A Training report On Automation through plc.

& scada

SESSION: 2011-12

SUBMITTED TO: Er. HARPREET SINGH (H.O.D) DEPTT: ELECTRICAL ENGG. TRAINNING INCHARGE PRIYANK SAWANT

SUBMITTED NIMIT ELECTRICAL ENGG.VII SEM

BY:

KUMAR

INSTITUTE OF ENGINEERING AND TECHNOLOGY ALWAR

TRAINING REPORT

In partial fulfilment of requirements of prescribed Course The Award of Bachelor of Technology In Electrical Engineering At Institute of Engineering & Technology ALWAR

SUBMITTED TO: Er. HARPREET SINGH (H.O.D) DEPTT: ELECTRICAL ENGG.

SUBMITTED BY: NIMIT KUMAR ELECTRICAL ENGG. VIIsem

Preface

An industrial PLC and SCADA system is to for the development of automatic control of machinery. PLC and SCADA system are methods to achieve Automation. Automation industry has fast growth potential in a country like India, which has a large industry base. This report focuses on brief concepts of PLC and SCADA system, their development, and also mentions possible applications of these systems. Almost every industry that has some electrical machinery may need Automation Services. Attention is also paid to the security issues which have arisen with time.

NIMIT KUMAR

Acknowledgment

We wish to express our deep sense of gratitude to our H.O.D of Electrical Er. Harpreet Singh for suggesting and guiding us for Prolific technologies & Pvt. Ltd. We are thankful to Mr. Priyank Sawant, for their valuable guidance and cooperation without which it was not possible to get so much knowledge. We are equally obliged to all those engineers technical personnel and operators at Prolific technologies, who gave us their valuable time and rendered practical knowledge in our training period. And at last we want to thank our colleagues. Without their help, guidance and suggestions it was not possible to produce this training report.

INDEX

CONTENTS
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PAGE NO

TITLE PAGE TRAINING REPORT PREFACE ACKNOWLEDGMENT INDEX AUTOMATION INTRODUCTION TYPES OF AUTOMATION FEATURES ADVANTAGES DISADVANTAGES APPLICATIONS PROGRAMMABLE LOGIC CONTROLLERS INTRODUCTION TYPES OF PLC BLOCK DIAGRAM OF PLC BASIC PLC COMPONENTS INSIDE A PLC SCAN CYCLE SINKING AND SOURCING CONCEPT ADVANTAGES COMMUNICATIONS LANGUAGES OF PLC 13 - 24 5 6 - 12 3 4 2

1. 2. 3. 4.
5.

6.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

ALLEN BRADELY 1. 2. 3. 4.
5.

25 - 32

TYPES OF PLC ADDRESSING PROGRAMMING TIMERS AND COUNTERS FILE SHIFT AND SEQUENCER SCADA INTRODUCTION TYPES OF SCADA FEATURES MANUFACTURER ARCHITECTURE APPLICATIONS CONCLUSION FIGURES: Shows KUKA Industrial Robots being used at a bakery for food production BLOCK DIAGRAM OF PLC PLC COMPONENTS STRUCTURE OF MODULAR TYPE PLC OUTPUT MODULE & INPUT MODULE OF PLC SCAN CYCLE OF PLC NO AND NC CONNECTIONS
6

33 - 39

1. 2. 3. 4. 5.
6.

40

FIG 1. FIG 3. FIG 4. FIG 5. FIG 6. FIG 7. FIG 8.

FIG 2. BLOCK STRUCTURE OF AUTOMATION.

FIG 9.

LADDER DIAGRAM OF TIMER ON DELAY

FIG 10. LADDER DIAGRAM OF TIMER OF DELAY FIG 11. LADDER DIAGRAM OF RETENTIVE TIMER ON FIG 12. Typical Hardware Architecture FIG 13. Generic Software Architecture

AUTOMATION Introduction:
Automation is the use of control systems and information technologies to reduce the need for human work in the production of goods and services. In the scope of industrialization, automation is a step beyond mechanization. Whereas mechanization provided human operators with machinery to assist them with the muscular requirements of work, automation greatly decreases the need for human sensory and mental requirements as well. Automation plays an increasingly important role in the world economy and in daily experience. Automation has had a notable impact in a wide range of industries beyond manufacturing (where it began). Once-ubiquitous telephone operators have been replaced largely by automated telephone switchboards and answering machines. Medical processes such as primary screening in electrocardiography or radiography and laboratory analysis of human genes, sera, cells, and tissues are carried out at much greater speed and accuracy by automated systems. Automated teller machines have reduced the need for bank visits to obtain cash and carry out transactions. In general, automation has been responsible for the shift in the world economy from industrial jobs to service jobs in the 20th and 21st centuries.

TYPES OF AUTOMATION:
Different types of Automation tools exist are as follows:
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ANN - Artificial neural network DCS - Distributed Control System HMI - Human Machine Interface SCADA - Supervisory Control and Data Acquisition PLC - Programmable Logic Controller PAC - Programmable automation controller Instrumentation Motion Control Robotics

Fig 1. shows KUKA Industrial Robots being used at a bakery for food production

FEATURES:

Reliability and Precision Health and Environment Convertibility and Turnaround time
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Reliability and precision

The old focus on using automation simply to increase productivity and reduce costs was seen to be short-sighted, because it is also necessary to provide a skilled workforce who can make repairs and manage the machinery. Moreover, the initial costs of automation were high and often could not be recovered by the time entirely new manufacturing processes replaced the old. (Japan's "robot junkyards" were once world famous in the manufacturing industry.) Automation is now often applied primarily to increase quality in the manufacturing process, where automation can increase quality substantially. For example, automobile and truck pistons used to be installed into engines manually. This is rapidly being transitioned to automated machine installation, because the error rate for manual instalment was around 11.5%, but has been reduced to 0.00001% with automation.

Health and environment

The costs of automation to the environment are different depending on the technology, product or engine automated. There are automated engines that consume more energy resources from the Earth in comparison with previous engines and those that do the opposite too. Hazardous operations, such as oil refining, the manufacturing of industrial chemicals, and all forms of metal working, were always early contenders for automation.

Convertibility and turnaround time

Another major shift in automation is the increased demand for flexibility and convertibility in manufacturing processes. Manufacturers are increasingly demanding the ability to easily switch from manufacturing Product A to manufacturing Product B without having to completely rebuild the production lines. Flexibility and distributed processes have led to the introduction of Automated Guided Vehicles with Natural Features Navigation. Digital electronics helped too. Former analogue-based instrumentation was replaced by digital equivalents which can be more accurate and flexible, and offer greater scope for more sophisticated configuration, parameterization and operation. This was accompanied by the field bus revolution which provided a networked (i.e. a single cable) means of communicating between control systems and field level instrumentation, eliminating hard-wiring.

ADVANTAGES:
The main advantages of automation are:

Replacing human operators in tasks that involve hard physical or monotonous Replacing humans in tasks done in dangerous environments (i.e. fire, space, Performing tasks that are beyond human capabilities of size, weight, speed, Economy improvement: Automation may improve in economy of enterprises, society

work.

volcanoes, nuclear facilities, underwater, etc.)

endurance, etc.

or most of humanity. For example, when an enterprise invests in automation, technology recovers its investment; or when a state or country increases its income due to automation like Germany or Japan in the 20th Century.

DISADVANTAGES:
The main disadvantages of automation are:

Unemployment rate increases due to machines replacing humans and putting Technical Limitation: Current technology is unable to automate all the desired tasks. Security Threats/Vulnerability: An automated system may have limited level of

those humans out of their jobs.

intelligence; hence it is most likely susceptible to commit error.

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Unpredictable development costs: The research and development cost of automating a High initial cost: The automation of a new product or plant requires a huge initial

process may exceed the cost saved by the automation itself.

investment in comparison with the unit cost of the product, although the cost of automation is spread in many product batches.

APPLICATIONS

Automated Video

Surveillance

The Defence Advanced Research Projects Agency (DARPA) started the research and development of automated Visual surveillance and Monitoring (VSAM) program 1997-99 and airborne Video Surveillance (AVS) program 1998-2002. Currently there is a major effort underway in the vision community to develop a fully automated tracking surveillance system. Automated video surveillance monitors people and vehicle in real time within a busy environment. Existing automated surveillance systems are based on the environment they are primarily designed to observe, i.e., indoor, outdoor or airborne, the amount of sensors that the automated system can handle and the mobility of sensor, i.e., stationary camera vs. mobile camera. The purpose of a surveillance system is to record properties and trajectories of objects in a given area, generate warnings or notify designated authority in case of occurrence of particular events.

Automated Highway Systems

As demands for safety and mobility have grown and technological possibilities have multiplied, interest in automation have grown. Seeking to accelerate the development and introduction of fully automated vehicles and highways, The United States Congress authorized more than $650 million over 6 years for intelligent transport systems (ITS) and demonstration projects in the 1991 Intermodal Surface Transportation Efficiency Act (ISTEA). Congress legislated in ISTEA that The secretary [of transportation] shall develop an automated highway and vehicle prototype from which future fully automated intelligent vehicle-highway systems can be developed. The goal of this program is to have the first fully automated highway roadway or an automated test track in operation by 1997. This system shall accommodate installation of equipment in new and existing motor vehicles." [ISTEA 1991, part B, Section 6054(b)].

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Full automation commonly defined as requiring no control or very limited control by the driver; such automation would be accomplished through a combination of sensor, computer, and communications systems in vehicles and along the roadway. Fully automated driving would, in theory, allow closer vehicle spacing and higher speeds, which could enhance traffic capacity in places where additional road building is physically impossible, politically unacceptable, or prohibitively expensive. Automated controls also might enhance road safety by reducing the opportunity for driver error, which causes a large share of motor vehicle crashes.

Automated manufacturing:

Automated manufacturing refers to the application of automation to produce things in the factory way. Most of the advantages of the automation technology has its influence in the manufacture processes. The main advantage of the automated manufacturing are: higher consistency and quality, reduce the lead times, simplification of production, reduce handling, improve work flow and increase the morale of workers when a good implementation of the automation is made.

Home Automation

Home automation (also called domestics) designates an emerging practice of increased automation of household appliances and features in residential dwellings, particularly through electronic means that allow for things impracticable, overly expensive or simply not possible in recent past decades.

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PROGRAMMABLE LOGIC CONTROLLERS (P.L.C.)

INTRODUCTION
A programmable logic controller (PLC) or programmable controller is a digital computer used for automation of electromechanical processes, such as control of machinery on factory assembly lines, amusement rides, or lighting fixtures. PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is designed for multiple inputs and output arrangements, extended temperature ranges, immunity to electrical noise, and resistance to vibration and impact. Programs to control machine operation are typically stored in battery-backed or non-volatile memory. A PLC is an example of a hard real time system since output results must be produced in response to input conditions within a bounded time, otherwise unintended operation will result. A PLC can be divided into four main sections : Inputs Outputs
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The memory - where the user program instructions and data are stored The processor-which reads the input data and controls the outputs according to the user

program instructions.

TYPES OF PLC

COMPACT TYPE PLC( SMALL SIZE PLC ):

In this type of PLCs, the CPU and the main power supply exists in same module. So this is called COMPACT TYPE OF PLC. The slots available in these PLCs are limited. EX- MICRO LOGIX 1000, 1100, 1200

MODULAR TYPE PLC( MEDIUM SIZE PLC ):

In this type of PLCs, the CPU and the main power supply exists in different module. So this is called MODULAR TYPE OF PLC. The slots available in these PLCs are not limited. And Rack of this module is larger than the COMPACT type. EX- SLC 500-01, 02, 03, 04, 05

BLOCK DIAGRAM OF PLC

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FIG 2. BLOCK DIAGRAM OF PLC

BASIC PLC COMPONENTS

Programmable controllers have grown throughout industrial control applications because of the ease they bring to creating a controller: ease of programming, ease of wiring, ease of installation, and ease of changing. PLCs span a wide range of sizes, but all contain six basic components:

processor or central processing unit (CPU); rack or mounting; input assembly; output assembly; power supply; programming unit, device, or PC/software

15

FIG 3.PLC COMPONENTS

RACK ASSEMBLY

16

FIG 4. STRUCTURE OF MODULAR TYPE PLC Most medium to large PLC systems are assembled such that the individual components CPU, Input/Output, Power Supply - are modules that are held together within a rack. In smaller PLC systems - all of these components may be contained in a single housing or "brick" - these smaller systems are sometimes referred to as "bricks" or "shoebox" PLCs.

POWER SUPPLY
The power supply provides power for the PLC system. The power supply provides internal DC current to operate the processor logic circuitry and input/output assemblies. Common power levels used are 24V DC or 120 VAC.

PROCESSOR (CPU)
The processor, central processing unit, or CPU is the "brain" of the PLC. The size and type of CPU will determine things like: the programming functions available, size of the application logic available, amount of memory available, and processing speed. Understanding the CPU can be a complex subject and we will tackle that in other articles.

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INPUT /OUTPUT ASSEMBLY

Inputs carry signals from the process into the controller, they can be input switches,

pressure sensors, operator inputs, etc. These are like the senses and sensors of the PLC. Outputs are the devices that the PLC uses to send changes out to the world. These are the actuator the PLC can change to adjust or control the process - motors, lights, relays, pumps, etc. Many types of inputs and outputs can be connected to a PLC, and they can all be divided into two large groups - analog and digital. Digital inputs and outputs are those that operate due to a discrete or binary change - on/off, yes/no. Analog inputs and outputs change continuously over a variable range - pressure, temperature, potentiometer.

PROGRAMMING DEVICE
The PLC is programmed using a specialty programmer or software on a computer that can load and change the logic inside. Most modern PLCs are programmed using software on a PC or laptop computer. Older systems used a custom programming device.

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OUTPUT MODULE

INPUT MODULE

FIG 5. OUTPUT MODULE & INPUT MODULE OF PLC

INSIDE A PLC
The Central Processing Unit (CPU), contains an internal program that tells the PLC how to perform the following functions: Execute the Control Instructions contained in the User's Programs. This program is stored in "non volatile" memory, meaning that the program will not be lost if power is removed Communicate with other devices, which can include I/O Devices, Programming Devices, Networks, and even other PLCs. Perform Housekeeping activities such as Communications, Internal Diagnostics, etc.

1.

THE CPU
The microprocessor or processor module is the brain of a PLC system. It consists of the microprocessor, memory integrated circuits, and circuits necessary to store and retrieve information from memory. It also includes communications ports to other peripherals, other PLC's or programming terminals. Today's processors vary widely in their capabilities to control real world devices. Some control as few as 6 inputs a n d o u t p u t s (I/O) and others 40,000 or more. One processor can control more than o n e p r o c e s s o r manufacturing line. Processors are often linked together in order

to provide continuity throughout the process. The number of inputs and outputs PLCs can control are limited by the overall capacity of the PLC system hardware and memory
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capabilities. The job of the processor is to monitor status or state of input devices, scan and solve the logic of a user program, and control on or off state of output devices.

2.

RAM
RAM or Random Access Memory is a volatile memory that would lose i t s i n f o r m a t i o n i f p o w e r w e r e removed. This is why some processor units incorporate a battery back-up. The type of RAM normally used is CMOS or Complementary Metal Oxide Semiconductor. CMOS RAM is used for storage of the user's program(ladder logic diagrams) and storage memory.

3.

ROM
ROM or Read Only Memory is a non-volatile type of memory. This means you don't need an external power source to keep information. In this type of memory, information can be read, but not changed. For this reason the manufacture sometimes calls this firmware. It is placed there for the internal use and operation of processor units.

4.

EEPROM
EEPROM or Electrically Erasable Programmable Read Only Memory is usually an add-on memory module that is used to back up the main program in CMOS RAM of the processor. In many cases, the processor can b e p r o g r a m m e d t o l o a d t h e E E P O M ' s p r o g r a m t o R A M if RAM is lost or corrupted.

FIG 6. BLOCK STRUCTURE OF AUTOMATION.

5.

INPUT MODULE
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There are many types of input modules to choose from. The type of input module used is dependent upon what real world input to the PLC is desired. Some examples of inputs are limit switches, electric eyes, and p u s h b u t t o n s . D C i n p u t s , s u c h a s t h u m b w h e e l s w i t c h e s , c a n b e u s e d t o e n t e r i n t e g e r v a l u e s t o b e manipulated by the PLC. DC input cards are used for this application. Since most industrial power systems are inherently noisy, electrical isolation is provided between the input and the processor. Electromagnetic interference (EMI) and Radio Frequency Interference (RFI) can cause severe problems in most solid state control systems. The component used most often to provide electrical isolation within I/O cards is called an optical isolator or optocoupler. The wiring of an input is not complex. The object is to get a voltage at a particular point on the card. Typically there are 8 to 32 input points on any one input module. Each point will be assigned a unique address by the processor. Analog input modules are special input cards that use analog to digital conversion (A to D) to sense variables such as temperature, speed, pressure, and position. The external device normally is connected to a controller (transducer) producing an electrical signal the analog input card can interpret. This signal is usually 4 to20 Ma or a 0 to 10 volt signal.

6.

OUTPUT MODULE
Output modules can be for used for ac or dc devices such as solenoids, relays, contractors, pilot lamps, and LED readouts. Output cards usually have from 6 to 32 output points on a single module. The output device within the card provides the connection from the user power supply to the load. Usually silicon controlled rectifiers (SCR), triac, or dry contact relays are used for this purpose. Individual outputs are rated most of ten at 2 to 3 amperes. Output cards, like input cards have electrical isolation between the load being connected and the PLC. Analog output cards are a special type of output modules that use digital to analog conversion (D to A). The analog output module can take a value stored in a 12 bit file and convert it to an analog signal. Normally this signal is 0 -10 volts dc or 4 to 20 Ma. This analog signal is often used in equipment such as motor operated valves and pneumatic position control devices.

SCAN CYCLE:
There are four basic steps in the operation of all PLCs : which continually take place in a repeating loop.
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FIG 7. SCAN CYCLE OF PLC

Input Scan : Detects the state of all input devices that are connected to the PLC Program Scan: Executes the user created program logic. Output Scan: Energizes or de-energize all output devices that are connected to the PLC. Housekeeping: This step includes communications with programming terminals, internal diagnostics...

SINKING AND SOURCING CONCEPT

In general, Sinking (NPN) and Sourcing (PNP) are terms that define the control of direct current flow in a load. They are only pertinent with DC components and should not be associated with AC control structures. Devices like relay outputs, reed switches, etc, are typically not affected since they are not current direction dependent (unless they have an internal polarity sensitive devices like LEDs or unidirectional spike suppressors). Note that this document assumes the positive to negative current flow convention. From an electro-pneumatic control perspective, it is important to understand this concept

because it dictates which solenoid valve type (sinking or sourcing) is required for proper operation with a specific (sinking or sourcing) output module. The same issues also apply for inputs and sensor devices.
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The following is a detailed explanation of these concepts that, in short, dictate:

Sinking (NPN) provides a path to 0 VDC (-DC) Sourcing (PNP) provides a path to +24 VDC (+DC)

ADVANTAGES OF PLCs
PLCs not only are capable of performing the same tasks as hard-wired control, but are also capable of many more complex applications. In addition, the PLC program and electronic communication lines replace much of the interconnecting wires required by hard-wired control. Therefore, hard-wiring, though still required to connect field devices, is less intensive. This also makes correcting errors and modifying the application easier. Some of the additional advantages of PLCs are as follows: Smaller physical size than hard-wire solutions. Easier and faster to make changes. PLCs have integrated diagnostics and override functions. Diagnostics are centrally available. Applications can be immediately documented. Applications can be duplicated faster and less expensively.

COMMUNICATIONS
There are several methods to communicate between a PLC and a programmer or even between two PLCs. Communications between a PLC and a programmer (PC or Hand held) are provided by the makers and you only have to plug in a cable from your PC to the programming port on the PLC. This communication can be R S 2 3 2 ; R S 4 8 5 o r T T Y . C o m m u n i c a t i o n s b e t w e e n t w o P L C s c a n b e c a r r i e d o u t b y d e d i c a t e d l i n k s supplied/ programmed

by the makers (RS 232 etc) or via outputs from one PLC to the inputs on another PLC. This direct link method of communication can be as simple as, if an output on the first PLC is on then the corresponding input on the second PLC will be on and then this input is used within the program on the second PLC. If a word of input/outputs (16 bits) are used then
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numerical data can be transferred from one PLC to the other (refer back to the section on numbering systems).

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)

Ladder Logic:
Ladder logic is the main programming method used for PLC's. As mentioned before, ladder logic has been developed to mimic relay logic. The decision to use the relay logic diagrams was a strategic one. By selecting ladder logic as the main programming method, the amount of retraining needed for engineers and trades people was greatly reduced. The first PLC was programmed with a technique that was based on relay logic wiring schematics. This eliminated the need to teach the electricians, technicians and engineers how to program - so this programming method has stuck and it is the most common technique for programming in today's PLC.

Mnemonic Instruction:
There are other methods to program PLCs. One of the earliest techniques involved mnemonic instructions. These instructions can be derived directly from the ladder logic diagrams and entered into the PLC through a simple programming terminal.

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Sequential Function Charts (SFC):

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.

Structured Text (ST):

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.

Function Block Diagram (FBD):

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.

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ALLEN BRADELY PLC

Allen Bradley is a part of Rockwell Automation Integrated Architecture and offers controllers that are suitable for drives, for motion, and for process controlling. No matter what you need, if you have to have high performance or value based in your programmable logic controller system, you will find just the right controller with the Allen Bradley programmable logic controllers. The many different offerings from Allen Bradley-Rockwell Automation Integration include the NetLinx, the Kinetix, and the Logix. All of these will offer you maximum capabilities, easy use, reuse capacity of program, flexibility in the communications system and fast easy use so that you can spend less of your company's time and money on the entire setup process. Along with NetLinx open networks, Kinetix integrated motion and visualization products, Logix platforms provide the maximum in control integration, program re-use, communication flexibility, and overall ease-of-use so you'll spend less on setup, operation, and maintenance.

TYPES OF AB PLC:
Allen Bradley uses five different types of programmable logic controllers. These different types of PLCs perform specialized functions. This allows Allen Bradley to use the best PLC for your company specific needs.

Pico Controllers are simple, as well as flexible and small, performing logic, counting, time
MicroLogix PLCs are a cost-effective solution for micro-control that will expand as needed. SLC 500s are small, modular programmable controllers that are chassis-based. It is often the

and clock operations.

choice for I/O and power supply functions.

PLC-5 is the most popular Allen Bradley PLC and can be found worldwide, providing COMPACT LOGIX- The Compact Logix system is designed to provide a Logix solution for

flexibility in networking, I/O and programming and being suitable for a wide variety of applications. small and mid-size applications. Typically, these applications are machine-level control applications. A simple system can consist of a standalone

26

controller with a single bank of I/O modules and Device Net communication. A more complex system may include other networks, motion control, and safety control

CONTROL LOGIX- The Control Logix system provides discrete, drives, motion, process,

and safety control together with communication and state-of-the-art I/O in a small, cost-competitive package. The system is modular, so you can design, build, and modify it efficiently - with significant savings in training and engineering.

1758-RTU It is a programmable logic controller designed for rugged and harsh environments

as a Remote Terminal Unit (RTU).

ADDRESSING
The Allen Bradley SLC-500 can have up to eight racks in its 5/25 version. The rack containing the processor is automatically defined as rack 0, but the designer can allocate addresses of the other racks (in the range1-7) by set-up switches. The racks other than rack 0 connect to the processor via a remote I/O serial communications cable. There are three different ways in which an Allen Bradley rack can be configured, but we shall discuss the simplest(and possibly the most logical) method. Each rack contains 16 card positions which are grouped in pairs called a slot. A rack thus contains eight slots, numbered 0-7. A slot can contain one 16-way input card and one 16-way output card or two eight way cards usually (but not necessarily) of the same type. For example, slot 1 contains a 16-way input card and 16-way output card, and slot 2 contains two eight-way output cards. The addressing for inputs is

I:0.0/0 Input with Rack Slot/ Bit with Bit being two digits. Allen Bradley use octal addressing for bits, so allowable numbers are 00-07 and 10-17. The address I: 2.7/14 is input 14 on slot 7 in rack 2. Outputs are addressed in a similar manner:

O:0.0/0 Output with Rack Slot/Bit so O:3.5/06 is output 6 in slot 5 of rack 3. Note that if 16-way cards are used, an input and an output can have the same rack/slot/bit address, being distinguished only by the I: or the O:. With eight-way cards there can be no sharing of rack/slot/bit addressing.

PROGRAMMING
27

1.

Normally open contact:

This can be used to represent any input to the control logic - a switch or sensor. When "solved" the referenced input is examined for an ON (logical 1) condition. If it is ON, the contact will close and allow power (logic) to flow from left to right. If the status is OFF (logical 0), the contact is Open, power (logic) will NOT flow from left to right.
2.

Normally Closed Contact:

This can be used to represent any discrete output from the control logic. When "solved" if the logic to the left of the coil is TRUE, the reference output is ON (logical 1).

FIG 8. NO AND NC CONNECTIONS

TIMERS AND COUNTERS

Many times we will want to take action in a control program based on more than the states of discrete inputs and outputs. Sometimes, we will want to turn something on after a delay, or count the number of times a switch is hit. To do these simple tasks, we will need Timers & Counters. Simple Timers (TIM) A timer is simply a control block that takes an input and changes an output based on time. There are two basic timer types we will deal with initially (there are other advanced timers, but we will start with the basics first) - On-Delay Timer and the Off-Delay Timer. On-Delay Timer - this timer takes an input, waits a specific amount of time, then turns ON an output (or allows logic to flow after the delay).

From the LogixPro Simulations Menu, select the I/O Simulation. Clear out any existing program by selecting the "New" entry in the File menu, and then
28

select the "Clear Data Table" entry in the Simulations menu.

Now enter the following program being careful to enter the addresses exactly as shown. Confirm that you have entered the number 100 as the timer's preset value. This value

represents a 10 second timing interval (10x0.1) as the time base is fixed at 0.1 seconds

FIG 9. LADDER DIAGRAM OF TIMER ON DELAY

Once you have completed this addition to your program, download your program to the Toggle the state of switch I:1/0 to ON and observe the operation of the timers in your Bring the Data Table display into view, and pay particular attention to the way in which Try changing the value of one of the timer presets by double clicking on the preset Run the timers through their timing sequence a number of times. Don't move on until

PLC and select RUN.

program.

the timers are cascaded (one timer starts the next).

value in the Data Table display, and then entering a new value.

you are satisfied that the timers are working as you would expect

29

Off-Delay Timer -this timer takes turns ON an output (or allows logic to flow) and keeps that output ON until the set amount of time has passed, then turns it OFF (hence off-delay) In Allen Bradley PLC programming, the TON timer is by far the most commonly used

type of timer. Most people consider TON timers to be simple to use and understand. In comparison, many people find the operation of the Allen Bradley TOF (Timer OFF delay) timer to be less intuitive, but I'm going to let you decide Once you have your program entered, and have ensured that it is correct, download it to the PLC.

Make sure that switch I:1/0 is Closed, and then enter or modify your existing program Once you have your program entered, and have ensured that it is correct, download it to Ensure that Switch I:1/0 is Closed, and then place the PLC into the Run mode. Right click on the Timer instruction, and select "Go To Data Table" from the dropNote the initial value of timer T4:1's accumulator and preset in the spaces below. Also

to match the one shown below.

the PLC.

down menu. indicate the state of each of the timer's control bits in the spaces provided: Initial State (Switch I:1/0=Closed):

T4:1.ACC = _____ T4:1.PRE = ______ T4:1/EN = ____ T4:1/TT = ____ T4:1/DN = ____ Open switch I:1/0, and carefully observe the incrementing of the timer's accumulator, Once the Timer stops incrementing, note the final value of timer T4:1's accumulator,

and the state of each of it's control bits. preset, and the state of it's control bits below: Final State (Switch I:1/0= Open):

T4:1.ACC = _____ T4:1.PRE = ______ T4:1/EN = ____ T4:1/TT = ____ T4:1/DN = ____

Toggle the state of switch I:1/0 a number of times, and observe the operation of the Confirm that when the rung is taken true, the accumulator and all 3 control bits are reset

Timer in both the Data Table display and in the Ladder Rung program display. to zero. The TOF timer like the TON timer is also a non-retentive instruction and can be reset by changing the truth of the rung.

30

FIG 10. LADDER DIAGRAM OF TIMER OF DELAY Retentive Timer On-RTO -this type of timer does NOT reset the accumulated time when the input condition goes false.

Rather, it keeps the last accumulated time in memory, and (if/when the input goes true

again) continues timing from that point. In the Allen-Bradley construction this instruction goes true once set point (preset) time has been reached, and stays true until a RES (RESet) instruction is made true to clear it.Make sure that switch I:1/0 is Open, and then replace the TOF timer in your program with a RTO retentive timer.

Now insert a new rung below the timer, and add the XIC,I:1/1 and RES,T4:1 Your program should now match the one shown below:

instructions.

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FIG 11. LADDER DIAGRAM OF RETENTIVE TIMER ON

Once you have your program entered, and have ensured that it is correct, download it to Ensure that both Switches are Open, and then place the PLC into the Run mode. Right click on the Timer instruction, and select "GoTo DataTable" from the drop-down Note the initial value of timer T4:1's accumulator, preset and control bits. Are we Close switch I:1/0 for 2 or 3 seconds and then Open it again. Note that the timer stopped timing when the rung went false, but the accumulator was Close the switch again and leave it closed which will allow the timer to time-out Once timed out, note the state of the control bits Open the switch, and once again note the state of the control bits. Now close Switch I:1/1 and leave it closed. This will cause the Reset instruction to go Close switch I:1/0 momentarily to see if the timer will start timing again. It should not! Open Switch I:1/1 which will cause the Reset instruction return to false. Now toggle switch I:1/0 several times and note that the timer should again start timing

the PLC.

menu.

starting off with the same values we had in the TON exercise? You should be answering Yes.!

not reset to zero.

(ACC=PRE).

true.

as expected.
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Repeat the foregoing steps, until you are satisfied that you clearly understand the

operation of both the RTO timer, and the Reset instruction.

Simple Counter (CNT)

A counter simply counts the number of events that occur on an input. There are two basic types of countersUp counter and a Down counter. Up Counter(CTU) - as its name implies, whenever a triggering event occurs, an up counter increments the counter. Down Counter(CTD) - whenever a triggering event occurs, a down counter decrements the counter.

FILE SHIFT AND SEQUENCER

BSL: Bit Shift Left- Loads a bit of data array, shifts the pattern of data through the array to the left and unloads the last bit of data in the array. BSR Bit Shift Right Loads a bit of data array, shifts the pattern of data through the array to the right and unloads the last bit of data in the array. SQO Sequencer Output Controls sequential machine operation by transfering 16-bit through a mask to image addresses for controlling outputs. SQC Sequencer Compare Controls sequential machine operation by transfering 16-bit through a mask to image addresses to reference data for monitoring inputs. SQL Sequencer Load Capture reference conditions by manually stepping the machine through its operating sequences.
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SUPERVISIORY CONTROL AND DATA ACQUISITION (SCADA)

INTRODUCTION
Widely used in industry for Supervisory Control and Data Acquisition of industrial processes, SCADA systems are now also penetrating the experimental physics laboratories for the controls of ancillary systems such as cooling, ventilation, power distribution, etc. SCADA systems have made substantial progress over the recent years in terms of

functionality, scalability, performance and openness such that they are an alternative to in house development even for very demanding and complex control systems as those of physics experiments. SCADA stands for Supervisory Control And Data Acquisition. As the name indicates, it is not a full control system, but rather focuses on the supervisory level. As such, it is a purely software package that is positioned on top of hardware to which it is interfaced, in general via Programmable Logic Controllers (PLCs), or other commercial hardware modules. SCADA systems are used not only in industrial processes: e.g. steel making, power generation(conventional and nuclear) and distribution, chemistry, but also in some experimental facilities such as nuclear fusion. The size of such plants range from a few 1000 to several 10 thousands input/output (I/O) channels. However, SCADA systems evolve rapidly and are now penetrating the market of plants with a number of I/O channels of several 100 K: we know of two cases of near to 1 M I/O channels currently under development. SCADA systems used to run on DOS, VMS and UNIX; in recent years all SCADA vendors have moved to NT and some also to Linux.

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TYPES OF SCADA
1. D+R+N (Development +Run + Networking) 2. R+N (Run +Networking) 3. Factory focus

FEATURES OF SCADA
Real time and Historical trending

Collect, store and display real time process data using ASTRA historical trends. One can use this archived data for records, documentation, reporting and analytical purpose. Alarm management

Monitor the system parameters constantly through ASTRA alarm management and alert the user about critical problems either by Email (Extended SMTP), SMS ( GSM Modem) or playing a sound file. Alarms can be individual or group with built-in security and are stored with date and time, stamping in a chronological order of their appearance. OLE for process control

An OPC client application communicates to an OPC server through the specified custom and automation interfaces. OLE for Process Control (OPC) is designed to allow client applications access to plant floor data in a consistent manner With OPC, System integration in a heterogeneous computing environment will become simple. The COM/DCOM technologies provided the frame work for software products. Scalable, Compatible and Open

Expand your ASTRA into multi-node, plant wide SCADA by simply adding the PC to your network. One can also upgrade ASTRA for the features, number of tags or for wider connectivity.

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Client- Server architecture Configure your ASTRA as a stand-alone or network application. One can configure ASTRA in Client Server architecture and share the data instantly across the enterprise for faster better informed business decisions. Security (Application Security)

Configure security levels (up to 256) to control and maintain the data access. One can precisely control all access to data control and system applications. Remote data access

The ASTRA comes with web server, where HTML pages can be configured for viewing real time data from remote locations through any Internet browser. On client side user can also view and access script based report database and export to excel. Excel report generator

ASTRA provides user friendly way to generate customized reports in Excel format. It is easy to save / view / print some specific reports directly using templates. The reports can also be generated after specific span of time or an event has been occur in Word, Excel or Text format using powerful scripts.

Advanced component library

ASTRA has wide range of components to design Mimics and screens to create applications quickly and easily.

Recipe management

Create, edit, modify, and download the batch and setup parameters instantly to apply them to plant equipment. Recipes are simple text files, which can be created within ASTRA or using any text editor.
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MANUFACTURER OF SCADA
Allen Bradley Siemens Gefanuc KPIT Wonder ware ABB : Plant web : RS View : Win cc : Cimplicity : ASTRA :Intouch

ARCHITECTURE

Hardware Architecture One distinguishes two basic layers in a SCADA system: the "client layer" which caters for the man machine interaction and the "data server layer" which handles most of the process data control activities. The data servers communicate with devices in the field through process controllers. Process controllers, e.g. PLCs, are connected to the data servers either directly or via networks or field buses that are proprietary (e.g. Siemens H1), or non-proprietary (e.g. Profi bus). Data servers are connected to each other and to client stations via an Ethernet LAN. The data servers and client stations are NT platforms but for many products the client stations may also be W95 machines. Fig.1. shows typical hardware architecture.

Software Architecture The products are multi-tasking and are based upon a real-time database (RTDB) located in one or more servers. Servers are responsible for data acquisition and handling (e.g. polling controllers, alarm checking, calculations, logging and archiving) on a set of parameters, typically those they are connected to.
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However, it is possible to have dedicated servers for particular tasks, e.g. historian, data logger, alarm handler. Fig. 2 shows a SCADA architecture that is generic for the Products that were evaluated.

Figure 12: Typical Hardware Architecture

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Figure 13: Generic Software Architecture

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APPLICATION OF SCADA:
Control systems are used at all levels of manufacturing and industrial processing. A manufacturing plant that employs robotic arms will have a control system to direct robotic arms and conveyor belts on the shop floor. It may use that same system for packaging the finished product and tracking inventory. It may also use a control system to monitor its distribution network. A chemical company will use control systems to monitor tank levels and to ensure that ingredients are mixed in the proper proportions. A Las Vegas casino will use control systems to direct the spray from water fountains in coordination with the lights and music. Control systems are also used in the drilling and refining of oil and natural gas. They are used in the distribution of water and electricity by utility companies, and in the collection of wastewater and sewage. Virtually every sector of the economy employs control systems at all levels. The term "supervisory control and data acquisition" (SCADA), however, is generally accepted to mean the systems that control the distribution of critical infrastructure public utilities (water, sewer, electricity, and oil and gas). SCADA systems are still to come into widespread infrastructural use in India. In this country they are being used primarily for automation in industrial production, and to some extent for specialized process control. Ranbaxy Labs and Voltas are two of the companies in India using SCADA systems for process control.

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CONCLUSION
During the session of June July 2011, we took our practical training in PROLIFIC TECHNOLOGIES AND PVT. LTD as prescribed in our syllabus issued by RTU, for Electrical Engg. The Training conducted by PROLIFIC TECHNOLOGIES AND PVT.LTD on

AUTOMATION .This training is very useful and purposeful for us as it provides us with all type knowledge and information about a leading concern. Here we become familiar to industrial atmosphere that will be helpful for us in our future. These types of heartily atmosphere of friendly relation provide energy and inspiration for works.

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