EC6202: INDUSTRIAL INSTRUMENTATION

LABORATORY

Name: Roll No.

Sem: VI Branch: ECE

Session:SP’20

DEPARTMENT
OF
ELECTRONICS AND COMMUNICATION ENGINEERING

BIRLA INSTITUTE OF TECHNOLOGY

MESRA, RANCHI, JAIPUR CAMPUS
 EC6202: INDUSTRIAL INSTRUMENTATION LABORATORY

LIST OF EXPERIMENTS:

COMPULSORY EXPERIMENTS:

1. Calibration and measurement of level in the range 5 to 40 Cm using

LOAD Cell

2. Measurement of Speed using Photo Reflective and Magnetic Pick Up

3. Measurement of Flow rate using Orifice and U-Tube Manometer

4. Testing and Calibration of Pressure Instruments using Dead Weight

Pressure Gauge Tester

5. Implementation of Ladder Diagram using ABB PLC with Logic Gate

Simulation Modules

6. Implementation of Ladder Diagram using ABB PLC with Lift Control

Simulation Modules

7. Obtaining the Characteristics of P, PI and PID Controllers using Pressure

Control Loop Set-up

8. Measurement of Vibration using Piezoelectric Accelerator Sensor

9. To Perform actuations using advanced Pneumatic Trainer

10. Design and Development of Digital Storage Oscilloscope using LabVIEW

for two input channels, and verify its calibration using internal source

11. Simulation of the PID Controller Scheme using LabVIEW for Step input
and observation of Controllers output response for different controller
constants setting

12. Design and Development of a Robotic Arm having 3-degree of freedom

for pick and place operation
OPTIONAL EXPERIMENTS:

13. Measurement of the Phase and Frequency using Virtual CRO and Delay
Network (Implementation of Lissajous pattern)

14. Implementation of the following Boolean expression using DAQ:

Y = A.B + (C EX-OR D).E

15. Programming of Ladder Diagram using ABB PLC with Stepper Motor
Control Simulation Modules

16. Programming of Ladder Diagram using Mitsubishi PLC with different

Simulation Modules

17. Development of front panel for Displacement Measurement and Test on

Real Time

18. Development of panel for Speed Measurement and Test on Real Time

19. Development of front panel for Pressure Measurement and Test on Real
Time

20. Implementation of Virtual PID Controller for Pressure Control Loop

 DEPARTMENT
OF
ELECTRONICS AND COMMUNICATION ENGINEERING

INDUSTRIAL INSTRUMENTATION
LABORATORY

LAB INSTRUCTIONS FOR CARRYING OUT PRACTICAL

ON

CALIBRATION AND MEASUREMENT OF LEVEL IN THE

RANGE 5 TO 40 CM USING LOAD CELL

BIRLA INSTITUTE OF TECHNOLOGY

MESRA, RANCHI
AIM: Calibration and measurement of level in the range 5 to 40 cm using LOAD Cell.

APPARATUS:
1. Power Supply
2. Signal Condition and Amplifying
3. Analog to digital converter

THEORY:

PROCEDURE:
1. Connect the Load cell to the instrument.
2. Connect the power supply card to 230v 50 Hz power.
3. Fill the source tank with approximately 25 liters (2 bucket) of water.
4. Close the drain valve connected at the bottom of the Accralic Tank.
5. Switch on the instrument and allow the instrument in ON position 10 minutes for
initial warm-up.
6. Switch on the MOTOR ON switch the pump start pumping the water. Stop the
MOTOR when the water level reaches 5 cm. (Minimum Level)
7. Adjust the zero pot on the instrument panel till the display reads “000”.
8. Switch on the MOTOR and switch OFF as soon as the water level reaches 50 cm.
9. Adjust the SPAN pot on the instrument panel so that the display reads 50 cm.
10. Release the water, till the minimum level 5 cm is reached. The instrument should
read “00”. If the display does not come to zero, repeat the procedure 7 to 10 or
two to three times.
11. Drain out the water till 5 cm. The display will be reading “000” switch on the
motor and take the readings in steps of 5 cm.
12. Tabulate the readings in tabular column the actual level read by scale and the
instrument reading.
13. Plot the graph Actual reading v/s instrument reading. Calculation can be made for
linearity, hysteresis and accuracy of the instrument.

OBSERVATIONS:

Sl No ACTUAL INDICATED ERROR

READING READING

RESULT:

PRECAUTIONS:
 DEPARTMENT
OF
ELECTRONICS AND COMMUNICATION ENGINEERING

INDUSTRIAL INSTRUMENTATION
LABORATORY

LAB INSTRUCTIONS FOR CARRYING OUT PRACTICAL

ON

MEASUREMENT OF SPEED USING PHOTO REFLECTIVE

AND MAGNETIC PICK UP

BIRLA INSTITUTE OF TECHNOLOGY

MESRA, RANCHI
AIM: Measurement of Speed using Photo Reflective and Magnetic Pick Up

APPARATUS:
1. Power Supply
2. Oscillator
3. Signal Conditioner
4. Mixer and
5. Counter

THEORY:
Principle and working of
i) Magnetic Pickup : The voltage is induced in the coil around to a magnetic subjected to
change in magnetic field, this is principle of electromagnetic induction. The arrangement
is shown in fig. As shaft rotates, the teeth pass in front of pick up and produce a change
in field resistance of magnetic circuit. The density of a magnetic field increases and
decreases as each tooth approaches and leaves away from the end of the bar magnet per
second. Let T be no. of teeth on the rotor, N be be the revolutions per second and P be the
no. of pulse per sec. Then,
Speed N = Pulses per sec./ No. of teeth = P/Tx 60 rpm
ii) Photoelectric pickup : The photoelectric pick up tachometer utilize a rotating shaft to
the intercept a beam of light flow on a photoelectric or photo-conductive cell. The shaft
has an intermittent reflecting (white) and non reflecting (blade) surface. When a beam of
light the reflecting surface on a rotating shaft, light pulses are obtained and reflected light
is focused on the photoelectric cell. The frequency of the light pulses is proportional to
shaft speed and so will be frequency of electrical o/p pulses from photoelectric. Another
similar method consist in mounting an opaque disc on shaft. The rotating component the
disc has a no. of evenly spaced peripheral. Holes. A light source on the side of disc and
there is light sensor on opaque portion of disc between the lights source & the light
sensor, no light falls on sensor and consequently on o/p results. But a pulse of voltage is
produced every time a hole appear between the two is light illuminates the sensor. The
frequency of pulse generations is determined by no. of holes in disc and its speed of
rotations. Since no of holes is fixed, pulse of repetitions, frequency of transducers o/p is
proportional to angular velocity of moving member.

PROCEDURE:
Before Switching ON the instrument ensure that the connections are made
properly:
1. Switch ON the instrument by pushing down the toggle switch provided at the rear
side of the box, LED display glows to indicate the instrument ON.
2. Allow the instrument for 10 minutes in ON position for initial warm-up.
3. Select the sensor with the help of toggle switch.
4. Switch ON the electronic regulator. The fan rotates which will rotate the tone
wheels. The display will start indicating exact RPM of the motor.
5. Reading can be tabulated for both the sensors. Comparison can be made between
two sensors.
OBSERVATIONS:

A B C D
Sl.No. Actual Speed of Magnetic Pick- ERROR
Motor Photo Up B-C
reflective (RPM) (RPM)

RESULT:

PRECAUTIONS:
1. Always start the motor with help of zero speed., operate dimmerstat slowly.
2. Connect motor to earthing wire.
3. When experiment is over disconnect the photoelectric and magnetic pick up.
 DEPARTMENT
OF
ELECTRONICS AND COMMUNICATION ENGINEERING

INDUSTRIAL INSTRUMENTATION
LABORATORY

LAB INSTRUCTIONS FOR CARRYING OUT PRACTICAL

ON

MEASUREMENT OF FLOW RATE USING ORIFICE AND

U-TUBE MANOMETER
BIRLA INSTITUTE OF TECHNOLOGY
MESRA, RANCHI
AIM: Measurement of Flow rate using Orifice and U-Tube Manometer

APPARATUS:
1. Power Supply
2. Rotameter
3. Orifice
4. Pump
5. Manometer

THEORY:

PROCEDURE:
1. Connect the power chord to 230V supply.
2. Fill the source tank with water till the foot valve of the pump immersed in the
water (approx. 10Lts).
3. Switch on the motor using power ON switch. The motor starts pumping the water.
Rotate the control valve till float of the Rota meter reads zero.
4. Release the valve slowly so that the Rota meter float reads 25 LPM. Measure the
difference in monometer.
5. Note down the monometer reading in steps & 10 to 25 LPM increase in flow.
Tabular the reading in the given column.

FLOW CALCULATION
To calculate the rate using the orifice meter we have the formula
Q=A x CD x 3600 x 1000 x √(2 x g x H)/1000 LHP
Where, Q=Rate of flow in LPH
A=Area of orifice hole =(л x D2)/4
Where D is Diameter of the orifice in Mts.
A=л/4 x (0.0055)2 = 2.3758 x 10-5 m2
CD = Orifice Coefficient =0.7
g= Gravitational Constant =9.91
H= h x [Em/Ew-1]
Where, Em=Density of mercury = 13600kg/m2
Ew= Density of water in kg/m2=1000kg/m2
H=Level difference in manometer in mm.
H=(h/1000) x (13600/1000-1)
H=(h/1000) x 12.6
 Where h in mm.
We multiply by 3600 to convert from minutes to Hrs and multiply by 1000 to convert
from m3/hrs to liters.
Hence the equation can be simplified by calculating

Q=2.3758 x 105 x 0.7 x 3600 x 1000 x (√2 x 9.81 x h x 12.6 x 1000) LPH

Q=29.86 x √h=h1-h2 LPH

Where, h is in mm.

OBSERVATIONS:

Sl.No. ROTAMETER MANOMETER READING( in mm) Flow Q=

READING h1 h2 h=h1-h2 29.697 x √h
LPH

RESULT:

PRECAUTIONS:
 DEPARTMENT
OF
ELECTRONICS AND COMMUNICATION ENGINEERING

INDUSTRIAL INSTRUMENTATION
LABORATORY

LAB INSTRUCTIONS FOR CARRYING OUT PRACTICAL

ON

TESTING AND CALIBRATION OF PRESSURE INSTRUMENTS

USING DEAD WEIGHT PRESSURE GAUGE TESTER
(MODEL – UITM – 19
CAPACITY: 25 KG/CM2)

BIRLA INSTITUTE OF TECHNOLOGY

MESRA, RANCHI
AIM: Testing and Calibration of Pressure Instruments using Dead Weight Pressure
Gauge Tester (MODEL – UITM – 19 CAPACITY: 25 KG/CM2)

APPARATUS:
Pressure Gauge
Dead Weights

THEORY:

PROCEDURE:
1. Fill the Oil tank with sufficient Oil.
2. Release the AIR RELEASE VALVE provided at the bottom till the oil starts
dripping continuously about 10 to 12 drops and tighter the release valve.
3. Release the control valve and pump the oil so that the oil circulates through the
tubes. Pump for a while about a minute so that all the tubes will be filled with oil
and any air bubble inside the tube will be removed.
4. Now close the Control Valve, and pump the oil the plunger starts floating. Pump
till the line on the plunger is visible. Rotate the plunger gently. The pressure is
built inside the chamber proportion to the weight on the plunger. The Test Gauge
fixed will starts showing the pressure.
5. Add 1 Kg dead weight on the plunger and pump once again till the mark on the
plunger is visible. The pressure inside the chamber increases by 1 Kg/cm2.
6. Add the weights on the plunger and pump till the line on the plunger is clearly
visible.
7. The bourdon pressure gauge will read the pressure corresponding to the dead
weights on the plunger. Note down the readings on the pressure gauge and
tabulate the readings with the corresponding readings to the dead weight. Plot the
graphs for actual pressure (dead weights v/s pressure gauge reading. Calculate
the accuracy, linearity and hysteresis of the pressure gauge.
8. Release the control valve slowly and remove the dead weight from the plunger.

NOTE: -Rotate the plunger along with the weights while taking the
readings.
- Maintain sufficient quantity of oil in the oil tank.
- Do not pump when the AIR RELEASE VALVE is loosened.

OBSERVATION:

SL. WEIGHTS PRESSURE GAUGE READING

NO. IN KG. KG/CM2

RESULT:
 DEPARTMENT
OF
ELECTRONICS AND COMMUNICATION ENGINEERING

INDUSTRIAL INSTRUMENTATION
LABORATORY

LAB INSTRUCTIONS FOR CARRYING OUT PRACTICAL

ON

PLC TRAINER

BIRLA INSTITUTE OF TECHNOLOGY

MESRA, RANCHI
PLC Lab Manual:

To Run the Existing Project

1. Ensure the PLC software is installed in the computer
2. Ensure that the RS-232 cable is connected with the computer and PLC
panel
3. Double click the ABB AC31GRAF icon
4 select the existing project by double clicking the particular project name.
5. Connect the input and output of the panel with the input at output of the
PLC
Example-(DI0 of panel has to connected to DI0 of PLC
DO1 of panel to connected to DO1 of PLC)
24volt supply and grounds are connected to the panel from PLC
6. Realize the ladder diagram. Do the following operation to connect the
PLC with PC.
file->save
file->verify->verify
if there is no error then it will show ( 0-error detected)
if there is some error then modify the ladder diagram
7. If there is no error.
file->verify->verify->build->exit.
file ->PLC communicate->send->change PLC program->click on yes
(it will show EPROM is updated)
8. Ensure that the present program name will come in the control panel.
9. Operate the switches from the panel and observe the output.
To create a new Project

1. Follow Step 1-3.

2. Click the new option
Give filename
Language->quick ld
Series->40

To select different options for input and output and functional blocks use F2
to F9 icons. Use I?I icon to have a complimentary input.

3. Use the inputs and outputs of the PLC from the Input Panel and Output
Panel.

4. Follow the steps 6-8 to get the desired outpour.

 PLC TRAINER
1. U1- PLC1-1-2

DOOR BELL SIMULATION & SWITCHING OF LIGHT

(a) DOOR BELL SIMULATION

Door Bell simulation is just a simple application where operation of

doorbell is simulated using PLC. Here switch is used as sensor. When he/she
comes near to the door the sensor senses the person and the door bell is ringing.

SEQUENCE:
1. Press the BELL ON button (SENSE), the buffer starts blowing.

(b) SWITCHING OF LIGHT

There are three rooms, where the person enters ROOM –1 stays in
for a will on work, then enters ROOM –2 finishes work and enter
ROOM –3 finishes works and returns. Assume sensors are provided
to sense the person entry to the rooms.
SEQUENCE:
1. Switch ON S-1 (SENSE) the person is in ROOM –1,
ROOM –1 Light glows
2. Switch ON S-2 (SENSE) the person enters ROOM –2,
ROOM –1 Light switches off and ROOM –2 light glows.
3. Switch ON S-3 (SENSE) the person enters ROOM –3,
ROOM –2 Light switches off and ROOM –3 light glows.
4. Switch OFF S-3 (SENSE) the person leaves ROOM –3 and enters
ROOM -2,
ROOM –3 Light switches off and ROOM –2 light glows.
5. Switch OFF S-2 (SENSE) the person leaving ROOM –2 and enters
ROOM –1,
ROOM –2 Light switches off and ROOM –1 light glows.
Switch OFF S-1 (SENSE) the person leaving ROOM –1.
 2. U1 –PLC1 –3-4

STARTER CONTROL & SILO CONTROL SIMULATION

This SAP module is a simulation of starter control and silo control

applications. For starter control a motor is connected to the starter.
By using PLC the motor is switched ON and OFF. The silo control is
a conveyer application where the bottle moves on the conveyer and
fills and goes to standby mode.

(a) STARTER CONTROL

ON and OFF of a Motor using PLC.

SEQUENCE:
1. PRESS the MOTOR ON button.
LED glows indicating the Motor in running.
2. PRESS the MOTOR OFF button.
LED Switches off indicating the Motor is off.
(b) SILO CONTROL SIMULATION:

Simulation of automatic bottle filling.

SEQUENCE:
1. Press Cycle Start button.
Run LED glows to indicate the conveyer is moving.
2. Switch ON SENS Bottle position. Switch Fill LED glows for a will to
indicate the bottle is filling and then FULL LED glows to indicate the
bottle is full.
 3. U1 – PLC1 –5

SEVEN SEGMENT LED DISPLAY:

Three seven-segment LED display are mounted on PCB. A count Switch is

provided to increase the count from 0 to 9, using SHIFT Left and SHIFT Right buttons
the LED’s can be selected.

NOTE: DO-7,DO-8 and DO-9 should be connected to ground.

SEQUENCE:
1. Press COUNT button.
LED 3 showing ZERO will increase in steps of 1 till NINE.
2. Press SHIFT LEFT button
LED 2 starts glowing the same value LED 3 is glowing the and
LED 1 will glow by pressing again.
3. Press SHIFT RIGHT button.
LED 2 Starts glowing and LED 1 will glow by pressing again.

4. U1 – PLC -6

SEQUENCIAL CONTROL OF MOTORS:

Three motors has to run in sequence say the motors are connected to three
Conveyer where the Box moves from one conveyer to another in sequence.
Three LED’s are connected to indicate the status of Motor. Loading of Box
on to the conveyer is sensed by the sensors provided an toggle switch.

SEQUENCE:
1. Press CYCLE START button.
Say the box in loading on to the conveyer.
2. Switch ON “SENS BOX CONVEYER –1”
MOTOR 1 LED glows to indicate the conveyer –1 is moving.
3. Switch ON “SENS BOX CONVEYER –2”
MOTOR –2 LED glows to indicate the Conveyer –2 is moving and
the Conveyer –1 steps after leading BOX to Conveyer –2.
4. Switch ON “SENS BOX CONVEYER –3”
MOTOR -3 LED glows to indicate the Box is loaded from
conveyer 2 to conveyer 3 and conveyer 3 is moving, conveyer 2
stops.
The above sequences continue at constant interval till the “CYCLE STOP” button
is pressed.
 5. U1 – PLC1 –7 -8

STAR-DELTA STARTER & TRAFIC LIGHT CONTROL

(a) STAR-DELTA STARTER SIMULATION:

This module is to demonstrate the Sequence of star delta starter. LED’s

are provided to indicate the power supply to the motor and Star relay Delta relay.

SEQUENCE:
1. Press MOTOR ON button.
MAIN RELAY LED glows to indicate the power to the Starter
along with the STAR RELAY LED will be on for a will for initial
motor starting and then DELTA RELAY LED Switches ON
Continuously to indicate the Motor is running in Delta mode.
2. Press MOTOR OFF button.
The DELTA RELAY LED Switches off indicating the Motor is
Switched OFF.

6. U1 – PLC1 –9

TANK LEVEL CONTROL SIMULATION:

This module is simulated to control Water level in both overhead tank and Sump.
Switching of Water pump depends on Water levels in both the overhead tank and sump.
To sense the water level and to switch on the pump, toggle Switches are provided.

SEQUENCE:
1. Switch ON ‘SUMP SENS LO’ Switch.
SUMP LEVEL LOW LED glows to indicate the water level is low in the
sump.
2. Switch ON ‘TANK SENS LO’ Switch.
TANK LEVEL LOW LED glows to indicate the water level is low in the
tank.
3. Switch ON ‘PUMP ON’ Switch.
LED will not glow indicating the pump is not ON because the water level in
the sump is low.
4. Switch ON ‘SUMP SENS HI’ Switch.
The SUMP LEVEL HI LED will glow indicating the sump is filled with water
and simultaneously PUMP ON LED will also glow indicating the pump is
ON.
5. Switch ON the ‘TANK SENS HI’ Switch.
 The TANK LEVEL HI LED will glow indicating the TANK in filled and
Simultaneously the PUMP ON LED Switches OFF indicating the pump is
OFF.

7. U1 – PLC1 –10

BOTTELING PLANT SIMULATION:

This SAP Module is a simulation of Automatic bottle filling plant. The bottle
moves on Conveyer 1, 2, and 3 during the bottle get filled and cap in screwed to it and
then unloaded.

SEQUENCE:
1. Press CYCLE START button.
‘CONVEYER 1 RN’ LED starts glowing to indicate the bottle in moving on
the conveyer.
2. Switch ON, ‘SENSE BOTTLE FILL’ switch
‘CONVEYER 1 RN’ LED stitches of indicating the conveyer stops moving
and the ‘BOTTLE FILL’ LED glows indicating the bottle is filling then
switches off BOTTLE FULL LED glows along with CONVEYER 2 RUN
LED And switches off as the bottle moves to the CONVEYER 2.
3. Switch ON ‘SENSE BOTTLE SCREEN’, and switch OFF ‘SENSE BOTTLE
FILL’.
SCREW CAP LED switches ON for few seconds indicating the cap is fitted to
the bottle and CONVEYER RUN LED glows to indicating the bottle is
moving.
4. Switch OFF ‘SENSE BOTTLE UNLOAD’ switch.
BOTTLE UNLOAD LED glows for few seconds indicating the bottle is
unloaded and the cycle stops.

8. UI – PLC1 – 11-12

OVEN CONTROL DRINK DISPENCER SIMULATION:

(a) OVEN CONTROL:

SEQUENCE:
1. Switch on POWER ON switch.
HEATER ON LED glows indicating the oven is getting heated.
2. Switch ON SENSE TEMP (S V) Switch.
HEATER ON LED Switches OFF indicating the heat is off.

(b) DRINK DISPENCER SIMULATION:

This SAP is a simulation of drink dispense, which are becoming very popular
everywhere. You select the drink you want it will add ingredient, prepare a cup of
drink and pours to the cup.
SEQUENCE:
1. READY LED in ON indicating the machine is ready to serve Tea, Coffee or
Milk of your choice.
2. PRESS COFFEE or TEA or MILK button.
Corresponded drink LED glows indicating that you have selected particular
drink.
3. Press MAKE button.
MAKE DRINK LED glows for few seconds indicating the machine is
preparing the drink selected and SOLD OUT LED glows for few seconds
indicating the drink is poring to the cup and then READY LED glows
indicating the machine is ready again to make drink.

9. UI – PLC1- 13

CAR PARKING SIMULATION

Parking of cars is also become a automated, where multistory parking buildings

are coming up, where hundreds of cars can be parked. Then parking slots has to
be identified to know whether the car is parked on vacant. If there is no space to
park the car then NO SPACE to park has to be indicated.

SEQUENCE:
1. Press SELECT button.
CAR –1 PARK LED stars blinking indicating the parking slot is selected.
2. Press CAR PARK button.
CAR –1 PARK LED stops blinking indicating the car is parked.
3. Press SELECT button twice.
CAR –1 PARK LED starts blinking and then CAR –2 PARK button starts
blinking.
4. Press CAR PARK button.
CAR –2 PARK LED stops blinking indicating the car is parked, in the same
way car can be parked for all the 6 parking slots. ALL CAR PARK LED will
be glowing indicating the cars are parked in all the slots, NO SPACE LED
starts glowing indicating there is no space to park another car.
5. Press SELECT button.
CAR –1 PARK LED stars blinking indicating the parking slot is selected.
6. Press CAR EXIT button
CAR –1 PARK LED switches off indicating the car is exited and the parking
slot is vacant. In the same way all the parking slots can be selected and cars
can be exited.
 Now, assume all the parking slots are filled.
7. Press SELECT button.
CAR –1 PARK LED starts blinking indicating the parking slot is selected.
8. Press CAR PARK button.
CAR –1 PARK LED along with NO SPACE LED stats blinking indicating the
car is excited.

10. UI – PLC1 -14

COMBIANTION LOCK SIMULATION

This SAP Model is a demo of digital locking system. Nowadays advanced

locking systems are coming where you need not have to use keys to open the lock,
instead the digital locks are available where the locks get locked just by entering
numeric codes. If you want to open the door the numerical code has to be entered
currently. In Combination Lock Simulation we have used numerical keypad.
Where the numeric code can be entered. Locking and unlocking of doors
indicated by LED’s.

SEQUENCE:

1. Initially OPENED LED will be glowing indicating the door is opened.

2. Press 1 2 3 as code and press CLOSE button.
OPENED LED switches off and CLOSED LED starts glowing indicating
the door is closed.
3. Press 1 2 3 (code used to lock) and press OPEN button.
CLOSED LED switches off and OPENED LED glows indicating the door
is opened.
4. Press 1 2 3 4 as new code and press CLOSE button.
The door gets closed.
5. Press 1 2 3 as code and press CLOSE button.
The door gets closed.
6. Press 1 2 3 as code and press OPEN button.
INVALID KEY LED glows indicating the code entered is invalid.
7. Check opening by using wrong code for twice.
Fourth time the lock will not respond at all even the correct code is entered
too.
8. Press RESET button.
The lock again starts accepting.

11. UI – PLC1 - 15

ELEVATOR SIMULATION
 This SAP module is a simulation of elevator for first, second and third floor. LED
shows the movement of the lift up and down. The lift reaching the floors is sensed
by toggle switches.

SEQUENCE:

1. Initially the display will be showing 0.

2. Switch ON FIRST FLOOR REACH.
The LED show 1 indicating the lift is in first floor.
3. Press SECOND FLOOR ON button
LIFT UP LED glows indicating the lift is moving up.
4. Switch off first FLOOR REACH and switch ON SECOND FLOOR REACH.
As the lift moves up it leave first floor and reaches second floor.
CREEP SPEED ON LED glows for a while and the display shows 2.
(* CREEP SPEED is nothing but the lift shows down when it comes near to the at
which it stops.)
5. Press THIRD FLOOR ON button.
LIFT UP LED glows indicating the lift is moving up.
6. Switch off SECOND FLOOR REACH and switch on THIRD FLOOR REACH
switch.
The lift leaves second floor and reaches third floor, CREEP SPEED
ON LED glows for a while and the display shows 3 indicating the lift is at third
floor.
7. Press FIRST FLOOR ON button.
LIFT DOWN LED glows indicating the lift is moving down.
8. Switch off THIRD FLOOR REACH switch and switch on SECOND FLOOR
REACH switch.
The lift reaches second floor immediately the display shows 2 the
lift is still moving down.
9. Switch of SECOND FLOOR REACH switch and switch ON FIRST FLOOR
REACH switch.
CREEP SPEED ON LED glows for a while and display show 1
indicating the lift reached first floor.

12. UI – PLC1 – 16

PROCESS CONTROLLER (AIR LEAK TEST RIG)

This SAP module is a simulation of automatic testing of a engine head for

any leakage in air. Here the plug is opened in the beginning. The plug closes
automatically closed, as the engine head is loaded. Then a compressor for a
 particular pressure builds air pressure and the component is tested for any
leakage. ON OFF timers are used for testing. The level if leakage point is set by
Analog Input (AI-0)and the level of air pressure built can be set at F B D > =
based on the pressure built the system waits for few seconds to test the leakage
and given out weather the component is passed or failed.

SEQUENCE:

1. Press PLUG CLOSE button.

The system starts closing the plug.
2. Switch ON PLUG CLOSED switch.
PLUG CLOSED LED glows indicating the plug is tightened.
3. Press CYCLE START button.
CYCLE ON LED glows indicating the system starts testing the components
(plug). Simultaneously AIR ON LED lows for few seconds indicating the air
pressure is building. After building required pressure the AIR TEST ON LED
glows for few seconds and tests for air leakage. Based on the set pint the
component PASS or FAIL LED glows.
4. Press CYCLE STOP button at the middle of testing.
The CYCLE ON LED switches off indicating the test stopped.

13. UI – PLC1 – 17

PROCESS CONTROL TRAINER (WASHING MACHINE):

This SAP module is a simulation of Washing Machine. The washing machine is

of front door opening, when clothes are loaded the door has to close. LED
indicates the door opened/closed position. After closing the door the cloth
washing cycle starts. The machine starts taking water. After the water level
reaches Hi the drum start rotating clockwise and anticlockwise at regular time
with pause period in between. Then the drum stops rotating and the water is
pumped out. The cycle completes after the low level.

SEQUENCE:

1. Switch ON DOOR O/P switch.

DOOR O/C LED switches on indicating the door is closed.
2. Press CYCLE START button.
WATER IN TAKE LED glows indicating the water is entering in to
the washing machine (solenoid is actuated)
3. Switch on WATER LEVEL LO switch and also WATER LEVEL HI switch.
Water fills the drum and water level are sensed as soon as the Hi level
 is sensed the DRUM ROTATE C W & C C W LED’s starts on and off one after
the other indicating the direction of the Drum rotation. After some cycle the
DRUM ROTATE LED’s stops and WATER PUMP ON LED glows.
4. Switch OFF WATER LEVEL HI and WATER LEVEL LO switch.
WATER PUMP ON LED switches off indicating the water is pumped out
completely and the cycle stops.

14. UI - PLC1 – 18

LOGIC GATE SIMULATION:

This SAP is an experimental module where the program is written is LD to

simulate the LOGIC GATES, such as INV, OR, NOR, AND, EX-OR for any two
given inputs. Two LED’s are given to indicate the status of output Q and. If the
LED’s in ON it indicates 1 if LED is off it indicates 0.

SEQUENCE:

1. Switch on the toggle switch to NORMAL position.

2. Select the INV using rotary switch.
3. Give input by switching on INPUT – 1 and INPUT – 2 observe the output.
Example: - for INV
Input 1=1
Input 2=0 then output is 1 (Q)

Input 1=0
Input 2=1 then output is 1 (Q)

Input 1=1
Input 2=1 then output is 0 ( )
4. In the same way logic can be tested for OR, AND, EX-OR also.
5. By switching the toggle switch to NOT position:
NOT – INU, NOT – OR, NOT – AND, NOT EX-OR status can also be
tested.
NOTE: Simulation can also be made for three inputs. This can be taken as an
assignment for students to program.
 14. UI PLC1 – 19

DC MOTOR CONTROL SET UP:

This application module is a complete setup where a small DC motor with

driver circuit is used for demo purpose. The driver works on 24 V supply.
The driver takes analog input by which the DC motor can be controlled as
per requirement using PLC. The analog output generated by PLC is feed to
the driver circuit, which in turn controls the DC motor.
Here we have written ladder diagram to control the motor in three ways:
I Continuous Rotation
II Speed Ascending & Descending
III Motor Control through times.
The maximum speed of the motor can be set by analog input by
setting through potentiometer.

SEQUENCE:

1. Press MOTOR ON button.

The motor starts rotating without interruption.
2. Press MOTOR OFF button.
The motor stops rotating.
3. Switch on SPEED ASCENDING & DESCENDING switch and press
MOTOR ON BUTTON.
The motor starts rotating. The speed ascends gradually till the
maximum speed set and decreases till the motor stops. This cycle
continuous till the SPEED ASCENDING & DESCENDING TIMER
and switch off.
4. Switch off SPEED ASCENDING & DESCENDING switch and ON
CONTROL THROUGH TIMER and press MOTOR ON BUTTON.
The motor starts rotating and stops rotating at regular interval based
on the timing set is ON & OFF Delay timer.

15. UI – PLC1 - 20

STEPPER MOTOR CONTROL SETUP

This application module is a complete setup where a small stepper

motor with driver circuit is used for demo purpose. The drives takes clock,
enable and direction control inputs by which the stepper motor can be
controlled as per requirement using PLC. The clock is generated by PLC and
is feed to the driver circuit, which in turn controls the stepper motor.
Here we have written ladder diagram to control the motor is three
ways:
 I Continuous Rotation
II Step Rotate
III Forward Reverse Rotation
The motor rotates at 0.3 degree for every clock pulse. Hence we use
functional block diagram ( F B D) Multiplier and divider to calculate the
exact pulse required for one degree of rotation.

SEQUENCE:

1. Press MOTOR ON button.

The motor starts rotating without interruption.
2. Press MOTOR OFF button.
The motor stops rotating.
3. Switch on STEP ROTATE and then press MOTOR ON.
The motor starts rotating till the pre-determined angle say 300 and
stops. The motor rotates only 300 whenever the MOTOR ON button is pressed.
By changing the degree the motor can rotate till the new degree is reached.
4. Switch off STEP ROTATE switch and switch ON FORWARD REVERSE
ROTATION and press MOTOR ON.
The motor rotates till the degree fixed and starts rotating is reverse till it
reaches original position. The degree of rotation can be changed as per
requirement.
 DEPARTMENT
OF
ELECTRONICS AND COMMUNICATION ENGINEERING

INDUSTRIAL INSTRUMENTATION
LABORATORY

LAB INSTRUCTIONS FOR CARRYING OUT PRACTICAL

ON

MEASUREMENT OF VIBRATION USING PIEZOELECTRIC

ACCELERATOR SENSOR
(USING TRAINER MODEL UITM-18)

BIRLA INSTITUTE OF TECHNOLOGY

MESRA, RANCHI
AIM: Measurement of Vibration using Piezoelectric Accelerator Sensor (USING
TRAINER MODEL UITM-18)

APPARATUS:
1. Shaker
2. Control Unit
i) Power Oscillator
ii) Vibration Meter
3. Accelerometer
4. Threaded steel studs M5.

THEORY:

PROCEDURE:
1. Connect the sensor to the instrument through the BNC socket provided on the rear
mentioned SENSOR.
2. Connect the Vibration generator to the instrument through the cable provided at
the rear panel of the instrument marked EXCITER.
3. Connect the instrument to the 230 V 50 Hz. Supply through cable provided at the
rear panel.
4. Keep the FREQ. Pot and the VOLT pot in the minimum position.
5. Switch on the instrument, the display glows to indicate the power is on.
6. Turn the VOLT pot to the max position.
7. Now turn the FREQ pot in steps of 100 Hz. And note down the readings of
Acceleration, Velocity and Displacement by selecting the MODE through selector
switch.
8. Tabulate the readings in the tabular column. Experiment can be repeated for
different voltage levels settable through VOLT knob provided.

OBSERVATION:

Output (Measurement Parameters):

Acceleration: +/-5% of the Reading Value

Velocity: +/-5% of the Reading Value
Displacement: +/-5% of the Reading Value
CALIBRATION READINGS:

Frequency Acceleration Velocity Displacement

Hz Measured Measured Measure
F (Peak) (rms) (p-p)
m/sec2 cm/sec mm

RESULT:

PRECAUTIONS:

Graph can be plotted for Frequency V/s Acceleration, Velocity and

displacement.

Acceleration
Velocity
Displacement

0,0 frequency
 DEPARTMENT
OF
ELECTRONICS AND COMMUNICATION ENGINEERING

INDUSTRIAL INSTRUMENTATION
LABORATORY

LAB INSTRUCTIONS FOR CARRYING OUT PRACTICAL

ON

TO PERFORM ACTUATIONS USING ADVANCED

PNEUMATIC TRAINER

BIRLA INSTITUTE OF TECHNOLOGY

MESRA, RANCHI
AIM: To perform actuation using Advanced Pneumatic trainer

APPARATUS:
1. Compressor
2. Single Acting cylinder
3. Double Acting cylinder
4. Valves
5. Connecting Pipes

THEORY:

Block Diagram: To be drawn by the student

PROCEDURE:
1. Ensure the compressor is having sufficient pressure(8 kg Maxim).
2. Connect the Pipes properly according to the block Diagram
Realize AND and OR function.

OBSERVATION:
Observe the operation of the single acting and double acting cylinder according to the
valve position

RESULT:

PRECAUTIONS: