Minor Project Report

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Table of Contents

1. INTRODUCTION ................................................................................................. 3

1.1 Normal Operating Condition........................................................................... 3

1.2 Overview of Project ........................................................................................ 4

1.2.1 Sequential:................................................................................................ 4

1.2.2 Dual: ......................................................................................................... 4

1.2.3 Forward Reverse: ..................................................................................... 4

1.2.4 Star Delta ................................................................................................. 5

1.3 Overview of Programmable logic controller (PLC) ........................................ 5

1.4 Project objectives ............................................................................................ 7

1.5 Project scope ................................................................................................... 7

1.6 Problem statement ........................................................................................... 7

2 SYSTEM HARDWARE........................................................................................ 8

2.1 Introduction ..................................................................................................... 8

2.2 Programmable Logic Controller...................................................................... 8

2.2.1 PLC configuration .................................................................................... 8

2.2.2 Basic PLC schema ................................................................................. 10

2.2.3 PLC Operation ....................................................................................... 11

2.2.4 Internal PLC ........................................................................................... 12

2.3 RX-LOGIX 5000 configuration ................................................................... 13

2.4 Hardware wiring diagram.............................................................................. 14

3 SYSTEM SOFTWARE ....................................................................................... 16

3.1 Introduction to RX-Programmer software .................................................... 16

3.2 Diagram workspace ....................................................................................... 17

3.3 Program development. .................................................................................. 18

4 EXECUTION OF WORK ................................................................................... 19

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4.1 REQUIERD MATERIALS: .......................................................................... 19

4.1.1 PLYWOOD BASE ................................................................................ 19

4.1.2 LED (pilot light) .................................................................................... 20

4.1.3 MULTI METER .................................................................................... 21

4.1.4 RELAY .................................................................................................. 21

4.1.5 CONTACTOR ....................................................................................... 22

4.1.6 VOLTMETER ....................................................................................... 23

4.1.7 AMMETER............................................................................................ 24

4.1.8 MCB....................................................................................................... 25

4.1.9 PUSH BUTTON .................................................................................... 27

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1. INTRODUCTION

1.1 Normal Operating Condition

Clearly the likelihood of arc flash incident is high when employees are working on
or near exposed live parts. Live parts are considered to be exposed when they are
not suitably guarded, isolated, or insulated. Normal operation of enclosed
equipment is not likely to result in an arc flash provided it is in a normal operating
condition. So how do we define normal operating condition? A great start is found
in the Standard for Electrical Safety in the Workplace, NFPA 70E. Here you will
find that to be in normal operating condition, the equipment must:

 be properly installed.

 be properly maintained.

 used in accordance with instructions included in the listing and labelling and in
accordance with manufacturer’s instructions.

 have doors closed and secured.

 have covers in place and secured.

 not show evidence of impending failure.

To consider the equipment in a normal operating condition all six of these


conditions must be met. If any of the criteria are not met, the equipment is not in a
normal operating condition and additional protective measures, including the use of
PPE, must be considered.

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1.2 Overview of Project

In this project multiple operations of electrical equipments have been shown.

This is to increase the durability and flexibility of the various equipments.

In this project four operations have been shown namely:

 Sequential
 Dual
 Forward Reverse
 Star Delta

1.2.1 Sequential:

A familiar example of a device with sequential logic is a television set with


"channel up" and "channel down" buttons.[1] Pressing the "up" button gives the
television an input telling it to switch to the next channel above the one it is
currently receiving. If the television is on channel 5, pressing "up" switches it to
receive channel 6. However, if the television is on channel 8, pressing "up" switches
it to channel "9". In order for the channel selection to operate correctly, the
television must be aware of which channel it is currently receiving, which was
determined by past channel selections.

1.2.2 Dual:

In dual mode of operation as the name suggest two equipments or led are turned ON
or OFF simultaneously This is carried out using plc logic and hence performed on
the board.

1.2.3 Forward Reverse:


This can be explained in terms of the forward reverse concept of motor The forward
reverse motor control is used in a system where forward and backward or upward and
downward movement in the operation are needed. Forward and Reverse Operation of

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motor can be obtained by interchanging any two of its three terminals Reversing a
capacitor start motor. ... Once started, a single phase induction motor will happily run
in either direction. To reverse it, we need to change the direction of the rotating
magnetic field produced by the main and starter windings.

1.2.4 Star Delta

This can also be understood by the concept of electric motor.During starting the
motor windings are connected in star configuration and this reduces the voltage
across each winding 3. This also reduces the torque by a factor of three. After a
period of time the winding are reconfigured as delta and the motor runs normally.

1.3 Overview of Programmable logic controller (PLC)

A programmable logic controller (PLC) is an industrial computer used to control


and automate complex systems. Programmable logic controllers are a relatively
recent development in process control technology. It is designed for use in an
industrial environment, which uses a programmable memory for the integral storage
of user-oriented instructions for implementing specific functions such as logic,
sequencing, timing, counting, and arithmetic to control through digital or analog
inputs and outputs, various types of machines or processes.

Programmable logic controllers are used throughout industry to control and


monitor a wide range of machines and other movable components and systems. PLC
is used to monitor input signals from a variety of input points (input sensors) which
report events and conditions occurring in a controlled process. Programmable logic
controllers are typically found in factory type settings. PLCs are used to control
robots, assembly lines and various other applications that require a large amount of
data monitoring and control.
A typical programmable logic controller employs a backplane to serve as the
communications bus for interconnecting the PLC processor with the array of
individual input/output devices with which the processor interacts in terms of
receiving input data for use in executing the control program and transmitting
control data for use in controlling the targeted objects. A PLC includes a rack into

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which a plurality of input/output cards may be placed. A rack includes several slots
into which these input/output cards are installed.
Each input/output card has a plurality of I/O points. The I/O modules are typically
pluggable into respective slots located on a backplane board in the PLC. An I/O bus
couples the cards in the slots back to the processor of the programmable logic
controller. The slots are coupled together by a main bus which couples any I/O
modules plugged into the slots to a central processing unit (CPU).

The CPU itself can be located on a card which is pluggable into a dedicated slot on
the backplane of the PLC. The particular processor employed in a PLC together
with the particular choice of input and output cards installed in the PLC rack are
often referred to as the hardware configuration of the programmable logic
controller. The hardware configuration also includes the particular addresses which
the I/O cards. Each option module typically has a plurality of input/output points.

The option modules are coupled through an interface bus, for example via a
backplane, to a main controller having a microprocessor executing a user program.
Option modules may also include a microprocessor and a memory containing
separate user programs and data directed to a particular operation of the PLC
system. During the execution of a stored control program, the PLC's read inputs
from the controlled process and, per the logic of the control program, provide
outputs to the controlled process. The outputs typically provide analog or binary
voltages or "contacts" implemented by solid state switching devices.

PLC's are normally constructed in modular fashion to allow them to be easily


reconfigured to meet the demands of the particular process being controlled. The
processor and I/O circuitry are normally constructed as separate modules that may
be inserted in a chassis and connected together through a common backplane using
permanent or releasable electrical connectors.

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1.4 Project objectives

This project is about develop and practice multiple operations of electrical


equipments and function them using software. In this project four modes of
operations were practiced which could be increased accordingly.

1.5 Project scope

 Programmed a ladder logic diagram to control the electrical equipments.


 Combine the software part and the hardware part to simulate a electrical
equipment system.

1.6 Problem statement

In many industries, airports etc. the multiple use of electrical machine is expected to
maintain an ease in process and communication. It demands machines and electrical
in particular to carry more than one operation at a time. Using only hardware may
increase in the manual process for industry or company therefore software part is
also essential to carry these multiple processes. Therefore using both hardware and
software develop a system which create suitable environment for use of multiple
operations.

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2 SYSTEM HARDWARE

2.1 Introduction

The hardware part of this project is Programmable logic controller (PLC) and a
traffic light model. RX-LOGIX 5000 is the type of PLC used in this project as the
processor to control the traffic light. This type of PLC was been chosen because the
characteristic is fully necessary by the development of traffic light system.

The four ways traffic light model is constructed to display how this traffic light
control system is running. This traffic light model has a complete set of traffic light

signal which are red, yellow and green as a traffic signal for each lane. Each lane
also has two limit switches represent as a sensor on the road. The first sensor placed
in front of the lane to detect the presence of a car at the junction and the second
sensor placed at certain length from first sensor to determine the volume of car at
that lane. The right connection between PLC and traffic light model is very
important because it can avoid the problem or conflict when the program is
transferred to PLC.

2.2 Programmable Logic Controller

2.2.1 PLC configuration

Many PLC configurations are available, even from a single vendor. But each of
these has common components and concepts. The most essential component is
are:
1. Power supply – This can be built into the PLC or be an external unit.

2. Common voltage levels required by the PLC are 24Vdc 120Vac 220Vac.

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3. CPU (central Processing Unit) – This is a computer where ladder logic is
stored and processed.

4. I/O (Input/output) – A number of input/output terminals must be provided so


that the PLC can monitor the process and initiate actions. Inputs to, and
outputs from, a PLC is necessary to monitor and control a process. Both
inputs and outputs can be categorized into two basic types: logical or
continuous. Consider the example of a light bulb. If it can only be turned on
or off, it is logical control. If the light can be dimmed to different levels, it is
continuous.

5. Indicator lights – These indicate the status of the PLC including power on,
program running, and a fault. These are essential when diagnosing
problems.

6. Rack Type : A rack can often be as large as 18” by 30” by 10”

7. Mini: These are similar in function to PLC racks, but about the half size.
Dedicated Backplanes can be used to support the cards OR DIN rail
mountable with incorporated I/O bus in module.

8. Shoebox: A compact, all-in-one unit that has limited expansion capabilities.


Lower cost and compactness make these ideal for small applications. DIN
rail mountable.

9. Micro: These units can be as small as a deck of cards. They tend to have
fixed quantities of I/O and limited abilities, but costs will be lowest. DIN rail
mountable

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2.2.2 Basic PLC schema

The basic PLC schema include CPU, power supply, memory, Input block, output
block, communication and expansion connections. Figure shows the PLC system
overview.

Figure 2.1 PLC system overview

CPU modules - The Central Processing Unit (CPU) Module is the brain of the
PLC.Primary role to read inputs, execute the control program, update outputs. The
CPU consists of the arithmetic logic unit (ALU), timing/control circuitry,
accumulator, scratch pad memory, program counter, address stack and instruction
register. A PLC works by continually scanning a program.

Memory - The memory includes pre-programmed ROM memory containing the


PLC’s operating system, driver programs and application programs and the RAM
memory. PLC manufacturer offer various types of retentive memory to save user
programs and data while power is removed, so that the PLC can resume execution of
the user-written control program as soon as power is restored. Some types of memory
used in a PLC include:

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1. ROM (Read-Only Memory)

2. RAM (Random Access Memory)

3. PROM (Programmable Read-Only Memory)

4. EPROM (Erasable Programmable Read-Only Memory)

5. EEPROM (Electronically Erasable Programmable Read-Only Memory)

6. FLASH Memory

7. Compact Flash – Can store complete program information, read & write text

8. files

9. I/O Modules - Input and output (I/O) modules connect the PLC to sensors and
actuators. Provide isolation for the low-voltage, low-current signals that the
PLC uses internally from the higher-power electrical circuits required by most
sensors and actuators. Wide range of I/O modules available including:
10. digital (logical) I/O modules and analogue (continuous) I/O modules.

2.2.3 PLC Operation

CHECK INPUT STATUS-First the PLC takes a look at each input to determine
whether it is on or off condition.
EXECUTE PROGRAM-Next the PLC executes a program by one instruction at a
time. If the first input is on then it should turn on the first output. Since it already
knows then it will be able to decide whether the first output should be turned on

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based on the state of the first input. It will store the execution results for use later
during the next step.

UPDATE OUTPUT STATUS-Finally the PLC updates the status of the outputs. It
updates the outputs based on which inputs are on during the first step and the results
of executing your program during the second step. Based on the example in step 2 it
would now turn “ON” the first output because the first input is “ON” and your
program said to turn “ON” the first output when this condition is true.

Figure 2.2 PLC operation block diagram

2.2.4 Internal PLC

INPUT RELAYS-(contacts) These are connected to the outside world. They


physically exist and receive signals from switches, sensors, etc.

INTERNAL UTILITY RELAYS-(contacts) These do not receive signals from the


outside world nor do they physically exist. They are simulated relays and are what
enables a PLC to eliminate external relays.

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OUTPUT RELAYS-(coils) These are connected to the outside world. They
physically exist and send on/off signals to solenoids, lights, etc.

DATA STORAGE -Typically there are registers assigned to simply store data. They
are usually used as temporary storage for math or data manipulation.
They can also typically be used to store data when power is removed from the PLC.

2.3 RX-LOGIX 5000 configuration

PLC RX-LOGIX5000 configuration. The main body of this PLC is power supply
unit, Central processor unit and input/output slot. The power supply unit receive the
required PLC voltage is 240Vac. For safety the voltage to PLC must connect to
automatic circuit breaker before connect to the PLC because to protect the PLC
from overload. The CPU covered by Analog input/output slot, RS232 port, and
processor. The inputs/outputs slot uses for system are using digital input and digital
output. There are not limited slot for input and output port and can use for multiple
inputs/outputs card.

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2.4 Hardware wiring diagram

Once hardware is designed ladder diagrams are constructed to document the wiring.
For this project, existed PLC cabinet box are use and connect with the traffic light
model. A basic wiring diagram is as shown in figure. The PLC would be supplied
with AC power 240V and then I/O card supplied with DC power 12V to 24V. The
common for input card is 24Vdc and for output card is 0Vdc. A fuse is used after
disconnect to limit the maximum current drawn by the system.

PLC cabinet box wiring diagram

The PLC input wiring address start with number 0.00 to 0.15 for every input card.
When the other input card is install to the PLC socket the address for this input card
will start with number 1.00 to 1.15 and so on. Figure shows the wiring diagram for
input card which this input card connects to sensor (limit switch) at traffic light
model.

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The PLC outputs wiring address start with number 100.00 to 100.07 for every output
card. When the other output card is install to the PLC socket the address for this
output card will start with number 101.00 to 101.07 and so on. The figure show the
wiring diagram for output card which output card connect to sensor (limit switch) at
traffic light model.

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3 SYSTEM SOFTWARE

3.1 Introduction to RX-Programmer software

RX-Programmer is a PLC programming tool for the creation, testing and


maintenance of programs associated with Omron CSI-series PLCs, CV-series PLCs
and C-series PLCs. It provides facilities for support of PLC device and address
information and for communications with OMRON PLCs and their supported
network

RX-Programmer operates on IBM compatible personal computers


with Pentium or better central processors, including Pentium II. It run in a Microsoft
windows environment. The information within a RX-Programmer project consists of
ladder programs, operands, required PLC memory content, I/O table, expansion
instructions (if applicable) and symbols. Each RX-Programmer project file is
separate and is a single document.

RX-Programmer can only open a single project at a time. However, it is possible to


deal with many project files by using RX-Programmer at once. A RX-Programmer
project has a RXP or RXT file extension (normally the RXP file is used and is a
compressed version of the RXT file).

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3.2 Diagram workspace

The diagram workspace can display a ladder program, the symbol table of that
program or the Mnemonic view. The details displayed depend upon the selection
made in the project workspace.

When a new project is created or a new PLC added to a project, an empty ladder is
automatically displayed on the right-hand side to the project workspace. The symbol
table and Mnemonics view must be explicitly selected to be displayed. All views
can be opened at the same time and can selected via option associated with the
window menu.

PLC program instruction can be entered as a graphical representation in ladder


form. Programs can be created, edited, and monitored in this view. The 3.1 shows
the diagram workspace appearance.

Figure 3.1 Programming section

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3.3 Program development.

Figure 3.2: ladder logic diagram

Before construct a ladder logic diagram, program flowchart is ideal for a process
that has sequential process steps. The steps will be executed in a simple order that
may change as the result of some simple decisions. The block symbol is connected
using arrow to indicate the sequence of the steps and different types of program
actions. The other functions may be used but are not necessary for most PLC
applications.

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4 EXECUTION OF WORK

4.1 REQUIERD MATERIALS:

4.1.1 PLYWOOD BASE

first of all we take the plywood of about 4*3 feet for making the base. for making
the base portable we can cut it into 2 pieces about 2*1.25.to place it in balanced
condition we can make a balancing wood for this we have to take a piece of wood
about 3*2 Inch and connect this cutted wood in the edge of the ply.rub the edges of
the ply through the sand paper to make it smooth

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Fig MAKING OF BASE

4.1.2 LED (pilot light)

A pilot light or indicator light from Grainger is designed to signal when a machine’s
process has started or ended. Mounted in an instrument panel, on machinery or in a
control room, the indicator light is a necessary safety measure in the manufacturing
facility, lab or chemical plant. Find pilot light options here in a variety of sizes and
voltage ratings and in assorted colors, including red and green.

Fig LED (240v pilot light)

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4.1.3 MULTI METER

A multimeter or a multitester, also known as a VOM (volt-ohm-milliammeter), is


an electronic measuring instrument that combines several measurement functions in
one unit. A typical multimeter can measure voltage, current, and resistance.

Fig multimeter

4.1.4 RELAY

fig: 11 pin relay

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In this project we are using 11 pin relay for isolation or protection of the over- all
circuit. We know that most of the high end industrial application devices have relays
for their effective working. Relays are simple switches which are operated both
electrically and mechanically. Relays consist of an electromagnet and also a set of
contacts. The switching mechanism is carried out with the help of the
electromagnet. There are also other operating principles for its working. But they
differ according to their applications. Most of the devices have the application of
relays.

4.1.5 CONTACTOR

fig. Contactor

A contactor is an electrically-controlled switch used for switching an electrical


power circuit. A contactor is typically controlled by a circuit which has a much
lower power level than the switched circuit, such as a 24-volt coil electromagnet
controlling a 230-volt motor switch.

Unlike general-purpose relays, contactors are designed to be directly connected to


high-current load devices. Relays tend to be of lower capacity and are usually

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designed for both normally closed and normally open applications. Devices
switching more than 15 amperes or in circuits rated more than a few kilowatts are
usually called contactors. Apart from optional auxiliary low-current contacts,
contactors are almost exclusively fitted with normally open contacts.

Contactors come in many forms with varying capacities and features. Unlike
a circuit breaker, a contactor is not intended to interrupt a short circuit current.
Contactors range from those having a breaking current of several amperes to
thousands of amperes and 24 V DC to many kilovolts. The physical size of
contactors ranges from a device small enough to pick up with one hand, to large
devices approximately a meter (yard) on a side.

A contactor has three components. The contacts are the current-carrying part of the
contactor. This includes power contacts, auxiliary contacts, and contact springs.

Working principle of AC contactor is when the coil is energized, the core is


magnetized to attract the armature to move down to make the normally closed
contact open and normally open contact closed. When the coil is powered off, the
electromagnetism disappears, the armature returns to its original position and
contact returns to its original state under the action of the reaction spring.

4.1.6 VOLTMETER

fig Voltmeter

The instrument which measures the voltage or potential difference in volts is known
as the voltmeter. It works on the principle that the torque is generated by the current
which induces because of measurand voltage and this torque deflects the pointer of

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the instrument. The deflection of the pointer is directly proportional to the potential
difference between the points. The voltmeter is always connected in parallel with
the circuit.

The voltmeter constructs in such a manner that their internal resistance always
remains high. If it connects in series with the circuit, it minimises the current which
flows because of the measurand voltage. Thus, disturb the reading of the voltmeter.

The voltmeter always connects in parallel with the circuit so that the same voltage
drop occurs across it. The high resistance of the voltmeter combines with the
impedance of the element across which it is connected. And the overall impedance
of the system is equal to the impedance that the element had. Thus, no obstruction
occurs in the circuit because of the voltmeter, and the meter gives the correct
reading.

4.1.7 AMMETER

FIG Ammeter

The principle of ammeter is that it must have a very low resistance and also
inductive reactance. Now, why do we need this? Can’t we connect an ammeter in
parallel? The answer to this question is that it has very low impedance because it
must have very low amount of voltage drop across it and must be connected in
series connection because current is same in the series circuit.

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Also due to very low impedance the power loss will be low and if it is connected in
parallel it becomes almost a short circuited path and all the current will flow through
ammeter as a result of high current the instrument may burn. So due to this reason it
must be connected in series. For an ideal ammeter, it must have zero impedance so
that it has zero voltage drop across it so the power loss in the instrument is zero. But
the ideal is not achievable practically.

4.1.8 MCB

FIG. MCB
Nowadays we use more commonly miniature circuit breaker or MCB in low voltage
electrical network instead of fuse.

The MCB has some advantages compared to fuse.


1. It automatically switches off the electrical circuit during abnormal condition
of the network means in over load condition as well as faulty condition. The
fuse does not sense but miniature circuit breaker does it in more reliable
way. MCB is much more sensitive to over current than fuse.
2. Another advantage is, as the switch operating knob comes at its off position
during tripping, the faulty zone of the electrical circuit can easily be

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identified. But in case of fuse, fuse wire should be checked by opening fuse
grip or cutout from fuse base, for confirming the blow of fuse wire.
3. Quick restoration of supply cannot be possible in case of fuse as because
fuses have to be rewirable or replaced for restoring the supply. But in the
case of MCB, quick restoration is possible by just switching on operation.
4. Handling MCB is more electrically safe than fuse. Because of too many
advantages of MCB over fuse units, in modern low voltage electrical
network, miniature circuit breaker is mostly used instead of backdated fuse
unit.
Only one disadvantage of MCB over fuse is that this system is more costly than fuse
unit system.
There are two arrangement of operation of miniature circuit breaker. One due to
thermal effect of over current and other due to electromagnetic effect of
over current. The thermal operation of miniature circuit breaker is achieved with a
bimetallic strip whenever continuous over current flows through MCB, the
bimetallic strip is heated and deflects by bending. This deflection of bimetallic strip
releases mechanical latch. As this mechanical latch is attached with operating
mechanism, it causes to open the miniature circuit breaker contacts.
But during short circuit condition, sudden rising of current, causes
electromechanical displacement of plunger associated with tripping coil or solenoid
of MCB. The plunger strikes the trip lever causing immediate release of latch
mechanism consequently open the circuit breaker contacts. This was a simple
explanation of miniature circuit breaker working principle.

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4.1.9 PUSH BUTTON

FIG Push Button

A push-button is a simple switch mechanism to control some aspect of a machine or


a process. Buttons are typically made out of hard material,
usually plastic or metal. The surface is usually flat or shaped to accommodate the
human finger or hand, so as to be easily depressed or pushed.

In the project three push button is used :


 NO (Normally Open ) - 2
 NC (Normally Close) - 1

 Normally Open Type Push Button is used in project for START operation
and for selection of MODE operation
 Normally Closed Type Push Button is used for executing STOP operation.

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Normally Open (NO) :

A Normally Open (NO) Push Button is a push button that, in its default state, makes
no electrical contact with the circuit. Only when the button is pressed down does it
make electrical contact with the circuit.

Normally Closed (NC) :

A Normally Closed (NC) Push Button is a push button that, in its default state, makes
electrical contact with the circuit.

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