MID-TERM REPORT

On
“SOFTWARE & INDUSTRIAL TRAINING”
At INFOWIZ, Chandigarh

Submitted in partial fulfilment of the requirement for the award of the degree of

Bachelor of Technology

In

Electrical Engineering

IK GUJRAL PUNJAB TECHNICAL UNIVERSITY

Submitted To : DR. AKHIL GUPTA Submitted by: Adarsh Kumar

ASSISTANT PROFESSOR Roll No. 2022633

Adarsh Kumar (2022633)

 DECLARATION

I hereby declare that the work entitled (“PLC AND SCADA”) is an authentic record of my own
work carried out at Infowiz Industry Pvt. Ltd. as requirement of training for the award of degree
of B.-Tech. (Electrical Engineering) IKGPTU under the guidance of Er. Amit Solanki, during
Jan- June 2023).

(Signature of student)

Date: ___________________

Certified that the above statement made by the student is correct to the best of our knowledge and
belief.

---------------
Assistant Professor
Training Coordinator

Adarsh Kumar (2022633)

 ABSTRACT

• It is a great pleasure for me to present the following mid-term report on my

industrial training otherwise one seldom gets the chance to go for the
industrial training. It outlines the course of my job details during my training
period of 6 Months at Infowiz Industry PVT. LTD.

• The training report consists of the various instructions used in the PLC
programming, various examples on ladder logic, using PLC and SCADA.

• Adequate layouts & diagrams have been provided for more

descriptive outlook & better clarity of understanding. All in I have
tried to provide the best from me in presenting this volume on my
training at Infowiz Industry Pvt. Ltd. in a very precise manner.

• However any suggestions & comments on this volume will be

gratefully accepted.

Adarsh Kumar (2022633)

 ACKNOWLEDGEMENT

First of all I would like to thank the Almighty, who has always guided me to work on the right
path of the life. I acknowledge with deep sense of gratitude and most sincere appreciation, the
valuable guidance and unfailing encouragement rendered to me by “Er. Amit Solanki” (Training
guide) for his proficient and enthusiastic guidance, useful encouragement and immense help. I
have been deep sense of admiration for them inmate goodness and inexhaustible enthusiasm.

I wish to extend my sincere gratitude to “DR. Y.S BRAR (HOD, EE) and faculty DR. AKHIL
GUPTA of EE Department ” for their guidance, encouragement and valuable suggestions which
proved extremely useful and helpful in completion of this industrial training.

My heartfelt gratitude and indebtness goes to all teachers and guidance group who with their
encouraging, caring words, constructive criticism and segmentation have contributed directly or
indirectly in a significant way towards completion of this training. My special thanks go to my
friends whose support and encouragement have been a constant source of assurance, guidance,
strength, and inspection to me.

I am immensely grateful to my parents, my family. They have always supported me and taught me
the things that matter most in life. I am proudly grateful to all of them.

Date:
Adarsh Kumar
(2022633)

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 S.No. Contents Page No.

1 Introduction 1-2

2 Literature Review 2-3

3 Problem Formulation 4

4 Method-logy 5-39

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 List of Figures:

Figure1: Connections of trainer kit using micrologix 1000

Figure2: Programmable logic controller (PLC)
Figure3: Architecture of PLC
Figure4: Parts of PLC
Figure5: PLC Pin Diagram
Figure6: Simple ladder logic
Figure7: PLC Trainer Kit
Figure8: RS Linx classic window

Figure9: RS WHO window

Figure10: RS Logix 500 window

Figure11: Latch output and Unlatch output

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 1. INTRODUCTION

The aim of this project is to design a PLC (Programming Logic Controller) Training kit that helps
to study about the basic programming and wiring of PLC. It also includes programming logics like
start stop, timer and logic gates.

• A Programmable Logic Controller, PLC or Programmable Controller is a digital computer

used for automation of electromechanical processes, such as control of machinery on factory
assembly lines.
• The abbreviation "PLC" and the term "Programmable Logic Controller" are registered trademarks
of the Allen-Bradley Company.
• Programmable logic controller (PLC) is a digital electronic device that uses a programmable
memory to store instruction and to implement specific functions such as logic, sequence, timing,
counting and arithmetic to control machines and process.
• PLCs are used in many industries and machines. Unlike general-purpose computers, the PLC is
designed for multiple inputs and output arrangements, extended temperature ranges, immunity to
electrical noise, and resistance to vibration and impact.
• A PLC is an example of a hard real time system since output results must be produced in response
to input conditions within a limited time, otherwise unintended operation will result
• PLC began in the 1970s, and has become the most common choice for manufacturing controls.
• “MODICON” was the first company of PLC.
• Software used in PLC is RsLogix 500.

The project also include the basic study of ladder logic (Programming Language).

Commonly, the language or command for PLC designing base on the ladder
logic diagram. There have numerical of symbol that have been used to developed the ladder logic
diagram which every symbols represent the different functions.

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 2. LITERATURE SURVEY

PLC Control Engineering has evolved over time. In the past humans was the main method for
controlling a system.

More recently electricity has been used for control and early electrical control was based on relays.
These relays allow power to be switched on and off without a mechanical switch. It is common to
use relays to make simple logical control decisions.

So, before the PLC, control, sequencing, and safety interlock logic for manufacturing automobiles
was accomplished using hundreds or thousands of relays, cam timers, and drum sequencers and
dedicated closed-loop controllers. The process for updating such facilities for the yearly model
change-over was very time consuming and expensive, as the relay systems needed to be rewired
by skilled electricians.

Then came the digital computers. The development of low cost computer has brought the most
recent revolution, the Programmable Logic Controller (PLC).

In 1968 GM Hydromantic (the automatic transmission division of General Motors) issued a request
for proposal for an electronic replacement for hard-wired relay systems.

The winning proposal came from Bedford Associates of Bedford, Massachusetts. The first PLC,
designated the 084 because it was Bedford Associates' eighty-fourth project, was the result.
Bedford Associates started a new company dedicated to developing, manufacturing, selling, and
servicing this new product: Modicum, which stood for Modular Digital Controller. One of the
people who worked on that project was Dick Morley, who is considered to be the "father" of the
PLC. The Modicum brand was sold in 1977 to Gould Electronics, and later acquired by German
Company AEG and then by French Schneider Electric, the current owner.

One of the very first 084 models built is now on display at Modicum’s headquarters in North
Andover, Massachusetts. It was presented to Modicum by GM, when the unit was retired after
nearly twenty years of uninterrupted service. Modicum used the 84 moniker at the end of its
product range until the 984 made its appearance.

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Early PLCs, up to the mid-1980s, were programmed using proprietary programming panels or
special-purpose programming terminals, which often had dedicated function keys representing the
various logical elements of PLC programs. Programs were stored on cassette tape cartridges.
Facilities for printing and documentation were very minimal due to lack of memory capacity. The
very oldest PLCs used non-volatile magnetic core memory.

Now a day’s PLC Kit is available which is used for the programming of PLC. The abbreviation
"PLC" and the term "Programmable Logic Controller" are registered trademarks of the Allen-
Bradley Company. The first PLC training kit was manufactured by by Allen Bretly Company.

But these training kits are very costly. So, we have decided to make a basic PLC training kit which
is cost effective. The PLC training kit is not made by anyone before in our college. Also, PLC not
being in our syllabus, we want to make the students aware of the component and give the basic
knowledge about is, as automation is a booming industry these days.

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 3. PROBLEM FORMULATION

• We were able to learn the wiring, the connections, the programming

language (ladder language) and implement various applications using this
language.

• Also this training kit is the best training kit for a beginner.

• PLC not being in our syllabus was altogether a new thing to learn. So, we
wanted the other students to have a overview about this concept so that they
can learn a new thing n might have interest in learning more about PLC.

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 4) METHODLOGY

PROGRAMMABLE LOGIC CONTROLLER

Automation of many different processes, such as controlling machines, basic relay control,
motion control, process control is done through the use of small computers called a
programmable logic controller (PLC). This is actually a control device that consists of a
programmable microprocessor, and is programmed using a specialized computer language.

A programmable logic controller (PLC) or programmable controller is a digital computer

used for automation of electromechanical processes, such as control of machinery on factory
assembly lines, amusement rides, or lighting fixtures. PLC’s are used in many industries and
machines, such as packaging and semiconductor machines. Unlike general-purpose computers,
the PLC is designed for multiple inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact. Programs to control machine
operation are typically stored in battery-backed or non-volatile memory. A PLC is an example of
a real time system since output results must be produced in response to input conditions within a
bounded time, otherwise unintended operation will result.

A modern programmable logic controller is usually programmed in any one of several languages,
ranging from ladder logic to Basic or C. Typically, the program is written in a development
environment on a personal computer (PC), and then is downloaded onto the programmable logic
controller directly through a cable connection. Programmable logic controllers contain a variable
number of Input/output (I/O) ports the programmable logic controller circuitry monitors the
status of multiple sensor inputs, which control output

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 Figure2: Programmable logic controller (PLC)

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 ARCHITECTURE OF PLC

Figure3: Architecture of Plc

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 PARTS OF PLC

POWER SUPPLY: PLC requires 24V switch mode power supply for its operation.

MCU: Its full form is microcontroller unit. It is the processor of PLC. It is basically the brain of
PLC. It performs various control operations of PLC.

INPUTS AND OUTPUTS: PLC has a set of isolated inputs and isolated outputs. Different PLC’s
have different number and different type of inputs and outputs. Like in Micrologix 1000 we have
total number of 6 inputs and 4 outputs whereas in Micrologix 1100 we have 10 inputs and 6
outputs.

EXPANSION PORT: In PLC there is an expansion port which is used for the addition of any
other equipment with PLC. For example analog cards.

MEMORY MODULE: The memory module in PLC is used for the storage of program in PLC
for future use.

COMMUNICATION PORT: The communication ports are used in PLC to communicate with
the computer. In PLC there are two types of communication ports i.e. RS 232 comport and Ethernet
port.

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 PIN DIAGRAM:-

Figure:- Pin Diagram Of PLC

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 INPUTS AND OUTPUTS OF PLC
PLC programs are made up of a combination of the "gates" together with inputs, outputs, timers,
counters, internal memory bits, analog inputs, analog outputs, mathematical calculations,
comparators etc.

INPUTS
These are the physical connections from the real world to the PLC. They can be limit switches,
push buttons, and sensors, anything that can "switch" a signal on or off. The voltages of these
devices are usually, but not always, 24 Volt DC. Manufacturers make inputs that can accept a
wide range of voltages both ac and dc. It should be remembered that an input will be ON, "status
1", when the voltage is present at the input connection and OFF, "status 0", when the voltage is
no longer present at the input connection.
TYPES OF INPUTS OF PLC:-
USER TYPE: These are the inputs and outputs that are physically present and are practical to
the inputs and outputs of the PLC.
BIT TYPE: These are the inputs and outputs that are not physically present and are functional in
the PLC only. These inputs/outputs are basically used to drive each other in the ladder logic
programming.

• XIC (Examine if closed):

• XIO (Examine if open):
• XIC (Examine if closed):

I/P O/P

0 0

1 1

• XIO (Examine if open):

I/P O/P

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 0 1

1 0

OUTPUTS

These are the connections from the PLC to the real world. They are used to switch solenoids,
lamps, contactors etc on and off. Again they are usually 24 Volt DC, either relay or transistor,
but can also be 115/220 Volt AC.

Expansion I/O modules

If an application requires more I/O than the built-in I/O provided by the MicroLogix 1100
controller, you can connect up to four 1762 expansion I/O modules to the MicroLogix 1100
controller to provide expanded I/O capacity. You can use digital and analog I/O modules in many
combinations. The current loading capacity of the controller’s built-in power supply may limit the
number of I/O modules that can be connected to the controller. MicroLogix 1100 expansion I/O
modules include an integral high-performance I/O bus. Software keying prevents incorrect
positioning within the system.

You may install expansion I/O modules to the right of the MicroLogix 1100 controller either on
a panel with two mounting screws or on a DIN rail. Each expansion I/O module includes finger-
safe terminal blocks for I/O wiring and a label to record I/O terminal designations.

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 PROGRAMMING OF PLC

PLC programs are typically written in a special application on a personal computer, and then
downloaded by a direct-connection cable or over a network to the PLC. The program is stored in
the PLC either in battery-backed-up RAM or some other non-volatile flash memory. Often, a
single PLC can be programmed to replace thousands of relays.

Under the IEC 61131-3 standard, PLCs can be programmed using standards-based programming
languages. A graphical programming notation called Sequential Function Charts is available on
certain programmable controllers.
Recently, the International standard IEC 61131-3 has become popular. IEC 61131-3 currently
defines five programming languages for programmable control systems: FBD (Function block
diagram), LD (Ladder diagram), ST (Structured text, similar to the Pascal programming language),
IL (Instruction list, similar to assembly language) and SFC (Sequential function chart). These
techniques emphasize logical organization of operations.
While the fundamental concepts of PLC programming are common to all manufacturers,
differences in I/O addressing, memory organization and instruction sets mean that PLC programs
are never perfectly interchangeable between different makers. Even within the same product line
of a single manufacturer, different models may not be directly compatible.
In Allen Bradley PLC’s the logic used for the programming is ladder logic. Ladder logic is a
programming language that represents a program by a graphical diagram based on the circuit
diagrams of relay-based logic hardware. It is primarily used to develop software for Programmable
Logic Controllers (PLCs) used in industrial control applications. The name is based on the
observation that programs in this language resemble ladders, with two vertical rails and a series of
horizontal rungs between them.

An argument that aided the initial adoption of ladder logic was that a wide variety of engineers
and technicians would be able to understand and use it without much additional training, because
of the resemblance to familiar hardware systems. This argument has become less relevant given
that most ladder logic programmers have a software background in more conventional

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programming languages, and in practice implementations of ladder logic have characteristics—
such as sequential execution and support for control flow features—that make the analogy to
hardware somewhat imprecise.

Ladder logic is widely used to program PLCs, where sequential control of a process or
manufacturing operation is required. Ladder logic is useful for simple but critical control systems,
or for reworking old hardwired relay circuits. As programmable logic controllers became more
sophisticated it has also been used in very complex automation systems.

Figure6: Simple ladder logic

The language itself can be seen as a set of connections between logical checkers (contacts) and
actuators (coils). If a path can be traced between the left side of the rung and the output, through
asserted (true or "closed") contacts, the rung is true and the output coil storage bit is asserted (1)
or true. If no path can be traced, then the output is false (0) and the "coil" by analogy to
electromechanical relays is considered "de-energized". The analogy between logical propositions
and relay contact status is due to Claude Shannon.

Ladder logic has contacts that make or break circuits to control coils. Each coil or contact
corresponds to the status of a single bit in the programmable controller's memory. Unlike
electromechanical relays, a ladder program can refer any number of times to the status of a single
bit, equivalent to a relay with an indefinitely large number of contacts.

So-called "contacts" may refer to physical ("hard") inputs to the programmable controller from
physical devices such as pushbuttons and limit switches via an integrated or external input module,

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or may represent the status of internal storage bits which may be generated elsewhere in the
program.

Each rung of ladder language typically has one coil at the far right. Some manufacturers may allow
more than one output coil on a rung.
--( )-- a regular coil, energized whenever its rung is closed
--(\)-- a "not" coil, energized whenever its rung is open
--[ ]-- A regular contact, closed whenever its corresponding coil is energized

--[\]-- A "not" contact, open whenever its corresponding coil is energized.

The "coil" (output of a rung) may represent a physical output which operates some device
connected to the programmable controller, or may represent an internal storage bit for use
elsewhere in the program.

Figure7: PLC Trainer Kit

The above figure shows the view of PLC trainer kit. On this kit various operations performed. It
has following components mounted:

PLC MicroLogix1000

SMPS (220V AC-24V DC)

A Contactor Relay

An Electromechanical Relay

Normally open Switch (4)

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Normally closed Switch (4)

Output LED’s (4)RS 232 Comport for communication with PC.

COMMUNICATION OF PLC WITH PC

To make communication of PLC with PC following steps are noted down:

• Connect PC and PLC via RS232 comport or Ethernet.

• Then click on RS Linx icon, a window will appear as shown in fig below:-

• In this window add drivers i.e. whether it is RS232 comport or Ethernet and configure the
drivers and closes the window.
• Then click on icon RS who on the RS Linx classic window, another window will appear
as shown in fig:-

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 • After opening the RS who window click on AB DF1-1 DH-485, the PLC is running is
shown on the window. Then close this window and double click on RS Logix 500 starter.

Figure9: RS WHO window

• When we double click on RS Logix 500 starter a window will appear as shown in fig.

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 Figure10: RS Logix 500 window

PLC INSTRUCTIONS
There are various instructions which are useful for making ladder logic for PLC programming.
These are as follows:

• XIC (Examine if closed):

Use the XIC instruction in your ladder program to determine if a bit is ON. When the instruction
is executed, if the bit addressed is on (1), then the instruction is evaluated as true. When the
instruction is executed, if the bit addressed is off (0), then the instruction is evaluated as false.

• XIC (Examine if closed):

I/P O/P

0 0

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 1 1

Examples of devices that turn on or off include:

• A push button wired to an input (addressed as I:0/4).
• An output wired to a pilot light (addressed as O:0/2).
• A timer controlling a light (addressed as T4:3/DN).

• XIO (Examine if open):

Use the XIO instruction in your ladder program to determine if a bit is OFF. When the
instruction is executed, if the bit addressed is off (0), then the instruction is evaluated as true.
When the instruction is executed, if the bit addressed is on (1), then the instruction is evaluated
as false.

• XIC (Examine if open):

I/P O/P

0 1

1 0

Examples of devices that turn on or off include:

• Motor overload normally closed (N.C.) wired to an input (I:0/10).
• An output wired to a pilot light (addressed as O:0/4).
• A timer controlling a light (addressed as T4:3/DN).

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 •
• Output Energize (OTE):
Use the OTE instruction in your ladder program to turn on a bit when rung conditions are
evaluated as true. An example of a device that turns on or off is an output wired to a pilot light
(addressed as O:0/4).

OTE instructions are reset when:

• The SLC enters or returns to the REM Run or REM Test mode or
Power is restored.
• The OTE is programmed within an inactive or false Master Control
Reset (MCR) zone.

• Output\t Latch (OTL) and Output Unlatch (OTU):

OTL and OTU are retentive output instructions. OTL can only turn on a bit, while OTU can only
turn off a bit. These instructions are usually used in pairs, with both instructions addressing the
same bit. Your program can examine a bit controlled by OTL and OTU instructions as often as
necessary.

Figure11: Latch output and Unlatch output

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