EX 512 Control System Lab Manual
EX 512 Control System Lab Manual
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Experiment No: 01
2. APPARATUS REQUIRED:
Theory:
The Transistor can act as a switch. To operate the transistor as a switch, it has to be
operated in saturation region for ON state and to be operated in cut off region
for OFF state.
Power BJT has 3 terminals — collector, base and emitter. It is a current controlled
device. It is the base current that controls the device
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Insulated Gate Bipolar Transistor (IGBT) has 3 terminals — Collector, Emitter
and Gate. It is also a voltage controlled device. It is the gate voltage that controls
the device.
Procedure:
CONCLUSION:
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Experiment No: 02
2. APPARATUS REQUIRED:
SI.No Apparatus Specification Quantity
1 SCR Kit 1
2 Voltmeter 0- 50V DC 1
3 Ammeter 0-500 mA DC 1
4 Ammeter 0-25mA DC 1
5 Resister 100omh 1
6 Patch cards - As per required
3. THEORY:
Reverse Blocking Mode: When cathode is made positive with respect to anode
with switch S open, Fig. (a), thyristor is reverse biased. Junctions J1 J3 are seen to
be reverse biased whereas junction J2 is forward biased. The device behaves as if
two diodes are connected in series with reverse voltage applied across them. A
small leakage current of the order of a few mill amperes (or a few microamperes
depending upon the SCR rating) flows. This is reverse blocking mode, called the
off-state, of the thyristor. If the reverse voltage is increased, then at a critical
breakdown level, called reverse break-down voltage VBR, an avalanche occurs at
J1 and J3 and the reverse current increases rap-idly. A large current associated with
VBR gives rise to more losses in the SCR. This may lead to thyristor damage as
the junction temperature may exceed its permissible temperature rise. It should,
therefore, be ensured that maximum working reverse voltage across a thyristor
does not exceed VBR. When reverse voltage applied across a thyristor is less than
VBR, the device offers high impedance in the reverse direction. The SCR in the
reverse blocking mode may therefore be treated as an open switch.
Note that V-I characteristic after avalanche breakdown during reverse blocking
mode is applicable only when load resistance is zero, Fig.(b). In case load
resistance is present, a large anode current associated with avalanche breakdown at
VBR would cause substantial voltage drop across load and as a result, V-I
characteristic in third quadrant would bend to the right of vertical line drawn at
VBR.
Forward Blocking Mode: When anode is positive with respect to the cathode,
with gate circuit open, thyristor is said to be forward biased. It is seen from this
figure that junctions J1, J3 are forward biased but junction J2 is reverse biased. In
this mode, a small current, called forward leakage current, flows. In case the
forward voltage is increased, then the reverse biased junction J2 will have an
avalanche breakdown at a voltage called forward break over voltage VB0. When
forward voltage is less than VBO, SCR offers high impedance. Therefore, a
thyristor can be treated as an open switch even in the forward blocking mode.
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Power Supply Module
This module is used to provide the required power to the whole PLC system. It converts
the available AC power to DC power which is required by the CPU and I/O module. PLC
generally works on a 24V DC supply. Few PLC uses an isolated power supply.
CPU reads the input data from sensors, processes it, and finally sends the command to
controlling devices. DC power source, as mentioned in the previous discussion is
required voltage signals. CPU also contains other electrical parts to connect cables used
by other units.
The output module of PLC works similarly to the input module but in the reverse process.
It interfaces the output load and processor. So here the first section would be logic
session and the power section comes next. The working of the output module is shown in
the below figure
PLC Output Module
Digital Input – DI
Digital Output – DO
Analogue Input – AI
Analogue output – AO
Apart from this, there are various other I/O types which are not discussed in this
article.Difference between DI, DO, AI and AO
Digital Input – DI
Digital inputs are binary inputs (0 or 1) that are applied to the PLC. Binary inputs are
basically voltages, varying from 5V to 230V depending upon the type of card used. In
simple words, any push-button, switches or sensors produces digital inputs to a PLC.
Digital inputs are used to check the status of any devices whether it is ON or OFF. For an
Input module of 24Vdc, 0Vdc acts as OFF state (Binary 0) and 24Vdc acts as ON state
(Binary 1).
Digital Output
Digital outputs are binary outputs (0 or 1) from the PLC. It is a processed control output
from the PLC to the field. It is used to ON or OFF any piece of field equipment. DO is
like a contact of a relay when the preprogrammed conditions are satisfied the contacts are
closed. DO can be used to operate solenoid valves, relays, indicating lamps or as a
command to any other devices.
Analog Input – AI
Analog input is a continuous input from the field to the PLC. Unlike digital signals, is not
a constant voltage signal. It can vary depending on the field conditions. The commonly
used analogue signals are 4-20mA signal and 0-10Vdc Signal. Depending on the field
conditions the input signal can vary between 4-20mA or 0-10Vdc. For Example, if you
are monitoring a pressure of water flowing through a pipe using a pressure transmitter of
range 0-10 Bar, the transmitter will give a signal between 0 and 10V proportional to the
pressure in the pipe.
Analog Output
Analogue output is a continuous output from PLC to the field devices. For example, if
you have a variable frequency drive and you want to give a speed reference signal to it
you can use analogue output. Otherwise, if you are measuring the pressure using
analogue input as explained above and you would like to display it on an analogue meter
you can use an analogue output of PLC.
Execute the different Ladder Diagrams
Execute Ladder diagrams for different Logical Gates
Equipment
1. NOT GATE
In electronics, NOT GATE is also called an ‗Inverter‘ or ‗Buffer‘.
Working: NOT gate works as inversion. It takes one input and gives one output.
When the input is high then the output is low and vice-versa.
Input Output
(I1) (Q1)
0 1
1 0
NOT Gate in PLC programming:
In the case of PLC ladder, there will be a push button to provide input. When (I1)
is pressed then the coil (Q1) is on. And when Input (I1) is released then coil( Q1 is
off.
Symbolic Representation.
2. AND GATE
Working: In AND Gate, when both inputs (I1 and I2) are high then the output
(Q1) will be high. For all other inputs, output (Q1) will be the low.
0 0 0
0 1 0
1 0 0
1 1 1
3. OR GATE
Working: If both inputs are low in the OR gate, then the output will be low. For
all other cases, the output will be high.
0 0 0
0 1 1
1 0 1
1 1 1
In the above circuit diagram, switch (I1) is pressed then the coil (Q1) will be
energized. After releasing switch (I1), the energizing coil (Q1) is providing supply
to switch (I2). Then switch (I2) will become automatically activated.
4. NAND GATE
NAND gate is operated as an AND gate and followed by the inverter.
Working: In NAND Gate, the output will be low when both inputs are high. For
all other cases, the output will be high.
0 0 1
0 1 1
1 0 1
1 1 0
5. NOR GATE
NOR Gate is operated OR Gate followed by the NOT Gate.
When both inputs are low then the output will be high. Otherwise, the low output
will occur if both inputs are high.
0 0 1
0 1 0
1 0 0
1 1 0
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Symbolic Representation as,
6. EX-OR GATE
Working: If both inputs are high or low, the output will become low. For any
other input condition, the output will be high.
0 0 0
0 1 1
1 0 1
1 1 0
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Symbolic Representation as,
7. EX-NOR GATE
Working: When both inputs (I1 and I2) are high or low then the output will high.
If anyone input is high or low then the output will become low.
0 0 1
0 1 0
1 0 0
1 1 1
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Symbolic Representation as,
Procedure:
Conclusion:
This is all about different logic gates using PLC ladder programming. As well
as PLC programming rules and programming instructions are also important for
writing the program.
AIM: To differentiate the usage of the timer and counter in Ladder Diagram.
Equipment
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1) Computer with SIMATIC software.
2) Siemens S7-1200 PLC.
3) LEDs.
4) Switches.
5) Connecting wires
THEORY
TIMERS
On-Delay Timer The On-Delay Timer (TON) instruction counts time when the
enabling input is ON. When the current value (Txxx) is greater than or equal to the
present time (PT), the timer bit is ON. The On-Delay timer current value is cleared
when the enabling input is OFF. This timer continues counting after the Preset is
reached, and it stops counting at the maximum value of 32767.
The timer shown in figure will delay for 1000*1ms= 1000ms = 1 second then it
will be activated ON. Here when you activate the input I0.0, the timer T37 starts
delaying time, until it reaches 1000ms, then T37 bit turns ON, hence Q0.0 will be
ON. As a result Q0.0 will be activated after 1 second activating I0.0.
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Off-Delay Timer
The Off-Delay Timer (TOF) is used to delay turning an output OFF for a
fixed period of time after the input turns OFF. When the enabling input turns
ON, the timer bit turns ON immediately, and the current value is set to 0.
When the input turns OFF, the timer counts until the elapsed time reaches the
preset time. When the preset is reached, the timer bit turns OFF and the current
value stops counting. If the input is OFF for a time shorter than the preset
value, the timer bit remains ON. The TOF instruction must see an ON to OFF
transition to begin counting.
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(Ladder logic diagram for off-delay timer. The timing diagram)
COUNTER
Count Up Counter
The Count Up (CTU) instruction counts up from the current value each time
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the count-up input CU makes the transition from off to on. When the current
value (Cxxx) is greater than or equal to the Preset Value (PV), the counter bit
(Cxxx) turns on. The counter is reset when the Reset (R) input turns on, or
when the Reset instruction is executed. The counter stops counting when it
reaches the maximum value (32,767).
Counter ranges: Cxxx=C0 through C255
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PROCEDURE:
1. Turn the PC ON.
2. Turn the PLC ON.
3. Start V4.0 STEP 7 Micro WIN SP5.
4. Select View>>Ladder.
5. Form Bit Logic double, click the normally open contact.
6. Click on the red question marks, and rename the normally open contactor with
a physical input name, I0.0- I0.7 or I1.0-I1.5, let us say I0.0.
7. Now from the Bit Logic, double click the output, and name it with a physical
output name, Q0.0-Q0.7 or Q1.0-Q1.1, let us say Q0.0, the result rung will be
as shown in the next figure.
8. Select PLC>>Compile All; make sure that the "Total Errors" is zero.
9. Select PLC>>STOP to place the PLC in the stop mode.
10. To download the ladder diagram to the PLC, click download (shown to the
right), the window for downloading appears then click to download.
11. Now place the PLC in the run mode, by selecting PLC>>RUN.
12. Now the PLC is ready for use performing the function of the ladder diagram
that you have drawn.
Conclusion:
This is all about different timer and counter using PLC ladder programming.
As well as PLC programming rules and programming instructions are also
important for writing the program.
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Execute the Ladder Diagrams with model applications (i) DOL starter
(ii)Star- Delta starter
AIM: Execute the Ladder Diagrams with model applications (i) DOL starter
(ii)Star- Delta starter
THEORY
Star Delta Motor Starter
The following figure shows the winding connections in star and delta configuration
one by one.
It can be seen that in star connection, one end of all three windings are shorted to
make star point while other end of each winding is connected to power supply.
In delta configuration, the windings are connected such that to make a close loop.
The connection of each winding is shown in above figure. In actual motor the three
phase connections are provided in the following order as shown
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So in order to make winding connection in star and delta style in practical motor,
the connection is shown above.
Main contractor is used to supply power to the windings. It must be turned on all
the time. Initially the star contactor is closed while delta contactor is open It makes
the motor windings in star configuration.
The contactors are controlled by using PLC. The following section of PLC
tutorial will explain the ladder programming for star delta motor starter.
PROCEDURE
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PLC Ladder Logic
The main contactor depends upon the normally open input start push button (I1),
normally closed stop button (I2) and normally closed overload relay.
It means that Main contactor will only be energized if start button is pressed, while
stop is not pressed and overload relay is not activated. A normally open input
named (Q1) is added in parallel to the start button I1.
By doing so, a push button is created which means that once motor is started, it
will be kept started even if start button is released
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Rung 2 Star contactor:
Star contactor depends upon main contactor, normally close contacts of timer (T1),
and normally close contacts of output delta contactor (Q3).
So star contactor will only be energized if main contactor is ON, time output is not
activated and delta contactor is not energized.
Timer T1:
Timer T1 measures the time after which the winding connection of star delta starter
is to be changed. It will start counting time after main contractor is energized.
Delta contactor will be energized when main contactor (Q1) is energized, timer T1
is activated and star contactor (Q3) is de-energized.
Also see Programming of push button and other requirements for simple motor
starter is explained in PLC Tutorial: Motor starter
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PROCEDURE
START push button for starting of the starter
STOP push button to stop the circuit
CONTACTOR for holding
When START push button is pressed contactor will be ON and it starts until the
STOP push button is not pressed. When we have pressed the start push button the
contactor NO behind the start push button holds the circuit. STOP push button is
pressed the CONTACTOR will be OFF untill START button is not pressed again.
We can also made this program using latching here is the ladder diagram of dol
starter using latching.
CONCLUSION:
This is all about the Ladder Diagrams with model applications (i) DOL starter
(ii)Star- Delta starter.
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Execute Ladder diagrams with model applications (i) Stair case lighting (ii)
Traffic light controller
AIM: Execute Ladder diagrams with model applications Stair case lighting.
Equipment:
I0.0 & I0.1: Input toggle switches.
Q0.0: Output signaling device.
THEORY;
This ladder logic of stair-case wiring works on the X-OR logic i.e.Y is (A.B^) +
(A^. B)
Suppose initially only I0.0 is pressed and I0.1 remains open physically as shown
then the upper branch of rung 1 goes TRUE and Q0.0 gets energized.
Now, if I0.0 is also pressed then it will make its interlock N-C contact I0.1 to go
open and as a result Q0.0 de-energizes .
Again, if switch I0.0 is pressed it will also make its interlock contact I0.0 in
parallel branch to go again N-C, which in turn makes the parallel branch logic true
and Q0.0 again energizes but if the I0.1 input is also pressed again the logic goes
FALSE and Q0.0 again de-energizes. This is the basic concept of an X-OR logic
gate.
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PROCEDURE:
For this application, we used S7-1200 PLC and TIA portal software for
programming.
In above program, we have added two NO contacts of SW 1 (I0.1) and SW 2
(I0.2) in series and NC contacts of SW1 (I0.1) and SW2 (I0.2) in parallel of
this series SW1 & SW2 NO Contacts.
If the status of the bottom switch (SW1) and status of the top switch (SW2)
are same then lamp will be ON. And if either status of the bottom or top
switch is different from other then lamp (Q0.0) will be OFF.
When lamp (Q0.0) is OFF then user can ON the lamp by changing status of
any switch. Also user can turn OFF the lamp by changing the status of one of
the two switches.
List of inputs/outputs
Digital Inputs
SW1 : I0.1
SW2 : I0.2
Digital Outputs
Lamp : Q0.0
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Runtime Test Cases
CONCLUSION:
The above PLC Logic provided for basic idea about application of PLC for Stair
case lighting Two Way Switch Logic.
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AIM: PLC Program to Control Traffic Lights
Equipment:
1) Computer with SIMATIC software.
2) Siemens S7-1200 PLC.
3) LEDs.
4) Switches.
5) Connecting wires
THEORY:
We most often come across four way traffic jam in our city. This PLC
ladder logic gives the solution to control city traffic using
programmable logic control.
4 Way Traffic Light Control
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List of Inputs and Outputs
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13 O:0/9 West Green Output
Sequence of Operation
Below tabular column gives the Steps or sequence of outputs to turn ON the traffic
system lamps (RED, GREEN, YELLOW)
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PLC Ladder Logic
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PROCEDURE
RUNG000 again here is for Master Start and Stop the process.
File; #N7:0 and File length is 10, hence output sequence is varied
from N7:0 to N7:10 with each input.
Destination is set to O:2 hence with each transition, N7:0 to N7:10
are moved to O:2 with masking.
O:2/0 to O:2/5 are used as the output address to Traffic Lights and
hence Mask has value 003Fh which means data flow of
N7:0/0…N7:10/0 to N7:0/5…N7:10/5 is passed and the remaining
N7:0/6…N7:10/6 to N7:0/15…N7:10/15 are blocked.
Control parameters are assigned to register R6:0.
Sequence of traffic lights to be operated are stored in the registers
from N7:0 to N7:10 as following
Time base is set to 4secs, hence after every 4secs, output sequence
is changed to its next register pattern outputs which is then
transferred to O:2 and O:2/0 to O:2/5 are energized accordingly.
As we can see, from N7:1 to N7:4 have the same bit pattern. So,
these bits are set to 1 for 4 cycles that is 16secs. These bits are
used for South-North Green light and East-West Red light.
Similarly the entire sequence is followed.
When Stop I:1/1 is pressed, Position is reset to 0 and all the
outputs are de- energized.
Conclusion:
The above explained 4 ways traffic light control using PLC is for
example only. It may vary from real time. We can use this example
program to understand the working of timers and Interlocking function in
PLC.
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