Government of Pakistan

National Vocational and Technical Training Commission

Prime Minister’s Hunarmand Pakistan Program

"Skills for All"

Course Contents / Lesson Plan

Course Title: INDUSTRIAL AUTOMATION (PLC)

Duration: 6 Months

Course Details / Description & Preliminaries

FVTLM002
Page 1
 Course Title INDUSTRIAL AUTOMATION (PLC)
Objectives and
Expectations Employable skills for DAE in Electrical / Electronics through an
intensive course on industrial Automation (PLC)

This is a special course designed to address unemployment in the

youth. The course aims to achieve the above objective through hands
on practical training delivery by a team of dedicated professionals
having rich market/work experience. This course is therefore not just
for developing a theoretical understanding/back ground of the trainees.
Contrary to that it is primarily aimed at equipping the trainees to
perform commercially in a market space in independent capacity or as
a member of a team.

The course therefore is designed to impart not only technical skills but
also soft skills (i.e interpersonal/communication skills; personal
grooming of the trainees etc) as well as entrepreneurial skills (i.e
marketing skills; free lancing etc). The course also seeks to inculcate
work ethics to foster better citizenship in general and improve the
image of Pakistani work force in particular.
Main Expectations:
In short, the course under reference should be delivered by
professional instructors in such a robust hands- on manner that the
trainees are comfortably able to employ their skills for earning money
(through wage/self-employment) at its conclusion.
This course thus clearly goes beyond the domain of the traditional
training practices in vogue and underscores an expectation that a
market centric approach will be adopted as the main driving force while
delivering it. The instructors should therefore be experienced enough to
be able to identify the training needs for the possible market roles
available out there. Moreover, they should also know the strengths and
weaknesses of each individual trainee to prepare them for such market
FVTLM002
Page 2
 roles during/after the training.

i. Specially designed practical tasks to be performed by the

trainees have been included in the Annexure-I to this
Key Features of
Training& Special document. The record of all tasks performed individually or in
Modules
groups must be preserved by the management of the training
Institute clearly labeling name, trade, session etc so that
these are ready to be physically inspected/verified through
monitoring visits from time to time. The weekly distribution of
tasks has also been indicated in the weekly lesson plan
given in this document.
ii. In order to materialize the main expectations, a special
module on Job Search & Entrepreneurial Skills has been
included in the later part of this course (5 th & 6th month)
through which, the trainees will be made aware of the Job
search techniques in the local as well as international job
markets (Gulf countries). Awareness around the visa process
and immigration laws of the most favored labour destination
countries also forms a part of this module. Moreover, the
trainees would also be encouraged to venture into self-
employment and exposed to the main requirements in this
regard. It is also expected that a sense of civic duties/roles
and responsibilities will also be inculcated in the trainees to
make them responsible citizens of the country.
iii. A module on Work Place Ethics has also been included to
highlight the importance of good and positive behavior at
work place in the line with the best practices elsewhere in the
world. An outline of such qualities has been given in the
Appendix to this document. Its importance should be
conveyed in a format that is attractive and interesting for the
trainees such as through PPT slides +short video

FVTLM002
Page 3
 documentaries. Needless to say that if the training provider
puts his heart and soul into these otherwise non-technical
components, the image of Pakistani workforce would
undergo a positive transformation in the local as well as
international job markets.

In order to maintain interest and motivation of the trainees throughout

the course, modern techniques such as:
• Motivational Lecture
• Success Stories
• Case Studies
These techniques would be employed as an additional training tool
wherever possible (these are explained in the subsequent section on
Training Methodology).
Lastly, evaluation of the competencies acquired by the trainees will be
done objectively at various stages of the training and proper record of
the same will be maintained. Suffice to say that for such evaluations,
practical tasks would be designed by the training providers to gauge
the problem solving abilities of the trainees.

(i) Motivational Lectures

The proposed methodology for the training under reference employs
motivation as a tool. Hence besides the purely technical content, a
Training Tools/ trainer is required to include elements of motivation in his/her lecture
Methodology
to inspire the trainees to utilize the training opportunity to the full and
strive towards professional excellence. Motivational lectures may also
include general topics such as the importance of moral values and civic
role & responsibilities as a Pakistani. A motivational lecture should be
delivered with enough zeal to produce a deep impact on the trainees. It
may comprise of the following:

 Clear Purpose to convey message to trainees effectively.

 Personal Story to quote as an example to follow.

FVTLM002
Page 4
  Trainees Fit so that the situation is actionable by trainees and
not represent a just idealism.
 Ending Points to persuade the trainees on changing themselves.

A good motivational lecture should help drive creativity, curiosity and

spark the desire needed for trainees to want to learn more.
Impact of a successful motivational strategy is amongst others
commonly visible in increased class participation ratios. It increases the
trainees’ willingness to be engaged on the practical tasks for longer
time without boredom and loss of interest because they can clearly see
in their mind's eye where their hard work would take them in short (1-3
years); medium (3 -10 years) and long term (more than 10 years).

As this tool is expected that the training providers would make

arrangements for regular well planned motivational lectures as part of a
coordinated strategy interspersed throughout the training period as
suggested in the weekly lesson plans in this document.

(ii) Success Stories

Another effective way of motivating the trainees is by means of
Success Stories. Its inclusion in the weekly lesson plan at regular
intervals has been recommended till the end of the training.
A success story may be disseminated orally, through a presentation or
by means of a video/documentary of someone that has risen to fortune,
acclaim, or brilliant achievement. A success story shows how a person
achieved his goal through hard work, dedication and devotion. An
inspiring success story contains compelling and significant facts
articulated clearly and easily comprehendible words. Moreover, it is
helpful if it is assumed that the reader/listener knows nothing of what is
being revealed. Optimum impact is created when the story is revealed
in the form of:-
 Directly in person (At least 2-3 cases must be arranged by the
training institute)

FVTLM002
Page 5
  Through an audio/ videotaped message (2-3 high quality videos
must be arranged by the training institute)
It is expected that the training provider would collect relevant high
quality success stories for inclusion in the training as suggested in the
weekly lesson plan given in this document.
Suggestive structure and sequence of a sample success story and its
various shapes can be seen at annexure III.

(iii) Case Studies

Where a situation allows, case studies can also be presented to the
trainees to widen their understanding of the real life specific
problem/situation and to explore the solutions.
In simple terms, the case study method of teaching uses a real life
case example/a typical case to demonstrate a phenomenon in action
and explain theoretical as well as practical aspects of the knowledge
related to the same. It is an effective way to help the trainees
comprehend in depth both the theoretical and practical aspects of the
complex phenomenon in depth with ease. Case teaching can also
stimulate the trainees to participate in discussions and thereby boost
their confidence. It also makes class room atmosphere interesting thus
maintaining the trainee interest in training till the end of the course.
Depending on suitability to the trade, the weekly lesson plan in this
document may suggest case studies to be presented to the trainees.
The trainer may adopt a power point presentation or video format for
such case studies whichever is deemed suitable but it’s important that
only those cases are selected that are relevant and of a learning value.
The Trainees should be required and supervised to carefully analyze
the cases.
For the purpose they must be encouraged to inquire and collect
specific information / data, actively participate in the discussions and
intended solutions of the problem / situation.

Case studies can be implemented in the following ways: -

FVTLM002
Page 6
 i. A good quality trade specific documentary ( At least 2-3
documentaries must be arranged by the training institute)
ii. Health &Safety case studies (2 cases regarding safety
and industrial accidents must be arranged by the training
institute)
iii. Field visits( At least one visit to a trade specific major
industry/ site must be arranged by the training institute)
Intake to the Training Since intake level is DAE in Electrical / Electronic so expectations from
the trainees are:

 understanding of basics electrical wiring

 Interpretation of basics of engineering drawing & standard symbols
 Interpretation of basics of electrical measuring instruments & their
uses
 Should have concept of Basic Electronics
 Should have concept of fundamentals of Digital & Industrial
Electronics
 Should have concept of Electrical machines & its applications
 Should have concept of Computer system
Learning Outcome of After completion of this course, the trainees must be able to
the Course demonstrate their underpinning knowledge of:

 Occupational Health & Safety.

 Interpretation of number systems, logic gates & Boolean algebra.
 Understanding the function & uses/applications of different types of
switches, Push buttons, fuses/circuit breakers, Relays, Contactors,
Timers, counters, sensors, Transducers etc.
 To gain knowledge of basic concepts of control systems &
automation.
 Demonstration of different types of control systems like on/off
Control
 PLC, its components & Types.
 Types of PLC based machines and their applications
 Fundamentals of ladder logic diagram
 Translate the logic implementation into PLC coding.

FVTLM002
Page 7
  Translate relay ladder diagram into PLC coding.
 Assign real I/O and internal addresses to inputs and outputs.
 Review machine logic of operation and optimize when possible.
 Understand the actual process or machine function.
 Motor control switchgear and its applications with PLC
 Should be able to interpret manufacturer’s instructional manual in
order to install and connect the PLC system according to the
functional diagram
 Knowledge & understanding to install, operate & repair PLC
systems.
 Interpretation of circuit diagrams, service manuals, technical
sketches, graphic symbols, wiring diagrams and manufacturer’s
specifications etc.
 Can locate/trace and repair/replace the faulty components of PLC
system and also carry out the function tests.
 Trouble shooting of the faults in the PLC system, input/output
devices and PLC based machines
 Common faults in industrial PLC based machines
 Knowledge of ADC, DAC and data acquisition systems.
 Must be able to make HMI for industrial control room.

Course Execution Total Duration of Course: 6 Months (26 Weeks)

Plan

Class Hours: 4 Hours per day (06 Days/Week)

Theory: 20% Practical: 80%

Weekly Hours: 24 Hours Per week

Total Contact Hours: 600 Hours

FVTLM002
Page 8
 Companies Offering Most of Pakistani industries are moving their processes to automatic
Jobs in the
systems so a person having this knowledge& skill, will have all the
respective trade
industrial opportunities at his choice and can secure job with ease. It is
expected that by acquiring sufficient knowledge and skills, the
prospects of employability of passed out graduates increases many
folds.
Job Opportunities
 PLC/SCADA Technician in industry (Textile, Leather,
Pharmaceuticals, Food Processing, Automotive, Cement etc.)
 PLC/SCADA consultant for industry and commerce.
 Automation trainer for workers and lower management of industries.
No of Students
25

Learning Place
Classroom / Lab / Workshop / Industry

WEEKLY SCHEDULE OF TRAINING

Scheduled
Module Title Learning Units Remarks
Week
Week 1  Course Introduction
Introduction  Motivational Lecture(For further detail Home
please see Page No: 4) Assignment No. 1
Details may be
 Course Applications
seen at Annexure-
 Institute/Work ethics (For further II
detail please see Annexure-III at the
end)
 Health & Safety
 Job market
Week 2 Logic Gates &  Binary Number System
Boolean Algebra  Review of Arithmetic Operation of Task No. 1
Binary Numbers Details may be
seen at Annexure-I
 Logic Gates (Symbol, Truth Table
etc.)
 Boolean Algebra Home Assignment
 K-Map No. 2
 Success story (For further detail Details may be seen

FVTLM002
Page 9
 please see Page No: 5 and at Annexure-II
Annexure-IV at the end)
Week 3 Basic  Motivational Lecture( For further
Components, their detail please see Page No: 4) Task No. 2
symbols and  Control Transformer Details may be
Applications seen at Annexure-I
 Fuses& Circuit Breakers
 Switches Home
 Push Buttons Assignment No. 3
 Indicators Details may be
seen at Annexure-
II

Week 4 Relays &  Relay:

Contactors Construction, Operation/working
Principal, Types & Applications.
Task No. 3
 Contactors: Details may be seen
Construction, Operation/working at Annexure-I
Principal, Types & Applications.
 Case Study-1 (Health & Safety) (For Monthly Test 1
further detail please see Page No: 6)
Week 5
Timers & Counters  Motivational Lecture( For further Task No. 4
detail please see Page No: 4) Details may be
 Timers: seen at Annexure-I
Construction, Operation/working
Principal, Types & Applications.

 Counters:
Construction, Operation/working Home
Principal, Types & Applications. Assignment No. 4
Details may be
seen at Annexure-
II

Week 6 Industrial  Institute/Work ethics (For further

Automation
detail please see Annexure-III at the
end) Home
Assignment No. 5
 Control System Details may be
 Types of Industrial Automation seen at Annexure-
 Advantages of Industrial Automation II
 Role of PLC in Automation
 Success story (For further detail
please see Page No: 5 and

FVTLM002
Page 10
 Annexure-IV at the end)

Week 7 Introduction to PLC  Definition.

 History.
 Types. Home
Assignment No. 6
 Configuration. Details may be
 Sizes & Brands. seen at Annexure-
II
 Applications.
 Advantages.
 Case Study-2 (For further detail
please see Page No: 6)
Week 8 PLC Hardware  Motivational Lecture( For further Home Assignment
detail please see Page No: 4) No. 7
 Block Diagram of PLC Details may be seen
at Annexure-II
 Components of PLC
 Analog & Digital I/O Modules
Monthly Test 2
 Special Modules
 RS232 and 485 Communication
Protocols
Week 9 PLC Software  System Requirement
Task No. 5
 Installation of PLC Software Details may be
 Integrate the simulator in PLC seen at Annexure-I
Software Home
 Configure Software for Desired Task Assignment No. 8
Details may be
 Industrial Simulation (Online and seen at Annexure-
Offline) II

 Success story (For further detail

please see Page No: 5 and
Annexure-IV at the end)

FVTLM002
Page 11
 Week 10 PLC Languages
 Motivational Lecture( For further Task No. 6
detail please see Page No: 4) Details may be seen
 Introduction to PLC Languages at Annexure-I

 Types of PLC Languages

Ladder Diagram (LD)
Function Block Diagram (FBD)
Sequential Function Chart (SFC)
Instruction List (IL)
Structured Text (ST)
 Ladder Logic (LL)
Week 11 Ladder Logic  Master control reset
Programming  Latching Task No. 7
Details may be seen
 Interlocking
at Annexure-I
 Logic Gates Ladder Logic
Programming
 On-Delay Timer Ladder Logic
Programming
 Off-Delay Timer Ladder Logic
Programming
 Retentive On-Delay Timer Ladder
Logic Programming
 Retentive Off-Delay Timer Ladder
Logic Programming
 Pulse Timer Ladder Logic
Programming
 Online and Offline Simulation of
Above tasks
 Real Time Clock
 Case Study-3 (For further detail
please see Page No: 6)

FVTLM002
Page 12
 Week 12 Ladder Logic  Motivational Lecture( For further
Programming detail please see Page No: 4)
 Counters Ladder Logic Programming
Task No. 8
 Up Counter
Details may be seen
 Down Counter at Annexure-I
 Up down Counter
 Special Instructions Midterm
 Online and Offline Simulation of Assessment
Above tasks
 Practical industrial applications
Week 13 Task No. 9
Overview of the previous weeks & Mid Term Details may be seen
Examination at Annexure-I

Week 14 Comparators  Greater than and equal to

Programming Comparator Programming
 Less than and equal to Comparator
Programming
 Equal to Comparator Programming
 Online and Offline Simulation of
Above tasks
 Timers Comparison Programming Task No. 10
Details may be seen
 Counters Comparison Programming
at Annexure-I
 Data Registers Comparison
Programming
 Online and Offline Simulation of
Above tasks
 Demonstrate the basic function of
Proximity sensors
 Demonstrate the basic function of
limit switch
 Success story (For further detail
please see Page No: 5 and
Annexure-IV at the end)
Week 15 Analog data
 Motivational Lecture( For further
detail please see Page No: 4) Task No. 11
 ADC and DAC Details may be seen
 Analog Values Scaling at Annexure-I
 Related Problems
 Case Study-4 (For further detail
please see Page No: 6)

FVTLM002
Page 13
 Week 16 Analog  Motivational Lecture( For further
Programming detail please see Page No: 4)
 Analog IOs Programming
Task No. 12
 Applications of Analog Programming
Details may be seen
in Industry at Annexure-I
 Online and Offline Simulation of
Analog Programming
 Practical industrial scenarios for
Analog I/Os
Week 18 Analog Sensors II  Motivational Lecture( For further
detail please see Page No: 4)
 Interfacing Load cell with PLC
Automation of Load cell via PLCs
Programming for Automation of Task No. 14
Load cell Details may be seen
 Interfacing Level Sensor with at Annexure-I
PLC
Automation of Level Sensor via
PLCs
Programming for Automation
Level Sensor
Job Search  Session on CV Building.
 How to make notable CV.
 Dos and Don’ts of CV making.
Week 19 HMI Programming  Overview of HMIs
 Types of HMIs Task No. 15
Details may be seen
 Planning and Designing of HMIs
at Annexure-I
 Recipes of HMI
 Case Study-5 (For further detail
please see Page No: 6)

FVTLM002
Page 14
 Week 20 Project Design  Success story (For further detail
please see Page No: 5 and
Annexure-IV at the end)
Task No. 16
 PLC based mini Projects Details may be seen
 Idea generation and Planning for at Annexure-I
project etc.
 Discussions for selection of
project and assessing
requirements etc.
 Groups formation
 Problems indented solution
Business  Commissioning testing etc
Development &  Session on Self-Employment
entrepreneurship  How to start a Business.
 Requirements ( Capital, Physical
etc)
 Benefits/Advantages of self-
employment
Week 21 Employable  Guidelines to the Trainees for
Project/Assignment selection of employable project like Task No. 17
(6 weeks i.e. 21- final year project (FYP) Details may be seen
26) in addition of at Annexure-I
 Assign Independent project to each
regular classes.
Trainee
 A project based on trainees acquired  Project
skills and interests.

 Designed by keeping in view the

emerging trends in the local market
as well as across the globe.
 The project idea may be based on
Entrepreneurship.
 Leading to the successful
employment.
 The duration of the project will be 6
weeks
 The project will be presented in front
of Industrialists for commercialization
 The best business idea will be placed
in NAVTTC business incubation
center for commercialization.

FVTLM002
Page 15
 Week 22 Case Study 01: Automation in Textile sector
 Demonstration of Site Visit/ by Task No. 18
Laboratory Trainer Details may be seen
at Annexure-I
 Survey
 Feasibility Report Project
 Model Simulation (Prototype) Continued…
 Motivational Lecture( For further
detail please see Page No: 4) Monthly Test 5
 Session on General Overseas
General Oversees
Employment opportunities.
Employment
 Job search Avenues.
 Visa Processes and other
necessary requirements.
 Immigration Information (Legal
age requirements, Health
Certificate, Police Clearance
&Travel Insurance)

Week 23 Case Study 02: Automation in Batching sector

 Demonstration of Site Visit/ by Task No. 18
Laboratory Trainer Details may be seen
at Annexure-I
 Survey
 Feasibility Report Project
 Model Simulation (Prototype) Continued…
Week 24 Case Study 03: Automation in Manufacturing sector
 Demonstration of Site Visit/ by Project
Laboratory Trainer Continued…
 Survey
 Feasibility Report
 Model Simulation (Prototype)
Motivational Lecture( For further detail
please see Page No: 4)
 Selection of two countries of
Oversees
Employment destination (Gulf Countries,
Malaysia, South Korea
etc)focusing on:-
I. Trade specific Job Prospects and
Earning levels in that country.
II. Country Specific Labor laws,
entry and exit requirements
(Legal age requirements, Health
Certificate, Police Clearance &
Travel Insurance etc.).

FVTLM002
Page 16
 Week 25  Selection of two countries of
Oversees destination (Gulf Countries, Project
Employment Malaysia, South Korea Continued…
etc)focusing on:-
III. Trade specific Job Prospects and
Earning levels in that country.
IV. Country Specific Labor laws,
entry and exit requirements
(Legal age requirements, Health
Certificate, Police Clearance &
Travel Insurance etc.).
 Automation in Pharma sector
Case Study 04:  Demonstration of Site Visit/
Laboratory Trainer
 Survey
 Feasibility Report
 Model Simulation (Prototype)
 Success story (For further detail
please see Page No: 5 and
Annexure-IV at the end)

Week 26 Entrepreneur  Fundamentals of Business

ship and Final Development
Assessment in  Entrepreneurship&Startup Funding
project
 Business Incubation and Acceleration  Project
 Business Value Statement completion and
 Business Model Canvas testing/launching
 Sales and Marketing Strategies
 How to Reach Customers and
Engage CxOs
 Stakeholders Power Grid  Final Assessment
 RACI Model, SWOT Analysis, PEST
Analysis
 SMART Objectives
 OKRs
 Cost Management (OPEX, CAPEX,
ROCE etc.)
 Final Project
 Final Assessment

FVTLM002
ANNEXURES Page 17
 Annexure-I

TASKS FOR INDUSTRIAL AUTOMATION (PLC)

FVTLM002
Page 18
Task
Task Description
No.
1 Make an OR & AND
Make an OR & AND circuit, draw it logic and circuit diagrams,
circuits.
also draw the truth table for this circuit.
2 Controlling of a lamp/LED Make a circuit to control one lamp/LED from two different
from two different places. places using SPDT switch and also draw,
Circuit diagram, logic diagram and truth table.
3 Operating lamp/LED & Make a circuit using Relay & Contactor logic to control a lamp
buzzer using Relay & & buzzer in the following way,
Contactor logic. When the lamp is “ON” the buzzer remaining deactivated.
When the lamp turned “OFF” the buzzer circuit is then
activated automatically until the lamp is again operated.
Draw logic, circuit diagrams and truth table.
4 Circuit to control 2 lamps Make a circuit to control 2 lamps. First, L1 is “ON” for 7 sec
automatically. then turned “OFF” automatically & at that instant L2 become
energized and remained “ON” for 3 sec, this cycle is repeated
until interrupted.
Draw circuit, logic diagrams and truth table.
5 Implement given Boolean Simulate PLC Program to implement the following Boolean
Functions with the help of functions with Don’t Care Condition.
PLC Program.
F(A,B,C,D)=∑m(0,1,5,9,13,14,15) + d(3,4,7,10,11)

6 Using PLC Program to Run a 3-phase motor in the Forward and Reverse direction
make Forward- Reverse with the help of PLC using Ladder Diagram programming
Circuit (with limit switches) language. This circuit is used to change the direction of rotation
for a 3-Phase Motor. of a 3-Phase induction motor (i.e. forward &backward or
upward & downward). Forward-Reverse movement of a 3-
Phase motor can be obtained by changing its phase sequence.
Also draw its electrical and Ladder Logic diagrams.
7 PLC Program to Latch and
Prepare, execute, and demonstrate a PLC Program to
Unlatch Output With Time
implement Latching and Unlatching of output with a particular
Delay.
time delay in PLC using Ladder Diagram.
8 Operating Seven Segment
Display using PLC Prepare, execute, and demonstrate a PLC Program to
Program. displaying 0-9 digits using 7 Segment LED Display interfacing
with PLC using Ladder Diagram programming language.

Task
Task Description
No.

FVTLM002
Page 19
 9 Using PLC Program to
Drive two Motors Two Motors are running in a sequence one by one for a
Simultaneously with particular time. If the start button is pressed Motors run in
Interlocking. sequence such that 1st Motor stays ON for 5secs and then 2nd
Motor is turned ON and stays ON for 5secs. And the cycle is
repeated until it is interrupted. While motors are running in the
sequence, if one motor is running and the button of other motor
is pressed, then the running Motor should stop and the other
motor should run. Implement this logic in PLC using Ladder
Diagram programming language. Also draw its electrical and
Ladder Logic diagrams.
10 PLC Program for Burglar
Prepare, execute, and demonstrate a PLC Program for Burglar
Alarm Security System
Alarm Security System. Consider the design of a Burglar Alarm
for a house. This alarm will be activated if an unauthorized
person is detected by a Window Sensor or a Motion Detector.
Implement this Alarm System in PLC using Ladder Diagram
programming language.
11 PLC Program for a Car A parking plot has total capacity of Cars. Number of empty
Parking System spots are displayed on the display outside the Parking Plot and
which spots are available is to be indicated by LEDs.
Implement this in PLC using Ladder Diagram programming
language.
12 Automatic Door Open Prepare, execute, and demonstrate a PLC Program to
Close Control System with implement logic for the automatic door open & close
the help of PLC Program. system using ladder diagram programming language.

Task
Task Description
No.

FVTLM002
Page 20
 13 PLC Program for Heating Implement the process to control Heating and maintaining high
water in the Tank by and low level of water in the tankusing PLC Ladder Diagram
Heater using RTD as programming language.
temperature detector.

14 PLC Program to Control A feeder drops material on the conveyor which sends the
the Sequence of dropped material to collector through one more conveyor.
Conveyors and Conveyor must start automatically.When material falls on
Interlocking Them conveyor belt 1, motor 1 should start, and when material in
present on conveyor belt 2, motor 2 remain On.Implement
automation of this in PLC using Ladder Diagram programming
language.

Task
Task Description
No.

FVTLM002
Page 21
 15 PLC Program to Maintain A classroom has a capacity of maximum 25 students. There
the Capacity of a Particular are two doors, one for Entry and the other for Exit. When
Classroom using HMI number of students in the classroom is less than 25, Entry door
Interface.
has a Green light on it which remains ON. When number of
students in the classroom is 25 or more than that, Red light
goes ON turning OFF the Green light which indicates that the
classroom has reached its maximum capacity and is full.
16 Mini Project: Making of an This circuit is widely used in industries. The trainees have to
ATS Circuit, with the help make such circuit with the following options.
of PLC Program. 1. When the main supply goes down, The Generator Will
Turn ON automatically after 5 Min.
2. When the Generator Turned ON, the load shifts to
Generator after 3 min. automatically.
3. When the main supply become available, shift load
immediately on main while the Generator will then run
without load for 3 min. and then turn OFF automatically.
Implement this logic in PLC using Ladder Diagram
programming language. Also draw its electrical and Ladder
Logic diagrams.
17 Making in Automatic Star- 3-phase induction motors (squirrel cage) are needed some
Delta Starter with the help suitable starting mechanism/arrangement because at the time
of PLC Program. of starting it draw a huge amount of current and when such
large machines are started directly, it ultimately can cause
damage to the machine or attached equipment. Implement the
logic in PLC using Ladder Diagram programming language.
Also draw its electrical and Ladder Logic diagrams.
18 PLC Program to Control A deep well pump (P1) is used to fill tank-1 mounted on first
Level of Two Tanks floor, while a 0.25hp pumping motor (P2) is used to pump the
water from tank-1 to tank-2 which is at some further height
from tank-1. Both the Tanks are defined to store water between
upper & lower limits.

When the operating switch is turned “ON”, one of the following

action will take plece,

1. If water in tank-1 is adequately above the lower limit or it

is filled, P2 starts pumping water to tank-2 till upper limit
of tank-2 or lower limit of tank-1 whichever reach first,
once the water level reaches to upper limit of Tank-2 or
lower limit of Tank-1, P2 stops and P1 start to fill tank-1
and then stop automatically.

2. If water level in tank-1 is not sufficient, P1 is operated to

FVTLM002
Page 22
 fill it and then stop automatically. In order to fill tank-2,
the main switch needs to reoperated manually. After
tank-2 get filled, P2 stops and P1 start to complete the
less water level of tank-1 and then stop autmatically.

Implement this logic in PLC using Ladder Diagram

programming language. Also draw its electrical and Ladder
Logic diagrams.

Annexure-II
ASSIGNMENTS FOR INDUSTRIAL AUTOMATION (PLC)
Assign
Assignment
. No.
FVTLM002
Page 23
 1 Prepare safety charts. Showing general & Trade specific safety measure
(text/pictorial). Each trainee will prepare different chart.
2 Simplify the following Boolean expression using K-Map, also draw logic
diagrams (Before & after simplification)

f (W,X,Y,Z) = ∑ (1,3,4,6,9,11,12,14)
3 Draw neat & clean sketches (along with their symbols) of various components
you have learnt in this week on drawing sheet(s)/Chart(s).
4 What is the difference between timers & counters? Explain function of Timer &
Counter in PLC, enlist different types of timers and counters and draw their
symbols, also write down its advantages.
5 What do you mean by automation? What are their types? Write down
advantages of industrial automation with examples.
6 What is PLC? Enlist different the different sizes & brands of PLC, also write
down the uses and advantages of PLC.
7 What do you mean by physical protocol of communication? What is the
difference between RS232 and 485? How & why we can convert RS232 to
485? Draw the Block diagram of PLC and Pinout of RS232 & 485 connector
(both male, female) on drawing sheet(s)/Chart(s).
8 Enlist the complete step by step procedure to install PLC software. Also write
the method to configure PLC software for desired task. Evident screenshots is
mandatory.

Annexure-III
Workplace/Institute Ethics Guide
Work Ethics is a standard of conduct and values for job performance. The modern definition of what
constitutes good work ethics often varies. Different businesses have different expectations. Work

FVTLM002
Page 24
ethic is a belief that hard work and diligence have a moral benefit and an inherent ability, virtue or
value to strengthen character and individual abilities. It is a set of values centered on importance
of work and manifested by determination or desire to work hard.

The following ten work ethics are defined as essential for employee’s success:

1. Attendance:
Be at work every day possible, plan your absences don’t abuse leave time. Be punctual every
day.
2. Character:
Honesty is the single most important factor having a direct bearing on the final success of an
individual, corporation, or product. Complete assigned tasks correctly and promptly. Look to
improve your skills.
3. Team Work:
The ability to get along with others including those you don’t necessarily like. The ability to
carry your own weight and help others who are struggling. Recognize when to speak up with
an ideas and when to compromise by blend ideas together.

4. Appearance:
Dress for success, set your best foot forward, personal hygiene, good manner, remember that
the first impression of who you are, can last a life time
5. Attitude:
Listen to suggestions and be positive, accept responsibility. If you make a mistake, admit it.
Values workplace safety rules and precautions for personal and co-worker safety. Avoids
unnecessary risks. Willing to learn new processes, systems and procedures in light of
changing responsibilities.
6. Productivity:
Do the work correctly, quality and timelines are prized. Get along with fellows, cooperation is
the key to productivity. Help out whenever asked, do extra without being asked. Take pride in
your work, do things the best you know how. Eagerly focuses energy on accomplishing tasks,
also referred to as demonstrating ownership. Takes pride in work.
7. Organizational Skills:

FVTLM002
Page 25
 Make an effort to improve, learn ways to better yourself. Time management; utilize time and
resources to get the most out of both. Takes an appropriate approach to social interactions at
work. Maintains focus on work responsibilities.
8. Communication:
Written communication, being able to correctly write reports and memos.
Verbal communications, being able to communicate one on one or to a group.
9. Cooperation:
Follow institute rules and regulations, learn and follow expectations. Get along with fellows,
cooperation is the key to productivity. Able to welcome and adapt to changing workplace
situations and the application of new or different skills.
10. Respect:
Work hard, work to the best of your ability. Carry out orders, do what’s asked the first time.
Show respect, accept and acknowledge an individual’s talents and knowledge. Respects
diversity in the workplace, including showing due respect for different perspectives, opinions
and suggestions.

Annexure-IV
SUGGESTIVE FORMAT AND SEQUENCE ORDER OF SUCCESS STORY
S. No Key Information Detail/Description

FVTLM002
Page 26
 1. Self & Family  Self-introduction
background  Family background and socio economic status,
 Education level and activities involved in
 Financial hardships etc

2. How he came on board  Information about course, apply and selection

NAVTTC Training/ or  Course duration, trade selection
got trained through any  Attendance, active participation, monthly tests,
other source interest in lab work

3. Post training activities  How job / business (self-employment) was set

up
 How capital was managed (loan (if any) etc).
 Detail of work to share i.e. where is job or
business being done; how many people
employed ( in case of self-employment/
business )
 Monthly income or earnings and support to
family
 Earning a happy life than before

4. Message to others  Take the training opportunity seriously

(under training)  Impose self-discipline and ensure regularity
 Make Hard work pays in the end so be always
ready for the same.

Note: Success story is a source of motivation for the trainees and can be presented in a
number of ways/forms in a NAVTTC skill development course as under: -
1. To call a passed out successful trainee of institute. He will narrate his success story to
the trainees in his own words and meet trainees as well.
2. To see and listen to a recorded video/clip (5 to 7 minutes) showing a successful trainee
Audio video recording that has to cover the above mentioned points.
3. The teacher displays the picture of a successful trainee (name, trade, institute,
organization, job, earning etc) and narrates his/her story in teacher’s own motivational
words.

FVTLM002
Page 27