Internship Report

On

Programmable Logic Controller

(PLC)

Prepared by

Nafis Karim ID-143010600007

Elias Ali ID-143010600014
Shipen Chandra Barmon ID-151010600002

Supervisor
Dr. Md Mizanur Rahman
Associate Professor and Head Department of EEE

Department of Electrical & Electronic Engineering

University Of Information Technology and Sciences (UITS)

1
 Internship Certificate

This is to certify that this internship report on “Programmable Logic Controller”

on Bangladesh Automation Technology (BAT), submitted by Nafis Karim ID NO-
14301060007, Elias Ali ID NO- 143010600014, Shipen Chandra Barmon ID NO-
151010600002 has been carried out under my supervision and guidance in partial
fulfillment for the requirement of the degree of “Bachelor of Science” In Electrical
and Electronic Engineering, University of Information Technology and
Sciences (UITS), Dhaka, Bangladesh

Supervisor

Dr. Md Mizanur Rahman

Associate Professor and Head, Department of EEE

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3
 Student’s Declaration

We are very much glad to declare that the Internship report on “Programmable Logic Controller
(PLC)” It has only been prepared as a partial fulfillment of the Bachelor of Science in Electrical
and Electronics Engineering (EEE) program. It has not been prepared for any other purpose of
reward or presentation. All data and information given here are verified by the supervisor and the
report does not bear any false data. I believe this will fulfill all the requirements of my supervisor
and examiners of this report.

Nafis Karim
ID# 143010600007
Program EEE

Elias Ali
ID# 14301060014
Program EEE

Shipen Chandra Barmon

ID#151010600002
Program EEE

4
 Acknowledgement

First of all, we would like to thank Almighty Allah for giving us mental and physical strength to
complete our internship and gather practical knowledge.

This internship report which is entitled as “Programmable Logic Controller (PLC)” is a

concrete effort of a number of people. We would like to express my gratitude and respect to some
generous persons for their immense help and enormous cooperation.

We are very much grateful to Dr. Md. Mizanur Rahman, Associate Professor and Head,
Department of EEE for his helping hand all through our internship. We also like to thank all our
faculty members of EEE department of UITS

Then we would like to extend our warmest appreciation and thanks to Bangladesh Automation
Technology (BAT) Training institution with all Teachers and others stuffs, their supports,
guidance and lesson helped us to complete our internship

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 Abstract

This internship report is on Programmable Logic Controller (PLC). In Bangladesh Automation

Technology (BAT) Training Institution we learnt about PLC. This PLC we learn how to design
applications for Low voltage devices, Direct on line starter –DOL starter, some Industrial
controlling.

Another importance terms which we have learnt that is how application works by PLC which is
using in industries like Automatic Forward-Reversed motor, object detect and reaction, analogue
input identify and various types of PLC Brand and software with practical implementation.

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 OBJECTIVE OF THE REPORT

The objective of the report can be viewed in two forms:

General Objective:
This internship report is prepared primarily to fulfill the Bachelor of Electrical and Electronic
Engineering (EEE) degree requirement under the Faculty of EEE department of University of
Information Technology and Sciences.
Specific Objective:
# PLC basic learning.
# PLC operation.
#Practical implement applications by plc.
#More specifically, this study entails the following aspects, to give an overview of Bangladesh
Automation Technology.

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B A T (Bangladesh Automation Technologies)
B A T (Bangladesh Automation Technologies) is a one of the best technical training centers in
Bangladesh. We are basically providing all kind of technical and Engineering training for
Electrical & Electronics engineering, Mechanical Engineering, Computer engineering and Civil
Engineering students for their better performance on the related field. We have an expert and skill
full Engineer for teaching. Need any kind of technical or engineering support such as Industrial
automation, industrials attachment, university project and thesis, we are available here. We are
serving two main focusing area one is professional training for engineer, innovative person and
technologist, on another focus is industrial automation support apparently PLC, HMI, Inverter,
SCADA, FPGA, Microcontroller, Webpage Development and AutoCAD with various simulation
tools. There is available a research & development center to analysis pure engineering and Inspire
to engage new student for contribution in modern science. We are sharing our research
achievement, technical theme to implement for supporting university project idea. Please feel like
to contact with us without any hesitation, we are always ready to any kind of technical help.
Bangladesh Automation Technologies is better technical solution center in Bangladesh.

Our mission & Visions

We are committed to reach a world class engineering solution with quick and expert hand. Also
we determined to produce skilled man power by giving technical training.

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Index
Topic Page no
Internship Report 1

Internship Certificate 2

Student Declaration 4

Acknowledgement 5

Abstract 6

Objective of the report 7

Bangladesh Automation Technology 8

Mission & Vision 8

`Chapter I
Basic Concept on Low Voltage Device

1.1 Introduction 11

1.2 Relay 11

1.3 Timer 12

1.4 Magnetic Contractor 13

1.5 DOL-Starter 14

1.6 Industrial Controlling without PLC example 1 16

1.7 Industrial Controlling without PLC example 2 17

1.8 Industrial Controlling without PLC example 3 18

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1.9 Industrial Controlling without PLC example 4 19

Chapter II
About PLC
2.1 What is PLC 20
2.2 History of PLC 21
2.3 What is inside a PLC? 22
2.4 Block Diagram of PLC 22
2.5 Input Module 26
2.6 Output Module 27
2.7 Operation of PLC 28
2.8 Program languages of PLC 30
2.9 Ladder Diagram 30
Chapter III
PLC Basic Learning
3.1 Type of PLC Brands 31
3.2 Software installation 31
3.3 General used instruction and symbol 31
3.4 Data upload from PC to PLC 32
3.5 Data format to PLC by PC 32
3.6 Start the PLC for operation 32
Chapter IV
PLC Practical Application
4.1 Star Delta automatic switch 33
4.2 4 step any button on off 34
4.3 Boiler control 35
4.4 conveyer Belt 38
4.5 Car Parking monitoring 39
Chapter V
Conclusion
5.1 conclusion 40
5.2 Reference 41

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 Chapter I
Basic Concept on Low Voltage Device
1.1 Introduction
Before PLC learning, we have to know about some elements of low voltage devices which is very
important for PLC. For example, we have to use push button. If we don’t know what is push button,
the difference between electro-magnetic and mechanical switch then it is more difficult to
understand plc.

In low voltage device we have to learn what is Timer, Magnetic contractor, Relay, Dol-Starter.

1.2 Relay
A Relay is an electrically operated switch. It consists of a set of input terminals for a single or
multiple control signals, and a set of operating contact terminals. The switch may have any number
of contacts in multiple contact forms, such as make contacts, break contacts, or combinations
thereof.

Relays are used where it is necessary to control a circuit by an independent low-power signal, or
where several circuits must be controlled by one signal. Relays were first used in long-
distance telegraph circuits as signal repeaters: they refresh the signal coming in from one circuit
by transmitting it on another circuit. Relays were used extensively in telephone exchanges and
early computers to perform logical operations.

The traditional form of a relay uses an electromagnet to close or open the contacts, but other
operating principles have been invented, such as in solid-state relays which
use semiconductor properties for control without relying on moving parts. Relays with calibrated
operating characteristics and sometimes multiple operating coils are used to protect electrical
circuits from overload or faults; in modern electric power systems these functions are performed
by digital instruments still called protective relays.

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Latching relays require only a single pulse of control power to operate the switch persistently.
Another pulse applied to a second set of control terminals, or a pulse with opposite polarity, resets
the switch, while repeated pulses of the same kind have no effects. Magnetic latching relays are
useful in applications when interrupted power should not affect the circuits that the relay is
controlling.

Fig: 1.2 Relay

1.3 Timer
Their purpose is to control an event based on time. The difference between relays and time delay
relays is when the output contacts open & close: on a control relay, it happens when voltage is
applied and removed from the coil; on time delay relays, the contacts can open or close before or
after some time delay. Time Delay Relay (TDR) is a device use electromagnetic to operate a packet
all of switch. Usually there are the coil turn in iron. The operation like induction magnetic.
Many relays use an electromagnet to operate a switching mechanism mechanically, but other
operating principles are also used. Relays are used where it is necessary to control a circuit with
low-power signal with complete electrical isolation between control and controlled circuits, or
where several circuits must be controlled by one signal. Relay first used in the long-distance
telegraph circuits, repeating the signal coming from one circuit and re-transmitting to another
circuit. Function of Time Delay relay is a timer for controlled equipment. Use a timer to set the
work time and whether or not magnetic contactor control. For example, to set the time the electric
motor turn left and right, changing the relationship of the triangle and set the time of his regular

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electric motor turns in a certain time and other. Working principle of magnetic induction using a
timer and using electronic circuits. Timer with magnetic induction works like-principle the
induction motor, while the electronic timer that uses the principle of having a series of R and C
are connected in series and parallel, if the voltage have filled the timer relay will be connected and
the long time delay based on the size of the charging capacitor. Part timer input given the output
coil symbol in the form of contacts normally open and normally closed

Fig: 1.3 Timer

1.4 Magnetic contractor

Magnetic contactors are a form of electrical relay found on most electrically powered motors. They
act as a go-between for direct power sources, and high-load electrical motors in order to
homogenize or balance out changes in electrical frequency which may come from a power supply
as well as to act as a safeguard. It should be noted that though they are similar in design, magnetic
contactors are not circuit breakers. They do not sever the connection between appliance, and power
source during a short circuit. They are detachable from a motor so that an operator may work with
that motor; disassemble or maintain it, without the possibility of live current still passing through
the device.

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Design
The exterior of the magnetic contactor is square and boxlike. Depending on the electrical device
to which it attaches, it can be small enough to fit in the hand or over a yard in length. They are
made of a heat-resistant, non-conductive plastic such as Bakelite, and have two metal contacts
which fit into the contacts of their parent device. Inside, one contact leads to a small
electromagnetic coil. The other contact leads to a soft iron core which stays separated from the
coil because of a spring.

Function

When electricity flows through the magnetic contactor, it causes the electromagnet to generate a
strong magnetic field. This field pulls the iron core into the coil, and creates an electrical arc.
Electricity passes in through one contact and into the contactor’s parent device in this manner. To
deactivate, the contactor can be physically pulled from the parent device. Also, in the absence of
electrical current, the spring pushes the core away from the coil, breaking the connection.

Fig: 1.4 Magnetic contractor

1.5 DOL Starter

There are different types of methods used to start induction motor as these motors utilize more
power for starting. When the flow of current through windings is high then there will be a chance
to damage the motor. To overcome this problem, different kinds of starter techniques are used. The

14
simple type of starter method is DOL (Direct on Line Starter). The Direct Online starter includes a
circuit breaker or MCCB, overload relay and contactor for the protection of motor. The unlocking
of an electromagnetic contactor can be done through the thermal overload relay beneath fault
conditions. Usually, the controlling of contactor can be done by using separate buttons like start
and stop. An auxiliary contact is used on the contactor across the start button because the contactor
is electrically latched while the working of an induction motor. The most fundamental,
economical, as well as an easy method for running a three-phase induction motor is named as the
DOL starter. This starter joints three phase motors straight across the supply of three phases. The
attractiveness of this kind of starter is, it can be connected straightly to the motor, and it doesn’t
affect the induction motor. The Direct Online Starter consists of a protective device as well as
main contacts. Let us discuss an overview of DOL.

Fig 1.5: DOL Starter

Construction of DOL Starter

The DOL starter consists of two switches namely Green and Red where the green switch is used
to start and red switch is used to stop the motor. The DOL starter comprises a circuit breaker (or)
MCCB, overload relay & contactor for protecting the motor. The two switches of the motor
control the contacts. The motor can be started when we shut the contact by pressing the green
switch, and the full-line voltage comes out to the induction motor.

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1.6 Industrial Control without PLC example 1

#Switch number 1 push then M on after 10 second M will be turn off automatically.
#solution: We have to set timer relay at 10 second and in NO mode after 10 sec it will be turn off.
Here,
M means Motor
L means Line
R means Relay
T means Time
Here the diagram

Fig: 1.6 circuit diagram

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1.7 Industrial Control without PLC example 2
#Switch number 1 push then M is on after 10 second M off.
#solution:
Here,
M means Motor
L means Line
R means Relay
T means Time
Here the diagram

Fig 1.7 circuit diagram

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1.8 Industrial Control without PLC example 3

#Switch number 1 push then M1 is on after 10 second M1 off M2 is on

#solution: We need two Motor M1 and M2 then we will connect to timer relay with NO and NC
for M1 and M2 so that when M1 off that time M2 on automatically.
Here,
M means Motor
L means Line
R means Relay
T means Time
Here the diagram

Fig 1.8: circuit diagram

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1.9 Industrial Control without PLC example 4

# four step any switch on off

#solution: For off the connection should be series and for on switch the connection should be
parallel
Here is the diagram

Fig 1.9: circuit diagram

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 Chapter II
PLC

2.1 PLC
A programmable logic controller (PLC) or programmable controller is an industrial digital
computer which has been ruggedized and adapted for the control of manufacturing processes, such
as assembly lines, or robotic devices, or any activity that requires high reliability control and ease
of programming and process fault diagnosis.

PLCs were first developed in the automobile manufacturing industry to provide flexible,
ruggedized and easily programmable controllers to replace hard-wired relays, timers and
sequencers. Since then, they have been widely adopted as high-reliability automation controllers
suitable for harsh environments. A PLC is an example of a "hard" real-time system since output
results must be produced in response to input conditions within a limited time, otherwise
unintended operation will result.

A PLC is an industrial-grade digital computer designed to perform control functions—especially

for industrial applications.

The majority of PLCs today are modular, allowing the user to add an assortment of functionality
including discrete control, analog control, PID control, position control, motor control, serial
communication, and high-speed networking. Compared to older technologies, the PLC is easier to
troubleshoot, more reliable, more cost-effective, and far more versatile.

Shortened from modular digital controller, is both the name of the first PLC product and the
brand that invented it.

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 Fig 2.1: PLC

2.2 History of PLC

The PLC or Programmable Logic Controller has revolutionized the automation industry. Today
PLCs can be found in everything from factory equipment to vending machines, but prior to New
Year’s Day 1968 the programmable controller didn’t even exist. Instead what existed was a unique
set of challenges that needed a solution. In order to understand the history of the PLC we must first
take some time to understand the problems that existed before programmable controllers. Before
the days of the PLC the only way to control machinery was through the use of relays. Relays work
by utilizing a coil that, when energized, creates a magnetic force to effectively pull a switch to the
ON or OFF position. When the relay is de-energized, the switch releases and returns the device to
its standard ON or OFF position. So, for example, if I wanted to control whether a motor was ON
or OFF, I could attach a relay between the power source and the motor. Then I could control when
the motor is getting power by either energizing or de-energizing the relay. Without power, of
course, the motor would not run, thus I am controlling the motor. This type of relay is known as a
power relay. There could be several motors in one factory that need to be controlled, so what do
you do? You add lots of power relays. So factories started to amass electrical cabinets full of power
relays. But wait, what switches the coils in the power relays ON and OFF before the power relay
turns the motor ON, and what if I want to control that? What do you do? More relays. These relays

21
are known as control relays because they control the relays that control the switch that turns the
motor ON and OFF. I could keep going, but I think you get the picture of how machines were
controlled pre-PLC, and, more importantly, I think you start to see some of the problems with this
system of electromechanical control via relays.

Modicon created the first programmable logic controller (PLC) in the United States in 1968. ...
1968 with a core group of engineers, Richard E. Morley founded Bedford Associates and invented
the first programmable logic controller or PLC. He established the Modicon Company, deriving
its name from Modular Digital Control.

2.3 What is inside a PLC?

The PLC mainly consists of a CPU, memory areas, and appropriate circuits to receive input/output
data. We can actually consider the PLC to be a box full of hundreds or thousands of separate relays,
counters, timers and data storage locations. Do these counters, timers, etc. really exist? No, they
don't "physically" exist but rather they are simulated and can be considered software counters,
timers, etc. These internal relays are simulated through bit locations in registers.

2.4 Block Diagram of PLC

A simplified block diagram of a PLC shown in above Fig 2.4. It has three major units/sections.

 I/O (Input/Output) Modules.

 CPU (Central Processing Units).
 Programmer/Monitor.
The input section converts the field signals supplied by input devices/sensors to logic-level signals
that the PLC's CPU can read.
The Processor Section reads these inputs, Processes the signal, and prepares the output signals.
The output section converts the logic level output signals coming from processor section to high
level signals and used to actuate various output field devices.
The programmer/monitor is used to enter the user's program into memory and to monitor the
execution of the program.

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1) I/O Section:-
The I/O section establish the interfacing between physical devices in the real world outside
the PLC and the digital arena inside the PLC.

The input module has bank of terminals for physically connecting input devices, like push
buttons, limit switches etc. to a PLC. the role of an input module is to translate signals from input
devices into a form that the PLC's CPU can understand.

The Output module also has bank of terminals that physically connect output devices like
solenoids, motor starters, indicating lamps etc. to a PLC. The role of an output module is to
translate signals from the PLC's CPU into a form that the output device can use.

The tasks of the I/O section can be classified as:

 Conditioning
 Isolation
 Termination
 Indication
An electronic system for connecting I/O modules to remotely located I/O devices 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.

2) CPU Section: -
The Central Processing Unit, the brain of the system is the control portion of the PLC. It
has three Subparts.

 Memory System
 Processor
 Power Supply

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The memory is the area of the CPU in which data and information is stored and retrieved. The total
memory area can be subdivided into the following four Sections.

 I/O Image Memory:

The input image memory consists of memory locations used to hold the ON or OFF states of
each input field devices, in the input status file.
The output status file consists of memory locations that stores the ON or OFF states of
hardware output devices in the field. Data is stored in the output status file as a result of solving
user program and is waiting to be transferred to the output module's switching device.

 Data Memory:
It is used to store numerical data required in math calculation, bar code data etc.

 User Memory:
It contains user's application program.

 Executive Memory:
It is used to store an executive program or system software. An operating system of the
PLC is a special program that controls the action of CPU and consequently the execution
of the user's program. A PLC operating system s designed to scan image memory, interprets
the instruction of user's program stored in main memory, and executes the user's application
program the operating system is supplied by the PLC manufacturer and is permanently held
in memory
The processor, the heart of CPU is the computerized part of the CPU in the form of
Microprocessor / Micro controller chip. It supervises all operation in the system and
performs all tasks necessary to fulfill the PLC function.

 It reads the information i.e. status of externally connected input devices with input module.
 It stores this information in memory for later use.
 It carries out mathematical and logic operations as specified in application program.
 After solving the user's program, it writes the result values in the memory.

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 It sends data out to external devices like output module, so as to actuate field hardware.
 It performs peripheral and external device communication.
 It performs self-diagnostics.
The power supply provides power to memory system, processor and I/O Modules.

 It converts the higher-level AC line Voltage to various operational DC values.

 for electronic circuitry.
 It filters and regulates the DC voltages to ensure proper computer operations.

3) Programmer/Monitor: -
The Programmer/Monitor (PM) is a device used to communicate with the circuits of the PLC. The
programming unit allows the engineer/technicians to enter the edit the program to be executed.

In its simplest form it can be hand-held device with membrane keypad for program entry, and a
display device (LED or LCD) for viewing program steps of functions.

More advanced systems employ a separate industrial terminal or personal computers with type-
writer type keyboard and CRT monitors. With the help of proprietary software, it allows
programmer to write, view and edit the program and download it into the PLC. It also allows user
to monitor the PLC as it is running the program. With this monitoring systems, such things as
internal coils, registers, timers and other items not visible externally can be monitored to determine
proper operation. Also, internal register data can be altered, if required. to fine tune program
operation while debugging. Communication between PM and PLC is done via a cable connected
to a special programming port on PLC. Connection to the personal computer can be through a
serial port or from a dedicated card installed in the computer.

25
 Fig2.4: block diagram

2.5 Input Module

Every programmable logic controller must have some means of receiving and interpreting
signals from real-world sensors such as switches, and encoders, and also be able to effect control
over real-world control elements such as solenoids, valves, and motors.
This is generally known as input/output, or I/O, capability. Monolithic (“brick”) PLCs have a
fixed amount of I/O capability built into the unit, while modular (“rack”) PLCs use individual
circuit board “cards” to provide customized I/O capability. The advantages of using replaceable
I/O cards instead of a monolithic PLC design are numerous.

First, and most obvious, is the fact that individual I/O cards may be easily replaced in the event
of failure without having to replace the entire PLC.

Specific I/O cards may be chosen for custom applications, biasing toward discrete cards for
applications using many on/off inputs and outputs, or biasing toward analog cards for
applications using many 4-20 mA and similar signals.

26
 Fig2.5: input module

2.6 Output Module

Output module is like motor, heater, lamp, solenoid valve, fan, light etc. The output always
depends on input and the program of the plc.

27
 Fig 2.6: output module

2.7 Operation of PLC

The operation of the PLC system is simple and straightforward. The Process or CPU completes
three processes: (1) scans, or reads, from the input devices (2) executes or “solves” the program
logic, and (3) updates, or writes, to the output devices.

PLC Program

For the PLC to be useful, it must first have a Program or Logic for the CPU to execute. A system
engineer or PLC programmer will first create the program logic in a programming device (these
days it is usually software running on a personal computer). This logic can be written in Ladder
Logic, Instruction List, Sequential Function Charts, or any of the IEC languages.

28
The programmer will then download the program to the PLC. This is usually done by temporarily
connecting the programmer to the PLC. Once the program is installed or downloaded to the CPU
– it is usually not necessary for the PC to remain connected.

Basic Scan

Once the program is in the CPU – the PLC is then set to “run”, and the PLC executes the application
program repeatedly. In addition to executing the program, the CPU regularly reads the status of
the input devices, and sends data to the output devices. The Input system senses the status of the
real-world inputs (a switch, a level, etc.), translates them to values that can be used by the CPU,
and writes those values to the Input table. The application program is executed, and writes values
to the Output table. The Output system then converts the output value to a real world change (motor
turns on, valve opens, etc.)

This process of reading inputs, executing logic, and writing outputs is called the PLC Scan or
Sweep.

Fig2.7: block diagram

29
2.8 Program languages of PLC

The following is a list of programming languages specified by this standard:

 Ladder diagram (LD)
 Sequential Function Charts (SFC)
 Function Block Diagram (FBD)
 Structured Text (ST)
 Instruction List (IL)

One of the primary benefits of the standard is that it allows multiple languages to be used within
the same programmable controller. This allows the program developer to select the language best
suited to each particular task.
SFC have been developed to accommodate the programming of more advanced systems. These
are similar to flowcharts, but much more powerful. This method is much different from flowcharts
because it does not have to follow a single path through the flowchart.
Programming has been developed as a more modern programming language. It is quite similar to
languages such as BASIC and Pascal.
Structured Text (ST) is a high-level textual language that is a Pascal like language. It is very
flexible and intuitive for writing control algorithms.
FBD is another graphical programming language. The main concept is the data flow that start from
inputs and passes in block(s) and generate the output.
The Ladder diagram is the easiest language for plc.

2.9 Ladder Diagram

Ladder logic is a programming language that creates and represents a program through ladder
diagrams that are based on circuit diagrams. It is mainly used in developing programs or software
for programmable logic controllers (PLCs), which are used in industrial applications.

The language evolved from originally being a method for documenting the design and construction
of relay racks used in manufacturing and process control, with each relay rack represented by a
symbol on the ladder diagram that has connections to devices below them that look like vertical
rails. The relay symbols themselves look like rungs in a ladder.

30
 Chapter III
PLC Basic Learning

3.1 Type of PLC Brands

There are many brands of PLC

Siemens Mitsubishi Delta LS Omron Allen Bradley Schneider Fatek Panasonic Delta

Every brand has also many different series for example Siemens has S Logo S7 200 S7 300 S7
1200

Here we are using Siemens Logo

3.2 Software installation

1. Locate and download an .exe file Siemens logo
2. Locate and double-click the .exe file. It will usually be in your Downloads folder or CD rom of
Siemens logo.
3. A dialog box will appear. Follow the instructions to install the software.
4. The software will be installed. On your destination drive like C Programs files.
5. Install the suitable driver by device by manager searching the best driver by internet.

3.3 General used instruction and symbol

No
Make contact

NC
Break contact

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3.4 Data upload from PC to PLC
Open LOGO soft Comfort then open tools then transfer PC>LOGO

Fig3.4: PC to Plc.

3.5 Data upload from PLC to PC

Open LOGO soft Comfort then open tools then transfer LOGO >PC

Fig3.5: PLC to PC

3.6 Start the PLC for operation

Now we have to open a new file and choose leader diagram here we are ready for upload a
program to plc.

32
 Chapter IV
PLC Practical Application

4.1 Star Delta automatic switch

Most induction motors are started directly on line, but when very large motors are started that way,
they cause a disturbance of voltage on the supply lines due to large starting current surges. To limit
the starting current surge, large induction motors are started at reduced voltage and then have full
supply voltage reconnected when they run up to near rotated speed.

Fig 4.1: star delta

33
4.2 4 step any button on off
Sometimes we need many switches to control a motor or another devices so here we can use plc
so that many number switch can perform independent.

Fig 4.2: 4 step switch

34
4.3 Boiler control
Boiler control system programming and panel design fall hand in hand. Building and programming
a boiler control system that meets NFPA85 code requirements is very challenging. Just a few
examples are interposing relays, a watch dog timer, the handshake between the Burner
Management System and the Combustion Control System and performing critical input checks
once a minute to verify the PLC input cards do not have stuck bits. Further, design requirements
will call for things like having the wiring fail safe (on is a good state), high voltage AC and low
voltage DC separation, PLC power requirements and total wattage heat dissipation.

Programming for a boiler control system takes a lot of years to learn and should never be attempted
without a thorough understanding of how boilers work as well as what needs to be accomplished
and lastly how to program with the PLC platform chosen.

To explain the fundamental logic, we can use a fully metered cross limited combustion control
system as an example. The principal function of this type of system is to have the air always lead
the fuel when increasing the firing rate and follow behind the fuel when decreasing the firing rate.
This will prevent the boiler from going into a rich condition during load swings. Programming
cross limited systems is accomplished by using a high select for the air set point (fuel flow or boiler
master) and a low select for the fuel set point (air flow or boiler master). There will be oxygen trim
loop which is changing (multiplier) the characterized air flow to add or subtract from its
measurement and force the fuel to react by cross limiting the set points and maintain proper boiler
tune.

The air flow measurement will have a function generator for characterizing the transmitter reading
from minimum fire to 100% span so the X or input values will be adjusted and the Y or output
values will be scaled in eleven steps from 0 to 100%.

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The flow control outputs for fuel and air will also have function generators and are characterized
from minimum fire to 100% span so the X or input values will inversely be scaled in eleven steps
from minimum to 100% while the Y or output values will be appropriately scaled for the
controlling devices during the tune.

Fig4.3: Boiler
These three function generators are always or should always be found on fully metered systems.
To explain why these three function generators should always be used instead of only the air flow
requires understanding loop tuning and could lead to a debate but through years of experience we
have found it is best to have all three. Other characterization requirements are the set point for
oxygen trim which is driven from gas flow and characterizing the fuel gas re circulation (FGR) if
so equipped. Lastly there may be characterization for air flow related components like the fresh
air inlet damper, wind box damper and the fan VFD. If running on oil there has to be a separate
set of function generators for each oil controlling device as well.

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Minimum Safety requirements should be but are not always limited to tripping if a bad quality
condition exists for air or fuel flow and if the fuel to air flow set points deviate a specified amount
(in a running rich condition) for a short-timed period. There are other reasons one may need or
prefer to have the boiler trip but these are the most important.

There are many more functions that need to be addressed when programming a boiler combustion
control system and it is easy to see why it is important to have it done by professionals with a
proven track record. Having a bulletproof panel ready to go before the boiler installation and
commissioning has been completed is a big-time saver.

Fig4.3: Boiler plc.

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4.4 conveyor Belt
Conveyor belt is the carrying medium of a belt conveyor system (often shortened to belt conveyor).
A belt conveyor system is one of many types of conveyor systems. A belt conveyor system consists
of two or more pulleys (sometimes referred to as drums), with an endless loop of carrying
medium—the conveyor belt—that rotates about them. One or both of the pulleys are powered,
moving the belt and the material on the belt forward. The powered pulley is called the drive pulley
while the unpowered pulley is called the idler pulley. There are two main industrial classes of belt
conveyors; Those in general material handling such as those moving boxes along inside a factory
and bulk material handling such as those used to transport large volumes of resources and
agricultural materials, such as grain, salt, coal, ore, sand, overburden and more.

Fig 4.4: conveyor belt

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4.5 Car parking monitoring
A car parking system is a mechanical device that multiplies parking capacity inside a parking lot.
Parking systems are generally powered by electric motors or hydraulic pumps that move vehicles
into a storage position.

Car parking systems may be traditional or automated. Automatic multi-stored automated car park
systems are less expensive per parking slot, since they tend to require less building volume and
less ground area than a conventional facility with the same capacity. In the long term, automated
car parking systems are likely to be more cost effective than traditional parking garages. Both
automated car parking systems and automated parking garage systems reduce exhaust gas — cars
do not drive around in search of parking spaces.

Fig4.5: car parking by plc.

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 Chapter V

Conclusion
PLC applications are typically highly customized systems. PLC is low compared to the cost of a
specific custom-built controller design. In general, PLCs are more robust and require less
maintenance, thus making the things they control work better, in spite of the environment. Overall,
PLCs appear to be an excellent solution for many different problems. Future of PLC Continuation
of new product developments and making integration of PLCs with other control. PLC technology
include features such as GUIs and more human-oriented machine interfaces. New PLC instructions
are developed to add intelligence to a controller. Concept of the flexible manufacturing system
(FMS) will determine the control philosophy of the future. PLC Designed for extreme industrial
environments Integrated command interpreter (proprietary) No secondary memory available
Optimized for Single task Computer Designed mainly for data processing and calculation
Optimized for speed Lost of secondary memory available Multitasking capability PLC Vs.
Computer

Advantages Flexibility Large Quantities of Contacts Lower Cost Visual Observation Reliability
and Maintainability

Single-function applications do not pay to use a PLC that includes multiple programming
capabilities. Their operational sequence is seldom or never changed. if the power fails, the system
stops.

Now industry are being replaced by Automation and robotics. All process and work are carried
out by machines and robotics process automation. Every industrial sector like manufacturing,
process industries, chemical, food & beverages, Oil Gas , Transport, machine tools every where
Industrial automation is used. Bangladesh has just stepped in Industrial Automation field , So now
over period of time some good of technologies and training center will merging with Operational
Technologies like PLC SCADA DCS and that is the reason future will be bright in Automation.
Here will be multiple openings & Job opportunities in IT as well as OT sectors, IT companies are
hiring as Analyst, Tester and developer for SCADA or IIOT application & software.

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 5.2 Reference

Bangladesh automation Technology

Technical training center in Bangladesh

Web sites
1. http://batbd.net/about-us/ (2.1-2.5)
2. https://automationforum.in/t/boiler-level-control-system/2730 (4.3)
3. https://www.slideshare.net/VikashRanjan16/training-report-on-plc-scada-and-automation (2.1)
4. http://www.plcmanual.com/plc-installation-commissioning (2.7)
5. http://www.kronotech.com/PLC/Languages.htm (5.2)

Thank You

END

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