process automation practical connection diagram

DIPLOMA IN MECHANICAL ENGINEERING

Process Automation Practical

1. Direct operation of a motor using latching circuit.

CONNECTION DETAILS

Output motor connection:

PLCPLCPLCPLC MOTORMOTORMOTORMOTOR

Q5 ----------------- coil – 1(Q5)

Q6 ----------------- coil – 2(Q6)

Q7 ----------------- coil – 3(Q7)

Q8 ----------------- coil – 4(Q8)

Input connection:

I01 ---------------- ON switch (SW-1)

I02 ---------------- OFF switch (SW-2)

PROCEDURE:

1. Connect the Computer and PLC using RS232 serial cable

2. Open the SG2client software and open the “New ladder document”. Now view the

program Window like LAD VERSION 3.2 then File MENU ---> Open and browse the

respective folder in your saved location and double click or open the required program

(ex:pgm.gen) and view the ladder program page.

3. Then click the Operation Menu ---> it shows the Link com port in the menu list ,then

click the link com port, one window open it shows selecting com you select the “default

com port” in your computer, and mode is single mode selection only. then ensure after

selecting the com port and mode selection correctly click the link button in your

window. if your process is correct means it shows “connect successfully”, if it is wrong

means “communication error”.(check the communication serial cable if it connected or

not)

4. Then click the Operation Menu --->select the Write it shows the pop-up message like

this “Old data will be lost, continue?” YES or NO button. You click “Yes” button allow to

write the current data to the PLC.

5. Then click the Operation Menu --->select the RUN it shows the pop-up message Like

this “Do you want to read program from module?” YES or NO button. You click “NO” it

means avoid to read the current program again. Then the PLC Ready to the RUN mode.

6. Now the PLC is act as the working mode. Connections are connecting as per the

connection diagram.

NOTE: - working principles

� If you press the “SW-1”(I01) push button then the motor will be start to rotate

continuously.

� If you press the “SW-2”(I02) push button then the motor will be stop the rotation.

2. Operation of a motor using ‘AND’ logic control.

CONNECTION DETAILS

Input connection:

I01 ---------------- switch (SW-1)

I02 ---------------- switch (SW-2)


PLC MOTOR

Q5 ----------------- coil – 1(Q5)

Q6 ----------------- coil – 2(Q6)

Q7 ----------------- coil – 3(Q7)

Q8 ----------------- coil – 4(Q8)

PROCEDURE:






3. Then click the Operation Menu ---> it shows the Link com port in the menu list, then






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connection diagram.


� In this program work the “AND” Gate operation. “AND gate” logic truth table are

following tabulation.

� If you press the both “SW-1” and “SW-2” push buttons then the motor will be start

to rotate continuously. Otherwise the motor will be stop.

TRUTH TABLE

I01 I02 OUT

0 0 0

0 1 0

1 0 0

1 1 1

3. Operation of a motor using ‘OR’ ‘control.

CONNECTION DETAILS

Input connection:

I01 ---------------- switch (SW-1)

I02 ---------------- switch (SW-2)


PLC MOTOR

Q5 ----------------- coil – 1(Q5)

Q6 ----------------- coil – 2(Q6)

Q7 ----------------- coil – 3(Q7)

Q8 ----------------- coil – 4(Q8)

PROCEDURE:






3. Then click the Operation Menu ---> it shows the Link com port in the menu list, then






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connection diagram.


OR GATE - TRUTH TABLE

I01 I02 OUT

0 0 0

0 1 1

1 0 1

1 1 1

� In this program work the “OR” Gate operation. “OR” gate logic truth table is

attaching the above tabulation.

� If you press the “SW-1” or “SW-2” push buttons then the motor will be start.

� Similarly if you press the both “SW-1” and “SW-2” push buttons also the

motor will be start to rotate continuously.

4. On-Delay control of a motor.

CONNECTION DETAILS

Input connection:

I01 ---------------- ON switch (SW-1)

I02 ---------------- OFF switch (SW-2)


PLC MOTOR

Q5 ----------------- coil – 1(Q5)

Q6 ----------------- coil – 2(Q6)

Q7 ----------------- coil – 3(Q7)

Q8 ----------------- coil – 4(Q8)

PROCEDURE:












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connection diagram.


� In this program work the “ON” time delay of the motor.

� If you press the switch“SW-1 ON” condition the delay time is running at a

particular user defined time (the user can set the delay time or can vary

the delay time accordingly using the program). Once the delay time is

over, then the motor gets ON continuously.

� If you press the switch “SW-2” then the motor will be stop the rotation.

5. Off –Delay control of a motor.

CONNECTION DETAILS

Input connection:

I01 ---------------- ON switch (SW-1)

I02 ---------------- OFF switch (SW-2)


PLC MOTOR

Q5 ----------------- coil – 1(Q5)

Q6 ----------------- coil – 2(Q6)

Q7 ----------------- coil – 3(Q7)

Q8 ----------------- coil – 4(Q8)

PROCEDURE:












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connection diagram.


� In this program work the “OFF” time delay of the motor.

� If you press the switch “SW-1” then the motor will be start to rotate.

� If you press the switch“SW-2 ON” condition the off delay time is running

at a particular user defined time (the user can set the delay time or can

vary the delay time accordingly using the program). Once the delay time

is over, then the motor gets OFF continuously.

6. Automatic operation of a Double acting cylinder-single cycle.

CONNECTION DETAILS

Input connection:

I01 ---------------- ON switch (SW-1)

I05 ---------------- Read switch


PLC D.S.VALVE

Q1 ----------------- coil – 1(S1)

Q2 ----------------- coil – 2(S2)

PROCEDURE:












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connection diagram.


� In this exercises double acting cylinder is act as the single acting cylinder using

PLC programming.

� Connect the switch “sw-1” (I01) connector using cable and, Reed switch“I05”

connector also connect. Then the output side Q1 is connect the S1 relay of the

solenoid valve, Q2 is connect the S2 relay of the solenoid valve.

� Initially switch ON the ‘sw-1’ now Q1 output is enable S1 relay ON so the

cylinder is move to forward direction.

� Suddenly Reed switch ‘I05’ is sense and ON the PLC input signal. So the PLC

output Q2 is enable so cylinder is automatically return.

7. Automatic operation of a Double acting cylinder-single cycle - forward, time Delay, return.

Input connection:

I01 ---------------- ON switch (SW-1)

I05 ---------------- Read switch (A1)


PLC D.S.VALVE

Q1 ----------------- coil – 1(S1)

Q2 ----------------- coil – 2(S2)

PROCEDURE:












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connection diagram.


� In this exercises double acting cylinder is act as the single cycle - forward, time

Delay, return.

� Connect the switch “sw-1” (I01) connector using cable and, Reed switch“I05”

connector also connect. Then the output side Q1 is connect the S1 relay of the


� Initially switch ON the ‘sw-1’ now Q1 output is enable S1 relay ON so the

cylinder is move to forward direction.

� Suddenly Reed switch ‘I05’ is sense and ON the PLC input signal. So the delay

time is running at a particular user defined time. When the delay time is

end PLC output Q2 is enable cylinder is automatically return.

8. Automatic operation of Double acting cylinder-Multi cycle.

Input connection:

I01 ---------------- ON switch (SW-1)

I02 ---------------- OFF switch (SW-2)

I04 ---------------- Read switch (A0)

I05 ---------------- Read switch (A1)


PLC D.S.VALVE

Q1 ----------------- coil – 1(S1)

Q2 ----------------- coil – 2(S2)

PROCEDURE:












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connection diagram.


� In this exercises double acting cylinder is Automatic operation of -Multi cycle

� Connect the switch “sw-1” (I01), “sw-2” (I02), (I04), (I05) connector are

connect using cable. Then the output side Q1 is connect the S1 relay of the


� Switch ON the ‘sw-1’ switch now Q1 output is enable S1 relay ON so the

cylinder piston is move to outside. Then the Reed switch is sense and signal is

passed the PLC input terminal ‘I05’. So the PLC output Q2 enable, now cylinder

piston is move to return to initial position. Then the ‘I04’ reed switch is sense

the piston magnet so the reed switch is ON. When the ‘I04’ is ON automatically

PLC output Q1 also ON so the cylinder piston is move to outside. In this process

continuously running.

� If you press the ‘I02’ push button the PLC output signals are disable. And also

solenoid valve relay’s supply voltage also off. So the cylinder operations are off.

9. Automatic operation of Double acting cylinder-N cycles (using counter function Block)

Input connection:

I01 ---------------- ON switch (SW-1)

I02 ---------------- OFF switch (SW-2)

I04 ---------------- Read switch (A0)

I05 ---------------- Read switch (A1)


PLC D.S.VALVE

Q1 ----------------- coil – 1(S1)

Q2 ----------------- coil – 2(S2)

PROCEDURE:












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connection diagram.


� In this exercises double acting cylinder is Automatic operation of N cycles

(using counter function Block)

� Connect the switch “sw-1” (I01), “sw-2” (I02), (I04), (I05) connector are

connect using cable. Then the output side Q1 is connect the S1 relay of the


� In this program two counter functions are used, input counter and output

counter. (Example : input counter ‘ 2 ’, output counter ‘ 6 ’)

� If you press the push button ‘Sw-1’ switch now input counter is read the first

count, again press the switch counter is read the second count. So the Q1 output

is enable S1 relay ON so the cylinder piston is move to outside. Then the Reed

switch is sense and signal is passed the PLC input terminal ‘I05’. So the PLC

output Q2 enable, now cylinder piston is move to return to initial position.

Whenever the Q2 enables, output counter will be increased.

� PLC outputs will be stopped, while the counter reaches ‘6’.

10. Sequential operation of a Double Acting Cylinder and a motor.

Input connection:

I01 ---------------- ON switch (SW-1)

I04 ---------------- Read switch (A0)

I05 ---------------- Read switch (A1)


PLC D.S.VALVE

Q1 ----------------- coil – 1(S1)

Q2 ----------------- coil – 2(S2)

Q5 ----------------- S.M – 1(Q5)

Q6 ----------------- S.M – 2(Q6)

Q7 ----------------- S.M – 3(Q7)

Q8 ----------------- S.M – 4(Q8)

PROCEDURE:












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connection diagram.


� In this exercises Sequential operation of a Double Acting Cylinder and a motor.

� Connect the switch “Sw-1” (I01), “Sw-2” (I02), (I04), (I05) connector are

connect using cable. Then the output Q1 is connect the S1 relay of the solenoid

valve, Q2 is connect the S2 relay of the solenoid valve. And also stepper motor

connections are connecting using the connection diagram.

� In this program work the sequential input and output operation of the motor

and cylinder.

� When will be press the “SW-1” push button Q1 is ON so the cylinder piston

move to outside, in this same time stepper motor will be start to run. When the

Q1 is enable time delay is ON.

� PLC output Q2 is ON Motor will be stopped and also cylinder piston, while the

delay time reaches.

11. Sequential operation of two Double Acting Cylinders for the sequence A+,B+, B-, A-.

Input connection:

I01 ---------------- ON switch (SW-1)

I03 ---------------- ON switch (SW-3)

I04 ---------------- Read switch (A0)

I05 ---------------- Read switch (A1)

I06 ---------------- Read switch (B0)

I07 ---------------- Read switch (B1)


PLC D.S.VALVE

Q1 ----------------- coil – 1(S1)

Q2 ----------------- coil – 2(S2)

Q3 ----------------- coil – 3(S3)

Q4 ----------------- coil – 4(S4)

PROCEDURE:












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connection diagram.


� In this exercises Sequential operation of two Double Acting Cylinders for the

sequence A+,B+, B-, A-.

� Connect the switch “sw-1” (I01), “sw-3” (I03), (I04), (I05), (I06), (I07),

connector is connecting using cable. Then the output side Q1 is connect the S1

relay of the solenoid valve, Q2 is connect the S2 relay of the solenoid valve. Q3 is

connecting S3 solenoid valve and also Q4 is connect the S4 solenoid valve.

� If you press the push button ‘Sw-1’ the sequential operation will start from Q3

then the cylinder A+ will go outside., after this Q1 will be enabled then B+ will

go outside then Q2 will enable the B- to move inside and the Q4 will make A- go

inside.

� After this full sequence the operation can be stopped by pressing the ‘SW-2’

push switch.

process automation practical connection diagram

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