GOAL REPORT: PROJECT SEMESTER

On

PLC AUTOMATION

Submitted by:
Harpriya singh
101306066

Under the Guidance of Faculty Supervisor

Rohit Khosla Amanpreet Kaur

Director Assistance Professor, ECED

Netmax technologies Thapar University

2017

Electrical and Instrumentation Engineering Department

Thapar University, Patiala
(Declared as Deemed-to-be-University u/s 3 of the UGC Act., 1956)
Post Bag No. 32, Patiala – 147004
Punjab (India)
 1. ORGANISATION OVERVIEW
1.1 Organization information
a) Organization name - Netmax Technologies

b) Organization address- No. 198/200, 3rd Floor, Himalaya Marg,

Sector 34A, Chandigarh
c) email- training@netmaxtech.com

1.2 Organization overview

Netmax Technologies is a leader in network support, embedded systems, and
software & web development services. Netmax Technologies group of
companies is divided into two:
Netmax Technologies (Core) & Netmax Web solutions.
Netmax Technologies (Core) takes care of IT support, embedded systems R&D
and Implementation services, whereas Netmax web solutions is a web and
software development company that takes care of Software development and web
service solutions. It offers a vast portfolio of IT solutions to customers spread
across Punjab, Haryana & Himachal Pradesh. Netmax Technologies is a
pioneer in the field of IT education in north India. Netmax Technologies was set
up in 2001 by young Indian entrepreneurs. It has pioneered the concept of high
quality IT education in North India and has trained over 10,000 plus networking,
embedded systems & software professionals in the country. In 2001, Netmax
Technologies set up education centre in Chandigarh (Punjab) and followed them
with centers in Patiala, Jalandhar, Ludhiana & Bhatinda in the years that
followed. In 2005, Netmax Technologies introduced corporate training programs
which as an initiative were highly appreciated by the industry and corporate alike.
Area of Focus:
Netmax Technologies focus areas include network support, network
implementation, embedded system research & development and robotics.
Netmax Technologies addresses the needs of well-defined industry segments
such as BPO’s, IT & ITES, and government Agencies like CSIO &
TBRL etc. It has alliances with global IT majors such as Microsoft, CISCO and
Red Hat.
1.3 Course overview
Control engineering has evolved over time. In the past humans were the main
method for controlling a system. More recently electricity has been used for
control and early electrical control was based on relays. These relays allow power
to be switched on and off without a mechanical switch. It is common to use relays
to make simple logical control decisions. The development of low cost computer
has brought the most recent revolution.
The advent of the PLC began in the 1970s, and has become the most common
choice for manufacturing controls. A programmable logic controller (PLC) or
programmable controller is a digital computers used for automation of
electromechanical processes, such as control of machinery on factory assembly
lines, amusement rides, or lighting fixtures. PLCs are used in many industries and
machines. PLCs have been gaining popularity on the factory floor and will
probably remain predominant for some time to come. Most of this is because of
the advantages they offer.
• Cost effective for controlling complex systems.
• Flexible and can be reapplied to control other systems quickly and easily.
• Computational abilities allow more sophisticated control.
• Trouble shooting aids make programming easier and reduce downtime.
• Reliable components make these likely to operate for years before failure.
2 Work Done
2.1 OrCAD
OrCAD is a proprietary software tool suite used primarily for electronic design
automation (EDA). The software is used mainly by electronic design engineers
and electronic technicians to create electronic schematics and electronic prints for
manufacturing printed circuit boards.
The name OrCAD is a portmanteau, reflecting the company and its software's
origins: Oregon + CAD.
OrCAD Capture is a schematic capture application, and part of the OrCAD
circuit design suite. Easy-to-use and powerful, Capture component information
system (CIS) is the most widely used schematic design solution, supporting both
flat and hierarchical designs from the simplest to the most complex. Capture
CIS allows designers to back-annotate layout changes, make gate/pin swaps, and
change component names or values from board design to schematic using the
feedback process. It also comes with a large library of schematic symbols and can
export net lists in a wide variety of formats. Capture CIS integrates the schematic
design application with the added capabilities of a CIS. The CIS allows designers
to search, identify, and populate the design with preferred parts. With easy access
to company component databases and part information, designers can reduce the
amount of time spent researching needed parts.

2.2 PROGRAMMABLE LOGIC CONTROLLER

A PLC is an example of a hard real time system since output results must be
produced in response to input conditions within a bounded time, otherwise
unintended operation will result.

A programmable logic controller (PLC) or programmable controller is a digital

computers used for automation of electromechanical processes, such as control
of machinery on factory assembly lines, amusement rides, or lighting fixtures.
PLCs are used in many industries and machines.
PLCs can range from small "building brick" devices with tens of inputs and
outputs (I/O), in a housing integral with the processor, to large rack-mounted
modular devices with a count of thousands of I/O, and which are often networked
to other PLC and SCADA systems. Unlike general-purpose computers, the PLC
is designed for multiple inputs and output arrangements, extended temperature
ranges, immunity to electrical noise, and resistance to vibration and impact.
Programs to control machine operation are typically stored in battery-backed or
non-volatile memory. A PLC is an example of a hard real time system since
output results must be produced in response to input conditions within a bounded
time, otherwise unintended operation will result.

IC ULN2803is used in the circuit to form Darlington pair to invert the input
supply voltage.

Figure 2.1 PLCs

PLC Hardware
Many PLC configurations are available, even from a single vendor. But, in each
of these there are common components and concepts. The most essential
components are:

Power Supply - This can be built into the PLC or be an external unit. Common
voltage levels required by the PLC (with and without the power supply) are

24Vdc, 120Vac, 220Vac. CPU (Central Processing Unit) - This is a computer

where ladder logic is stored and processed.

I/O (Input/output) - A number of input/output terminals must be provided so

that the PLC can monitor the process and initiate actions.

Indicator lights - These indicate the status of the PLC including power on,
program running, and a fault. These are essential when diagnosing problems.
The configuration of the PLC refers to the packaging of the components. Typical
configurations are listed below from largest to smallest as shown in Figure 3.1.

Rack - A rack is often large (up to 18” by 30” by 10”) and can hold multiple
cards.
When necessary, multiple racks can be connected together. These tend to be the
highest cost, but also the most flexible and easy to maintain.

Mini - These are similar in function to PLC racks, but about half the size.

Shoebox - A compact, all-in-one unit (about the size of a shoebox) that has
limited expansion capabilities. Lower cost and compactness make these ideal for
small applications.
Micro - These units can be as small as a deck of cards. They tend to have fixed
quantities of I/O and limited abilities, but costs will be the lowest.

Software - A software based PLC requires a computer with an interface card, but
allows the PLC to be connected to sensors and other PLCs across a network.

Advantages of PLC

 Programming a PLC is easier than wiring the relay control panel.

 One single Programmable Logic Controller can easily run many machines
 In old days, with wired relay-type panels, any program alterations required
time for rewiring of panels and devices. With PLC control any change in
circuit design or sequence is as simple as retyping the logic. Correcting
errors in PLC is extremely short and cost effective.
 Today's Programmable Logic Control memory is getting bigger and bigger
this means that we can generate more and more contacts, coils, timers,
sequencers, counters and so on. We can have thousands of contact timers
and counters in a single PLC. Imagine what it would be like to have so
many things in one panel.
 Prices of Programmable Logic Controllers vary from few hundreds to few
thousands. This is nothing compared to the prices of the contact and coils
and timers that you would pay to match the same things. Add to that the
installation cost, the shipping cost and so on.
 PLC can be reprogrammed. Conventional controls must be rewired and are
often scrapped instead.
 PLC takes less floor space then relay control panels.
 A PLC has facility for extensive input/output arrangements.
 Maintenance of the PLC is easier, and reliability is greater.
 PLC can be connected to the plant computer systems more easily than a
relay.
 PLC has very few hardware failures compared to electromechanical relay.
2.2.1 Examples of PLC
A programmable logic controller (PLC) or programmable controller is a digital
computers used for automation of electromechanical processes, such as control
of machinery on factory assembly lines, amusement rides, or lighting fixtures.
PLCs are used in many industries and machines.

Figure 2.2 Car Garage

Figure 2.3 Bottle Counting Application

 Figure 2.4 Mixer Application

2.3 CODESYS
CODESYS (an acronym for controller development system, previously
stylised CoDeSys) is a development environment for programming controller
applications according to the international industrial standard IEC 61131-3. it is
a complete development environment for a PLC. CoDeSys puts a simple
approach to the powerful IEC language at the disposal of the PLC programmer.
Use of the editors and debugging functions is based upon the proven development
program environments of advanced programming languages such as Visual C++.
All five programming languages for application programming defined in the IEC
61131-3 are available in the CODESYS development environment.

 IL (instruction list) is an assembler like programming language

 ST (structured text) is similar to programming in Pascal or C
 LD (ladder diagram) enables the programmer to virtually combine relay
contacts and coils
 FBD (function block diagram) enables the user to rapidly program both
Boolean and analogue expressions
 SFC (sequential function chart) is convenient for programming sequential
processes and flows
Additional graphical editor available in CODESYS not defined in the IEC
standard:

 CFC (Continuous Function Chart) is a sort of freehand FBD editor. Other than
in the network-oriented FBD editor where the connections between inputs,
operators and outputs are set automatically they have to be drawn by the
programmer. All boxes can be placed freely which makes it possible to
program feedback loops without interim variables.
Integrated compilers transform the application code created by CODESYS into
native machine code (binary code) which is then downloaded onto the controller.

Visualization
CoDeSys provides visualizations so that you can display your project variables.
You can plot geometric elements off-line with the help of the visualization. In
Online mode, these can then change their form/colour/text output in response to
specified variable values. Visualization can be used as a pure operating interface
for a PLC with CoDeSys HMI or as a Web-Visualization or Target-Visualization
running via Internet resp. directly on the PLC. Supported Languages: CoDeSys
supports all languages described by the standard IEC-61131. PROJECT
EXAMPLES: Lighting 3 bulbs using 2 switches, Using button 1 bulb 1 &2 lights
up, Using button 2 bulb 2 lights up, Using button 1 & 2 bulb 3 lights up.
Ladder Logic
Ladder logic is the main programming method used for PLCs. As mentioned
before, ladder logic has been developed to mimic relay logic. The decision to use
the relay logic diagrams was a strategic one. By selecting ladder logic as the main
programming method, the amount of retraining needed for engineers and trades
people was greatly reduced.
Modern control systems still include relays, but these are rarely used for logic. A
relay is a simple device that uses a magnetic field to control a switch. When a
voltage is applied to the input coil, the resulting current creates a magnetic field.
The magnetic field pulls a metal switch (or reed) towards it and the contacts
touch, closing the switch. The contact that closes when the coil is energized is
called normally open. The normally closed contacts touch when the input coil is
not energized. Relays are normally drawn in schematic form using a circle to
represent the input coil. The output contacts are shown with two parallel lines.
Normally open contacts are shown as two lines, and will be open (non-
conducting) when the input is not energized. Normally closed contacts are shown
with two lines with a diagonal line through them. When the input coil is not
energized the normally closed contacts will be closed (conducting).
2.3.1 Examples of Codesys
2.3.1.1 2 inputs 3 output3

Figure 2.5 2 inputs 3 outputs

Visualization

Figure 2.6 visualization of 2 inputs 3 outputs

2.3.1.2 Bridge opening

Figure 2.7 Bridge opening

Visualization

Figure 2.8 visualization of Bridge opening

2.4 RS MicroLogix
The MicroLogix 1000 programmable controller is a packaged controller
containing a power supply, input circuits, output circuits, and a processor. The
controller is available in 10 I/O, 16 I/O and 32 I/O configurations, as well as an
analog version with 20 discrete I/O and 5 analog I/O. The MicroLogix power
supply does not require or need a high inrush current. However, if the power
source can supply a high inrush current, the MicroLogix power supply will accept
it. There is a high level of inrush current when a large capacitor on the input of
the MicroLogix is charged up quickly.
The RSLogix family of IEC-1131-compliant ladder logic programming packages
helps you maximize performance, save project development time, and improve
productivity. This family of products has been developed to operate on Microsoft
Windows operating systems. Supporting the Allen-Bradley SLC 500 and
MicroLogix families of processors, RSLogix 500 was the first PLC programming
software to offer unbeatable productivity with an industry-leading user
interface. When you connect a MicroLogix 1000 controller to a network, it
automatically finds which protocol is active (DF1 or DH-485), and establishes
communication accordingly. Therefore, no special configuration is required to
connect to either network.

2.5 SIMATIC Step7 Software

SIMATIC is the name of an automation system which was developed by the
German company Siemens. The automation system controls machines used for
industrial production. This system makes it possible for machines to run
automatically. Depending on the needed function of the machine you have to
upload the right program on your Simatic unit. This unit is kept in a control
cabinet near the machine. STEP 7 is a software for
the programming of programmable logic controllers (PLC) of the SIMATIC -S7
family of Siemens AG and succeeds STEP 5 for the SIMATIC S5
controller. STEP 7 has become a quasi-standard in Germany due to the
widespread use of SIMATIC controllers (PLC and PC-based controllers) and is
in competition with other programming tools, which are also based on IEC
61131-3.

2.6 SCADA
Supervisory control and data acquisition (SCADA) is a control
system architecture that uses computers, networked data communications
and graphical user interfaces for high-level process supervisory management, but
uses other peripheral devices such as programmable logic controllers and
discrete PID controllers to interface to the process plant or machinery. The
operator interfaces which enable monitoring and the issuing of process
commands, such as controller set point changes, are handled through the SCADA
supervisory computer system. However, the real-time control logic or controller
calculations are performed by networked modules which connect to the field
sensors and actuators. PLCs are connected to sensors and actuators in the process,
and are networked to the supervisor14.

SCADA: computer systems that monitor and control industrial, infrastructure, or

facility-based processes, as described below:
 Industrial processes include those of manufacturing, production, power
generation, fabrication, and refining, and may run in continuous, batch,
repetitive, or discrete modes.

 Infrastructure processes may be public or private, and include water

treatment and distribution, wastewater collection and treatment, oil and gas
pipelines, electrical power transmission and distribution, wind farms, civil
defence sirens systems, and large communication systems.

 Facility processes occur both in public facilities and private ones, including
buildings, airports, ships, and space stations. They monitor and control
HVAC, access, and energy consumption.

In every power/substation certain measurements, supervision, control, operation

and protection functions are necessary.

Traditionally these functions were performed manually by system operator from

control rooms. With the progress in digital electronics, data processing, data
communication and microprocessors, a host of new devices and systems are being
introduced for power system automation. SCADA is a computer based
programmable and distributed supervisory control and data acquisition system. It
is mainly used for remote and local supervision and control of electricity and
distribution on medium voltage level. Distribution SCADA supervises the
distribution system.

DAQ Factory
DAQ Factory is measurement and automation software from AzeoTech. DAQ
Factory Express, supports the T7/U3/U6/UE9/U12. To get DAQ Factory Express,
download the normal DAQ Factory Pro Trial from AzeoTech, and the Express
version is included.
DAQ Factory allows non-programmers to make custom applications. It is easy
to collect input data, convert to engineering units, display it, and log it to file,
without any programming (see the quick tutorial below). Scripting is also
supported so you can do advanced applications with control and automatic setting
of outputs.

2.7 HMI
Typical basic SCADA animations
A human machine interface or HMI is the apparatus which presents process data
to a human operator, and through which the human operator controls the process.
An HMI is usually linked to the SCADA system's databases and software
programs, to provide trending, diagnostic data, and management information
such as scheduled maintenance procedures, logistic information, detailed
schematics for a particular sensor or machine, and expert-system troubleshooting
guides.
The HMI system usually presents the information to the operating personnel
graphically, in the form of a mimic diagram. This means that the operator can see
a schematic representation of the plant being controlled. For example, a picture
of a pump connected to a pipe can show the operator that the pump is running and
how much fluid it is pumping through the pipe at the moment. The operator can
then switch the pump off. The HMI software will show the flow rate of the fluid
in the pipe decrease in real time. Mimic diagrams may consist of line graphics
and schematic symbols to represent process elements, or may consist of digital
photographs of the process equipment overlain with animated symbols.
The HMI package for the SCADA system typically includes a drawing program
that the operators or system maintenance personnel use to change the way these
points are represented in the interface. These representations can be as simple as
an on-screen traffic light, which represents the state of an actual traffic light in
the field, or as complex as a multi-projector display representing the position of
all of the elevators in a skyscraper or all of the trains on a railway.
An important part of most SCADA implementations is alarm handling. The
system monitors whether certain alarm conditions are satisfied, to determine
when an alarm event has occurred. Once an alarm event has been detected, one
or more actions are taken (such as the activation of one or more alarm indicators,
and perhaps the generation of email or text messages so that management or
remote SCADA operators are informed). In many cases, a SCADA operator may
have to acknowledge the alarm event; this may deactivate some alarm indicators,
whereas other indicators remain active until the alarm conditions are cleared.
Alarm conditions can be explicit—for example, an alarm point is a digital status
point that has either the value NORMAL or ALARM that is calculated by a
formula based on the values in other analogue and digital points—or implicit: the
SCADA system might automatically monitor whether the value in an analogue
point lies outside high and low limit values associated with that point. Examples
of alarm indicators include a siren, a pop-up box on a screen, or a coloured or
flashing area on a screen (that might act in a similar way to the "fuel tank empty"
light in a car); in each case, the role of the alarm indicator is to draw the operator's
attention to the part of the system 'in alarm' so that appropriate action can be
taken. In designing SCADA systems, care is needed in coping with a cascade of
alarm events occurring in a short time, otherwise the underlying cause (which
might not be the earliest event detected) may get lost in the noise. Unfortunately,
when used as a noun, the word 'alarm' is used rather loosely in the industry; thus,
depending on context it might mean an alarm point, an alarm indicator, or an
alarm event.