature.and a helpful nature.

I am thankful to MR. YOGESH SINGH (HEAD OF MAINT. DEPTT.)I am thankful to MR. YOGESH SINGH (HEAD OF MAINT. DEPTT.)Under the guidance of whom I completed my training project.Under the guidance of whom I completed my training project.

I express my gratitude to ER. VIPIN KUMAR and MR. RAJ KUMARI express my gratitude to ER. VIPIN KUMAR and MR. RAJ KUMAR

BHARDWAJ for their guidance, encouragement, incalculable helpBHARDWAJ for their guidance, encouragement, incalculable help

and support for the completion of training project.and support for the completion of training project.

Once again I thankful to all FMAL members, and specially MAINT. DEPT.Once again I thankful to all FMAL members, and specially MAINT. DEPT.

for their love and kind instructions.for their love and kind instructions.

VIKAS KUMARVIKAS KUMAR


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INTRODUCTION OF P.L.CINTRODUCTION OF P.L.CP.L.C. is a programmable logic control device. It is a solid state device design toP.L.C. is a programmable logic control device. It is a solid state device design toperform the logic function previously accomplished by components such asperform the logic function previously accomplished by components such aselectrometrical relays, drum switches, mechanical timers and counters for theelectrometrical relays, drum switches, mechanical timers and counters for thecontrol and operation of manufacturing process equipment and machinery. Evencontrol and operation of manufacturing process equipment and machinery. Eventhough electromechanically relays control relays, numeric timer relay etc.) havethough electromechanically relays control relays, numeric timer relay etc.) haveserved well for many generations, often under adverse condition.served well for many generations, often under adverse condition.

The ever increasing sophistication and complexity of modern processingThe ever increasing sophistication and complexity of modern processing

equipment require faster acting more reliable control function thatequipment require faster acting more reliable control function thatelectromechanical relay cannot offer. Relay has to be hard wired to performelectromechanical relay cannot offer. Relay has to be hard wired to performspecific functions and when the system requirements change the relay wiring hasspecific functions and when the system requirements change the relay wiring hasto be change or modified. The requirement of highly specialized, high speedto be change or modified. The requirement of highly specialized, high speedmanufacturing processes created a demand for smaller faster acting, more reliable,manufacturing processes created a demand for smaller faster acting, more reliable,low power consuming, expandable, eliminating much of hard wiring controllow power consuming, expandable, eliminating much of hard wiring control

devices is called P.L.C.devices is called P.L.C.

P.L.C. has also a memory like computer for storing the user program orP.L.C. has also a memory like computer for storing the user program orlogic as well as memory for controlling the operation of process machine. P.L.C.logic as well as memory for controlling the operation of process machine. P.L.C.is programmed in LADDER LOGIC.is programmed in LADDER LOGIC.

The P.L.C. is also design to operate in the industry environment withThe P.L.C. is also design to operate in the industry environment withwide range of ambient temperature, temperature, vibration, and humidity and iswide range of ambient temperature, temperature, vibration, and humidity and isnot usually affected by electrical noise that is inherent in most industrial locations.not usually affected by electrical noise that is inherent in most industrial locations.


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DEFINITION OF P.L.CDEFINITION OF P.L.C

A Programmable Logic Controller (PLC or programmable

controller) is a device that a user can program to perform a series or

sequence of events. These events are triggered by stimuli. (usually

called inputs) received at the PLC or through delayed actions such

as time delays or counted occur-rences. Once an event triggers, it

actuates in the outside world by switching ON or OFF electronic

control gear or the physical actuation of devices. A programmable

controller will continually loop through its Internal user defined

program waiting for inputs and givingoutputs at the programmed specific times.


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PICTORIAL VIEW OF P.L.CPICTORIAL VIEW OF P.L.C


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WORKING OF P.L.CWORKING OF P.L.C

Working of PLC is totally based upon programming. Which isWorking of PLC is totally based upon programming. Which isdone in PLC by an operator working on PLC. Programming isdone in PLC by an operator working on PLC. Programming is

done according to sequence in which we want to operate adone according to sequence in which we want to operate a

machine. After programming it will create a signal and sent themachine. After programming it will create a signal and sent the

signal to machine to operate in wanted sequence. First it willsignal to machine to operate in wanted sequence. First it will

scan the input applied to PLC and then the processor scan thescan the input applied to PLC and then the processor scan the

logic formed in PLC. It will scan all the logic top to bottomlogic formed in PLC. It will scan all the logic top to bottom

and then left to right. And then force the machine to operateand then left to right. And then force the machine to operateaccording to logic formed. And then scan the output. foraccording to logic formed. And then scan the output. for

example:example: In scrapping machine working of P.L.C explainedIn scrapping machine working of P.L.C explained

bellow.bellow.


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PROGRAM IN P.L.CPROGRAM IN P.L.C


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PASSWORDPASSWORD

II00 BACKWARD REED SWITCH BACKWARD REED SWITCH I1 FORWARD REED SWITCHI1 FORWARD REED SWITCH

I2 DOWN POSITION REED SWITCHI2 DOWN POSITION REED SWITCH I3 LEFT SIDE BOBBIN CONTINUEITY OKI3 LEFT SIDE BOBBIN CONTINUEITY OK

I4 RIGHT SIDE BOBBIN CONTINUEITY OKI4 RIGHT SIDE BOBBIN CONTINUEITY OK

I5 PUSH BUTTON FOR RESETI5 PUSH BUTTON FOR RESET Q0 CYLINDER SOLQ0 CYLINDER SOL Q1 LEFT SIDE BOBBIN CONTINUEITY OKQ1 LEFT SIDE BOBBIN CONTINUEITY OK Q2 RIGHT SIDE BOBBIN CONTINUEITY OKQ2 RIGHT SIDE BOBBIN CONTINUEITY OK


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Let cylinder 1 is used to move the bobbin inside the cylinder 2 which is used toLet cylinder 1 is used to move the bobbin inside the cylinder 2 which is used to

scrap the bobbin. At initial when cylinder 1 will be in forward then i0 will be inscrap the bobbin. At initial when cylinder 1 will be in forward then i0 will be in

off condition and i1 must be on to make the internal flag m0 on. In logic we knowoff condition and i1 must be on to make the internal flag m0 on. In logic we know

that when m0 will be on then m0 will be hold because m3 is off and it willthat when m0 will be on then m0 will be hold because m3 is off and it willbecome independent of i0 and i1. and from logic now m0 is on . I0 will be on andbecome independent of i0 and i1. and from logic now m0 is on . I0 will be on and

i1 will be off because now cylinder is in backward direction. And now m1 will bei1 will be off because now cylinder is in backward direction. And now m1 will be

on and it will hold on because m3 is off. Now it also independent of i0,i1,m0.on and it will hold on because m3 is off. Now it also independent of i0,i1,m0.

from logical diagram when m1 is on then output Q0 will be on and cylinder 2from logical diagram when m1 is on then output Q0 will be on and cylinder 2

will come in down ward direction for scrapping. I2 is on which indicate thatwill come in down ward direction for scrapping. I2 is on which indicate thatcylinder 2 is in down ward direction. When i3 and i4 will be on then m3 will becylinder 2 is in down ward direction. When i3 and i4 will be on then m3 will be

on and cylinder 2 move up ward. Here i3 and i4 indicate that continuity ofon and cylinder 2 move up ward. Here i3 and i4 indicate that continuity of

bobbins is ok and if continuity of any one bobbin is not ok then m3 will be offbobbins is ok and if continuity of any one bobbin is not ok then m3 will be off

and cylinder 2 will be in down ward. Here push button i5 is used to force theand cylinder 2 will be in down ward. Here push button i5 is used to force the

cylinder in up ward. If i2 and i3 is on then Q1 will be on which indicate thatcylinder in up ward. If i2 and i3 is on then Q1 will be on which indicate that

continuity of one bobbin is ok. Similarly when i2 and i4 will be on then Q2 is oncontinuity of one bobbin is ok. Similarly when i2 and i4 will be on then Q2 is on

and continuity of second bobbin is ok. When continuity of both bobbin is ok thenand continuity of second bobbin is ok. When continuity of both bobbin is ok then

m3 is on and m0 and m1 will be reset and Q1 will be off and cylinder 2 move upm3 is on and m0 and m1 will be reset and Q1 will be off and cylinder 2 move up

ward.ward.


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BLOCK DIAGRAM OF P.L.CBLOCK DIAGRAM OF P.L.C


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NEED OF P.L.CNEED OF P.L.CA variety of tools are available to program the Mitsubishi FX family ofPLC s. Each of these tools can use and access the Instructions and deviceslisted in this manual for the identified

PLC.


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PARTS OF P.L.CPARTS OF P.L.C

A typical PLC has divided in to four mainA typical PLC has divided in to four maincomponents.components.

Processor unit.Processor unit.

Power supply.Power supply. Input &output section.Input &output section.

Programming device.Programming device.


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PROCESSOR UNITPROCESSOR UNIT Processor is the decision maker or brain of the system. The brain is a microprocessor basedProcessor is the decision maker or brain of the system. The brain is a microprocessor based

system that replace control relays, counters, timers, sequencers etc. and is designsystem that replace control relays, counters, timers, sequencers etc. and is designso that the user can enter the desirer program in LADDER LOGIC. The processor then makesso that the user can enter the desirer program in LADDER LOGIC. The processor then makesall decisions necessary to carry out the user program based on status of input and output forall decisions necessary to carry out the user program based on status of input and output forcontrol of machine.control of machine.

The processor unit houses the microprocessor, memory and the communicationThe processor unit houses the microprocessor, memory and the communicationcircuitry necessary for the processor to operate and communicate with the input and othercircuitry necessary for the processor to operate and communicate with the input and otherequipment. The dc power required for processor is provide separate power supply unit. Itequipment. The dc power required for processor is provide separate power supply unit. It

control the operation of the equipment to which it is connected .it is the brain of the PLC. Itcontrol the operation of the equipment to which it is connected .it is the brain of the PLC. Italso control operation of output device that are connected to output module based on the statusalso control operation of output device that are connected to output module based on the statusof input device. It control as few as 8 or as many as 40000 real world input & output . Theof input device. It control as few as 8 or as many as 40000 real world input & output . Theprocessor may be a self contained unit. Processor scan the following:processor may be a self contained unit. Processor scan the following:

Determine the status of input device .Determine the status of input device . Interpret logic of program.Interpret logic of program.

Up date ( turn on or off output devices)Up date ( turn on or off output devices) Communication with connected devices and house keeping.Communication with connected devices and house keeping.

before any output device can be turned on or off the processor has to scan the enter programbefore any output device can be turned on or off the processor has to scan the enter programthat is in user memory. The program may be only of a few rungs or it may be hundred of pagesthat is in user memory. The program may be only of a few rungs or it may be hundred of pagesin length depend on the equipment.in length depend on the equipment.


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MEMORY OF PROCESSOR UNITMEMORY OF PROCESSOR UNIT

It consist of hundred or thousand of location where information is stored andIt consist of hundred or thousand of location where information is stored andis divided in to two parts user and storage. The user memory is for storageis divided in to two parts user and storage. The user memory is for storageof user program which contain a ladder logic or instruction that control theof user program which contain a ladder logic or instruction that control thedriven equipment. The storage memory is used to store information such asdriven equipment. The storage memory is used to store information such asinput and output status. Timer or counter preset and internal control relaysinput and output status. Timer or counter preset and internal control relaysetc. that are necessary for the processor to control the equipment.etc. that are necessary for the processor to control the equipment.

The memory chip in processor separated in two group volatile andThe memory chip in processor separated in two group volatile andnonvolatile.nonvolatile.

Volatile memory:Volatile memory: It loss stored information when power supply is off.It loss stored information when power supply is off. Nonvolatile memory:Nonvolatile memory: It retained stored information when power supplyIt retained stored information when power supply

is off.is off.

Back up batteries are include in processor power supply protect the volatileBack up batteries are include in processor power supply protect the volatilememory. These batteries may be rechargeable or non rechargeable.memory. These batteries may be rechargeable or non rechargeable.


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MEMORYMEMORY The most common type of volatile memory is RAM (random access memory).The most common type of volatile memory is RAM (random access memory).

The information can be written in to or read from a RAM chip and refer to asThe information can be written in to or read from a RAM chip and refer to asread/write memory. Information can be retrieved or read. Write indicate thatread/write memory. Information can be retrieved or read. Write indicate thatuser can program or write information in to it. It refer to the ability of anyuser can program or write information in to it. It refer to the ability of anylocation in memory to be used. It is used both for user memory and storagelocation in memory to be used. It is used both for user memory and storagememory in many PLC. It must have battery back up to protect the storedmemory in many PLC. It must have battery back up to protect the stored

program. It include CMOS and MOS.program. It include CMOS and MOS.

most common nonvolatile memory is ROM it do not require battery back upmost common nonvolatile memory is ROM it do not require battery back upand retains information when power is off. It indicate the information can beand retains information when power is off. It indicate the information can beread only cannot be changedread only cannot be changed

other types of memories are explained bellow:other types of memories are explained bellow: P-ROM :P-ROM : programmable read only memory.programmable read only memory. EP-ROM:EP-ROM: Erasable programmable read only memory.Erasable programmable read only memory. UVP-ROM:UVP-ROM: Ultraviolet programmable only memory.Ultraviolet programmable only memory. EEP-ROM:EEP-ROM: Electrical erasable programmable read only memory.Electrical erasable programmable read only memory. EA-ROM:EA-ROM: Electrical alterable read only memory.Electrical alterable read only memory.


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TYPES OF MEMORYTYPES OF MEMORY


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P-ROM:P-ROM: Programmable read only memory allows initial or additional information to beProgrammable read only memory allows initial or additional information to bewritten in to the chip. P-ROM may be written in to only once after being receivedwritten in to the chip. P-ROM may be written in to only once after being receivedfrom the PLC manufacturer. This type of memory is used to prevent antiauthorityfrom the PLC manufacturer. This type of memory is used to prevent antiauthority

program change.program change. UVP-ROM:UVP-ROM: UUltra violet programmable read only memory is ideally suitedltra violet programmable read only memory is ideally suited

when program storage is to be semi permanent or additional security is needed towhen program storage is to be semi permanent or additional security is needed toprevent unauthorized program changes. UVP-ROM is also known as EP-ROMprevent unauthorized program changes. UVP-ROM is also known as EP-ROM.EP-ROM has a quartz window over a silicon material that contain the electronic.EP-ROM has a quartz window over a silicon material that contain the electronicICs. The window is covered with a opaque material. But opaque material isICs. The window is covered with a opaque material. But opaque material isremoved and is exposed in to ultra violet light then recorded data is removed.removed and is exposed in to ultra violet light then recorded data is removed.

EA-ROM:EA-ROM: Electrical alterable read only memory chips can have storeElectrical alterable read only memory chips can have storeprogram erase electrically this is accomplished by different positive and negativeprogram erase electrically this is accomplished by different positive and negativevoltage value to specific circuit. once erased can be reprogrammedvoltage value to specific circuit. once erased can be reprogrammed

EEP-ROM:EEP-ROM: EElectrical erasable programmable read only memory is alsolectrical erasable programmable read only memory is alsoreferred to as E2PROM. It is a chip that can be programmed using a standardreferred to as E2PROM. It is a chip that can be programmed using a standardprogramming device can be erased by applying proper signal to erased pin . EEP-programming device can be erased by applying proper signal to erased pin . EEP-ROM chip can be down load in ram. This is used as non volatile back up for userROM chip can be down load in ram. This is used as non volatile back up for user

program ram.program ram.


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INPUT AND OUTPUT MODULESINPUT AND OUTPUT MODULESThese are two types discreet and analog. Discrete input devices are either on or off, open or close.These are two types discreet and analog. Discrete input devices are either on or off, open or close.

Limit switch, push button etc. are the discrete input device. Analog device have infinite numberLimit switch, push button etc. are the discrete input device. Analog device have infinite numberof possible value like as temperature probes, pressure indicators etc.of possible value like as temperature probes, pressure indicators etc.

INPUT MODULESINPUT MODULES:: These provide the status (on or off) push button, limit switches etc. to theThese provide the status (on or off) push button, limit switches etc. to theprocessor so that decision can be made to control the operation of machine and process inprocessor so that decision can be made to control the operation of machine and process inproper sequence. output such as motor relay coil, indicator light and solenoid are interface toproper sequence. output such as motor relay coil, indicator light and solenoid are interface toprocessor through the output section of input. Once the decision has been made by processor aprocessor through the output section of input. Once the decision has been made by processor asignal is sent to output section to control the flow of current to output device. A decision issignal is sent to output section to control the flow of current to output device. A decision is

made to turn the outputs to on or off. i/o section is generally divided in two categories.made to turn the outputs to on or off. i/o section is generally divided in two categories. Fixed input and output.Fixed input and output. Modular i/o , they can be kept on remote location up to 10,000 feet away from the processor.Modular i/o , they can be kept on remote location up to 10,000 feet away from the processor. DC INPUT MODULES:DC INPUT MODULES: They can be used with a 12v dc proximity switch to turn onThey can be used with a 12v dc proximity switch to turn on

240v ac motor relay/contactor coil that is connected to a ac output modulus. The conversion an240v ac motor relay/contactor coil that is connected to a ac output modulus. The conversion aninterfacing is all accomplished automatically in input section of PLC.interfacing is all accomplished automatically in input section of PLC.

DISCRETE INPUT MODULES:DISCRETE INPUT MODULES: They come in wide range of voltage for variousThey come in wide range of voltage for variousapplication, 120v ac, 240v ac, 24v dc. Some manufacturer also give their modules on ac/dcapplication, 120v ac, 240v ac, 24v dc. Some manufacturer also give their modules on ac/dcrating to increase their flexibility. They come in wide range of input channel such as 4,8,16,32rating to increase their flexibility. They come in wide range of input channel such as 4,8,16,32that determine the number of field device connected to module.that determine the number of field device connected to module.


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OUTPUT MODULESOUTPUT MODULESDiscrete output modules:Discrete output modules: These are used to control the current flowThese are used to control the current flow

to real world devices such as motor relay coils, lights, control relays,to real world devices such as motor relay coils, lights, control relays,solenoids valves. This also works on digital or and off basis. Thissolenoids valves. This also works on digital or and off basis. Thisworks like a remote control switch that is control by a processor forworks like a remote control switch that is control by a processor forturning the output devices or on off. These are sized by the outputturning the output devices or on off. These are sized by the outputdevices connected to them.devices connected to them.

Ac output module:Ac output module: They contain a triac. Some manufacturer usedThey contain a triac. Some manufacturer usedscr. When processor decide that output tuned to be on a signal is sentscr. When processor decide that output tuned to be on a signal is sentfrom the i/o rack and LED is on and the light cause thefrom the i/o rack and LED is on and the light cause the

phototransistor to conduct. Which provide current for the gate of triacphototransistor to conduct. Which provide current for the gate of triacthis portion optical isolate the logic section of processor from linethis portion optical isolate the logic section of processor from linevoltage of output device. The triac is used as electronic device to turnvoltage of output device. The triac is used as electronic device to turnthe output device on and off.the output device on and off.

Dc output modules:Dc output modules: It is same as ac output modules. Difference isIt is same as ac output modules. Difference isthat power transistor used instead of triac to control the outputthat power transistor used instead of triac to control the output

current. It has a quicker switch capability.current. It has a quicker switch capability.


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INTRODUCTION TO PROGRAMINTRODUCTION TO PROGRAMA program is a connected series of instructions written in a language that the

PLC can understand. There are three forms of program format; instruction,ladder and SFC/STL. Not all programming tools can work in all programming

forms. Generally hand held programming panels only work with instruction

format while most graphic programming tools will work with both instruction and

ladder format. Specialist programming software will also allow SFC style

programming.


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BASIC DEVICE USED INBASIC DEVICE USED IN

PROGRAMMINGPROGRAMMING

There are six basic programming devices. Each device has its own unique use.To enable quick and easy identification each device is assigned a single

reference letter;-X: This is used to identify all direct, physical inputs to the PLC.

- Y: This is used to identify all direct, physical outputs from the PLC.

- T: This is used to identify a timing device which is contained within the PLC.

- C: This is used to identify a counting device which is contained within the

PLC.

- M and S: These are used as internal operation flags within the PLC.

All of the devices mentioned above are known as bit devices. This is a

descriptive title telling the user that these devices only have two states; ON or

OFF, 1 or 0.


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ELECTRICAL DIAGRAMELECTRICAL DIAGRAM

There are two types of electrical diagrams:There are two types of electrical diagrams:

Ladder diagram.Ladder diagram. Wiring diagram.Wiring diagram.

Wiring diagram:Wiring diagram: They show the circuit the wiring and itsThey show the circuit the wiring and itsassociated devices in there relative physical relation. Thisassociated devices in there relative physical relation. Thistype of diagram assist in locating component and show howtype of diagram assist in locating component and show howthe circuit is actual wired. It does not show the circuit inthe circuit is actual wired. It does not show the circuit insimple form and to simplifying the understanding of how asimple form and to simplifying the understanding of how a

circuit work.circuit work.Ladder diagram:Ladder diagram: ladder diagram is also raftered asladder diagram is also raftered asschematic or elementary diagram is used by engineers toschematic or elementary diagram is used by engineers tospeed their understanding of how a circuit work.speed their understanding of how a circuit work.


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LADDER DIAGRAMSLADDER DIAGRAMS

To perform the working of plcTo perform the working of plcefficiently we makes the certainefficiently we makes the certain

programs. These based upon theprograms. These based upon theladder logic. To understand theladder logic. To understand theladder logic certain diagrams usedladder logic certain diagrams usedcalled ladder diagrams.called ladder diagrams.

sequence motor starting rung onesequence motor starting rung onecontain the stop/start button andcontain the stop/start button andmotor relay coil M1for motor one.motor relay coil M1for motor one.notice that the holding contactnotice that the holding contactwired in parallel with the startwired in parallel with the start

button are not in M1contect butbutton are not in M1contect but

instead are M3 contact. With thisinstead are M3 contact. With thisarrangement rung1 cannot bearrangement rung1 cannot besealed in unless motor relay 3sealed in unless motor relay 3energized and close its contact.energized and close its contact.M1 contact in rung2 must close toM1 contact in rung2 must close toenergized motor relay2 (M2) andenergized motor relay2 (M2) andM2 contact in turn must close inM2 contact in turn must close in

rung3 to energized motor3.rung3 to energized motor3.


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PROGRAMMING A P.L.CPROGRAMMING A P.L.C

STEP 7-Micro/WIN32 is the program software used with the S7-200 PLC to createthe PLC operating program. STEP 7 consists of a number of instructions that must

be arranged in a logical order to obtain the desired PLC operation. Theseinstructions are divided into three groups: standard instructions, special instructions,and high-speed instructions.

Standard InstructionsStandard instructions consists of instructions that are foundin most programs. Standard instructions include: timer, counter, math, logical,increment/decrement/invert, move, and block instructions.

Special InstructionsSpecial instructions are used to manipulate data. Specialinstructions include: shift, table, find, conversion, for/next, and real-timeinstructions.

High-Speed InstructionsHigh-speed instructions allow for events and interrupts tooccurs independent of the PLC scan time. These include high-speed counters,interrupts, output, and transmit instructions. It is not the purpose of this text to

explain all of the instruction sand capabilities. A few of the more commoninstructions necessary for a basic understanding of PLC operation will be discussed.PLC operation is limited only by the hardware capabilities and the ingenuity of the

person programming it . Refer to the SIMATIC S7-200 ProgrammableController System Manual for detailed information concerning these instructions.


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PROGRAMMING TYPESPROGRAMMING TYPES

On line programming:On line programming: It change the program while processor andIt change the program while processor anddriven equipment is running. it is done by a person with a completedriven equipment is running. it is done by a person with a completeunderstanding of circuit operation and processor.understanding of circuit operation and processor.

Off line programming:Off line programming: This program is being developed off lineThis program is being developed off line( with out connected to processor or driven equipment). Few program( with out connected to processor or driven equipment). Few program

are ever created with out mistake. It is the most common and safeare ever created with out mistake. It is the most common and safemethod of programming . After testing and verifying the program offmethod of programming . After testing and verifying the program offline the PLC can be put in on line mode for final verification,line the PLC can be put in on line mode for final verification, operationoperationand testing.and testing.

Programming with computer:Programming with computer:

Many company have developed s/wMany company have developed s/w

for programming PLC s. RS logix s/w is created by rock well forfor programming PLC s. RS logix s/w is created by rock well forprogramming the Allen Bradley Family of PLC. This s/w in variousprogramming the Allen Bradley Family of PLC. This s/w in variousversion can be used to program all Allen Bradley PLC s .version can be used to program all Allen Bradley PLC s .


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PROGRAMMING TIMERPROGRAMMING TIMER

The timer consist of a timing blockThe timer consist of a timing blockcontaining a timer number, timer basecontaining a timer number, timer base

and the preset and accumulated timersand the preset and accumulated timers

preset time can have the value 0 topreset time can have the value 0 to

32767 if time base is one second32767 if time base is one second

assigned 32767 equal to 9:1.assigned 32767 equal to 9:1.

EN and DN indicate the status ofEN and DN indicate the status of

timer. Timer address timer file numbertimer. Timer address timer file number

and timer number. EN bit is set to 1.and timer number. EN bit is set to 1.

whenever there is logic path to timerwhenever there is logic path to timer

block. The DN bit is is equal to 1. thenblock. The DN bit is is equal to 1. thenaccumulated value is equal the setaccumulated value is equal the set

value.value.


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PROGRAMMING COUNTERPROGRAMMING COUNTERCount down:Count down: CD bit is set to one when rung is true as long as downCD bit is set to one when rung is true as long as down

counter is enabled and CD goes false when rung is false. count downcounter is enabled and CD goes false when rung is false. count down

done bit is set to 1 when accumulated is greater than preset value anddone bit is set to 1 when accumulated is greater than preset value andreset to 0 when accumulated value is less then preset value.reset to 0 when accumulated value is less then preset value.

Count up:Count up: CU bit is set to 1 when rung is true and remain true as longCU bit is set to 1 when rung is true and remain true as longas counter is enabled and CU bit false when rung goes false. CU bit isas counter is enabled and CU bit false when rung goes false. CU bit is

used only in up counter. Count up done bit is set to 1 whenused only in up counter. Count up done bit is set to 1 whenaccumulated count equal to preset count and remain set to 1. as long asaccumulated count equal to preset count and remain set to 1. as long as

accumulated value equal to 1or greater than preset value .accumulated value equal to 1or greater than preset value .


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PROGRAM SCANNINGPROGRAM SCANNING

The PLC first determine the status ofThe PLC first determine the status ofinput device and then scan the userinput device and then scan the user

program and then up date theprogram and then up date theoutput . in this way PLC scan theoutput . in this way PLC scan the

program. One common method toprogram. One common method toscan the program from left to rightscan the program from left to rightand top to bottom. In this methodand top to bottom. In this methodPLC first scan the first rung ofPLC first scan the first rung of

program from left to right andprogram from left to right and

continue until all rung scanned. Incontinue until all rung scanned. Innext section its scan the all rungnext section its scan the all rungfrom top to bottom. And it takesfrom top to bottom. And it takesmilliseconds to complete.milliseconds to complete.


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PROGRAM CONTROLPROGRAM CONTROL

INSTRUCTIONINSTRUCTION

Master control relay instructions:Master control relay instructions: It often used to control power to theIt often used to control power to theentire circuit or just to selected rungs. This allows selected rung to be deentire circuit or just to selected rungs. This allows selected rung to be deenergized by turning off master control relay that control power for the wholeenergized by turning off master control relay that control power for the wholecircuit.circuit.

Immediate input instruction:Immediate input instruction: It is used when it become necessary to upIt is used when it become necessary to update the status of input word in the input image table. For some high speeddate the status of input word in the input image table. For some high speed

processes it is necessary to know about the status of certain bit in particularprocesses it is necessary to know about the status of certain bit in particularinput word.input word.

Immediate output instruction:Immediate output instruction: It is used when it is necessary to up date theIt is used when it is necessary to up date thestatus of output image table to completion of normal program scan. Whenstatus of output image table to completion of normal program scan. Whenimmediate output table is true the instruction will interrupt the normalimmediate output table is true the instruction will interrupt the normal

program scan and up date a word in output image table.program scan and up date a word in output image table. Always false instruction:Always false instruction: It is used when debugging a new or modifiedIt is used when debugging a new or modified

program. By inserting the always false instruction in rung, the rung willprogram. By inserting the always false instruction in rung, the rung willalways be false regardless of status of other instruction.always be false regardless of status of other instruction.


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USES OF P.L.CUSES OF P.L.C

PLC can be used as a counter.PLC can be used as a counter. It can also be used as a timer.It can also be used as a timer.

It can be used as a shift register.It can be used as a shift register.

It can be used as a arithmetic unit.It can be used as a arithmetic unit. It can be used in computer interface.It can be used in computer interface.

It can be used for analog manipulation of data.It can be used for analog manipulation of data.

It can be used as lanterns.It can be used as lanterns.


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ADVANTAGE AND DISADVANTAGEADVANTAGE AND DISADVANTAGE

AdvantagesAdvantages Less area occupation.Less area occupation. less time consuming.less time consuming. Easily reprogrammable.Easily reprogrammable.

Input and output list easily made by an electrician.Input and output list easily made by an electrician. Less costly.Less costly. It can be easily troubleshooting.It can be easily troubleshooting. fault can be easily detected.fault can be easily detected.

more flexible.more flexible. compexibility of circuit is lesscompexibility of circuit is less..

DisadvantagesDisadvantages Well skilled person is required for programming.Well skilled person is required for programming.


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ADVANTAGES

Smaller physical size than hard-wire solutions Easier and faster to make changes PLCs have integrated diagnostics and override

functions Diagnostics are centrally available Applications can be immediately documented Applications can be duplicated faster and less

expensively


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ANNEXUREANNEXURE


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SAFETY OF USER AND PROTECTIONSAFETY OF USER AND PROTECTION

OF P.L.COF P.L.Ca) Any engineer who is responsible for the planning, design and construction of automaticequipment using the product associated with this manual should be of a competent

nature, trained and qualified to the local and national standards required to fulfill that

role. These engineers should be fully aware of all aspects of safety with regards to

automated equipment.

b) Any commissioning or service engineer must be of a competent nature, trained and

qualified to the local and national standards required to fulfill that job. These engineers

should also be trained in the use and maintenance of the completed product. This

includes being completely familiar with all associated documentation for the said

product. All maintenance should be carried out in accordance with established safety

practices.

c) All operators of the completed equipment should be trained to use that product in a safeand coordinated manner in compliance to established safety practices. The operators

should also be familiar with documentation which is connected with the actual operation

of the completed equipment.


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5s A SYSTEMATIC APPROACH5s A SYSTEMATIC APPROACH

TO GOOD HOUSEKEEPINGTO GOOD HOUSEKEEPING 1s1s SORT OUT UNNECESSARY ITEMS IN THE WORK PLACE ANDSORT OUT UNNECESSARY ITEMS IN THE WORK PLACE AND

DISCARD THEM.DISCARD THEM. 2s2sARRANGE NECESSARY ITEMS IN GOOD ORDER SO THATARRANGE NECESSARY ITEMS IN GOOD ORDER SO THAT

THEY CAN BE EASILY PICKED UP FOR USE.THEY CAN BE EASILY PICKED UP FOR USE.

# A PLACE FOR EVERYTHING.# A PLACE FOR EVERYTHING.

# EVERYTHING IN ITS PLACE.# EVERYTHING IN ITS PLACE. 3s3s - CLEAN YOUR WORK PLACE COMPLETELY SO THAT THERE- CLEAN YOUR WORK PLACE COMPLETELY SO THAT THERE

IS NO DUST ON FLOOR, MACHINE AND EQUIPMENT.IS NO DUST ON FLOOR, MACHINE AND EQUIPMENT. 4s4s MAINTAIN HIGH STANDARD OF HOUSE KEEPING AND MAINTAIN HIGH STANDARD OF HOUSE KEEPING AND

WORK PLACE ORGANISATION AT ALL TIMES.WORK PLACE ORGANISATION AT ALL TIMES.

5s5s TRAINED PEOPLE TO FOLLOW GOOD HOUSE KEEPING TRAINED PEOPLE TO FOLLOW GOOD HOUSE KEEPINGDISCIPLINE AUTONOMOUSLY.DISCIPLINE AUTONOMOUSLY.


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ANALYSISANALYSIS

For completing this project we used variousFor completing this project we used various

types of data, table and statistical tools.types of data, table and statistical tools.

Photographs of various parts are attached .Photographs of various parts are attached .These are listed below-These are listed below-

Photograph of P.L.C.Photograph of P.L.C.

List of components.List of components.


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POWER SUPPLY

PROCESSORUNIT

INPUT UNIT

OUT PUT UNIT

POWER SUPPLY

project report on p.l.c

Documents