A REPORT OF INDUSTRIAL TRAINING

At

Electronics service and training centre, Kaniya

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE

AWARD

OF THE DEGREE OF

BACHELOR OF TECHNOLOGY

Electronics and Communication Engineering

SUBMITTED BY

Rakesh Kumar Joshi

UNIVERSITY ROLL NO. : 180970102008

SUBMITTED TO : HARDEV SINGH PAL

THDC INSTITUTE OF HYDROPOWER ENGINEERING & TECHNOLOGY

TEHRI ,UTTRAKHAND,INDIA
(Uttarakhand Technical University, Dehradun)
2018-2022

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CERTIFICATE

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ACKNOWLEDGEMENT

The internship opportunity I had with Electronics and training centre, Kaniya (ESTC) was a
great chance for learning and professional development in electronics department. Therefore,
I consider myself as a very lucky individual as I was provided with an opportunity to be a
part of it. I am also grateful for having a chance to meet so many wonderful people and
professionals who led me though this internship period.

I express my deepest thanks to Mr Neeraj sir for teaching me and clearing all my doubts &
giving necessary advices and guidance and arranging all the facilities . I choose this moment
to acknowledge his contribution gratefully. I also express my thanks to for his kind support
during training.

I am sure that the knowledge & information that I have gained during this period would be of
immense value for my growth in the field of Electronics Engineering.

I am also thankful to my colleagues and friends who for their cooperation during the course
of my training. Last but not the least I would like to thank all of the staff members,
supervisors and workers for their help and co-operation during the training.

I perceive as this opportunity as a big milestone in my career development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives.

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 PREFACE

If you know the laws of buoyancy it doesn’t mean that you know how to swim. It is only
through jumping in the water that you get the feel of the depth. This is applicable to every
aspect of life. Therefore practical training is of utmost importance.

The object of undergoing this training was to get familiar with the weary waters of the
industry and to learn how to put theory into practice. I have been greatly privileged to have
undergone training at Electronics and training centre, Kaniya(ESTC).

I am very fortunate to have had a chance to feel the gravity of what role Electronics
Engineering plays in the industry. It was a golden opportunity for me to get a chance to
experience what it feels to be in a institute where discipline, quality and hard work are the
motto. This training helped me a lot in bridging the gap between the theoretical and the
practical aspects of my knowledge. This report contains the extract of things I learned during
my training period.

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 INDEX

Contents

CHAPTER 1: INTRODUCTION TO ORGANISATION...................................................8

1.1 ABOUT ESTC................................................................................................................8

1.2 AIMS AND OBJECTIVES............................................................................................8

CHAPTER 2: PROGRAMMABLE LOGIC CONTROLLER............................................9-23

2.1 INTRODUCTION.........................................................................................................9
2.2ADVANTAGES OF PLC...............................................................................................9-10

2.3BASIC COMPONENTS OF PLC.................................................................................10-12

2.4BASIC REQUIREMENTS............................................................................................13-16

2.5 TERMINOLOGY.........................................................................................................17-23

CHAPTER 3: PROGRAMMING IN PLC.........................................................................24-32

3.1 INTRODUCTION.........................................................................................................24

3.2Micro/WIN 32................................................................................................................24

3.3 SYMBOLS..................................................................................................................25-27

3.4. Bit logic......................................................................................................................27-29

3.5. TIMERS.......................................................................................................................30

3.6. COUNTERS................................................................................................................31-32

CHAPTER 4: CONCLUSION........................................................................................33

REFRENCES...................................................................................................................34

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 LIST OF FIGURES
Figure 1.1: Inputs and outputs of PLC...................................................................................9

Figure 2.1: Basic components of PLC...................................................................................12

Figure 2.2: Motor Starter Example........................................................................................13

Figure 2.3: Basic Requirements.............................................................................................14

Figure 2.4: SIEMENS S7-200 PLC.....................................................................................14

Figure 2.5 SIEMENS SIMATIC S7 programming device....................................................15

Figure 2.6: PC with STEP 7 Micro/WIN installed................................................................15

Figure 2.7: Programming device cable...................................................................................16

Figure 2.8 Sensor...................................................................................................................17

Figure 2.9 Actuators..............................................................................................................17

Figure 2.10 Discrete Input.....................................................................................................18

Figure 2.11Analog Input.......................................................................................................18

Figure 2.12:Discrete Output..................................................................................................19

Figure 2.13 Analog Output....................................................................................................19

Figure 2.14: CPU....................................................................................................................20

Figure 2.15: Firmware.............................................................................................................21

Figure 2.16: Ladder logic diagram..........................................................................................22

Figure 2.17: Functional Block Diagram..................................................................................23

Figure 3.1: Plc program software............................................................................................24

Figure 3.2: Micro/WIN............................................................................................................25

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Figure 3.3: Contacts................................................................................................................25

Figure 3.4: Coils.....................................................................................................................26

Figure 3.5: Boxes...................................................................................................................26

Figure 3.6: Entering Elements................................................................................................27

Figure 3.7: OR gate................................................................................................................27

Figure 3.8: AND gate.............................................................................................................28

Figure 3.9: NOT gate..............................................................................................................28

Figure 3.10: X-NOR gate.......................................................................................................28

Figure 3.11: NAND gate........................................................................................................29

Figure 3.12: NOR gate...........................................................................................................29

Figure 3.13: Traffic lights controller by plc...........................................................................30

Figure 3.14: Timers.................................................................................................................30

Figure 3.15: Counting of bottles.............................................................................................31

Figure 3.16 Counters...............................................................................................................32

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 CHAPTER 1: INTRODUCTION TO ORGANISATION

1.1 ABOUT ESTC

Electronics Service & Training Centre has been established as a Govt. of India, Society -
registered in April, 1986, under the Societies Registration Act. 1860. As per the Project
Document, the main objective of setting up this project is to develop human resources to meet
the essential requirements for transfer of technology in assembly and manufacturing of
electronics items and parts.

1.2 AIMS AND OBJECTIVES

 Training of the personnel in the areas of production and quality control for electronic
and I.T. industry.
 Providing common facilities to the entrepreneurs in the region.
 To render counselling and guidance to new entrepreneurs in setting up of small scale
electronics and I.T. units.
 To develop products and processes involving advanced technologies in industry.
 To evolve a consultancy cell for the small scale industries in the region.
 To establish Library-cum-Documentation Centre.
 To identify and promote ancillary industrial units for the large/medium enterprises in
the region.
 To conduct market research and development of the above products for domestic and
export markets.

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CHAPTER 2: PROGRAMMABLE LOGIC CONTROLLER

2.1 INTRODUCTION

A Programmable Logic Controller (PLC) also referred to as programmable controller is the

name given to a type of computer commonly used in commercial and industrial control
applications. PLCs differ from office computers in the types of tasks that they perform and
the hardware and software they require to perform these tasks. While the specific applications
vary widely, all PLCs monitor inputs and other variable values, make decisions based on a
stored program and control outputs to automate a process or machine.

Figure 1.1: Inputs and outputs of PLC

2.2ADVANTAGES OF PLC
 Easier and faster to make changes.
 Smaller physical size than hard wired system.
 Diagnostics are easily available.
 Applications can be immediately documented.
 Applications can be duplicated faster and less expensively.
 The program can be entered on the factory floor by anyone.

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  Designed for an electrically noisy environment no extra filtering is required.
 The program can be entered on the factory floor by anyone.
 Energy Saving
 Ease of Maintenance
 Economical
 Greater Life and Reliability
 Shorter Project Time

2.3. BASIC COMPONENTS OF PLC

The major components are

1. Power Supply module

2. Input module
3. Central processing unit
4. Output modules
5. Software

a) Power supply module:

Usually input output modules require 24V DC and processor require 5V DC. Usually power
supply is integral part of PLC. Power supply units convert 120/230 V AC line voltage to
standard supply of 24 VDC or 5V DC using standard rectifier circuits

b) Input module

Input devices include push buttons, sensors, potentiometers, pressure switches. The function
of the input module is to convert high voltages from input devices to low level logic voltages
that the CPU uses internally for processing.

Input module can process both analog input and digital input. Digital inputs are more
preferred in Industry.

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c) Analog input module

These are used to convert analog signal form analog devices like temperature
sensors, pressure sensors etc. to digital signals using ADC (Analog –to digital convertor).
Analog signal is varying voltage in the range of 0-12 V or current in the range of 5-20 mA.
These values of current or voltage is converted into integer value (say16 bit word)

Digital is used to convert signal digital input to 5V digital signals that CPU uses internally to
execute a user program.

d) Central processing unit

The central processing unit controls and processes all operations within the PLC and hence
called brain of the PLC. The CPU can perform various arithmetic and data manipulation
function with the local and remotely located Input/output sections.

Further, the processor can perform many communication functions it needs to interface with a
personal computer, remote Input/Output, other PLCs and peripheral devices

Functions of CPU are:

1. It receives input from various sensing devices and switches

2. It executes the user program
3. It makes various decisions to control the operation of the equipment or process
4. It can perform various arithmetic and data manipulation functions
5. It delivers corresponding output signals to various load control devices such as relay
coils and solenoids

e) Output module

Output devices include contactor coils, solenoid coils, lamps, etc. Output module amplifies
the low–level logic signals generated by the CPU and pass these modified signals to the final
control elements to operate the output devices.

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f) Software

PLC consists of two parts: Operating systems and user program. The PLC operating system
provides effective support ranging from the creation of project structure to the creation of
user programs. The OS system is accessed through a graphical user interface window ( also
known as Main window .User program can be written in any standard PLC programming
language like ladder diagram or statement list.

While processing a PLC program, the CPU scans and executes the main program cyclically;A
program scan cycle consists of sequential operations that include input scan, program scan,
and output scan. In the input scan, the CPU updates the process image input table, in the
output scan; the CPU updates the process image output table.

After the completion of each scan cycle, the CPU returns to the beginning of the next cycle
and again repeats the cycle. The time taken to scan one program is called scan –cycle time.

Figure 2.1: Basic components of PLC

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 In the simple example shown below, pushbuttons (sensors) connected to PLC inputs, are used
to start and stop a motor connected to a PLC output through a motor starter (actuator). No
programming device or operator interface are shown in this simple example.

Fig 2.2 Motor Starter Example

Figure 2.2: Motor Starter Example

2.4 BASIC REQUIREMENTS

The following items are needed to create or change a PLC program: PLC, programming
device, programming software, and connector cable

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 Figure 2.3: Basic Requirements

a) PLC: We used the S7-200 for specific examples of PLC concepts. The S7-200 is used
for this purpose because of its ease of use and wide-spread application.

Figure 2.4: SIEMENS S7-200 PLC

b) Programming Devices: The program is created in a programming device (PG) and then
transferred to the PLC. The program for the S7-200 can be created using a dedicated Siemens
SIMATIC S7 programming device, such as a PG 720 (not shown) or PG 740, if STEP 7
Micro/WIN software is installed.

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 Figure 2.5 SIEMENS SIMATIC S7 programming device

A personal computer (PC), with STEP 7 Micro/WIN installed, can also be used as a
programming device with the S7-200.

Figure 2.6 : PC with STEP 7 Micro/WIN installed

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c) Software A software program is required in order to tell the PLC what instructions it must
follow. Programming software is typically PLC specific. A software package for one PLC, or
one family of PLCs, such as the S7 family, would not be useful on other PLCs. The S7-200
uses a Windows based software program called STEP 7-Micro/WIN32. The PG 720 and PG
740 have STEP 7 software pre-installed. Micro/WIN32 is installed on a personal computer in
a similar manner to any other computer software.

d) Connector Cables PPI (Point-to-Point Interface):

Connector cables are required to transfer data from the programming device to the PLC.
Communication can only take place when the two devices speak the same language or
protocol. Communication between a Siemens programming device and the S7-200 is referred
to as PPI protocol (point-to point interface). An appropriate cable is required for a
programming device such as a PG 720 or PG 740. The S7-200 uses a 9-pin, D-connector.
This is a straight-through serial device that is compatible with Siemens programming devices
(MPI port) and is a standard connector for other serial interfaces.

Figure 2.7: Programming device cable

A special cable is needed when a personal computer is used as a programming device. Two
versions of this cable are available. One version, called an RS-232/PPI Multi-Master Cable,
connects a personal computer’s RS-232 interface to the PLC’s RS-485 connector. The other
version, called a USB/PPI Multi-Master Cable, connects a personal computer’s USB
interface to the PLC’s RS-485 connector.

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2.5 TERMINOLOGY

a) Sensors: Sensors are devices that convert a physical condition into an electrical signal for
use by the PLC. Sensors are connected to the input of a PLC. A pushbutton is one example of
a sensor that is connected to the PLC input. An electrical signal is sent from the pushbutton to
the PLC indicating the condition (open/closed) of the pushbutton contacts.

Figure 2.8 Sensor

b) Actuators : Actuators are devices that convert an electrical signal from the PLC into a
physical condition. Actuators are connected to the PLC output. A motor starter is one
example of an actuator that is connected to the PLC output. Depending on the output PLC
signal the motor starter will either start or stop the motor.

Figure 2.9
Actuators

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c) Discrete input :A discrete input, also referred to as a digital input, is an input that is
either on or off. Pushbuttons, toggle switches, limit switches, proximity switches, and contact
closures are examples of discrete sensors which are connected to the PLCs discrete or digital
inputs. In the ON condition a discrete input may be referred to as a logic 1 or a logic high. In
the OFF condition a discrete input may be referred to as a logic 0 or a logic low.

Figure 2.10 Discrete Input

d) Analog Input :An analog input is a continuous, variable signal. In the following example,
a level transmitter monitors the level of liquid in a tank. Depending on the level transmitter,
the signal to the PLC can either increase or decrease as the level in the tank increases.

Figure 2.11Analog Input

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e) Discrete Outputs : A discrete output is an output that is either on or off. Solenoids,
contactor coils, and lamps are examples of actuator devices connected to discrete outputs.
Discrete outputs may also be referred to as digital outputs. In the following example, a lamp
can be turned on or off by the PLC output it is connected to.

Figure 2.12:Discrete Output

f) Analog Outputs : An analog output is a continuous, variable signal. The output may be as
simple as a 0-10 VDC level that drives an analog meter. Examples of analog meter outputs
are speed, weight, and temperature. The output signal may also be used on more complex
applications such as a current-to-pneumatic transducer that controls an air-operated flow-
control valve.

Figure 2.13 Analog Output

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g) CPU: The central processor unit (CPU) is a microprocessor system that contains the
system memory and is the PLC decision-making unit. The CPU monitors the inputs, outputs,
and other variables and makes decisions based on instructions held in the program memory.
Typical CPU operations include relay, counting, timing functions, data comparison,
sequencing, and arithmetic operations.

Figure 2.14: CPU

h) Software: Software is the name given to computer instructions regardless of the

programming language. Essentially, software includes the instructions or programs that direct
hardware.

i) Hardware: Hardware is the name given to all the physical components of a system. The
PLC, the programming device, and the connecting cable are examples of hardware.

j) Memory size: Kilo, abbreviated K, normally refers to 1000 units. When talking about
computer or PLC memory, however, 1K means 1024. This is because of the binary number
system (210=1024). This can be 1024 bits, 1024 bytes, or 1024 words, depending on memory
type.

k) RAM: Random Access Memory (RAM) is memory where data can be directly accessed at
any address. Data can be written to and read from RAM. RAM is used as a temporary storage
area. RAM is volatile, meaning that the data stored in RAM will be lost if power is lost. A
battery backup is required to avoid losing data in the event of a power loss.

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l) ROM: Read Only Memory (ROM) is a type of memory that data can be read from but not
written to. This type of memory is used to protect data or programs from accidental erasure.
ROM memory is non-volatile. This means a user program will not lose data during a loss of
electrical power. ROM is normally used to store the programs that define the capabilities of
the PLC.

m) EPROM: Erasable Programmable Read Only Memory (EPROM) provides some level of
security against unauthorized or unwanted changes in a program. EPROMs are designed so
that data stored in them can be read, but not easily altered. Changing EPROM data requires a
special effort. UVEPROMs (ultraviolet erasable programmable read only memory) can only
be erased with an ultraviolet light. EEPROM (electronically erasable programmable read only
memory), can only be erased electronically.

n) Firmware: Firmware is user or application specific software burned into EPROM and
delivered as part of the hardware. Firmware gives the PLC its basic functionality.

Figure 2.15: Firmware

o) Programming: A program consists of instructions that accomplish one or more tasks. The
degree of complexity of the PLCs program depends upon the complexity of the task to be
performed, the number and type of input and output devices, and the types of instructions
used. Some PLC programs are made up primarily of ladder logic instructions, but other
approaches such as statement lists or function block diagrams are also common.

p) Ladder Logic: Ladder logic (LAD) is one programming language used with PLCs.
Ladder logic uses components that resemble elements used in a line diagram format to
describe hard-wired control.

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q) Ladder logic diagram: The left vertical line of a ladder logic diagram represents the
power or energized conductor. The output element or instruction represents the neutral or
return path of the circuit. The right vertical line, which represents the return path on a hard-
wired control line diagram, is omitted. Ladder logic diagrams are read from left-to-right, top-
to-bottom. Rungs are sometimes referred to as networks. A network may have several control
elements, but only one output coil.

Figure 2.16: Ladder logic diagram

In the example program shown example I0.0, I0.1 and Q0.0 represent the first instruction
combination. If inputs I0.0 and I0.1 are energized, output relay Q0.0 energizes. The inputs
could be switches, pushbuttons, or contact closures. I0.4, I0.5, and Q1.1 represent the second

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instruction combination. If either input I0.4 or I0.5 are energized, output relay Q0.1
energizes.

r) Functional block diagram: Function Block Diagrams (FBD) provide another view of a
set of instructions. Each function has a name to designate its specific task. Functions are
indicated by a rectangle. Inputs are shown on the left-hand side of the rectangle and outputs
are shown on the right-hand side. The function block diagram shown below performs the
same function as shown by the ladder diagram and statement list.

Figure 2.17: Functional Block Diagram

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CHAPTER 3: PROGRAMMING IN PLC

3.1 INTRODUCTION

STEP 7-Micro/WIN32 is the program software used with the S7-200 PLC to create the PLC
operating program. STEP 7 consists of a number of instructions that must be arranged in a
logical order to obtain the desired PLC operation. These instructions are divided into three
groups: standard instructions, special instructions, and high-speed instructions.

Figure 3.1: Plc program software

3.2Micro/WIN 32

The programming software can be run off-line or on-line. Off-line programming allows the
user to edit the ladder diagram and perform a number of maintenance tasks. The PLC does
not need to be connected to the programming device in this mode. On-line programming
requires the PLC to be connected to the programming device. In this mode, program changes
are downloaded to the PLC. In addition, status of the input/output elements can be monitored.
The CPU can be started, stopped, or reset.

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 Figure 3.2: Micro/WIN

3.3 SYMBOLS

The language of PLC ladder logic consists of a commonly used set of symbols that represent
instructions. Understanding the basic symbols is essential to understanding PLC operation.

a) Contacts: One of the most confusing aspects of PLC programming for first-time users is
the relationship between the device that controls a status bit and the programming function
that uses a status bit. Two of the most common programming functions are the normally
open (NO) contact and the normally closed (NC) contact. Symbolically, power flows
through these contacts when they are closed. The normally open contact (NO) is closed when
the input or output status bit controlling the contact is 1. The normally closed contact (NC) is
closed when the input or output status bit controlling the contact is 0.

Figure 3.3: Contacts

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b) Coils: Coils represent relays that are energized when power flows to them. When a coil is
energized, it causes a corresponding output to turn on by changing the state of the status bit
controlling that output to 1. That same output status bit may be used to control normally open
and normally closed contacts elsewhere in the program.

Figure 3.4: Coils

c) Boxes: Boxes represent various instructions or functions that are executed when power
flows to the box. Typical box functions are timers, counters, and math operations.

Figure 3.5: Boxes

d) Entering elements: Control elements are entered in the ladder diagram by positioning
the cursor and selecting the element from a list. In the following example the cursor has been
placed in the position to the right of I0.2. A coil was selected from a pull-down list and
inserted in this position.

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 Figure 3.6: Entering Elements

3.4. Bit logic

Figure 3.7: OR gate

27
Figure 3.8: AND gate

Figure 3.9: NOT gate

Figure 3.10: X-NOR gate

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 Figure 3.11: NAND gate

Figure 3.12: NOR gate

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3.5TIMERS

Timers are devices that count increments of time. Traffic lights are one example where
timers are used. In this example timers are used to control the length of time between signal
changes

Figure 3.13: Traffic lights controller by plc

Timers are represented by boxes in ladder logic. When a timer receives an enable, the timer
starts to time. The timer compares its current time with the preset time. The output of the
timer is a logic 0 as long as the current time is less than the preset time. When the current
time is greater than the preset time, the timer output is a logic 1. S7-200 uses three types of
timers: On-Delay (TON), Retentive On-Delay (TONR), and Off-Delay (TOF).

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a) ON delay Timer:When the On-Delay Timer (TON) receives an enable (logic 1) at its
input (IN), a predetermined amount of time (preset time - PT) passes before the timer bit (T-
bit) turns on. The T-bit is a logic function
Figureinternal to the timer and is not shown on the
3.14: Timers
symbol. The timer resets to the accumulated time to zero when the enabling input goes to a
logic 0.

b) Retentive On-Delay Timer (TONR) :The Retentive On-Delay Timer (TONR) functions
in a similar(TONR) manner to the On-Delay Timer (TON). Just like the On-Delay timer
(TON), the Retentive On-Delay Timer (TONR) times as long as the enabling input is on, but
does not reset when the input goes off. The timer must be reset with a RESET (R) instruction.

c) Off-Delay Timer (TOF):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 bit turns on, the
timer bit turns on immediately, and the time value is set to 0. When the input turns off , the
timer times until the preset time has elapsed. At that time, the timer bit turns off.

3.6. COUNTERS

Counters used in PLCs serve the same function as mechanical counters. Counters compare
an accumulated value to a preset value to control circuit functions. Counters can be used to
initial an operation when a count is reached or to prevent an operation from occuring until a
count has been reached.

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A bottling machine, for example, may use a counter to count bottles into groups of six for
packaging.

Figure 3.15: Counting of bottles

Counters are represented in an S7-200 program by boxes in ladder logic. Counters

increment or decrement one count each time the input transitions from off (logic 0) to on
(logic 1). Counters are reset when a RESET instruction is executed. S7-200 uses three types
of counters: Count Up Counter (CTU), Count Down Counter (CTD), and Count
Up/Down Counter (CTUD).

Count Up Counter (CTU) : The Count Up Counter (CTU) counts up from the current value
each time the count up (CU) input goes from off to on. When the current value is greater than
or equal to the preset value (PV), the counter bit for designated counter is a logic 1. The
course resets when the reset (R) input turns on. The counter stops counting when it reaches its
maximum value of 32,767.
Figure 3.16 Counters

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Count Down Counter (CTD): The Count Down Counter (CTD) counts down from the
current value each time the count down (CD) input goes from off to on. When the current
value is equal to zero, the counter bit for designated counter is a logic 1. The counter stops
counting at zero. The counter resets and loads the current value with the preset value (PV)
when the load input (LD) turns on.

Up/Down Counter (CTUD): The Count Up/Down Counter (CTUD) counts up each time the
(CTUD) count up (CU) input turns on and counts down each time the count down input (CD)
turns on. When the current value is equal to or greater than the preset value (PV), the counter
bit for the designated counter is a logic 1. Otherwise, the counter bit is a logic 0. If the count
reaches 32,767, the next count changes the current value to -32,768. The counter current
value is reset to zero when the reset (R) input turns or when the Reset instruction is executed

33
CHAPTER 4: CONCLUSION

During one month training period I have gained, a lot of experience, knowledge and exposure
. All disclosures were awaken myself in a boost of self-confidence to face life more
challenging now. Practical is a complement to the science or theory learned. This is clearly
the concept of science and charity, where they have learned without practice will be lost and
will not give anything . So if we do without the knowledge of course there will be problems
in terms of grip and stance ever - changing.
During my industrial training, there are many changes from the point of learning
environments and discussion among colleagues. It can directly increase the dedication and
rational attitude toward myself.
However, there are still some weaknesses that can be improved in the future. Therefore I
conclude that the industrial training program has provided many benefits to students even if
there are minor flaws that are somewhat disfiguring condition , so that this weakness can be
rectified in the future.
I can conclude that this industry is through training I received a lot of exposure in the
computing world. I would like to thank also ESTC Kaniya for giving students such a chance
to gain such knowledge .

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REFRENCES

 Basic of PLC programming industrial fall control 2006

 PLC S7 200 special catalo

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