GOVERNMENT POLYTECHNIC, MUMBAI

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1 GOVERNMENT POLYTECHNIC, MUMBAI INDUSTRIAL AUTOMATION - EE LABORATRY MANUAL ELECTRICAL ENGINEERING DEPARTMENT Course Teacher Dr. Mahesh S. Narkhede, LEE Special Thanks to Mr. Avinash Dabade (Faculty & Expert PLC)

2 Certificate 1

3 Index 2

4 Experiment No-1 Aim: To develop ladder diagrams for ON/OFF inputs to produce ON/OFF outputs Objective: 1) To study fixed and modular PLC. 2) To study the ladder program for ON/OFF input and output. Equipments: 1) Name of PLC used. 2) RS232 Communication cable. 3) RS Linx and RSlogix500 software. Theory: FixedPLC: A Fixed PLC consist of a fixed or built in input and output sections. The I/O of a fixed PLC is built in and not changeable. 3

5 There is one fixed or built in non removable screw terminal strip containing all input signal screw terminals connections and another screw containing all output control signal screw terminals. ModularPLC: Modular PLC does not have a terminal strip built into the processor unit. Modular PLC s have their I/O points on plugin type removable units called, I/O Modules. PLC with modular Input and Outputs consist of chassis,rack, or base plate where Power supply, CPU, and all Input Output modules are present as separate hardware items. Procedure: RSLinx Software: 1) Open RSLinx software to configure the serial driver- RS232 DF1, for communication with Micrologix 1000/ 1200 PLC. Click on Start.Click on All Programs.Click on Rockwell Software.Click on RS Linx. Click on Communication menu. 4

6 Click on Configure Drivers. Select RS232 DF1 in Available Driver Types field. Click on Add New. Click on OK. Click on Auto Configure button. Click on OK.Click on Close. Again Click on Communication menu. Click on RS Who. Select AB_DF1_1. Observe the status in Right pan. (If PLC is not communicating with RS Linx software then it will show cross bar on PLC.) 2)Write a Ladder Program in right pan and make sure that you have followed the same I/O addresses as shown in fig. below. 3) Download the Ladder Program to the Micrologix 1000/ 1200 PLC and place PLC in RUN mode. 4) Make sure that all push buttons/toggle switches are physically off, before testing the Ladder Program. 5) Test /Simulate the Ladder Program using push button / toggle switch and by observing lamps, provided on PLC control panel. Fig. 5

7 Conclusion : We have made use of following two programming instructions of Ladder Logic Instruction Symbol Instruction Name 1) XIC 2) XIO 3) OTE Performance Date Completion Date Sign 6

8 Experiment No-2 Aim: Basic Logic functions using Ladder Logic. Objective: 1) To Study Fixed & Modular PLC. 2) To write Input and Output List. 3) To write the Ladder Program to satisfy the truth table for Gates. 4) To test / simulate the ladder program. Equipments: 1) Name of PLC used. 2) RS232 Communication cable. 3) RS Linx and RSlogix500 software. Theory: FixedPLC: A Fixed PLC consist of a fixed or built in input and output sections. The I/O of a fixed PLC is built in and not changeable. There is one fixed or built in non removable screw terminal strip containing all input signal screw terminals connections and another screw containing all output control signal screw terminals. 7

9 ModularPLC: Modular PLC does not have a terminal strip built into the processor unit. Modular PLC s have their I/O points on plugin type removable units called, I/O Modules. PLC with modular Input and Outputs consist of chassis,rack, or base plate where Power supply, CPU, and all Input Output modules are present as separate hardware items. Logic: (Write down the truth tables ) 1. AND Gate Sr.No. A B Y Sr.No. SW1 SW2 Lamp OR Gate Sr.No. A B Y Sr.No. SW1 SW2 Lamp

10 3.NOR Gate Sr.No. A B Q Sr.No. SW1 SW2 Lamp XOR Gate Sr.No. A B $O Sr.No. SW1 SW2 Lamp Procedure: 9

11 RSLinx Software: 1) Open RSLinx software to configure the serial driver- RS232 DF1, for communication with Micrologix 1000/ 1200 PLC. Click on Start.Click on All Programs.Click on Rockwell Software. Click on RS Linx.Click on RS Linx. Click on Communication menu. Click on Configure Drivers. Select RS232 DF1 in Available Driver Types field. Click on Add New. Click on OK. Click on Auto Configure button. Click on OK.Click on Close. Again Click on Communication menu. Click on RS Who. Select AB_DF1_1. Observe the status in Right pan. (If PLC is not communicating with RS Linx software then it will show cross bar on PLC.) 2) Write a Ladder Program in right pan and make sure that you have followed the same I/O addresses as shown in Fig (A) and Input- Output List prepared by you. 3) Download the Ladder Program to the Micrologix 1000/ 1200 PLC. And place PLC in RUN mode. 4) Make sure that all push buttons / Toggle switches are physically off, before testing the Ladder Program. 5) Test /Simulate the Ladder Program using push button / toggle switch and by observing Lamps, provided on PLC control panel. 10

12 SW1 SW2 +24 VDC 24 GND DC COM IN0 IN1 IN2 IN3 IN4 PLC L N E VAC OUT OUT VAC OUT OUT VDC 0 1 VDC V AC Lamp Figure A. 11

13 1.AND Gate: 2.OR Gate: 12

14 3.NOR Gate: 4. XOR Gate: (Ladder Logic) 13

15 Performance Date Completion Date Sign 14

16 Experiment No-3 Aim: Develop a Ladder Logic for Traffic light Control System and test it through PLC using Ton instruction. Objective: 1) To write Input and Output List. 2) To write the Ladder Program. 3) To test / simulate the ladder program. Equipment: 1) Micrologix 1000 PLC / Micrologix 1200 PLC. 2) RS232 Communication cable. 3) RS Linx and RSlogix500 software. Logic: 1. Press Start Push Button to start the function. 2. Red lamp should be ON for 25 seconds. 3. After 25 seconds Red lamp should be OFF. Then Green lamp should be ON for 35 seconds. 4. After 35 seconds Green lamp should be OFF. Now Yellow lamp should be ON for 15 seconds. 5. After 15 seconds Yellow lamp should be OFF. Again Red lamp should be made ON for next 25 seconds. 6. Repeat the cycle from step 2, to autostart. 7. Press Stop Push Button to stop the function. 15

17 Procedure: RSLinx Software: Open RSLinx software to configure the serial driver- RS232 DF1, for communication with Micrologix 1000/ 1200 PLC. RSLOGIX500 Software: 1) Open RSLogix500 software, to design a ladder program in RSLOGIX500 software and make sure that you have followed the same I/O addresses as shown in Fig (A) and Input- Output List prepared by you. 2) Download the ladder program to the Micrologix 1000/ 1200 PLC. And place PLC in RUN mode. 3) Make sure that all push buttons / Toggle switches are physically off, before testing the ladder program. 4) Test /Simulate the ladder program using push button / toggle switch and by observing Lamps, provided on PLC control panel. 16

18 Figure A. NO NC +24 VDC 24 GND DC COM IN0 IN1 IN2 IN3 IN4 PLC L N E VAC OUT OUT VAC OUT OUT VDC 0 1 VDC V AC RED GREEN YELLOW 17

19 Ladder Logic: 18

20 RED GREE N YELLOW RED GREE N YELLOW Figure B. 19

21 Conclusion: We have made use of following programming instruction of Ladder Logic Instruction Symbol Instruction Name 1) TON 2) XIC 3) XIO Performance Date Completion Date Sign 20

22 Experiment No- 4 Aim: Ladder Logic for counting the objects. Objective: 1) To write Input and Output List. 2) To write the Ladder Program. 3)To test / simulate the ladder program. Equipments: 1) State the name of PLC used 2) RS232 Communication cable. 3) RS Linx and RSlogix500 software. Logic: 1.Press Start Push Button to start the function. 2.Motor will get ON, when function starts. 3.Conveyor belt will start moving and so the objects place on it. Sensor detects the objects and gives signal to the counter. Counter counts the objects moving on Conveyor belt. 4. Motor shall stop when counter counts 200 objects. 5.Press Stop Push button to stop the function. 21

23 Procedure: RSLinx Software: Open RSLinx software to configure the serial driver- RS232 DF1, for communication with Micrologix 1000/ 1200 PLC. RSLOGIX500 Software: 1) Open RSLogix500 software, to design a ladder program in RSLOGIX500 software and make sure that you have followed the same I/O addresses as shown in Fig (A) and Input- Output List prepared by you. 2) Download the ladder program to the Micrologix 1000/ 1200 PLC. And place PLC in RUN mode. 3) Make sure that all push buttons / Toggle switches are physically off, before testing the ladder program. 4) Test /Simulate the ladder program using push button / toggle switch and by observing Lamps, provided on PLC control panel. 22

24 (Ladder Logic) 23

25 Start PB Stop PB Sensor +24 VDC 24 GN DC CO IN 0 IN 1 IN 2 IN 3 IN 4 PLC L N E VAC OUT OUT VAC OUT OUT VDC 0 1 VDC V AC Motor Figure A. 24

26 Sensor Objects moving on Conveyor Belt M Conclusion : Figure B. Conveyor Delivery System We have made use of following programming instruction of Ladder Logic Instruction Symbol Instruction Name 1) CTU The instruction is used in combination with sensor to count the objects. Performance Date Completion Date Sign 25

27 Experiment No- 5 Aim: A program for Temperature Measurement. Objective: 1) To write Input and Output List. 2) To write the Ladder Program. 3)To test / simulate the ladder program. Equipments: 1) Micrologix 1000 PLC / Micrologix 1200 PLC. 2) RS232 Communication cable. 3) RS Linx and RSlogix500 software. Logic: 1. Use PT100 to measure the temperature of oven. 2. Assume PT100 output ( 4 to 20 ma ) is connected at input terminal N7: Use SCP instruction to measure the temperature of oven. 4. Input mean to 6241 and max to with respect to 4 to 20 ma. 5. Input scale mean value to Input scale max value 2 to Assume output to be store to N7:0. 26

28 Procedure: RSLinx Software: 1) Open RSLinx software to configure the serial driver- RS232 DF1, for communication with Micrologix 1000/ 1200 PLC. RSLOGIX500 Software: 1) Open RSLogix500 software, to design a ladder program in RSLOGIX500 software and make sure that you have followed the same I/O addresses as shown in Fig (A) and Input- Output List prepared by you. 2) Download the ladder program to the Micrologix 1000/ 1200 PLC. and place PLC in RUN mode. 3) Make sure that all push buttons / Toggle switches are physically off, before testing the ladder program. 4) Test /Simulate the ladder program using push button / toggle switch and by observing Lamps, provided on PLC control panel. 27

29 (Ladder Program) PT 100 Furnace Heat er Figure A. Furnace Temparature Control 28

30 Conclusion: We have made use of following programming instruction of Ladder Logic Instruction Symbol Instruction Name 1) SCP Performance Date Completion Date Sign 29

31 Experiment No-6 Aim: To Develop a simple programmes for comparison instructions. Objective: Equipments: 1) To write Input and Output List. 2) To write the Ladder Program. 3)To test / simulate the ladder program. 1) Micrologix 1000 PLC / Micrologix 1200 PLC. 2) RS232 Communication cable. 3) RS Linx and RSlogix500 software. 4) Furnace along with Heater and RTD Diagram : RTD Furnace Heater Figure :1 30

32 Procedure: 1) Temperature of furnace as shown in the Figure: 1 is controlled by heater. RTD (PT100) is used to measure the temperature of furnace. 2) Assume set point is stored in memory location N7:0. 3) Input set point = 45 C. 4) Assume tolerance is stored in memory location N7:1. 5) Input Tolerance=5 C. 6) Destination set point (effective set point) is stored at N7:2. It will be addition of both above if we select ADD instruction. 7) Select GRT instruction. 8) Assume process value temperature (actual temperature) to be stored at N7:3 (source A). 9) Now alarm will be ON if actual temperature > effective set point 31

33 (Ladder Logic) 32

34 Conclusion: We have made use of following programming instruction of Ladder Logic Instruction Symbol Instruction Name 1) ADD 2) GRT Performance Date Completion Date Sign 33

35 Experiment No - 7 Expt Name : Design of ON and OFF switch in SCADA Equipment: Any IBM compatible PC with a Pentium II processor or higher (minimum: 400MHz on a single node system, recommended: 1.2GHz or higher). At least 2GB of free hard disk space. At least 256MB of random-access memory (RAM), 512MB of RAM is recommended. Wonderware, InTouch Software Procedure & Observation: [1] Open the Intouch Application Manager. [2] Create a new application named as Light On Off [3] Create the new windows as Switch and Light [4] In the Switch windows through wizard add fixture switch [5] In the light window add light through wizard. [6] Give tag names to both. [7] Write down the expressions for green and red lights as per the switch positions. [8] Save and run the application 34

36 Fig.1 Switch-On, Light- Green Fig.2 Switch-Off, Light- Red Output : Conclusion: We have made use of Intouch application Manager to design ON and OFF switch in SCADA. Performance Date Completion Date Sign 35

Experiment No - 8 Experiment Name : Calculation of Step Angle of Steeper Motor Equipment: Stepper Motor Construction & operation Video, PC Procedure &Observation: [1] In a Full Step Drive mode (Fig.

37 Experiment No - 8 Experiment Name : Calculation of Step Angle of Steeper Motor Equipment: Stepper Motor Construction & operation Video, PC Procedure &Observation: [1] In a Full Step Drive mode (Fig.1 & 2), the rotor rotates through 90 0 in one step, so the step angle is [2] In a Half step Drive mode (Fig.3 & 4), the rotor rotates through 45 0 in one step, so the step angle is Fig. 1 Fig.2 Fig. 3 Fig.4 36

38 Conclusion: The step angle of stepper motor in Fig.1 is 90 0 and Fig.3 & 4 is Performance Date Completion Date Sign 37

39 Part - A Experiment No - 9 Aim : To plot characteristics of Potentiometer Apparatus : Potentiometer, Voltmeter, Scale Theory : A Potentiometer is a potential measuring device. It measures the unknown e.m.f. or p.d. by balancing it, wholly or in part, against a known difference of potential. There are two types of Potentiometers Linear potentiometer Rotary Potentiometer Potentiometers work by having a resistive element inside. Both end terminals are attached to it, and do not move. The wiper travels along the strip when the knob is turned. The closer the wiper is to the end terminal it is wired in conjunction with, the less the resistance, because the path of the current will be shorter. The further away it moves from the terminal, the greater the resistance will be. 38

40 Circuit Diagram: Procedure: 1) Connect DC supply to the two ends of the translation potentiometer 2) Connect multimeter across variable arm and ground 3) Move the variable terminal in steps of 1 cm. 4) Measure the voltage across the output terminals. 5) Repeat the steps 3 and 4 till the variable terminal is at the extreme end. 6) Plot the graph of displacement vs output voltage. 7) Calculate the sensitivity from the graph by using formula V/ 39

41 Observation : Potentiometer P1 = K Supply voltage V1i = V D.C. Result: Sensitivity of Linear Potentiometer is Part -B Application of Potentiometer as error Detector:- It can also be used to measure the current flowing through a circuit and unknown low resistance of the circuit. Potentiometer also can be used as error detector. When potentiometer is used as error detector, two identical potentiometers are used. The constant stabilized DC Supply is connected to fixed ends of pots. 40

42 The variable points are taken as output. The error voltage is directly proportional to difference angular displacement / linear displacement of two potentiometers. The DPM is provided to read the error voltage between two pots. Fig.1 Fig.2 41

43 Here the difference of voltage between two potentiometers is amplified and is given to motor which is rotated by particular angle. Characteristics :- Fig.3 Conclusion : Potentiometers can be effectively used as an error detectors. Performance Date Completion Date Sign 42

44 EXPERIMENT NO.10 AIM:- Understand and draw the Symbol sheet for different Pneumatic and Hydraulic components. Handdrawn 43

45 44

46 45

47 46

48 Performance Date Completion Date Sign 47

1. PLC - Introduction

1. PLC - Introduction What does PLC stand for? PLC - programmable logic controller PLC implements logic control functions by means of a program PLC introduction 1 Features PLC introduction 2 Features PLC introduction 3 An application