28-08-2014, 12:51 PM
This report has been prepared as a textbook to give an insight to Programmable Logic Controllers (PLC) based automation which is emerged out of the latest technological advancements in computers and communication, that guides the Modern industrial environment. Programmable Logic Controllers (PLC) is the conglomeration these two areas. PLC based automation forms the lifeline of modern automated Industries. With the advent of versatile networking techniques, PLCs are used in a complicated networked environment to enhance the efficiency of industries. This gives rise to a growing need for PLC training. Presented in a lucid language, the report helps the reader to understand the subject step-by-step. This book is divided into seven chapters and provides a comprehensive treatment of Programmable Logic Controllers. Throughout the preparation of the report, the authors have kept all the valuable details about the various training modules of PLC.
ACKNOWLEDGEMENT
Before we get into thick of the things I would like to add a few heart- felt words for the people who were par of this study in numerous way, people who gave unending support right from the very beginning of this report. Their support cannot be acknowledged in words. I want to thank all those people who made my study possible and wish that my feelings of gratitude reached their hearts.
First of all, I would like to thank the supreme powers, the Almighty God for his blessings showered on me that I’m able to complete this project work in this topic relevant to the present time.
I also thank my beloved parents who supported me emotionally & financially to prepare this training report. Their motivation is unmatchable. I pay my deep gratitude to Mr. Harish Jindal, Head of the Department (ECE), Gulzar Group Of Engg. And Technology, Khanna for his motivation and supervision. I am also highly indebted to Ms. Amandeep Kaur and Ms. Rosy Kaplesh , Training Coordinator, Automation Systems (Schneider Electric), Ludhiana for their invaluable guidance throughout the work & this training report became realistic with her assistance.
I am also grateful to my friends whose contribution cannot be described in words. And finally heartfelt appreciation to all those people who helped me to reach the completion of this report.
Thanks.
RAGHAV SHARMA
PREFACE
This report has been prepared as a textbook to give an insight toProgrammable Logic Controllers (PLC) based automation which is emerged out of the latest technological advancements in computers and communication, that guides the Modern industrial environment. Programmable Logic Controllers (PLC) is the conglomeration these two areas. PLC based automation forms the lifeline of modern automated Industries. With the advent of versatile networking techniques, PLCs are used in a complicated networked environment to enhance the efficiency of industries. This gives rise to a growing need for PLC training.
Presented in a lucid language, the report helps the reader tounderstand the subject step-by-step. This book is divided into seven chapters and provides a comprehensive treatment of Programmable Logic Controllers. Throughout the preparation of the report, the authors have kept all the valuable details about the various training modules of PLC.
CONTENTS
LIST OF FIGURES………………………………………….7
LIST OF TABLES…………………………………………...8
COMPANY PROFILE
About Automation System………………………………………...9
Schneider All Over India – Service and Sales Network………….10
Key Milestone…………………………………………………...11
Vision……………………………………………………………..11
Activities………………………………………………………...12
Associations………………………………………………………12
Recent References………………………………………………...12
Training Module………………………………………………..13
1. AUTOMOTIVE DESCRIPTION
1.1 Automation and Automation Device…………………………14
1.2 Need of Automation…………………………………………..14
1.3 Program and Programmable Controller………………………14
1.4 Basics Before studying PLC………………………………...15
2. INTRODUCTION TO PLC
2.1 Definition and History of PLC……………………………..19
2.2 Manufacturing and Assembly Processes……………………...20
2.3 Overall PLC System…………………………………………..20
2.4 Programming a PLC…………………………………………...23
2.5 Advantages and Disadvantages……………………………..25
2.6 Leading brands of PLC
3. INTRODUCTION TO ZELIO LOGIC
3.1 Introduction…………………………………………………...26
3.2 Description of Serial Number………………………………...27
3.3 Diagrammatic Startup with Zeliosoft V 2.0…………………..28
3.4 Programming Language……………………………………..29
3.5 Elements Of Ladder Language……………………………….30
3.6 Programming Using ZELIOSOFT V 2.0……………………..37
3.7 Advantages and Disadvantages……………………………….38
4. TWIDO PLC
4.1 Introduction of Twido………………………………………...40
4.2 Types of Twido PLC………………………………………….40
4.3 Description of Serial Number…………………………………42
4.4 Communication Overview…………………………………….43
4.5 Expansion I/O Module to Base………………………………..45
4.6 Special Features of Twido Soft………………………………..46
4.7 Twido-Programming Software………………………………...50
4.8 Advantages…………………………………………………….50
4.9 Disadvantages………………………………………………….50
5. MODICON M340 PLC
5.1 General Information……………………………………………51
5.2 Power Supply…………………………………………………..52
5.3 Memory Card…………………………………………………..52
5.4 Digital Input/Output……………………………………………53
5.5 Programming Software-Unity Pro V4.0……………………….53
5.6 Project Browser………………………………………………...54
5.7 Start New Project………………………………………………55
5.8 Methodology to Develop New Program……………………….55
6. INTRODUCTION TO M218 PLC
6.1 Introduction…………………………………………………….57
6.2 M218 System Architecture…………………………………….58
6.3 M218 System Expansion Architecture………………………...59
6.4 SoMachine V3.0 Software……………………………………..60
6.5 Creation Of Project……………………………………………64
7. HUMAN MACHINE INTERFACE
7.1 Introduction To HMI………………………………………….66
7.2 STU Series Touch HMI………………………………………..67
7.3 Creation Of Project…………………………………………….68
7.4 XBTr400- HMI Using Keypad………………………………...70
7.5 Application Of HMI…………………………………………..71
8. SCADA
8.1 Introduction…………………………………………………….72
8.2 Architecture Of SCADA……………………………………….73
8.3 System Concept………………………………………………...74
8.4 Trends In SCADA……………………………………………...76
8.5 Application Of SCADA………………………………………...77
9. AUTOMATION OF BOTTLING INDUSTRY
9.1 Statement……………………………………………………..78
9.2 Inputs/Outputs………………………………………………..78
9.3 Procedure……………………………………………………..79
9.4 Program………………………………………………………..80
10. INDUSTRY APPLICATION OF PLC 81
CONCLUSION……………………………………………..81
BIBLIOGRAPHY…………………………………………..81
LIST OF FIGURES:
1.4.4 Types Of Switches…………………………………………………………...16
2.1.2 History Of PLC………………………………………………………………19
2.3.1 Operation Of PLC…………………………………………………………….20
2.3.2 PLC And Their Units………………………………………………………….21
3.2.1 Serial Numbers………………………………………………………………...27
3.3 Diagrammatical Startup with Zelio Soft v2.0..………………………………….28
3.4 Programming Language…………………………………………………………29
3.5.7 Clock…………………………………………………………………………..35
3.6 Programming with Zelio Soft v2.0………………………...……………………37
4.7 Twido Programming Software………………………………………………….50
5. Modicon M340 PLC……………………………………………………………...51
5.5 Programming Software Unity Pro v40………………………………………….53
5.6 Project Browser…………………………………………………………………54
5.7 Start New Project………………………………………………………………..55
5.8 Methodology To Develop New Project…………………………………………56
6.1 Introduction To M218 PLC……………………………………………………..57
6.2 M218 System Architecture……………………………………………………...58
6.3 M218 System Expansion………………………………………………………..59
6.4 So-Machine v3.0 Software……………………………………………………...60
6.4.3.1 Overview…………………………………………………………………….61
6.5 Creation Of Project……………………………………………………………...64
7.2 STU Series Touch HMI…………………………………………………………67
7.3 Creation Of Project……………………………………………………………...68
7.4 XBTr400-HMI Using Keypad…………………………………………………..70
8.2 Architecture Of SCADA………………………………………………………..73
8.3 System Concept…………………………………………………………………75
8.4 Trends In SCADA………………………………………………………………76
9.4 Program.…………………………………………………………………………80
List of Tables:
1.4.1 Number System……………………………………………………………..15
1.4.2 Brief Description Of The Logic Gates……………………………………….15
1.4.5 Input Devices………………………………………………………………...18
1.4.6 Output Devices……………………………………………………………….18
2.4.4 Basic Instructions……………………………………………………………..24
3.2.5 Power Supply………………………………………………………………..27
3.5.1 Graphical Elements…………………………………………………………...30
3.5.3 Discrete Outputs……………………………………………………………...32
3.5.5 Counters……………………………………………………………………..33
3.5.7 Clock………………………………………………………………………….35
3.5.8.2 Timing Diagram…………………………………………………………….36
4.5 Assembling An Expansion I/O Module To Base……………………………….45
4.6.1.4 Special Cases………………………………………………………………..46
4.6.4.2 Animation Table…………………………………………………………...48
4.6.5 Counters……………………………………………………………………...49
5.3 Memory Card…………………………………………………………………..52
7.4.1 Characterstics………………………………………………………………...70
8.5 Application Of SCADA……………………………………………………...71
9.2 Inputs/Ouputs………………………………………………………………..78
9.3 Procedure……………………………………………………………………..79
COMPANY PROFILE
ABOUT AUTOMATION SYSYTEM
Automation System was founded in 1995 and starting from scratch, got built it into a viable entity with annual sales of INR 30 million with small PLC, drives and SCADA system and grew into a company of repute in the industrial automation market in India.
Appointed as the System Integrator of Schneider Electric in 1996, The Company got a bandwidth of products connecting sensors to boardrooms. The company has a staff of 20 engineers specialized in PLC systems; AC and DC drive applications and SCADA implementations. It has built long lasting relationships with corporate clients and is one of Schneider Electric’s top performing System Integrators. Marketing, system conceptualization, strategy and personnel motivation/training are the main areas of operation although being a small concern. Specialized in PLC’s, drives and other automation components for implementation of Automation schemes for a broad range of industries (Paper, Steel, Wire and Cable, Rubber, Automobile mfg etc.). Some of the projects handled are as follows:
§ Designed & commissioned control system for complete biscuit plant using PLC, Drives and HMI on Unitelway network for an OEM of Punjab and commissioned the system in Kenya (Africa) and completed similar job for a plant to be commissioned in Nigeria
§ Worked as a consultant to M/s Ralson Industries Ltd., one of the leading bicycle tyre manufacturers in India and helped them to buy complete second hand machinery from Germany and Holland, dismantled the complete machinery and then successfully commissioned the plant in Bhopal (Central India) using PLC, Drives, SCADA, and HMI on MODBUS plus Network
§ Designed & Commissioned Automatic Tyre curing line of 28 barometric presses using PLC, SCADA on MODBUS Plus Network for M/s Continental of Germany installed at M/s Metro Tyres.
§ Partnered Schneider Electric in commissioning, execution and after sales support for OSP SCADA project of Reliance Infocomm Ltd., one of the biggest projects of Transparent Factory in World with over 426 Telemecanique Micros.
Schneider All Over India - Service and Sales Network
Schneider Electricis a Frenchglobal company. It was founded in 1836 by two Schneider brothers. From 1836 to today, Schneider Electric has transformed itself into the global specialist in energy management.Starting from its roots in the iron and steel industry, heavy machinery, and ship building, it moved into electricity and automation management. After 170 years of history, Schneider Electric has become today the solution provider that will help you make the most of your energy. It is among the fortune 500 companies which deal in electrical only. In 1981-1997Schneider Group continued to focus on the electrical industry by separating from its non-strategic activities.This policy was given concrete form through strategic acquisitions by Schneider Group: Telemecanique in 1988, Square D in 1991 and Merlin Gerin in 1992 and it came to India in 1995.
Schneider All Over India
SERVICE NETWORK SALES NETWORK
KEY MILESTONE
VISION
To bring innovation in the automation solution provided, and adding values in every stakeholder's life by providing the Right product/services, at Right time & at Right price.
We wish to be universally admired & benchmarked as an organization for customer care, employee satisfaction & business operations of the highest integrity, forging an enduring and profitable relationship with stakeholders.
ACTIVITIES
Automation Systems takes prides in three specialized sectors;
Ø Industrial Automation
Ø Building Automation
Ø Home Automation.
ASSOCIATIONS
Schneider Electric India Pvt. Ltd. for
Ø Telemechanique AC Frequency Drives
Ø Telemechanique Modicon PLCs
Ø Lexium Servo motors & drives
Ø Magelis Display Units
Ø VijeoCitec SCADA
Ø Phaseo Power Supplies
Ø Clipsal products for Building & Home Automation
RECENT REFERNCES
Ø Ralson Industries
Ø Metro Tyres Ltd. ,Ludhiana
Ø Mangal Engineers, Patiala
Ø Vardhman Spinning, Ludhiana
Ø Rollcon Engg. Mohali
Ø Haldiram
Ø Hindustan Hydraulic, Jalandhar
Ø Reliance Info com
Ø Dunn Food, Baddi
Ø Crown Cap (Coca Cola), Amritsar
Ø G.S. Auto, Ludhiana
Ø Hind Products and many more.
TRAINING MODULE
SR.
CONTENTS
DESCRIPTION
1.
Basics
• Basic Control System
• Implementation of Digital logics in Industry
• Need of Automation
• Industrial Sensors
• Basics and architecture of PLC
2.
Zelio PLC (Schneider)
• Complete Software knowledge with Ladder Programming
• Hardware wiring and on board Simulation
• Software development of Industrial projects
3.
Twido PLC (Schneider)
• Complete Software knowledge including usage of functional blocks like Timers, Counters, etc.
• Implementation of mathematical functions.
• Usage of compare and operate blocks with Ladder Logic
• Transfer of program from Computer/ Laptop to Module and online Simulation
4.
Micro PLC (Schneider)
• Complete Software knowledge of all functional blocks
• Implementation of mathematical functions.
• Usage of compare and operate blocks
• Online Programming and use of runtime screens
5.
AC Drives (Schneider)
• Basics of AC Motors
• Full knowledge of Drive internal parameter settings
6.
HMI (Schneider)
• Creating application pages
• Creating alarm pages
• Interfacing through PLC
7.
SCADA
• Creating Display and Graphical User Interfaces which correspond to Automated plant
• Animating Displays by assigning different properties like orientation, position, action, etc. to the images
1. AUTOMOTIVE DESCRIPTION
1.1 AUTOMATION AND AUTOMATION DEVICE
1.1.1 AUTOMATION
To analyze and control all the process parameters in the plant by the help of automation devices.
1.1.2 AUTOMATION DEVICE
Automation device is a system, which on the basis of information fed in it, performs predefined actions with a bearing on its environment.
1.2 NEED OF AUTOMATION
1. To save energy
2. Bulk production
3. Less cost of production
4. Less human error that is high accuracy
5. High speed of operation
6. Simplification of the circuits
7. Easy faultfinding and troubleshooting
8. Lesser down timing of process / control
1.3 PROGRAM AND PROGRAMMABLE CONTROLER
1.3.1 PROGRAM
A program is the series of instruction that can be executed one after the other and can be easily written and modified using a programming terminal.
1.3.2 PROGRAMMABLE CONTROLLER
In an automated system, the programmable controller constitutes the data proceeding system. It’s the brain of the installation OR programmable controller is a real computer, which is also capable of receiving data via its inputs their sending command by its outputs.The bus enables all the parts of the system to communicate with each other. It is the internal dialogue tool of the PLC.
1.4 BASICS BEFORE STUDYING PLC
1.4.1 NUMBER SYSTEM
Number system is ordered set of digits, which are used to perform the arithmetic operations. There are different types of number systems: