‫تتىى‬

‫تقرير التدريب الميداني‬

‫مقدم من الطالبة ‪ :‬آمال خالد عبد المنعم‬
‫هندسة القوى واآلالت الكهربية‬
‫الصف الثاني ‪2022 - 2023‬‬

‫مكان التدريب ‪:‬‬

‫‪Jelecom Academy for Engineering & Professional‬‬
‫‪Technical Training‬‬
‫‪28‬ش ‪ 26‬يوليو وسط البلد ‪ -‬محافظة القاهرة‬
‫فترة التدريب ‪:‬‬
‫من ‪ 4/7/2023‬إلى ‪3/9/2023‬‬
Contents
General Introduction..................................................................................................4
Classic Control..........................................................................................................5
Introduction............................................................................................................5
 Electricity basics........................................................................................5
Components............................................................................................................7
 Power supply.............................................................................................7
 Switches.....................................................................................................8
 Electromechanical Relay.........................................................................10
 Electromechanical Contactor...................................................................12
 Interlock...................................................................................................12
 Timer Relay.............................................................................................13
 Sensors.....................................................................................................14
Starting Methods for 3φ Motor............................................................................16
ATS Concept........................................................................................................16
Applications.........................................................................................................17
Project...................................................................................................................22
PLC Basics..............................................................................................................23
Introduction..........................................................................................................23
PLC Siemens........................................................................................................23
 S7-200 (Compact)....................................................................................23
 S7-1200 (Compact)..................................................................................23
 S7-300 and S7-400 (Modular).................................................................23
PLC Hardware......................................................................................................23
 CPU..........................................................................................................23
 Memory....................................................................................................23

1
  I/P & O/P Ports........................................................................................23
 Connection Ports......................................................................................23
 Power Supply (if existed)........................................................................23
PLC Software.......................................................................................................23
 Programs..................................................................................................23
PLC Advanced.........................................................................................................23

2
List of Figures
Figure 1: DC Signal...................................................................................................5
Figure 2: AC Signal...................................................................................................6
Figure 3: Power Supply.............................................................................................7
Figure 4: Inverter.......................................................................................................7
Figure 5: AC Drive....................................................................................................7
Figure 6: Toggle Switch............................................................................................8
Figure 7: NO Push button..........................................................................................8
Figure 8: NC Push button..........................................................................................8
Figure 9: Start Stop Push button................................................................................9
Figure 10: Selector....................................................................................................9
Figure 11: Emergency Switch...................................................................................9
Figure 12: Key Switch.............................................................................................10
Figure 13: Electromechanical Relay.......................................................................10
Figure 14: Internal Structure of Relay.....................................................................10
Figure 15: Operation of Relay 1..............................................................................11
Figure 16: Operation of Relay 2..............................................................................11
Figure 17: Auxiliary Contacts.................................................................................12
Figure 18: Electromechanical Contactor.................................................................12
Figure 19: Mechanical Interlock.............................................................................12
Figure 20: Types of Timers.....................................................................................13
Figure 21: ON-Delay Timer Operation...................................................................13

3
General Introduction

4
 Classic Control
Introduction
What is Classic Control
Classic Control (Electromechanical control) is a type of automatic control that’s
used for controlling motors or valves (Loads) using electromechanical components
such as switches, sensors, relays, contactors, etc.
Advantages & Drawbacks
Advantages: The simplest control system
Drawbacks: No suitable memory to control and Difficulty in maintaining.

 Electricity basics
1. DC Signal :
flows in the same direction, but it may increase and decrease. A DC voltage
is always positive (or always negative), but it may increase and decrease.

Figure 1: DC Signal

5
 2. AC Signal :
The direction of the flow of electrons switches back and forth at regular
intervals or cycles.

Figure 2: AC Signal

Notes:
 In Egypt the range of the voltage input is 208:240VAC for 1φ and
380:420VAC for 3φ.
 Except for the factories there’s transformers to transform the voltage from
transmission lines 11kv to suitable voltages for loads (660v, 380v or 220v)
as 3φ and (V1φ = V3φ /√3).
 Make sure in the factory that the three phases carry almost same loads
(current) to make balance and avoid harmonics that can cause a problem.
 For constant voltage we use stabilizer that take the varying input voltage and
provide a stable voltage for the load (tap changer).

3. Electrical Power:
a. PDC = V*I
b. (PAC)1φ = V*I*p.f.
c. (PAC)3φ = √3*V*I*p.f.

6
Components
 Power supply
As we have different kinds of motors, we also supply them with different types of
sources.
For example, a 3φ motor requires a specific DC Voltage but it’s not available, so
we use converters to get the required type & value of the voltage (and frequency in
case of AC.
1. AC/DC Converter – Rectifier (AKA Power Supply)

Figure 3: Power Supply

2. DC/AC Converter – Inverter

Figure 4: Inverter

3. AC (1φ/3φ) – AC Drive – VSD – VFD – FC – VVVF

Figure 5: AC Drive
7
 Switches
1. Toggle Switch
An electric switch operated by means of a projecting
lever that is moved up and down.
It’s not right to use it in our applications for 2 reasons:
a. If the electricity ran out & went back the load
will be automatically turned on so it might be
harmful for the worker (Safety).
b. It can’t be connected directly to the loads with Figure 6: Toggle Switch
high current as it should have high cross-sectional area due to the equations:
V = IR, R = ρl/A

2. NO Push button
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, it makes electrical contact with the
circuit.

Figure 7: NO Push button

3. NC Push button
A Normally Closed (NC) Push Button is a push
button that in its default state, is closed to the
circuit. Only when the button is pressed down, it
disconnects from the circuit.

Figure 8: NC Push button

8
 4. Start Stop Push button
It’s a combination of NO & NC Push buttons.
As shown in fig. 9 it’s either SPDT or DPDT.

Figure 9: Start Stop Push button

5. Selector
This design is called ON-OFF-ON because as shown in fig. 10 it has 3 cases, either
turn path (A) on or turn path (B) or turn both off.

Figure 10: Selector

6. Emergency Switch
An emergency stop push button switch is used as a safety
measure to stop hazardous parts (loads).
When pressed down, it disconnects the path from the
circuit.
The path doesn’t reconnect to the circuit unless the switch
is rolled back.

Figure 11: Emergency Switch

9
 7. Key Switch
it’s a switch that is can’t be pressed down without a
specific key (Security).

Figure 12: Key Switch

 Electromechanical Relay
As we discussed that we can’t connect the toggle
switch directly with the high current loads, we also
can’t connect any other kind of switches directly with
them.
So, to link them indirectly we use Electromechanical
Relay (or Contactor).
We choose the relay we need based on 3 important
points:
a. The voltage of the coil
b. The current of the contacts Figure 13: Electromechanical Relay

c. No. of contacts or groups

The group in relays is 3 points (COM, NO, NC) that connected as shown in fig. 14:

10
 Figure 14: Internal Structure of Relay

Operation of the relay:

When the coil is fed by the required voltage, the points change its position by
closing the NO path and opening the NC path.

Figure 15: Operation of Relay 1

11
 Figure 16: Operation of Relay 2

Notes:
 Some brands use Make instead of NO and Break instead of NC.
 The higher the rated current of the contacts, the larger the relay.
 Electromechanical Contactor
It’s the same as the relay but larger & has higher contact rated current.
It contains of 3 main NO contacts which can be used in 3-phase motors.
Sometimes we need more contacts so there’s auxiliary contacts can be applied on
the contactor and work with it.

Figure 17: Electromechanical Contactor Figure 18: Auxiliary Contacts

12
 Interlock
1. Electric Interlock
It’s a connection between 2 contactors or more to prevent one from working while
the other is working.

2. Mechanical Interlock
It does the same function as Electric Interlock but it’s a
component that is connected to the 2 contactors.

Figure 19: Mechanical Interlock

 Timer Relay
There are different types of timers.

Figure 20: Types of Timers

13
 1. ON-Delay Timer Operation



Figure 21: ON-Delay Timer Operation
Sensors
1. Digital sensors 0/1
It’s either ON or OFF (no scale)
1: Contact change
0: Contact back
Ex: Digital temperature sensor
(Thermostat)Figure 22: Digital Sensor

2. Analog sensors
It gives a varying range of signals.
Ex: Analog temperature sensor
(Thermocouple)

Figure 23: Analog Sensor

a. Passive Sensor
Requires a Supply.

14
 Figure 24: Passive Sensor

b. Active Sensor
Doesn’t require a
Supply.
Figure 25: Active Sensor

Different types of sensors

1. Limit Switch

Figure 26: Limit Switch

2. Proximity Sensor
It’s either Inductive (For metals only) or Capacitive (For metals & non-
metals)
Note: Don’t use this sensor with hot materials (contains a transistor) or
sticky materials (contains plastic).

15
 Figure 27: Proximity Sensor

3. Magnetic Switch
4. Photo Sensor (close to proximity sensor)

Starting Methods for 3φ Motor

ATS Concept
With thus, power outage and waiting time for the generator to start, this may cause
it to fly Data or disruption of production, the solution is to compensate for this time
using UPS, which is an uninterruptible power source, but it cannot handle all
factory loads for a long time with Power outage, so the generator intervenes after a
certain period, and thus the conclusion:
In the presence of electricity, the loads are fed through the UPS and at the same
time they are charged Battery When the power goes out, the battery stops charging
and the UPS continues to charge The loads are fed by discharging the battery and
the generator starts working after a while The generator intervenes in feeding the
UPS and charging the battery returning electricity The UPS feed goes from the
generator to public electricity Note the placement of the MCB in the direction of
the control circuit and the placement of the MCCB in the power circuit.

16
Figure 28: UPS

17
Applications
Start/Stop a DC motor using 2 push buttons

Figure 29: Start/Stop a DC motor using 2 push buttons

Start a DC motor using 2 NO push buttons separately

Figure 30: Start a DC motor using 2 NO push buttons separately

18
Start a DC motor using 2 NO push buttons together (safety)

Figure 31: Start a DC motor using 2 NO push buttons together

Indirect reverse the direction of the DC motor using contactors

Figure 32: Indirect reverse the direction of the DC motor using contactors

19
Indirect reverse the direction of the 3φ motor using contactors

Figure 33: Indirect reverse the direction of the 3φ motor using contactors

Start/Stop DC motors with 5 seconds delay

Figure 34: Start/Stop DC motors with 5 seconds delay

20
Direct reverse the direction using contactors
Direct reverse the direction using timers
Star/Delta Connection
Washing Machine
Start/Stop a motor using one NO Push button
Automatic Transfer Switch (ATS) with UPS

21
Automatic Transfer Switch (ATS) without UPS

22
‫‪Project‬‬
‫عند الضغط علي مفتاح التشغيل يعمل السير السفلي ‪ K1‬إلى أن يأتي وع اء يش عر ب ه الحس اس ‪ S1‬فيتوق ف الس ير ‪K1‬‬
‫ويعمل السير العلوي ‪ K2‬فتتساقط قطع الشمع ويشعر بها الحساس ‪ S2‬إلى أن يتم تعبئة ‪ 24‬قطعة شمع فيتوقف حينها السير‬
‫‪ K2‬وبعد زمن يعمل السير السفلي ‪ K1‬ويتحرك الوعاء ويأتي وعاء آخر فيتوقف السير السفلي ‪ K1‬مرة أخ ري إلى أن‬
‫تتم التعبئة مرة أخري وهكذا‪.‬‬

‫‪23‬‬
 PLC Basics
Introduction
Programmable Logic Controller (PLC) definition

PLC Siemens
 S7-200 (Compact)
 S7-1200 (Compact)
 S7-300 and S7-400 (Modular)
PLC Hardware
 CPU
 Memory
 I/P & O/P Ports
 Connection Ports
 Power Supply (if existed)
PLC Software
 Programs

PLC Advanced
24
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