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PROGRESS REPORT

OF

SIX MONTHS INDUSTRIAL TRAINING

AT

NFI AUTOMATION INSTITUTE

IN

AUTOMATION

Supervised By: Submitted By:Er. Rohit Kaushal Rajinder singh

Er. Rajveer 90180517484

Electrical Engineering

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1. BASIC SYMBOLS USED IN AUTOMATION AND PLC

1.1 Contact Normally Open

Contacts are used in association with coils in contact relays. They can be normally open (NO) or

normally closed (NC). These two types characterize the electrical behavior of contacts when they

are not activated, i.e. when the coil to which they are associated is not activated. As soon as the

coil has a current going through it, contacts to which it is associated change their status.

Normally open (NO) contacts close, and normally closed (NC) contacts open. These two

contacts work as opposites. A normally open (NO) contact blocks the passage of current in a

circuit when not activated. Once activated, the contacts allow the passage of electrical current.

On the other hand, a normally close (NC) contact allows the passage of electrical current when

not activated and blocks it when activated. When the coil is under voltage, the contacts to which

it is associated change their status instantly. For this reason, they are sometimes called instant

contacts to differentiate them from delay contacts.

1.2 Contact Normally Close

Contacts are used in association with coils in the electrical behavior of contacts when they are

not activated, i.e. when the coil to which they are associated is not activated. As soon as the coil

has a current going through it, contacts to which it is associated change their status. Normallyopen (NO) contacts close, and normally closed (NC) contacts open. These two contacts work as

opposites. A normally open (NO) contact blocks the passage of current in a circuit when not

activated. Once activated, the contacts allow the passage of electrical current. On the other hand,

a normally close (NC) contact allows the passage of electrical current when not activated and

blocks it when activated. When the coil is under voltage, the contacts to which it is associated

change their status instantly. For this reason, they are sometimes called instant contacts to

differentiate them from delay contacts.

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1.3 Rising Edge Contact

Rising edge and falling edge contacts are associated with a coil. They detect a change of state, 0 -

->1 or 1 --> 0 A rising edge contact is a normally open contact that acts on the rising edge of the

intensity of the current that travels along the coil to which it is associated. When the current

starts traveling the coil, the rising edge contact closes momentarily, for a time equivalent to 1

simulation cycle. A falling edge contact is a normally open contact that acts on the falling edge

of the intensity of the current that travels along the coil to which it is associated. When the

current stops traveling the coil, the falling edge contact closes momentarily, for a time equivalent

to 1 simulation cycle. A rising edge or falling edge contact has to have the same tagname than

the coil to which it is associated. Also see .

1.4 Falling Edge Contact

Rising edge and falling edge contacts are associated with a coil. They detect a change of state, 0 -

->1 or 1 --> 0 A rising edge contact is a normally open contact that acts on the rising edge of the

intensity of the current that travels along the coil to which it is associated. When the current

starts traveling the coil, the rising edge contact closes momentarily, for a time equivalent to 1

simulation cycle. A falling edge contact is a normally open contact that acts on the falling edge

of the intensity of the current that travels along the coil to which it is associated. When the

current stops traveling the coil, the falling edge contact closes momentarily, for a time equivalent

to 1 simulation cycle. A rising edge or falling edge contact has to have the same tagname than

the coil to which it is associated. Also see .

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1.5 Coil

A coil is made of a rolled up copper wire. When the coil has current going through it, an electro-

magnetic force is generated in its core. The coil is used in many electrical applications, in contact

relays for example. In contact relays, the electro-magnetic force generated by the passage of the

current in the coil opens or closes the contacts of the relay that are associated with the coil. Three

types of coils are available in the Electrical control workshop, they are the coil, and the coil latch

and the coil unlatch. When a coil in under voltage, the normally open contacts associated with it

close whereas the normally closed contacts associated with it open. When the coil is no longer

under voltage, the contacts take back their initial status. The coil latch works as the coil except

that the contacts that are associated with it stay in their activated status even if the coil latch is no

longer under voltage. That way, when the coil latch is under voltage, the normally open contacts

close and the normally closed contacts open. The coil unlatch allows the contacts that were

activated by a coil latch to take back their initial status. When the coil unlatches is activated, the

normally open contacts become open again and the normally closed contacts become closed

again. The contacts will remain in that status even if the coil unlatches is no longer under

voltage. In Automation Studio, the coil has to have the same tag names than the contacts to

which it is associated.

1.6 Indicator Light

The indicator light is used to indicate the status of a component in a control system. Its color is

usually associated with the task to be done. For example, red can be used for the indicator light

of a push button used as an emergency stop button. Also, the indicator light of a push button

authorizing the start of an automatisms cycle is usually green. The indicator light can work with

voltages varying between 6 and 120 Volts, in AC as well as DC current. Models supporting a

small current use LED (light emitting diode). They occupy a small space and have a longer life

span; they consume little energy and have a low maintenance cost compared to neon or

incandescent type lights. In some applications, (a current limiting device) allows the indicator

light to work under a lower current than the one in the control circuit. This device cans a

transformer or more commonly a resistor. The working principle behind the indicator light using

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LEDs relies on an important characteristic of electronics. It uses a special p-n junction that emits

light when it is under direct current (when the anode-cathode voltage is positive).

1.7 Single-Phase Motor

The single-phase motor transforms electrical energy into mechanical energy. The main

parameters of the motor are its power and rotation speed. The single-phase motor can be

connected between two power lines of 120 or 240 Volts or, between a power line and a neutral.

The single-phase motor is made of a mobile part called the rotor and a static part called a stator.

The stator has a main coil turned to form poles. The number of poles gives the rotation speed of

the motor and they always come in an even number. The rotor is composed of a cylinder made of

sheet metal that has been punctured at the ends to form notches destined to receive conductors.

The conductors of the rotor are made of bare copper bars that are fitted in the notches. When a

voltage is applied on the stators coil, an alternate magnetic flux is generated. The variation of

this magnetic flux induces alternate current in the conductors of the rotor. The presence of this

induced current in the magnetic field created by the stators turn, produces an electro -magnetic

force that makes the rotor turn. In industrial applications, the power of motors is usually

expressed in horse power (HP). Finding its equivalent in the International System is done by the

relation 1HP = 746 W. The single-phase motors are used in applications that require little power,

like machine tool and fans. In those applications, the power generated by the motor varies from a

fraction of HP to a few HP.

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1.8 Three-Phase Motor

The three-phase motor requires a tri-phase current. It is very sturdy and reliable but its power

output tends to be poor under small load.

1.9 LED

The LED is used to see the logical state of the digital circuit where the LED is connected. The

logical state can be either 0 or 1. The component color undergoes a change according to the

logical state of its input signal.

1.10 Fuse

A fuse is a protection device. It can shut down a circuit in which the current going through is too

high (for example, in a short circuit situation). The fuse is calibrated to support a maximum

intensity for the circuit. As long as the intensity does not go over the set intensity value, the fuse

acts as a wire and does not influence the circuit. If the intensity of the current goes over the set

value, the internal element of the fuse melts rapidly, opening the circuit. All the voltage goes to

the terminals of the fuse and no current can circulate in the circuit. Fuses are usually made of a

zinc or silver filament enclosed in a glass, ceramic or fiber tube. The heat generated from the

current going through the circuit provokes, if it goes over the maximum intensity set for the fuse,

the melting of the filament and consequently, the opening of the circuit. Fuses are often used in

control circuits of motors.

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1.11 Power Supply L1

A power supply line is characterized by its voltage and supplies the electrical power to circuits

and motors. For example, a triple-phase motor supply needs three power lines, one for each of

the phases. In industrial and domestic electrical installations, power supply is available from the

local power company. The electrical company supplies many types of power sources, mainly a

triple-phase 600 Volts system with three lines and a triple-phase 208/120 Volts system with four

lines. The 600 Volts supply with three lines is used in industrial installations as a motive force

for the drive of triple-phase motors. The 208/120 Volts supply system with four lines supplies

three power lines with 208 Volts line to line and a neutral. A line to neutral connection is used to

supply a 120 Volts single-phase voltage. All three lines can be used to supply 208 Volts line to

line triple-phase motors. Each 208 Volts line to line bus can be combined with the neutral to

supply 120 Volts lighting circuits. In triple-phase power circuits, the line to neutral voltage is

equal to the line to line voltage divided by 1,73. For example, from a line to line 208 Volts triple-

phase supply it is possible to obtain a 208/1,73 = 120 Volts line to line single-phase supply.

1.12Power Supply L2








three power lines with 208 Volts line-to-line and a neutral. A line to neutral connection is used to

supply a 120 Volts single-phase voltage. All three lines can be used to supply 208 Volts line-to-

line triple-phase motors. Each 208 Volts line-to-line bus can be combined with the neutral to


equal to the line-to-line voltage divided by 1,73. For example, from a line-to-line 208 Volts

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triple-phase supply it is possible to obtain a 208/1,73 = 120 Volts line-to-line single-phase

supply.

1.13 Power Supply L3








three power lines with 208 Volts line-to-line and a neutral. A line to neutral connection is used to

supply a 120 Volts single-phase voltage. All three lines can be used to supply 208 Volts line-to-

line triple-phase motors. Each 208 Volts line-to-line bus can be combined with the neutral to


equal to the line-to-line voltage divided by 1,73. For example, from a line-to-line 208 Volts

triple-phase supply it is possible to obtain a 208/1,73 = 120 Volts line-to-line single-phase

supply.

1.14 Neutral

The neutral is used in electrical power circuits as a reference for the voltage on a single-phase ortriple-phase line. It is also used in triple-phase supply circuits to supply a smaller voltage than

the line to line voltage. In triple-phase power circuits, the combination of a power line with a

neutral allows the supply of a smaller voltage than the line to line voltage. For example, the

combination of a 208 Volts triple-phase line to line power line with the neutral, has an output

supply of 120 Volts line to neutral. In triple-phase circuits, the line to neutral voltage is equal to

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the line to line voltage divided by 1,73. For example, with a triple-phase supply of 208 Volts line

to line, it is possible to obtain a single-phase supply of 208/1,73 = 120 Volts line to neutral.

Sockets for ordinary domestic current are composed of two terminals. One terminal is connected

to the single-phase 120 or 240 Volts line (depending on the country) and the other terminal is

connected to the neutral.

1.15 Ground

The ground is equal to 0 Volts. It represents the reference by which the voltages

are measured. The term ground is used because one of the wires of a supply cord in

electrical installations is always linked to the ground by a low resistance wire. In

reality, in the case of commercial and residential buildings, this connection is done

by the water supply pipe located at the entrance of the building. In certain cases,

the ground is also called the common. In electrical installations, the main objective

of the ground is to reduce the danger of electrical shocks. Domestic electrical

appliances with a metallic casing are required to have a ground wire on their

casing. Such is the case for electric stoves, and water heaters for example. In that

type of appliance, the plug socket, has a third terminal used to connect the casing

to the ground. In industrial installations, the ground is usually achieved through a

grid stuck in the ground. All motors and machines in factories are fitted with a

ground.

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1.16 Power Supply 24 Volts

The power supply 24V is a source of 24 Volts.

1.17Common (0 Volts)

The common component is the equivalent to the Ground component but it is for circuits in DC

current.

1.18 Pushbutton Normally Open

Push buttons do the same thing as switches activated by finger pressure. They constitute the link

between the user and the circuit. Push buttons can be normally open (NO) or normally closed

(NC). Usually, push buttons have a return spring i.e. a spring that brings back the push button to

its initial position as soon as the button is released. That is why push buttons are said to be

momentary contact switches. Push buttons are made of a manual actuator and a contact. The typeof push button depends on the type of contact. Contacts can be normally open (NO) or normally

closed (NC). If the push button is normally open (NO), activating the switch closes the contact.

However, if the push button is normally closed (NC), activating the switch opens the contact. In

simulation diagrams, push buttons can be associated with switches that have the same tagname.

This association can be done with same type switches or opposite type switches.

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1.19 Pushbutton Normally Close

Push buttons do the same thing as switches activated by finger pressure. They constitute the link

between the user and the circuit. Push buttons can be normally open (NO) or normally closed

(NC). Usually, push buttons have a return spring i.e. a spring that brings back the push button to

its initial position as soon as the button is released. That is why push buttons are said to be

momentary contact switches. Push buttons are made of a manual actuator and a contact. The type

of push button depends on the type of contact. Contacts can be normally open (NO) or normally

closed (NC). If the push button is normally open (NO), activating the switch closes the contact.

However, if the push button is normally closed (NC), activating the switch opens the contact. In

simulation diagrams, push buttons can be associated with switches that have the same tag name.

This association can be done with same type switches or opposite type switches.

1.20 Toggle Switch Normally Open

A toggle switch is used to control a connection between two points by opening and closing the

arm switch.

1.21 Limit Switch Normally Open

Limit switches are associated with mechanical position sensors. They can be normally open

(NO) or normally closed (NC). They are made of two contacts, a mobile one and a fixed one. At

rest status, the NO limit switch is open and blocks the current. However, the NC limit switch is

closed allowing the passage of current. Limit switches allow the detection of a position or the

limitation of a translation movement. For example, when a cylinder rod comes in contact with

the roller of the position sensor to which it is associated, the mobile contact of the switchchanges position which provokes the status change for the limit switch. In fact, for a NO limit

switch, the mobile contact presses against the fixed contact and the switch closes. In the case of a

NC limit switch, the mobile contact moves away from the fixed contact and the switch opens.

Once the position sensor is no longer activated, the mobile contact of the limit switch takes back

its initial position, under the action of a return spring. The switch takes back its rest status. Limit

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switches need to have the same tag name that the mechanical position sensors to which they are

associated. Mechanical position sensors are components from other workshops.

1.21 Limit Switch Normally Close






the roller of the position sensor to which it is associated, the mobile contact of the switch

changes position which provokes the status change for the limit switch. In fact, for a NO limit

















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NC limit switch, the mobile contact moves away from the fixed contact and the switch opens.Once the position sensor is no longer activated, the mobile contact of the limit switch takes back




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1.24 Position Switch

The 2 position switches make it possible to connect the line 1 (initial position) or the line 2. The

change of state is triggered by a click on the pushbutton. The arrow of the symbol indicates the

conducting line.

1.25Position Switch

The 3 position switches make it possible to connect the line 1 or the line 2. Initially, the switch is

in the neutral position 3. The change of state is triggered by a click on the pushbutton. The arrow

of the symbol indicates the current conducting line or the neutral position.

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2.0 Basic Instruction IN plc programming:

2.1 General:

LD Load A contact

LDI Load B contactAND Series connection- A contact

ANI Series connection- B contact

OR Parallel connection- A contact

ORI Parallel connection- B contact

ANB Series connection (Multiple Circuits)

ORB Parallel connection (Multiple circuits)

MPS Store the current result of the internal PLC operations

MRD Reads the current result of the internal PLC operations

MPP Pops (recalls and removes) the currently stored result

2.2 Output:

OUT Output coil

SET Latch (ON

RST Clear the contacts or the registers

2.3 Timers, Counters:96 TMR 16-bit timer

97 CNT 16-bit counter

97 DCNT 32-bit counter

2.4 Main control:

MC Master control Start

MCR Master control Reset

2.5 Rising-edge/falling-edge detection:

90 LDP Rising-edge detection operation

91 LDF Falling-edge detection operation

92 ANDP Rising-edge series connection

93 ANDF Falling-edge series connection

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94 ORP Rising-edge parallel connection

95 ORF Falling-edge parallel connection

2.6 Rising-edge/falling-edge output:

89 PLS Rising-edge output

99 PLF Falling-edge output

2.7 End:

END Program end

2.8 Other:

NOP No operation

P PointerI Interrupt program marker

98 INV Inverting operation

2.9 Step ladder:

STL Step transition ladder start command

RET Step transition ladder return command

3.0 Transmission Comparison:

10 CMP Compare

11 ZCP Zone compare

12 MOV Data Move

13 SMOV Shift move

14 CML Compliment

15 BMOV Block move

16 FMOV Fill move

17 XCH Data exchange

18 BCD Convert BIN data into BCD

19 BIN Convert BCD data into BIN

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3.1 Four Fundamental Operations of Arithmetic:

20 ADD Perform the addition of BIN data

21 SUB Perform the subtraction of BIN data

22 MUL Perform the multiplication of BIN data

23 DIV Perform the division of BIN data

24 INC Perform the addition of 1

25 DEC Perform the subtraction of 1

3.2 Contact Type Logic Operation:

3.2.1 Contact Type Compare Instruction:

224 LD= Comparison contact is ON when S1 = S2 is true

225 LD> Comparison contact is ON when S1 > S2 is true

226 LD< Comparison contact is ON when S1 < S2 is true

228 LD Comparison contact is ON when S1 S2 is true

229 LD= Comparison contact is ON when S1 S2 is true

232 AND= Comparison contact is ON when S1 = S2 is true

233 AND> Comparison contact is ON when S1 > S2 is true

234 AND< Comparison contact is ON when S1 < S2 is true

236 AND Comparison contact is ON when S1 S2 is true

237 AND= Comparison contact is ON when S1 S2 is true

240 OR= Comparison contact is ON when S1 = S2 is true

241 OR> Comparison contact is ON when S1 > S2 is true

242 OR< Comparison contact is ON when S1 < S2 is true

244 OR Comparison contact is ON when S1 S2 is true

245 OR= Comparison contact is ON when S1 S2 is true

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PLC Exercises

1) Devise a circuit that can be used to start a motor and then after a delay of 10 sec start

a pump. When the motor is switched off there should be delay of 10 sec before the

pump is off.

2) Device a circuit in which

When X1 is pressed Y0 gets ON, Y1,Y2 get off,

When X1 is pressed again Y1 gets ON and Y0, Y2 get OFF

When X1 is pressed again Y2 gets ON and Y0, Y1 get OFF

(Interlocking mechanism)

Study and use the following commands:

MOV, INC, DEC, MUL, ADD, SUB, ZCMP

3) Switch on a Lamp after 5 sec, now using mov command change the timer to 10

second and change back to 5 sec. You have 1 maintained button and 2 push buttons

only. Maintained button to switch on/off the lamp. Other two push button for

changing the time from 5 to 10 sec and vice-versa

4) Device a circuit in which Y0 is on only when X1 is pressed in 10 sec. just after start of

the machine(X0). Otherwise if X1 is pressed after 10 sec. Nothing should happen.

5) Device a circuit in which if X1 does not get pressed just after 5 second after output Y0

is on by pressing X0, alarm (Y1) is ON and blinking with frequency of 2Hz.6) Device a circuit, in which if X0 is pressed once Y0 should ON and when X0 is pressed

again Y0 should turn off.

7) Device a circuit, in which

When X1+X2+X3 > Y0 ON FOR 5 SEC THEN OFF

X4+X2+X1 > Y1 ON FOR 6 SEC THEN OFF

X4+X5+X6 -> Y2 ON FOR 7 SEC THEN OFF

Cycle should repeat

8) Use one push button (X1) turn ON Y0 in following sequence:Y0 on for 2 sec. then off for 2 sec. then on for 3 sec. then off for 3 sec then on for 4 sec.

then continuously off.

9) When you press X0 Y0 and Y1 should blink after a delay of 2 sec continuously andwhen you press X1 Y0 and Y1 should blink after a delay of 3 sec.

10) Start a bulb as soon as PLC run and stop the bulb as soon as PLC stops.

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11) You have 5 outputs Y0, Y1, Y2, Y3, Y4 When M0 is pressed All five should ON

When M1 is pressed Y1, Y2, Y3 should OFF

When M2 is pressed

Y4 should off and Y1 should ON When M3 is pressed Y2, Y3 gets ON and Y0 goes OFF and Y4 goes ON again

(take M0~M3 as maintained button and dont use set-reset commands)

12) I have a constant K10 in D0

Multiply it with 100

Add 56 to it

Subtract 14 from it

Finally store it in D10

13) Design electrical circuit to start 220 V motor with 24 PLC output.

14) Automatic Cold Drink making machine:

Use X0Main selector switch to ON/OFF the machine

Use X1 & X2 as push buttons for selecting small/large cup

Make a small beep (Y3)of 2 sec when cup is filled

Blink an LED when cup is filling

Make an arrangement to change (increment or decrement) the timing of timers

for both small and large cups

(Assume small cup gets filled in 5 sec and big cups filled in 10 sec.)

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PLC Exercise -2

1) A toggle start switch and a limit switch (LS1) on a safety gate must both be on before a

motor is energized.

2) While the motor is energized, it must remain energized until a limit switch (LS2) is

activated. This second limit switch indicates the turn off of motor.

3) A cycle counter should also be included to allow counts of parts produced. When this

value exceeds 5 the machine should shut down and a light lit up.

4) A safety check should be included. If the solenoid has been on for more than 5 seconds,

it suggests that the cylinder is jammed or the machine has a fault. If this is the case, themachine should be shut down and maintenance light turned on.

5) Write ladder logic for a motor starter that has a start and stop button that uses latches

.Write the same ladder logic without latches.

6) Design ladder logic that uses a timer and counter to measure a time of 50.0 days

7) Develop the ladder logic that will turn on an output (light), 15 seconds after switch (A)

has been turned on

8) Develop the ladder logic that will turn on a output (light), after a switch (A) has been

closed 10 times. Push button (B) will reset the counters

9) Develop a program that will latch on an output (B), 20 seconds after input (A) has been

turned on. The timer will continue to cycle up to 20 seconds, and reset itself, until A has

been turned off. After the third time the timer has timed to 20 seconds, B will be

unlatched

10) A motor will be connected to a PLC and controlled by two switches. The GO switch willstart the motor, and the STOP switch will stop it. If the motor is going, and the GO

switch is thrown, this will also stop the motor. If the TOP switch was used to stop the

motor, the GO switch must be thrown twice to start the motor. When the motor is

running, a light should be turned on (a small lamp will be provided).

11) In dangerous processes it is common to use two palm buttons that require a operator to

use both hands to start a process (this keeps hands out of presses, etc.). To develop this

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there are two inputs that must be turned on within 0.25s of each other before a

machine cycle may begin.

12) Write a ladder logic program that does what is described below.

- When button A is pushed, a light will flash for 5 seconds.- The flashing light will be on for 0.25 sec and off for 0.75 sec.

- If buttonA has been pushed 5 times the light will not flash until the system is reset.

- The system can be reset by pressing button B

13) Write a program that will turn on a flashing light for the first 15 seconds and then off.

Dont use start stop button

14) Write a program that only uses one timer. When an input A is turned on a light will be

on for 10 seconds. After that it will be off for two seconds and then again on for 5

seconds. After that the light will not turn on again until the input A is turned off

progress_ report_1 (90180517489)

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