Issue: 01

Revision: 02/10-01-2019
Code: SOP-M-01/04

INFINITY SCHOOL OF ENGINEERING

PLC Training Course

Short Course (06 Month)

Prepared by: Engr. Nouman Ali, Engr. M. Majid and Engr. Haroon Rasheed

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This Course Work is structured and prepared under supervision of Engr. Umer Ayyub
[Assistant Manager Maintenance, Infinity Engineering PVT Ltd.] by Engr. Muhammad
Majid and verified by Engr. Nouman Ali for the PLC Training Courses Arranged by
Infinity School of Engineering (a project of Infinity Group of Engineering and in
Collaboration with Ravi Group of industries PVT Ltd.)

All Rights Reserved by Infinity School of Engineering. Any violation in the copyrights shall
be subjected to penalty as per laws.

Compiler

Engr. Nouman Ali

BSc Electrical Electronics Engineering
The University of Faisalabad

www.infinity.edu.pk

18-KM Lahore Sheikhupura Road.

Lahore- Pakistan

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Table of Contents

1 OHS, 5s and Kaizen.................................................................................................................................10

1.1 Occupational Health..........................................................................................................................10
1.1.1 Introduction................................................................................................................................10
1.1.2 Hazard Identification.................................................................................................................10
1.1.3 Fire and Fire Extinguisher.........................................................................................................10
1.1.4 OHS and Safety Precaution.......................................................................................................10
1.1.5 Personal Protection Equipment..................................................................................................10
1.2 Occupational Health..........................................................................................................................10
1.2.1 Introduction................................................................................................................................10
1.2.2 Importance and Benefits............................................................................................................10
1.3 Kaizen...............................................................................................................................................10
1.3.1 Introduction................................................................................................................................10
1.3.2 Importance and Benefits............................................................................................................10
1.3.3 PDCA Cycle..............................................................................................................................10
2 PLC Fundamentals...................................................................................................................................11
2.1 PLC Hardware Handling...................................................................................................................11
2.1.1 Introduction................................................................................................................................11
2.1.2 Processor....................................................................................................................................11
2.1.3 Input and Output Modules.........................................................................................................11
2.1.4 Power Supply.............................................................................................................................11
2.1.5 Programming Unit.....................................................................................................................11
2.1.6 System Block Diagram..............................................................................................................11
2.2 PLC Software Handling....................................................................................................................11
2.2.1 Software Installation..................................................................................................................11
2.2.2 Software Operations..................................................................................................................11
2.3 Basic PLC Programming..................................................................................................................11
2.3.1 Load Normally Open and Close Contacts.................................................................................11

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2.3.2 Output coil and End instruction.................................................................................................11

2.3.3 Load Rising-Edge & Falling-Edge Pulse Contacts...................................................................11
2.3.4 SET & RESET Command.........................................................................................................11
2.3.5 Alternate Command (ALT).......................................................................................................11
2.3.6 Arithmetic Commands (16-Bit & 32-Bit)..................................................................................11
2.4 PLC Wiring and Symbols.................................................................................................................11
2.4.1 Basic Electric Wiring Symbols..................................................................................................11
2.4.2 Need of JIC Symbols.................................................................................................................11
2.4.3 Symbols used in PLC Programming..........................................................................................11
2.4.4 Relay Wiring..............................................................................................................................11
2.4.5 Timer Wiring.............................................................................................................................11
2.4.6 Concept of Sourcing and Sinking..............................................................................................11
2.4.7 PLC Wiring................................................................................................................................11
2.4.8 Proximity Sensors and Limit Switches Wiring.........................................................................11
3 Basic Logic Design..................................................................................................................................12
3.1 Number System.................................................................................................................................12
3.1.1 Decimal Number System...........................................................................................................12
3.1.2 Octal Number System................................................................................................................12
3.1.3 Binary Number System..............................................................................................................12
3.1.4 Hexadecimal Number System...................................................................................................12
3.1.5 Binary Coded Decimal Number System....................................................................................12
3.2 One’s and Two’s Complement.........................................................................................................12
3.2.1 One’s Complement....................................................................................................................12
3.2.2 Two’s Complement...................................................................................................................12
3.3 Conversions.......................................................................................................................................12
3.4 Gray Code.........................................................................................................................................12
3.4.1 Definition...................................................................................................................................12
3.4.2 Applications...............................................................................................................................12
3.5 Logic Gates.......................................................................................................................................12
3.5.1 Types of Logic Gates.................................................................................................................12
3.5.2 Universal Gates..........................................................................................................................12

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3.6 Boolean Algebra...............................................................................................................................12

3.6.1 Definition...................................................................................................................................12
3.6.2 Laws of Boolean Algebra..........................................................................................................12
3.7 Variable Reduction Using DE Morgan’s Laws................................................................................12
3.7.1 Boolean and DE Morgan Theorem............................................................................................12
3.8 Variable Reduction using Karnaugh’s Maps....................................................................................12
3.8.1 Introduction................................................................................................................................12
3.8.2 Rules for K-Maps......................................................................................................................12
3.8.3 Two Variable K-Map.................................................................................................................12
3.8.4 Three Variable K-Map...............................................................................................................12
3.8.5 Four Variable K-Map................................................................................................................12
4 Timers and Counters................................................................................................................................13
4.1 Introduction to Timers......................................................................................................................13
4.2 Timer Instruction...............................................................................................................................13
4.3 Timer Resolution...............................................................................................................................13
4.4 Types of Timers................................................................................................................................13
4.4.1 ON-Delay Timer........................................................................................................................13
4.4.2 OF-Delay Timer.........................................................................................................................13
4.5 Time Arithmetic Instruction..............................................................................................................13
4.5.1 Time Addition Instruction.........................................................................................................13
4.5.2 Time Subtraction Instruction.....................................................................................................13
4.6 RTC Instructions...............................................................................................................................13
4.6.1 Time Read Instruction...............................................................................................................13
4.6.2 Time Write Instruction..............................................................................................................13
4.6.3 Hour Meter Instruction..............................................................................................................13
4.7 Introduction to Counters...................................................................................................................13
4.8 Counters Instruction..........................................................................................................................13
4.9 Types of Counters.............................................................................................................................13
4.9.1 Up Counter.................................................................................................................................13
4.9.2 Up/Down Counter......................................................................................................................13
4.9.3 High Speed Counter...................................................................................................................13

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5 Advance PLC Programming....................................................................................................................14

5.1 Move Instructions.............................................................................................................................14
5.1.1 MOV Instruction........................................................................................................................14
5.1.2 SMOV Instruction.....................................................................................................................14
5.1.3 FMOV Instruction.....................................................................................................................14
5.1.4 BMOV Instruction.....................................................................................................................14
5.2 Rotation Instructions.........................................................................................................................14
5.2.1 Rotation Right Instruction.........................................................................................................14
5.2.2 Rotation Left Instruction............................................................................................................14
5.2.3 Rotation Right with Carry Instruction.......................................................................................14
5.2.4 Rotation Left with Carry Instruction.........................................................................................14
5.3 Bit-Wise Data Control......................................................................................................................14
5.3.1 Bit Shift Right Instruction.........................................................................................................14
5.3.2 Bit Shift Left Instruction............................................................................................................14
5.3.3 BOUT Instruction......................................................................................................................14
5.3.4 BSET Instruction.......................................................................................................................14
5.3.5 BRST Instruction.......................................................................................................................14
5.3.6 BON Instruction.........................................................................................................................14
5.3.7 SUM Instruction........................................................................................................................14
5.4 Coding Instructions...........................................................................................................................14
5.4.1 Decoder Instruction...................................................................................................................14
5.4.2 Encoder Instruction....................................................................................................................14
5.4.3 7-Segment Decoder Instruction.................................................................................................14
5.4.4 Exchange Instruction.................................................................................................................14
5.5 Comparison Instructions...................................................................................................................14
5.5.1 CMP Instruction.........................................................................................................................14
5.5.2 ZCP Instruction..........................................................................................................................14
5.5.3 Contact Type Comparison.........................................................................................................14
5.5.4 Logic Contact Operation............................................................................................................14
5.6 Matrix................................................................................................................................................14
5.6.1 Matrix AND Instruction............................................................................................................15

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5.6.2 Matrix OR Instruction................................................................................................................15

5.6.3 Matrix XOR Instruction.............................................................................................................15
5.6.4 Matrix XNOR Instruction..........................................................................................................15
5.6.5 Matrix Inverse Instruction.........................................................................................................15
5.7 Floating Point Instructions................................................................................................................15
5.7.1 Move Floating Point Data Instruction.......................................................................................15
5.7.2 Floating Point Square Root Instruction.....................................................................................15
5.7.3 Floating Point Compare Instruction...........................................................................................15
5.7.4 Floating Point Zone Compare Instruction.................................................................................15
5.8 Trigonometry Instruction..................................................................................................................15
5.8.1 Sine Instruction..........................................................................................................................15
5.8.2 Cosine Instruction......................................................................................................................15
5.8.3 Tangent Instruction....................................................................................................................15
5.8.4 Arc Sine Instruction...................................................................................................................15
5.8.5 Arc Cosine Instruction...............................................................................................................15
5.8.6 Arc Tangent Instruction.............................................................................................................15
5.8.7 Degree to Radian Instruction.....................................................................................................15
5.8.8 Radian to Degree Instruction.....................................................................................................15
5.9 STL and RET Instruction..................................................................................................................15
5.10 Interrupts...........................................................................................................................................15
5.11 Subroutine Call Instructions..............................................................................................................15
5.12 Conditional Jump Instruction............................................................................................................15
5.13 MC and MCR Instruction.................................................................................................................15
6 Sensors......................................................................................................................................................16
6.1 Introduction to Sensors.....................................................................................................................16
6.2 Types of Sensors...............................................................................................................................16
6.2.1 Two Wire Sensor.......................................................................................................................16
6.2.2 Three Wire Sensor.....................................................................................................................16
6.2.3 Four Wire Sensor.......................................................................................................................16
6.3 Discrete Sensors................................................................................................................................16
6.3.1 Inductive Proximity Sensor.......................................................................................................16

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6.3.2 Capacitive Proximity Sensor.....................................................................................................16

6.3.3 Photo Sensor..............................................................................................................................16
6.3.4 Motion Sensor............................................................................................................................16
6.4 Temperature Sensing Devices...........................................................................................................16
6.4.1 Bimetallic Switch.......................................................................................................................16
6.4.2 Thermocouple............................................................................................................................16
6.4.3 RTD...........................................................................................................................................16
6.4.4 Temperature Gauges..................................................................................................................16
6.5 Pressure Sensing Devices..................................................................................................................16
6.5.1 Pressure Switches......................................................................................................................16
6.5.2 Pressure Sensors........................................................................................................................16
6.5.3 Pressure Gauges.........................................................................................................................16
6.5.4 Solenoid Valves.........................................................................................................................16
6.6 Water Level Sensor...........................................................................................................................16
6.6.1 Float Switch...............................................................................................................................16
6.7 Encoder.............................................................................................................................................16
6.7.1 Slotted Disk and Opto-Interrupter (Simple Rotary Encoder)....................................................16
7 Analog Handling......................................................................................................................................17
7.1 A/D Module......................................................................................................................................17
7.1.1 External Wiring.........................................................................................................................17
7.1.2 A/D Conversion.........................................................................................................................17
7.1.3 Module Specification.................................................................................................................17
7.1.4 CR (Control Register)................................................................................................................17
7.2 TO and FROM Instruction................................................................................................................17
7.2.1 TO Instruction............................................................................................................................17
7.2.2 FROM Instruction......................................................................................................................17
7.3 D/A Module......................................................................................................................................17
7.3.1 External Wiring.........................................................................................................................17
7.3.2 D/A Conversion.........................................................................................................................17
7.3.3 Module Specification.................................................................................................................17
7.3.4 CR (Control Register)................................................................................................................17

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7.4 PT Module.........................................................................................................................................17
7.4.1 External Wiring.........................................................................................................................17
7.4.2 Temperature Conversion...........................................................................................................17
7.4.3 Module Specification.................................................................................................................17
7.4.4 CR (Control Register)................................................................................................................17
8 Human Machine Interface (HMI).............................................................................................................18
8.1 Introduction and Types of HMI........................................................................................................18
8.2 Software Installation and Communication Setting...........................................................................18
8.2.1 Software Installation..................................................................................................................18
8.2.2 Communication Setting.............................................................................................................18
8.3 Meter and Gauges.............................................................................................................................18
8.4 Multistate Indicators.........................................................................................................................18
8.5 Numeric Entry and Numeric Display................................................................................................18
8.6 Alphabet Entry and Alphabet Display..............................................................................................18
8.7 Slider and Moving Display...............................................................................................................18
8.8 History Graph and Table...................................................................................................................18
8.9 Alarms...............................................................................................................................................18
8.10 HMI Passwords.................................................................................................................................18
9 Link Devices.............................................................................................................................................19
9.1 Variable Frequency Drive (VFD).....................................................................................................19
9.1.1 Introduction to VFD..................................................................................................................19
9.1.2 VFD Wiring...............................................................................................................................19
9.1.3 Acceleration and Deceleration Time.........................................................................................19
9.1.4 Speed Control............................................................................................................................19
9.1.5 Fwd / Rev operation...................................................................................................................19
9.1.6 Parameter Lock..........................................................................................................................19
9.2 Servo Motor and Servo Drive...........................................................................................................19
9.2.1 Introduction to Servo Drive and Servo Motor...........................................................................19
9.2.2 Servo Motor and Servo Drive Wiring.......................................................................................19
9.2.3 Servo Position and Speed Control Mode...................................................................................19
9.2.4 Servo Direction Control Mode..................................................................................................19

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9.2.5 Servo Torque Control Mode......................................................................................................19

9.3 PLC Link Communication................................................................................................................19
9.3.1 Data Sheet..................................................................................................................................19
9.3.2 Communication Rates and Format............................................................................................19
9.3.3 Communication between VFD and PLC...................................................................................19
9.3.4 Interfacing of different PLC’s...................................................................................................19
9.4 PLC Passwords.................................................................................................................................19
9.4.1 Limiting the Number of Failures Allowed................................................................................19
9.4.2 Setting a Subroutine Password..................................................................................................19
9.4.3 Setting PLC ID and Program ID................................................................................................19
9.4.4 Setting a Project Password.........................................................................................................19
9.4.5 Disabling the Uploading of a Program......................................................................................19

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 ‫‪Issue: 01‬‬
‫‪Revision: 02/10-01-2019‬‬
‫‪Code: SOP-M-01/04‬‬

‫‪1 OHS, 5s and Kaizen‬‬

‫‪1.1 Occupational Health‬‬

‫ف ظ‬ ‫ت‬
‫پ یش ہ ورا ن ہ صحت اور ح ا ت کا عارف‬
‫‪1.1.1 Introduction‬‬

‫ت عق‬ ‫ٹ‬ ‫ن‬ ‫ت‬ ‫نٹ‬ ‫ف‬

‫کام کرے والے‪ ،‬قوزی رزاور کام کی ج گہ فسےم ل ہ‬ ‫ن‪،‬کا ری کٹ کے حت ئ‬ ‫ف‬ ‫ی‬ ‫م‬ ‫الز‬ ‫ے ج وم‬ ‫ہ‬ ‫لڈ‬
‫ظ‬ ‫ی‬ ‫‪ OHS‬ای ک ای سی‬
‫ن‬ ‫ب‬ ‫ف‬
‫ے۔اس کام صدصحت م د اورمح وظ کام کے ماحول‬ ‫دوسرےلوگوں کی ح ا ت‪،‬صحت اور الح و ہب ود سےج ڑی ہ و ی ہ‬
‫ے۔‬ ‫می‬ ‫کی ف راہ‬
‫خ‬ ‫خ‬ ‫ت‬ ‫ہ‬
‫ے طرات کی‬ ‫ے۔ طرات سےبش چ اخؤکےضلی‬ ‫ی‬ ‫ا‬ ‫دی‬ ‫ر‬ ‫اؤ‬ ‫اس م ں ز ادہ ت و ہ کا م کی گہ ر م کن ہ خ طرات سےب‬
‫ن‬ ‫ج ہ‬ ‫چ پ‬ ‫ج پ م‬ ‫ی ی ج‬
‫ے۔‬ ‫ہ‬ ‫روری‬ ‫ت‬ ‫ا‬
‫‪1.1.2 Hazard Identification‬‬
‫شنخ‬ ‫خ‬
‫ت‬ ‫ن ن‬ ‫ق‬ ‫ن‬ ‫ت‬ ‫ت‬ ‫ا‬ ‫کی‬ ‫طرات‬ ‫خ‬
‫ن ہب ود کو ٹصان پ ہ چ ا خے کا تامکان موج ود ہ و ا‬ ‫کام کے دوران لو گوں قکی صحت ‪ ،‬ح ف ظ اور ف الح و ب‬ ‫خ‬ ‫ں‬ ‫م‬ ‫س‬ ‫ے‬
‫یہ ج‬ ‫ز‬ ‫چ‬ ‫سی‬ ‫ی‬ ‫ا‬ ‫طرہ‬
‫۔کام کی‬ ‫ے‬ ‫ا‬ ‫و‬ ‫ہ‬ ‫طرہ‬ ‫ل‬ ‫کے طور رمل ی ر ا کو طرہ کہا ات ا ے ‪،‬ج کہ ح یق ت م ں مل ر ا پ دا کرے نواال ب ی ک ر ا اص‬
‫ن‬ ‫ہ‬ ‫یش‬ ‫ی‬ ‫ھی ن‬ ‫ک‬ ‫نی ی ق‬ ‫ی‬ ‫ی‬ ‫ب‬ ‫فظ‬ ‫ہ‬ ‫ج‬ ‫ن‬ ‫خ‬ ‫یش‬ ‫ی‬ ‫پ‬ ‫ے مث ال خ‬ ‫ہ‬
‫ے والی م ی ن ری ‪،‬بل ن دی پر کام کر ا اور‬ ‫چ‬ ‫ت‬ ‫طا‬ ‫اہ‬ ‫ے‬
‫ب پ‬ ‫آزاد‬ ‫سے‬ ‫ت‬ ‫ا‬ ‫‪،‬ح‬ ‫مواد‬ ‫اک‬ ‫طر‬ ‫‪،‬‬ ‫ور‬ ‫ں‬ ‫ی‬ ‫م‬ ‫طرات‬ ‫ہ‬ ‫ن‬‫ک‬ ‫م‬ ‫ر‬
‫ج پ م‬ ‫گہ‬
‫ں۔‬‫ش دی د ت ن اؤ خوالے کام کے حاالت قش امل ہ ی ت ق‬
‫ت‬ ‫ت‬
‫ےہ ی ں۔‬ ‫ان ما م طرات کوہ م درج ذی ل ا سام می ں سی م کر سک‬
‫ن خ‬
‫٭ جسما ئی خ طرات‬
‫٭کی کم ی ا ی خطرات‬
‫٭م ی ن ی ک تلت خطرات‬
‫٭ ن ف حتی ا اخ ی طرات‬
‫٭ قس ی ا خی طرات‬
‫٭ ب ر ی طرات‬

‫‪1. Physical Hazards‬‬ ‫ن خ‬

‫طرات خ۔‬
‫ن‬ ‫ج سما ی‬
‫کا م کی ج گہ پر جسما ی طرات می ں درج ذی ل چ یزی ں ش امل‬
‫ہیں‬

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‫ئ‬ ‫ق‬ ‫ے‬‫‪،‬درد ‪،‬جنھ ٹ ک‬ ‫گرمی ‪--- :‬گرمی کے دھجپ ڑ ن ن‬ ‫ٹ‬ ‫٭‬
‫ب‬
‫ے وے پ اؤں ‪ ،‬خ ار‬ ‫ہ‬ ‫ج‬
‫ے کے اب ل م‬ ‫ن‬
‫م کا ‪ ،‬اہ ل‬ ‫ھ ڈ ن‪---:‬‬ ‫٭‬
‫ک‬ ‫س‬
‫ی‬
‫ے سے کان وں م ں خ را ی ‪،‬سی ٹی ا آوازوں کا گو ن ج ن‬ ‫مین‬ ‫ہ‬
‫‪ ----:‬آ جشن کی‬ ‫ش می‬ ‫٭‬
‫ے‬
‫ب‬ ‫اور‬ ‫ا‬ ‫ی‬ ‫ب‬ ‫ی‬ ‫ر‬ ‫ں‬ ‫ی‬ ‫م‬ ‫ور‬ ‫ر‬ ‫د‬ ‫ادہ‬
‫تی ی‬ ‫ذ‬ ‫‪------‬‬ ‫ور‪:‬‬ ‫ن‬ ‫٭‬
‫ے‬ ‫س‬ ‫ہ‬ ‫ن‬ ‫ج‬
‫ت‬ ‫ت ت‬ ‫ن‬ ‫ش ن‬ ‫ے آرام ی د تکا ب تاعثتو ک ی ہ‬ ‫آرامی و کہ ب‬
‫ھر ھراے اوزار ‪--:‬ب ھاری م ی وں ی ا ب ڑی کر ی وں کی ھر ھراہ ٹ کا ہ ا ھوں ی ا‬ ‫ث‬ ‫٭‬
‫ج‬
‫شن ن‬ ‫نف ش ئ‬ ‫ن کن‬ ‫ٹ‬ ‫ن‬ ‫پورے سم پر ا ر ۔ت‬
‫ی‬ ‫ک‬
‫ے والی ا راری ڈ عا ی ں اور سورج کی رو ی سر‬ ‫‪----‬ا کس ریز ‪،‬وی لڈ گ والی ارچ سے ل‬ ‫ی‬ ‫اب کاری‬ ‫٭ ظ‬
‫ت‬
‫‪ ،‬مورو ی ب ی ماریو ں کا ب اعث ب ن سک ی ہ ی ں‬
‫‪2. Chemical Hazards‬‬ ‫ئ خ‬
‫ظ‬ ‫ٹ‬ ‫ئ‬ ‫کی م یئا خی طرات‬
‫تی طرات‪،‬کام کی ج گہ پر گیس ‪،‬ما ع اور ھوس حالت می ں اہ ر‬ ‫کی م ی ا‬
‫غ‬ ‫ہ وے ہ ی ں‬
‫گردو بئ ار‬ ‫٭‬
‫دھو ی ں‬ ‫٭‬
‫ت‬
‫٭‬
‫خ‬ ‫ق‬ ‫ئ‬ ‫ئ‬ ‫خ‬ ‫زاب‬
‫ئ‬ ‫ی‬
‫ے طری وں سے جسم می ں دا ل ہ و‬ ‫کی م یت ا ی طرات ذی ل می ں دے گ‬
‫ن‬ ‫خ‬ ‫ن‬ ‫ےن ہ ی ں‬ ‫سک‬
‫ج‬ ‫ک‬ ‫ی‬‫ک‬
‫ے سے ‪--:‬کام کی ج گہ پر می لز کا سم می ں دا ل ہ وے‬ ‫٭سا س لی‬
‫ن‬ ‫ےن ن ت ن ش‬ ‫کا گسب نسے عام ذری عہ ہ‬
‫ے گل‬ ‫ے ی ا م ب ا کو و ی کے ذری ع‬ ‫ے سے ‪---:‬کھاے ‪ ،‬یپ‬ ‫٭ِن ل لی‬ ‫لن‬
‫ن‬ ‫ے سے ن‬ ‫ی‬
‫ے سے‬ ‫٭ج ذب کرے سے ‪-:‬جسم ‪،‬ج لد ی ا آ کھوں کے راب ط‬

‫ن‬ ‫خ‬
‫می کی کل طرات‬
‫‪3. Mechanical Hazards‬‬

‫ت‬
‫ے‬ ‫ن‬
‫‪:‬ان کی درج ہ ب دی ومومًا اس طرح کی ج ا ی ہ‬

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‫‪Code: SOP-M-01/04‬‬
‫ش‬ ‫ن‬ ‫ن‬ ‫ش‬ ‫ن‬ ‫ن‬
‫ے مواد رکھا‬ ‫ے عمل کاری کے لی‬ ‫ےاور م ی ن کے ذری ع‬ ‫ا‬
‫ج یج ہ‬ ‫ا‬ ‫ا‬ ‫د‬ ‫ام‬ ‫ا‬ ‫کام‬ ‫ر‬ ‫س‬
‫ح ج پ‬ ‫صہ‬ ‫وہ‬ ‫کا‬ ‫ن‬ ‫ی‬ ‫م‬ ‫‪--‬‬ ‫گہ‪:‬‬ ‫ج‬ ‫کی‬ ‫ے‬ ‫٭کام ا ج ی‬
‫د‬ ‫ام‬ ‫ت‬
‫ٹف‬ ‫ے۔‬
‫ش‬ ‫ہ ت گ ن‬ ‫ت‬ ‫ت‬
‫ہ‬
‫خ‬ ‫گ ن‬ ‫غ فظ‬ ‫ج ا گ ہن‬
‫ا‬
‫ے والی ا س ‪،‬‬ ‫ےھ نوالی تحرکات طرہ و ی ہ ی ں۔ح ٰی کہ آ س ہ ھوم‬ ‫ب‬
‫ےئوالی ب یحرکات‪--- :‬ن ی ر ح ا ت کے ھومک‬ ‫ٹ‬ ‫٭ ھوم‬
‫ں۔‬ ‫ے‬ ‫س‬ ‫چ‬ ‫ی‬ ‫کو‬ ‫الوں‬ ‫ا‬ ‫ڑے‬ ‫ک‬ ‫ر‬ ‫ے‬ ‫و‬ ‫ہ‬ ‫طہ‬ ‫را‬ ‫س‬ ‫ل‬ ‫اور‬ ‫گ‬
‫ک‬
‫ن‬ ‫غ ض‬ ‫مش ن‬ ‫ہ‬
‫ک ی‬ ‫یب‬ ‫پ پ‬ ‫ب‬
‫ت‬ ‫پ ل ی خاں‪ ،‬خ‬
‫ر‬ ‫ی‬
‫ے‬
‫ی وں کے ی ر روری طور پر ل‬ ‫خ‬ ‫٭ ئود سا ہ حرکات‪ :‬ت ئ‬
‫ت‬ ‫ے‪ ،‬ج و کارک ن‬
‫ےہی ں‬ ‫ک‬ ‫س‬ ‫کر‬ ‫می‬ ‫ز‬ ‫کو‬ ‫ان‬ ‫ص‬ ‫ہ وے ‪ ،‬آزادان ہ حرکت کرے ہ و ح‬
‫ے‬

‫‪4. Biological Hazards‬‬ ‫ت ت خ‬

‫ئ ت‬ ‫ن ن‬
‫طرات‬
‫ت ت خ‬ ‫حی ا ی ا ی‬
‫کا م کی ج گہ پر ح ی ا ی ا ی طرات ز دہ ج ا داروں کی صورت می ن پ اے ج اے ہ ی ں ج ن می ں درج ذی ل ش امل ہ ی ں‬
‫ڑے مکوڑے‬ ‫کی ئ‬ ‫٭‬
‫کا ئی‬ ‫٭‬
‫ٹوا رس‬ ‫٭‬
‫ب ی ن ک ی ری ا‬ ‫٭‬
‫ج ا نور‬ ‫٭‬
‫نپر دے‬ ‫٭‬
‫ا سان‬
‫نف ت خ‬
‫٭‬
‫‪5. Psychological Hazards‬‬
‫س ی ا ی طرات‬
‫ئ‬ ‫٭ن ن‬
‫خ ا دا ی مسا ل‬
‫ت ف‬ ‫٭‬
‫مالزمت کا ح ظ‬
‫٭‬
‫کام کا دب اؤ‬
‫ن٭ ن ف‬
‫اا صا ی‬

‫‪6. Electrical Hazards‬‬ ‫ق خ‬

‫ت‬ ‫ت‬ ‫م ق ق‬ ‫ق‬ ‫ت نئ‬ ‫نب ر ی طرات ن‬
‫ے ی ہ ش ای د سب سے‬ ‫ہ‬ ‫ا‬ ‫و‬ ‫ہ‬ ‫عمال‬ ‫س‬ ‫ا‬ ‫ادہ‬
‫ن‬ ‫ی‬‫ز‬ ‫سے‬ ‫سب‬ ‫کا‬ ‫ت‬ ‫طا‬
‫ت‬ ‫ی‬ ‫ر‬‫بن‬ ‫ع‬ ‫ب‬ ‫ن‬ ‫کا‬ ‫ت‬ ‫طا‬
‫ت‬ ‫ا‬ ‫ی‬ ‫گ‬ ‫اخ ٹ‬
‫ڈس ری اور ھر ندو ہوں ج گہوں پ ہ نوا ا ی‬
‫ن‬
‫ن‬
‫ے ب ہت دیر ہ و‬ ‫ے ہ ی ں اور محسوس کرے ے پہل‬ ‫ے اور ہ ہ ی سو گھ سک‬ ‫ے یک و کہ م اسے دی کھ ہی ں سک‬ ‫طرئاک ہ‬
‫ش‬ ‫خ‬ ‫ج اق خ‬
‫ے گی ۔‬
‫م‬
‫طرات ا ل ہغ ی ں‪:‬ف‬ ‫بر ی طرات می ں درج ذی ل ب‬
‫ے‬‫کے ت ی ر مح وظ حص‬ ‫ج لی ن ن‬ ‫٭‬
‫گی ن اروں تسے راب طہ‬ ‫٭‬
‫ِقص اری ں‬ ‫ش‬ ‫ن‬ ‫ا‬ ‫٭‬
‫ن‬ ‫ےک ک‬ ‫ل‬ ‫ھ‬ ‫ڈ‬
‫ب ج لی ی بکے ج ھ ٹ کو ں کی بو ہ سے گآ لگ ان‬ ‫٭‬
‫ن‬ ‫ج ن ئ غ ج‬
‫ے ب ی ر ج لی کے آال ت پر کام کر ا‬
‫٭‬
‫لی ب د یک‬ ‫٭‬
‫خ‬
‫‪:‬محدودج گہ کے طرات‬

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‫‪Revision: 02/10-01-2019‬‬
‫‪Code: SOP-M-01/04‬‬
‫ت‬ ‫ن‬
‫ے کا راست ہ ب ہت ت ن‬ ‫خ خ‬
‫ے ۔ای سی ج گہوں پ ہ دھواں ‪،‬گرد‬
‫ہ‬ ‫ا‬ ‫و‬ ‫ہ‬ ‫گ‬ ‫ے‪ ،‬راج اور ہ وا کے آ‬
‫ے جس می ںتدا ل‬ ‫ی ہ وہ حصہ ہ‬
‫ب‬
‫اور خ ارات ب ھی پ ی دا ہ و ت‬
‫ےہی ں خ‬ ‫س ن‬
‫طرات‬ ‫ق‬ ‫ل‬ ‫ے سے م ع‬
‫ٹ ن ن‬ ‫ٹ‬
‫‪:‬مواد ن ب ھال‬
‫ے رک نھ ن ا ‪،‬دھکا دی ن ا‬ ‫اسک منی ں غکام کی ج گہ پر می رین ل کو ا ھا ا ‪،‬یچ‬
‫ق‬
‫اور ھ چ ن ا و ی رہ ش امل ہ ی ں ۔ ا م ن اسب طری ہ س ج ی دہ چ وٹ‬
‫ف‬ ‫ے‬ ‫کا ب اعث ب ن سکت ا ظہ‬
‫‪:‬صحت اور ح ا ت کی اہ می ت‬
‫ف‬ ‫ن‬
‫اور مح وظ ماحول‬
‫صحت م د ت‬ ‫‪‬‬
‫کام پر ب ھر پور وج ہ‬ ‫‪‬‬
‫ف‬ ‫ٹ‬
‫کوال ی مئی ں اض ا ہ‬ ‫‪‬‬
‫ن‬
‫ب ہت ر ت ا ج‬ ‫‪‬‬
‫ادہ پ ی دوار‬ ‫ز‬
‫ی ت ٹ‬
‫‪‬‬
‫ک‬
‫پراع ماد س مر‬ ‫‪‬‬
‫‪1.1.3 Fire and Fire Extinguisher‬‬ ‫ب ن‬
‫ئ‬ ‫ت‬
‫ت‬
‫گآ اور گآ ج کھاے والے آال ت‬
‫ے ۔ ی ہ ای ن دھن ‪،‬آکس ی ڈ ا زاورحرارت کے ممب ع کا‬
‫زاج ہ و ہ‬
‫ی‬ ‫ام ت‬ ‫حرارت کا‬
‫ئ‬ ‫گآ ایت ن دھن ‪،‬آ یس ج ن اور درج ہ‬
‫گآ ‪ :‬ق‬
‫ہ‬ ‫عم‬ ‫ت‬ ‫ن‬
‫ے‬‫ای ک م ررہ اسب می ں ام زاج کا کی م ی ا ی رد ل و ا ہ‬

‫ت‬ ‫گآ کی درج ہ ب دی‬ ‫ن‬

‫ق‬ ‫ن‬ ‫ق‬ ‫ن‬ ‫ن‬
‫عام طور پر گآ کی درج ہ ب دی ای د ھن کی ا سام کی ب ی اد پر کی ج ا ی ہ ی ں ۔گآ کی ا سام درج زی ل ہ ی ں‬
‫ق‬ ‫ق‬
‫ای ن دھن کی ا سام‬ ‫گآ کی سم‬
‫ٹ‬ ‫غ‬
‫لکڑی‪ ،‬کا ذ‪ ،‬کپ ڑا ی ا ھوس ای ن د ھن‬ ‫کالس‪A‬‬
‫ئ‬ ‫ئ‬ ‫ٹ ن‬
‫ے گیسولی ن ‪،‬پ ی ن ٹ‪،‬آ ل اور محلول‬ ‫ے واال ما ع ج ی س‬‫ب ھڑک ا ھ‬ ‫کالس‪B‬‬
‫ن‬ ‫ٹ‬ ‫ت‬ ‫ت‬ ‫ج ق‬
‫ٹ‬ ‫م‬ ‫گی سوں والے ای ن دھن ی س‬
‫ے‬‫ے در ی گیس ( ی ھی ن )‪،‬پروپ ی ن ‪،‬اور دوسری ب ھ رک ا ھ‬ ‫کالس‪C‬‬
‫لت‬ ‫می گ ن ش‬ ‫والی گی سی تں‬
‫تش‬
‫ی‬
‫ی م ‪،‬سوڈی م اور ھی م ۔‬ ‫ی‬ ‫ے‬ ‫ج‬
‫آ ی دھا ی ں ی س‬ ‫کالس‪D‬‬

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 ‫‪Issue: 01‬‬
‫‪Revision: 02/10-01-2019‬‬
‫‪Code: SOP-M-01/04‬‬
‫ت‬ ‫ن‬ ‫بج‬
‫ے ‪،‬ی ہ ش ارٹ سرکٹ کی وج ہ‬
‫ے والی گآ کو ای کالس ک ی ا ج ا ا ہ‬ ‫لی کیتوج ہ سے لگ‬ ‫کالس‪E‬‬
‫ے‬‫سے لگ ی ہ‬
‫فظ‬
‫ن‬ ‫نق‬ ‫ن‬ ‫ب ن‬ ‫ن ا ت ‪:‬ت‬ ‫گآ سے ح‬
‫ے تاور اس سے ہ وش تے والے صان کی ش دت کو کم کرے‬ ‫ن‬ ‫ھا‬ ‫ج‬ ‫کو‬ ‫گآ‬ ‫ب ن‬‫آالت‬ ‫اور‬ ‫ں‬ ‫ک‬ ‫ی‬ ‫ک‬
‫ئ ت ن ی‬ ‫اور‬ ‫والی‬ ‫ے‬ ‫گآ ئسے تلڑ‬
‫م‬ ‫م‬
‫نن ئ‬ ‫ے‬
‫ہ‬
‫نہ‬ ‫ے ن یت ن اج زا ءپرئ ل‬ ‫والی چ یزی ںیچ‬ ‫ں۔گآ ج ھاے ن‬ ‫ن‬ ‫ےج اے ہ ی‬ ‫ے اس عمال ی‬
‫ک‬ ‫کےل‬
‫ن ا پ اے‬
‫ے‬‫ے کہ گآ لگ‬ ‫ےچ ا ی‬‫ے ج ائ‬ ‫ک‬
‫امات ین ن‬ ‫ےا ظ‬
‫ای دھن نہ ٹ ا ا‪---:‬ایس‬
‫ن‪----- :‬گآ نپ‬
‫٭‬
‫لگ ج اے کی صورت می ں )‬ ‫(گآ‬ ‫ن‬ ‫ے‬ ‫ا‬ ‫ا‬ ‫ے‬ ‫ھ‬‫ق‬ ‫ا‬ ‫ا‬ ‫ٹ‬ ‫ہ‬ ‫حدت‬
‫ئ‬ ‫یل پ‬ ‫ئ‬ ‫٭‬
‫ے‬ ‫ل‬ ‫کے‬ ‫ے‬ ‫کر‬ ‫کوکم‬ ‫صان‬ ‫اور‬ ‫گآ‬ ‫‪---‬‬ ‫ا‬ ‫ا‬ ‫ٹ‬ ‫ہ‬ ‫ر‬ ‫ز‬ ‫ڈا‬ ‫ک ی‬‫س‬ ‫آ‬ ‫٭‬

‫‪Types of Fire Extinguishers‬‬ ‫ب ن‬

‫ت‬ ‫ن‬ ‫نق‬ ‫ن‬ ‫ے والے آالت ‪ :‬ب ن‬ ‫گآ ج ھا ن‬
‫تش دت کو کمًالکرےکے لی‬
‫ے اس عما ل‬ ‫نہ وے والے ت صان کی‬
‫اس سے‬‫ب‬ ‫اور‬ ‫ے‬ ‫گآ ج ھاق‬
‫خ‬ ‫آالت‬ ‫لے‬ ‫خ‬
‫ا‬ ‫ےو‬ ‫سے لڑ‬
‫گآ ت‬
‫ے اس عمال ہ وے ہ ی ں۔مث ‪:‬‬‫ےج ا ے ہ ی ں ۔م ت لف آالت م ت لف سم کی گآ ج ھاے کے لئ ی‬
‫یک‬
‫ن‬
‫ت‬ ‫ن‬ ‫پ ان ی‪:‬‬
‫پ ا ی ت ب ی ار شندہ حالت می ں ہ تر ج گہ آسا تی سے دس ی اب ہ و ۔ج و کہ سپ رے ی ا چ ھڑ کاؤ کے ذری ع‬
‫ے‬
‫ے اس عمال ک ی ا ج ا ا ہ‬
‫ے۔‬ ‫گآ ج ھاے کے لئ ی‬

‫ب ن‬ ‫ری ت ‪ :‬ت‬
‫ے عام طور پر ری ت کی‬ ‫ی‬
‫ث ت‬
‫ل‬ ‫ڈا‬ ‫ر‬ ‫ا‬ ‫یسا‬ ‫ج‬ ‫ل‬ ‫ب‬ ‫ے ک ا ات ا قے ہ گآ تر کم‬
‫ئ‬
‫کے‬ ‫ے‬‫ھا‬ ‫ج‬ ‫گآ‬ ‫عمال‬ ‫ت‬ ‫ری ٹت کا اس‬
‫ہ‬ ‫پ‬ ‫ل ی جمست ہ ی‬
‫ے۔‬ ‫ب ال ی ا ں عمار وں اور کام کی ج گہ کے پ اس ل لگا دی ج ا ی ہ‬

‫ف‬
‫ت‬ ‫ت‬ ‫ب ن‬ ‫خ‬ ‫ق‬ ‫ب ن‬ ‫وم‪:‬‬ ‫ف‬
‫ے اس عمال ک ی ا ج ا ا ہ‬
‫ے‬ ‫وم کی طرح کا گآ ج ھاے واال آلہ م ت لف سم کی گآ ج ھاے کے لئ ی‬
‫سو ڈی م ‪HCO3 NaHCO3‬‬ ‫٭‬
‫بن‬ ‫‪ Sodium‬ئ‬ ‫‪Na‬‬
‫ن‬ ‫ب‬
‫( ی ک گ سوڈا )‬ ‫ب ا ی کار و ی ٹ‬ ‫٭‬
‫می س ف‬ ‫‪Bicarbonate‬‬ ‫‪(Baking‬‬ ‫‪Soda‬‬ ‫)‬
‫‪ Al2(SO)4‬ای لو ن ی م ل ی ٹ‬ ‫٭‬

‫ئ‬ ‫خش‬
‫ڈی سی پی ( ک کی م ی ا ی پ اؤڈر)‪DCP (Dry Chemical Powder) :‬‬
‫مش ت م ت‬ ‫می ف ف‬ ‫کلورائ‬
‫ٹش‬ ‫ئ‬ ‫خش‬
‫ے۔‬ ‫ہ‬ ‫ا‬ ‫و‬ ‫ہ‬ ‫ل‬ ‫ر‬ ‫ٹ‬
‫ی پ‬ ‫س‬ ‫ا‬ ‫م‬ ‫ی‬ ‫ن‬ ‫لو‬ ‫ی‬‫ا‬ ‫ت‬ ‫اور‬ ‫ڈ‬ ‫ی‬ ‫م‬‫ن‬‫ی‬ ‫ا‬ ‫و‬‫ک کی م ی ا پ ب پ‬
‫اؤڈر‪،‬‬ ‫ی‬
‫ے‬ ‫کے کام آ ا ہ‬ ‫ی ہ ہ ر طرح کی گآ ج ھاے‬

‫)‪(Bromo.Chloro.Difloro.Methene‬‬
‫ن‬ ‫ت‬ ‫ت‬ ‫ئ‬
‫‪B.C.F‬‬
‫ے ۔ یک وت کہ کلوری ن زہ ری لی ‪،‬ماحول کے‬‫ہ‬ ‫ا‬ ‫ا‬ ‫ج‬ ‫ا‬ ‫ی‬ ‫ت ی ڈ روجن قن کا اس ن ن‬
‫ک‬ ‫عمال‬ ‫‪ B.C.F‬کی ج گہ پر آج کل ہ ا‬
‫خ ن‬
‫ے۔‬ ‫ب‬ ‫ہہ کو صان پ‬
‫ن ہ چ ا ے کا ب تاعث ن تی ہ‬ ‫ب‬ ‫ے طر اک اور تاوزون کی‬‫یل‬
‫ے‬ ‫ے اس عمال ک ی ا ج ا ا ہ‬ ‫کی گآ ج ھاے کے یل‬ ‫‪ B.C.F‬کا اس عمال ہ ر طرح‬

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 ‫‪Issue: 01‬‬
‫‪Revision: 02/10-01-2019‬‬
‫‪Code: SOP-M-01/04‬‬

‫‪Pass Rule to Extinguish Fire‬‬

‫ف ظت ت‬
‫‪1.1.4 OHS and Safety Precaution‬‬
‫ن‬ ‫سیف ٹ ت‬ ‫ت‬ ‫نیر‬
‫ح ا ی داب‬
‫ست‬ ‫ت‬ ‫ے۔‬
‫ت‬ ‫ی‬ ‫ہ‬ ‫ا‬ ‫چ‬ ‫ی‬ ‫و‬ ‫ہ‬ ‫ت‬ ‫ش‬ ‫ی‬ ‫ب‬ ‫ر‬ ‫٭ب شڑے پ یماے پر ت مام مالزمی ن کو ی کی‬
‫ے ۔وہ‬ ‫ے اور ہ ہ ی سوچ ک ی ہ‬
‫ن‬
‫سن سشک ی ہ‬ ‫ے‪ ،‬ن ہ‬
‫ہ‬ ‫عاون کی ام ی د ن ہ رکھی ں ۔مئ ی غن ن ہ دی بکھ ٹسکتی‬ ‫٭م ی ن سے کب ھی ن‬
‫ے ہ می ہ محت اط اور چ وکس ہ ی ں۔‬ ‫ے ہ ی ں اس یل‬
‫ی‬
‫اگر کبآپ کو ی ہ لطینکر ت ھ‬ ‫اپ کا لحاظ ہی ں ک تری ں گی‬ ‫ت‬ ‫کب ھیتب ھی ظ‬
‫ف‬ ‫ف‬
‫ف ٹئ ن‬ ‫ں۔‬
‫ن‬ ‫ی‬ ‫٭ذاش ی ح اخ ی سامان کے اسنعمال می ںن شھی ال پروا ی ًال ہ بتر‬
‫ےڈھالےکپ ڑے‪ ،‬م لر‪ ،‬ا ی‪،‬ز ج یری ں ی اگھڑی‬ ‫وں(مث لی ھ ‪،‬مل گ)‪،‬پر ڈھ ی ل‬ ‫ے والےپ ھنک نن ہ خ ش‬ ‫اص کر ج جس پر گھو شم‬ ‫٭م ی ن ‪،‬‬
‫ن‬
‫ن‬ ‫ت‬ ‫خ‬ ‫ن‬ ‫ن‬ ‫ہ‬
‫ے کا ت د ہ و۔‬ ‫پ کبہن کر کام ہ کریش ں ن تکا م ینن می ں س‬
‫ے آپ ے اص ر ب ی ت ہ لی ہ و‪-‬‬
‫ک‬ ‫٭ ھی وہ آلہ ی ا م ی ن اس عمالن ہ کری ں ج تس کو ا ہ شعمال کر ٹے کے یل‬
‫س‬
‫٭را ہ تداری‪،‬کام کی ج گہ شاور ہ گامی ئراس وں کو می ہ رکاو وں سےپ اک صاف ر ھی ں۔‬
‫ے م ی ن کا فمعاًا فن ہ کری ں۔‬ ‫٭ہ ر انس عمالپسےن پہل‬
‫ف‬ ‫ں۔‬ ‫ی‬‫ر‬ ‫ک‬ ‫صاف‬ ‫سے‬ ‫رش‬ ‫ور‬ ‫کو‬ ‫زوں‬ ‫ے چ‬
‫والی‬ ‫٭گرے اور ت ھس‬
‫ک‬ ‫ن‬ ‫ک‬ ‫ب‬ ‫ی‬ ‫ل‬ ‫٭گ ن‬
‫ے می ں مح وظ ر ھی ں۔‬ ‫ے والے ڈب‬ ‫گآ تسے کچ اؤ کی صالحی ت ر ھ‬ ‫ش‬ ‫ن ی ل واے کپ ڑے‬ ‫دے اور‬ ‫ب‬
‫٭گآ ج ھاے والے آالت کو ہ می ہ ی ار ر ھی ں۔‬
‫٭میڈیکل سروسز کو یقینی بنایا جائے۔‬
‫٭ورکرز کو پتہ ہونا چاہیے کہ اگر ساتھی ورکر کو کوئی نقصان پہنچ جائے تو کیا کرنا ہے۔‬
‫٭فرسٹ ایڈ دینے کیلئے تیار رہنا چاہیے اور فرسٹ ایڈ کی سہولت موجود ہونی چاہیے اور ورکرز کو‬
‫ایمرجنسی نمبر مثًال ریسکیو ‪1122‬کا پتہ ہونا چاہیے۔‬
‫٭ایمرجنسی االرم کا پتہ ہونا چاہیے ایمرجنسی االرم کے بجنے پر تمام ورکرز کو ایک مخصوص جگہ‬
‫پر جمع ہو جانا چاہیے۔‬
‫٭جسم پر کیمیکل لگنے یا ہیٹ سے نقصان ہونے پر فورًا آ لودہ کپڑے اتار کر تازہ ہوا میں لے جانا‬
‫چاہیے۔‬
‫٭ناقص بجلی کے جوڑوں سے دور رہیں اور ان کو ٹھیک کروائیں۔سرکٹ پر زیادہ بوجھ نہ ڈالیں اس‬

‫ط‬ ‫ہوتا شہے۔ ف ًا ت ق ف‬ ‫نئ‬

‫آگ لگنے کا اندیشہ‬ ‫سے ث‬
‫م‬ ‫ی‬
‫٭ حادے کی صورت میئ ں آرگ ا ز فن می ں ور م عل ہ رد کو لع کری ں ۔‬ ‫خ‬
‫ز یمخ توں کو اب ت دانی بط ی امداد راہش م کری ں۔‬ ‫٭خ‬
‫٭ طرات کو م ی ا کم کرے کی مکمل کو ش کری ں۔‬

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‫‪Code: SOP-M-01/04‬‬
‫ت‬ ‫ت ق ف‬ ‫ن‬ ‫ق‬ ‫ت‬ ‫فظ‬
‫ے ج اے والے م عل ہ آ یسر سے مکمل عاون کری ں۔‬ ‫کے حت م رر کی‬ ‫ے ‪OHS‬ت‬ ‫کے یل‬ ‫٭کام قکی ج گہ صحت اور ح ا ت‬
‫خ‬ ‫ے م ن اسب ت ب دی ل ی اں کر ظ‬
‫ے ترہ ی ں ۔‬ ‫٭ م قست ل ب ہتش ری کے ی‬
‫ل‬
‫خ‬ ‫ف‬
‫٭ہ ر و ت ہ و ی ار رہ ی ں اور ج و ب ھی کری ں اس می ں ح ا ی پ ہلوؤں کا اص ی ال رکھی ں۔‬

‫ت‬ ‫ت فظ‬
‫‪1.1.5 Personal Protection Equipment‬‬
‫‪:‬ذا ی ح ا ت کا سامان اور اس کا اس عمال‬
‫ب ن‬ ‫نق‬ ‫خ‬ ‫ت فظ‬
‫م‬
‫ے و کام کی ج گہ پر الزمی ن کو طرےکے صان سے چ اےاور‬ ‫ج‬ ‫ذا یثح ا ی سامان(نپی‪-‬پی‪-‬ای)ایسا سامان‬
‫لےخ طر ن اک آالت سے ب‬
‫ہ‬
‫فظ‬ ‫ن‬ ‫ے۔‬ ‫ظ‬
‫فہ ت‬ ‫ا‬ ‫ت‬ ‫ن‬ ‫ب‬ ‫ب‬ ‫ب‬‫س‬ ‫اؤکا‬ ‫فظچ‬ ‫ن ن‬ ‫اعث ب ن‬
‫ے وا‬
‫ہ‬ ‫حادےکا فب ظ ت‬
‫ک‬
‫لمٹ‪ ،‬دست اے‪،‬آ ھوں کی ح ا ت کا سامان‪ ،‬ح ا ی کپ ڑے(ای پران)‪،‬کا وں کی ح ا ت کا‬
‫م‬ ‫ش‬ ‫اس می ں فح ظا ت ی یت غ‬
‫‪-‬سامان‪،‬ح ا ی ج وے و ی رہ ا ل ہ ی ں‬

‫ت ف‬
‫در کار ح ظ ات‬ ‫‪ :‬کام کی گہ ر‬
‫ج پ ت ف‬
‫ن‬
‫فظ‬ ‫ن‬ ‫ن‬ ‫کام کی ج گہ پر در کار ح ظ ات درج تذی فل ہ ی ں ف ظ‬
‫٭‪--‬گرتے ی اف ظگراے والی چ یزوں سے ح ا ت‬ ‫تن‬ ‫س کی ح ا‬ ‫٭‬
‫تظ‬ ‫ہ‬ ‫س‬
‫٭‪ --‬ا ھ کی ح ا ف‬ ‫ے‬‫ی‬ ‫٭ فظ‬
‫سماعت کی ح ا ت ف ظ‬ ‫ک‬
‫٭‪ --‬ن‬ ‫کی ح ا ت‬
‫٭‪--‬آ ھوں اور چہرے کی ح ا ت ف ظ‬ ‫پ اؤں‬ ‫٭ فظ‬
‫سر کی ح ا ت‬ ‫٭‬ ‫کی ح ا خ‬
‫ت‬
‫ن‬ ‫ٹ‬ ‫ئ‬ ‫ن‬ ‫‪:‬سر کے طرات‬
‫ب ی ک آے والی چ یزوں سے‬ ‫ٹ‬ ‫ل‬
‫یچ ی ب کی ہ و ی رکاو ی ں‬
‫ٹ٭ ن‬ ‫٭‬
‫ٹ ن‬ ‫ن‬ ‫کرا ا‬ ‫ج لی کی چ یزوں سے‬ ‫٭ثت ٹ‬
‫ئ سے کرا ا‬‫اڑ ی والی چ یزوں‬ ‫٭‬ ‫حاد ا ی کراؤ‬
‫ا جل ھ‬
‫ے ہ وے ب ال‬ ‫٭‬ ‫خ‬
‫کے طرات ئ‬ ‫سماعت خ‬
‫ن‬ ‫س‬ ‫سماعت کے طرات کے زرا ع درج ذی ل ہ ی ں‬
‫م لسل او چ ی آوازوں‬ ‫ہ‬
‫ای ک ی ج گہ‬
‫غ ت ق‬
‫٭‬ ‫٭‬
‫می ں رہ ن ا ۔‬ ‫پر ب ہت سارے ی ر م عل ہ آالت کا چ ل ن ا۔‬
‫مکمل ی ا ج زوی طور پر‬ ‫٭‬ ‫آالت کی‬ ‫٭‬
‫‪ ،‬ب ن د ج گ ہی ں‬ ‫حالت ا ب‬
‫خ‬ ‫۔‬ ‫حالی‬ ‫ی‬ ‫ن‬
‫آ کھوں اور چہرےکے طرات‬

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‫‪Code: SOP-M-01/04‬‬
‫ئ‬ ‫خ‬ ‫ن‬
‫اور چہرےکے طرات کے ذرا ع درج ذی ل ہ ی ں‬ ‫ھوں‬ ‫آک‬
‫غ‬
‫ن‬ ‫٭‪--‬گردو ب ار‬
‫٭‪--‬دھات بکے زروں کا اڑ ا‬
‫٭‪--‬گٹی نس اور خ ارات‬
‫ن٭‪--‬تک گ چ پس(ب رادہ)‬
‫خ‬ ‫ت٭ف‪ --‬اب ن‬
‫کاری‬
‫(سا س)کے ئ طرات‬ ‫ت نف س خ‬
‫کے طرات کے ذرا ع درج ذی ل ہ ی ں‬ ‫س غ‬
‫گردو ب ار‬ ‫٭‪--‬‬
‫٭‪--‬کم آک یس ج ن واال ماحول‬
‫٭‪--‬زہ ری لی گیخسی ں‬
‫ت‬
‫ئ‬ ‫کے طرات‬
‫خ‬ ‫ھ‬ ‫‪:‬ہ ا‬
‫ت‬
‫ہ ا ھ تکے طرات کے ذرا ع درج ذی ل ہ ی ں‬
‫٭‪ --‬ی زدھار والی چ یزی ں‬
‫٭‪--‬حرارت‬
‫٭‪--‬کیٹ نمی کل سے راب نطہ‬
‫٭‪--‬کخ گن چ پس کا اڑ ا‬
‫٭‪--‬ز م ( ف ی ش‬
‫رگڑ)‬
‫٭‪ --‬بج لد کا ا ک ن‬
‫٭‪ --‬ج لی کےخج ھ ٹ ک‬
‫ے‬
‫کے طرات ئ‬ ‫ے خ‬ ‫‪ :‬سن ی‬
‫ت‬ ‫ے کے طرات کے ذرا ع درج ذی ل ہ ی ں‬ ‫سن ی‬
‫٭‪--‬ک یی ل‬ ‫حرارت‬
‫غ‬ ‫‪--‬‬
‫ک‬ ‫خ‬
‫٭‬
‫ی‬
‫٭‪ --‬م ل‬ ‫٭‪--‬گردو ب ار‬
‫کے طرات ئ‬ ‫پ اؤں خ‬
‫پ اؤں کےس طرات کے ذرا ع درج ذی ل ہ ی ں‬
‫٭‪ --‬گ ی نلی سطحی ں‬
‫٭‪ --‬چ شک نی طحی ں ف‬
‫٭‪ --‬مخ ی گ چ پس( رش پ ہ پڑا ب رادہ)‬
‫خ‬ ‫٭ ت‪ --‬ز مئ( رگڑ)‬
‫ئ‬ ‫خ‬ ‫ن‬ ‫طرات‬
‫ئکے ت ئ‬ ‫تیزوں‬ ‫نگر تی ہ و ظی چ‬
‫ے‬‫ہ‬ ‫عہ‬ ‫ذر‬ ‫ڑا‬ ‫ب‬ ‫سے‬ ‫سب‬ ‫کا‬ ‫طرات‬ ‫لے‬ ‫ا‬ ‫و‬ ‫ے‬ ‫و‬ ‫ہ‬ ‫دا‬ ‫پی‬ ‫سے‬ ‫زوں‬ ‫چی‬ ‫ی‬ ‫و‬ ‫ہ‬ ‫ی‬ ‫ت‬ ‫‪،‬گر‬ ‫کام‬ ‫ے‬ ‫و‬ ‫ہ‬ ‫ے‬ ‫ت‬ ‫بل دی پ فر ہ و‬
‫ت ئ‬ ‫خ‬ ‫ت‬ ‫ف ظت‬ ‫ت‬ ‫ی سامان کاف ا ظس عمال‪ :‬ئ خ‬ ‫ذا ی ح ا ت‬
‫ن ت ی ار کرے ہ وے پی۔‬ ‫ےقکہ ح ا ت ی دابیر ا‬ ‫ہ‬
‫ئح ا ت می ں کو ی طرہ ہ و تو ی ہ سب زی ادہ ا م ہ‬ ‫ج ب کام پر تذا ی صحت و‬
‫سے ب ڑا م صد اس عمال کرے والے کے ج سمغکو‬ ‫ش‬ ‫سب‬ ‫کا‬ ‫عمال‬ ‫کے اس‬ ‫ن‬ ‫ت‬ ‫خ‬
‫ی۔ای‬ ‫پ‬ ‫ی۔‬ ‫خ‬ ‫پ‬ ‫ے۔‬ ‫عمال ک ی ا ج ا‬
‫ل‬ ‫س ن‬‫ب‬ ‫خپی۔ای کو ا‬
‫ے می ہ ہت اط رہ ی ں۔دوران کام پی۔پی۔ای کا ی ر‬ ‫م‬ ‫ہ‬ ‫خ‬ ‫س‬
‫ےض کن ی ہ تطرے نکو م ہی ئں کر ف ظکت ااس یل ت‬ ‫ی‬ ‫سے چ ا ا ہ‬ ‫طرے ت‬
‫م ن اسب اس عمال ی ا عار ی طور پر رک کر ا مہ ی ا کی گ ی ح ا ت کو م کردے گا۔‬

‫م اسب پی۔پی۔ای کا او‪:‬‬ ‫ن‬ ‫ن‬

‫نض‬ ‫ش‬ ‫خ‬
‫ت‬
‫خ‬ ‫ت‬
‫ظ‬ ‫نت چ ن ک ئ‬ ‫ن‬
‫ے ش‪-‬آپ‬ ‫ہ‬ ‫رور‬ ‫ا‬ ‫کر‬ ‫دہ‬
‫ن‬ ‫ا‬
‫نم ہ‬ ‫کا‬ ‫طرات‬ ‫لف‬
‫ن‬ ‫م‬ ‫سے‬ ‫اط‬ ‫ا‬ ‫ر‬ ‫گہ‬ ‫کی‬ ‫کام‬
‫ی ل یف ت ش ج پ ح ی‬‫ک‬ ‫ا‬ ‫ے‬ ‫ے‬ ‫کا ا حابنکر‬
‫م ن اسب پی۔پی۔ای م ت‬
‫ے ح ا ی پ ی ہ وروں ‪،‬پی۔پی۔ای کرے والوں اور ب اے والوں سے م ورہ کر‬ ‫م تاسب پی۔پی۔ای ن حب کرے کے یل‬
‫سک‬
‫ے ہ ی ں۔‬
‫شاپ فلور پر استعمال ہونے والے سیفٹی آالت‪:‬‬
‫ورکرز کو حفاظتی آالت کے استعمال کرنے اور کب اور کہاںاستعمال کرنا ہے اس کی ٹریننگ ہونی‬

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‫‪Code: SOP-M-01/04‬‬

‫چاہیے ۔‬
‫درج ذیل آالت کو سیفٹی کیلئے استعمال کیا جائے۔‬

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 ‫‪Issue: 01‬‬
‫‪Revision: 02/10-01-2019‬‬
‫‪Code: SOP-M-01/04‬‬

‫‪1‬۔ حفاظتی عینک کا استعمال‪:‬‬

‫شاپ فلور پر کام کرتے وقت آنکھوں میں ہیٹ ‪ ،‬کیمیکل ‪،‬کٹنگ چپس اور گردوغبار جا‬
‫سکتی ہے جس سے آنکھوں کو بہت نقصان پہنچ سکتا ہے اس لئے کا م کرتے وقت‬
‫حفاظتی عینک کا استعمال کرنا چاہیے۔‬

‫‪2‬۔ حفاظتی ہیلمٹ کا استعمال‪:‬‬

‫کام کرنے کے دوران کوئی چیز ورکر کے ُاوپر ِگ ر سکتی ہے اور کیمیکل یا‬
‫تیزاب وغیرہ سے سر کو نقصان پہنچ سکتا ہے اس لئے کام کرنے کے دوران ہیلمٹ کو‬
‫ضرور استعمال کرنا چاہیے۔‬

‫‪3‬۔ دستانوں کا استعمال‪:‬‬

‫کام کرتے وقت دستانوں کا استعمال کرنا چاہیے تا کہ ُپرزوں کی یا چپس کی ہینڈلنگ کے‬
‫دوران ہاتھوں کونقصان سے بچایا جا سکے اور ہاتھوں کو محفوظ رکھا جا سکے۔‬

‫‪4‬۔ سیفٹی شوز کا استعمال‪:‬‬

‫کام کرنے کے دوران سیفٹی شوز ضرور استعمال کرنے چاہیے تاکہ پاؤں کو زخمی ہونے‪،‬‬
‫بجلی کے جھٹکے یا پاؤں پر گرم چیز یا گرم پانی کےگرنے سے زخمی ہونے سے بچا جا‬
‫سکے۔‬

‫استعمال‪:‬‬ ‫‪5‬۔ ماسک کا‬

‫والی جگہوں پر کام کرتے وقت ماسک کا استعمال کرنا چاہیے تا کہ کیمیکل کے بخارات وغیرہ‬ ‫دھویں یا کیمیکل‬
‫دوران اندر نہ چلے جائیں جو کہ بہت نقصان دہ ہیں۔‬ ‫سانس لینے کے‬

‫کا استعمال‪:‬‬ ‫‪6‬۔ فیس شیلڈ‬

‫ہیٹ ٹریٹمنٹ یا ویلڈنگ میں کام کرنے کے دوران فیس شیلڈ کا استعمال بھی کرنا چاہیے تا کہ چہرے کو حرارت‬
‫سے بچایا جا سکے۔‬

‫‪7‬۔ ائیر پلگ کا استعمال‪:‬‬

‫مشینوں کے زیادہ شو رکرنے والی جگہ (جیسے فورجنگ) پرکام کرتے وقت ائیر پلگ کا استعمال کرنا‬
‫چاہیے تاکہ کانوں کو شور سے بچایا جا سکے جو کہ کانوں کیلئے نقصان دہ ہے۔‬
 ‫‪Issue: 01‬‬
‫‪Revision: 02/10-01-2019‬‬
‫‪Code: SOP-M-01/04‬‬

‫‪-8‬ایپران (حفاظتی لباس)‪:‬‬

‫ایپران ایک حفا ظتی لباس ہے جو دوسرے لباس کے اوپر پہنا جاتا ہے۔اس کامقصد‬
‫کپڑوں کو داغ اور نشانوں سے محفوظ رکھنااوربعض خطرات جیسے ایسڈ‪ ،‬الرجی‪ ،‬کٹنگ‬
‫چپس یا زیادہ گرمی سے تحفظ فراہم کرنا ہے۔‬
 ‫‪Issue: 01‬‬
‫‪Revision: 02/10-01-2019‬‬
‫‪Code: SOP-M-01/04‬‬

‫‪1.2‬‬
‫‪5S Technique‬‬
‫‪1.2.1‬‬
‫‪Introduction‬‬
‫‪ 5S‬کا تعارف‬
‫‪ 5S‬ایک جاپانی تکنیک کا نام ہےجو کہ شاپ فلور (کام‬
‫کرنےوالی جگہ) پر کام کی پر فا رمینس کو بہتراور نفیس‬
‫کرنے کے لیےپانچ اقدامات تجویز کرتی ہے۔‬

‫‪Letter‬‬ ‫‪Japanese‬‬ ‫‪English‬‬ ‫‪ Urdu‬ن ت ن‬ ‫ن‬

‫‪1S‬‬ ‫‪Seiri‬‬ ‫‪Sort‬‬ ‫چ ن ا‪،‬عیل حدہ عیل حدہ کر ا‪ ،‬ظ ی م‬
‫‪2S‬‬ ‫‪Seiton‬‬ ‫‪Straighten‬‬ ‫ترتیب لگانا‬
‫‪3S‬‬ ‫‪Seiso‬‬ ‫‪Shine‬‬ ‫صفائی ‪،‬ستھرائی‪،‬چمکا‬
‫نا‬
‫‪4S‬‬ ‫‪Seiketsu‬‬ ‫‪Standardize‬‬ ‫معیار قائم کرنا‪ ،‬با قا‬
‫عد گی‬
‫‪5S‬‬ ‫‪Shitsuke‬‬ ‫‪Sustain‬‬ ‫قائم ‪/‬برقرار رکھنا‪،‬‬
‫ڈسپلن‬
‫ن تن‬ ‫ن‬
‫‪:1S‬چ ن ا‪،‬عیل حدہ عیل حدہ کر ا‪ ،‬ظ ی م‬
‫کام کی جگہ تمام ضروری اور غیر ضروری چیزوں کو الگ الگ کرنا اور غیر ضروری چیزوں کوسکریپ یا‬
‫تلف کر دینا ‪ S1‬کہالتا ہے۔‬
 ‫‪Issue: 01‬‬
‫‪Revision: 02/10-01-2019‬‬
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‫‪:S2‬ترتیب لگانا‬
‫غیر ضروری چیزیں ہٹا نے کےبعدضروری چیزوں کو ترتیب سے رکھنا تا کہ ان کو فورًا اور آسانی سے حاصل‬
‫کیا جا سکے‪ S2،‬کہالتا ہے۔‬

‫‪ :S3‬صفائی ‪،‬ستھرائی‪،‬چمکانا‬
‫مشینوں اور کام کرنے والے ماحول کو صا ف ستھرا اور چمکا کے رکھنا‪ S3،‬کہالتا ہے۔‬
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‫‪:S4‬معیار قائم کرنا‪ ،‬با قا عد گی‬

‫کام کو اتنے اچھےطریقےسے کریں اور با قا عدگی سے چیک کرتے رہیں کہ معیار قا ئم ہوجائے اور ایک‬
‫خوشگوار ماحول کی عکاسی ہو۔‬

‫‪:S5‬قائم ‪/‬برقرار رکھنا‪ ،‬ڈسپلن‬

‫مندرجہ باال چاروں اصولوں (‪)S 4-S 1‬کو اپنائیں‪،‬ان پر مسلسل قائم ر ہیں اوران میں بہتری الئیں۔‬
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‫‪1.2.2 Importance and Benefits‬‬

‫خ‬
‫فوائد ش‬ ‫‪5S‬کی اہمیت اور‬
‫ے۔‬ ‫٭‪5S‬سے ماحول صاف اور و گوار رہ ت ا ہ‬
‫٭ ‪ Waste‬کو کم کیا جاسکتا ہے۔‬
‫٭پروڈکشن کو بہتر کیا جاسکتا ہے ۔‬
‫٭کام کی کارکردگی (‪)Efficiency‬کو بہتر کیا جاسکتا ہے۔‬
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‫‪1.3 Kaizen‬‬
‫‪1.3.1 Introduction‬‬ ‫ت‬ ‫ئ‬
‫کائ زن کا عا رف‬
‫کا زن ب ھی ‪5S‬کی طرح ایک جاپانی تکنیک ہےجس کا مقصدانڈسٹری میں ہونے والے تمام کاموں میں مسلسل بہتری‬
‫ت‬ ‫ئ‬
‫ے۔‬ ‫الناہے ۔جا پانی زبان میں کا زن کا م طلب ہ ی ب ہ ری(‪ )improvement‬ہ‬

‫پراسیسزمیں بہتری آتی ہےتو‬ ‫اب چونکہ ‪ 5S‬سے بھی‬

‫مان سکتے ہیں۔‬ ‫ہم اس کو بھی کائزن کا حصہ‬

‫ئ‬
‫‪1.3.2 Importance and Benefits‬‬
‫کا زن کی اہ می ت‬
‫کائزن کو لگاتار ترقی کیلئے استعمال کیا جاتا ہے کائزن ایسی سرگرمیوں کو کہتے ہیں جو تمام کاموں کو بہتر‬
‫کرنے کیلئے ہوتی ہے اور اس میں ‪ CEO‬سے لے کر تمام ورکرز شامل ہوتے ہیں پراسس کو بہتر کرنے اور اس‬
‫میں کم سے کم وقت لگنے کیلئے کائزن کو استعمال کیا جاتا ہے۔کائزن میں غیرضروری چیزوں کو ختم کیا جا تا‬
‫ہے یا تبدیل کیا جاتاہے۔‬
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‫ت‬ ‫ف‬ ‫ئ‬
‫ے۔‬ ‫ا‬ ‫ا‬ ‫ا‬ ‫کم‬ ‫سے‬ ‫کم‬ ‫کو‬ ‫حرکات‬ ‫ی‬ ‫ا‬ ‫٭کائ زن سے ٹ ا م کے ض ا ع اور تورکرز کی ا قض‬
‫یج ہ‬ ‫ک‬ ‫ی ن ن ت‬ ‫یت‬ ‫ی‬
‫ے۔‬ ‫س عمال کو ی ی ب ای ا ج ا اہ‬ ‫٭ اس سے موج ودہ ج تگہ کےب ہ رتی ن ا ت‬
‫ے۔‬ ‫روڈکٹ ٹکا مع ی ار ب ہ ر ت‬
‫سے ب ہ ر ک ی ا ج ا ا ہ‬ ‫٭پ ش‬
‫ے۔‬ ‫روڈک ن ری تس کو ب ڑھا ی ا ج ا ا ہ‬ ‫٭پ ف‬
‫٭م ن‬
‫ن‬ ‫ت‬ ‫ے۔‬ ‫ہ‬ ‫ا‬ ‫ا‬ ‫ج‬ ‫ڑھ‬ ‫ب‬ ‫ع‬ ‫ا‬
‫ے اور ج اب پراطم ن ا ی ت (‪Job‬‬ ‫ت‬ ‫ج‬
‫ے۔جس سے سب کا مورال ب ڑھت ا ہ‬ ‫٭اس سے ممو عی طور پر تکارکردگی ب ہ ر ہ و ی ہ‬
‫ت‬
‫ے۔‬ ‫‪)Satisfaction‬ب ہ ر ہ و ی ہ‬

‫یق ن‬
‫‪1.3.3 PDCA‬‬ ‫‪Cycle‬‬
‫ئ‬ ‫س‬ ‫ن ن‬ ‫س‬
‫ےج و کہ ادارے‪/‬کمپ ی ‪ /‬ا ڈسٹ ری کے پراسیسزمی ں م لسل ب ہت ری (کا ی زن) کو ی ی‬
‫سائکل ایک‪ 4‬ٹی ج ماڈل ہ‬
‫ت‬ ‫نن‬
‫‪PDCA‬‬
‫ے۔‬
‫ہ‬ ‫ا‬ ‫آ‬ ‫کام‬ ‫کے‬ ‫ے‬ ‫با‬

‫‪P: Plan‬‬
‫‪D: Do‬‬
‫‪C: Check‬‬
‫‪A: Act‬‬

‫ن‬
‫‪1. Plan‬‬ ‫نئ‬ ‫ن‬ ‫ت‬ ‫ٹ‬ ‫ت‬
‫مام معلو مات(‪ )data‬اک ھا کرکے اس کا ج زی ہ کر ا اور ج ہاں ج ہاں ب ہت ری کی گ ج ا ش ہ واس کو ب ہت ر کرےکے‬
‫کے حوالے سے ن‬ ‫پراسنیسز‬
‫ن‬
‫ے م صوب ہ ب دی (‪)plan‬کر ا‪.‬‬ ‫یل‬

‫‪2. Do‬‬
‫ن‬ ‫ئث ن‬ ‫ٹ‬ ‫ت ئ‬ ‫ئ‬
‫ے پ الن پر عمل پ یراہ وے ہ وے پراسیسز می ں ارگٹ ش دہ ب ہت ری کے لی‬
‫ے م و ر ا داز سے کام کر ا۔‬ ‫ےگ‬
‫یک‬
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‫‪3. Check‬‬
‫تن‬ ‫ئ‬ ‫ن‬ ‫ٹ‬ ‫ت‬ ‫ت‬
‫ےی ا ہی ں۔کہی ں کو ی می و ہی ں‬
‫ک‬ ‫وا‬ ‫ہ‬ ‫ک‬ ‫کام‬ ‫کہ‬ ‫ں‬ ‫ر‬ ‫ک‬ ‫ق‬ ‫صد‬ ‫اور‬ ‫ں‬ ‫ر‬ ‫ک‬ ‫ہ‬ ‫ز‬ ‫ج‬ ‫کا‬ ‫ان‬ ‫ں‬ ‫ر‬ ‫ک‬ ‫ل‬ ‫ے کام کو چ ک کری ں‪ ،‬عداد و ش مارحا ص‬
‫ن‬
‫ہ‬ ‫ی‬ ‫ھ‬ ‫ی‬ ‫ی‬ ‫ی‬ ‫ی‬ ‫ی‬ ‫ی‬ ‫اپ ئ‬
‫رہ گ ی۔‬
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‫ئ‬ ‫ئ‬
‫اگر راسیسز م ں کہ ں کو ی کمی ہ و ت و اس ہ کام کر کے دور کر ں پ ھرن ت ا ج کے دست او زات ت‬
4. Act
‫ن ی ار کری ں عمتل می ں ت ب دی لیوں کے ب ارے‬ ‫ی‬ ‫ئ ی‬ ‫پ‬ ‫ی ی‬ ‫پ‬
.‫ے ج ویزات دی ں‬ ‫ے پی ڈی سی اے سا ی کل می ں پراسیسزکو مزی د ب ہت ر کرے کے لی‬ ‫ اور اگل‬،‫می ں دوسروں کو م طلع کری ں‬
‫ئ‬
!‫ کو ج اری رکھی ں‬5S ‫ کا زن اور‬،‫اورپی ڈی سی اے‬

2 PLC Fundamentals
2.1 PLC Hardware Handling
2.1.1 Introduction
 PLC stands for programmable logic controllers)
 PLC is much like personal computers in that the user can be overwhelmed by the vast array
of options and configurations available

2.1.2 Processor
 The processor (called CPU sometimes) is generally specified according to memory
required for the program to be implemented. In the modularized versions, capability can
also be a factor.
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 The processor consists of the microprocessor, system memory, serial communication ports,
PLC LAN link and external programming device and, in some cases, the system power
supply to power the processor and I/O modules.

2.1.3 Input and Output Modules

 Input and Output (I/O) modules are specified according to the input and output signals
associated with the particular application.
 These modules fall into the categories of discrete, analog, high speed counter or register
types.
 Discrete I/O modules are generally capable of handling 8 or 16 and, in some cases 32, on-
off type inputs or outputs per module.
 The I/O module can be specified as AC only, DC only or AC/DC along with the voltage
values for which it is designed.

Figure 2-1| IO Module Figure 2-2|Mitsubishi PLC with extended IO modules

of Mitsubishi MELSEC
PLC

 Analog modules are also available which can directly accept thermocouple inputs for
temperature measurement and monitoring by the PLC...
 One new development is an I/O Module which allows the serial transfer of information to
remote I/O units that can be as far as 12,000 feet away.

2.1.4 Power Supply

 The power supply is heart of any Controller.
 In some cases a power supply capable of delivering all required power for the system is
furnished as part of the processor module.
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 If the power supply is a separate module, it must be capable of delivering a current

greater than the sum of all the currents needed by the other modules.

Figure 2-3| Types of Power Supplies used in Mitsubishi PLC Systems

2.1.5 Programming Unit

 The programming unit allows the engineer or technician to enter and edit the program to
be executed.
 In its simplest form it can be a hand held device with a keypad for program entry and a
display device (LED or LCD) for viewing program steps or functions, as shown in
Figure 2-4.
 More advanced systems employ a separate personal computer which allows the
programmer to write, view, edit and download the program to the PLC through a
software.

Figure 2-4| Handheld PLC Programmer

The software allows the programmer or engineer to monitor the PLC as it is running the program. With
this monitoring system, such things as internal coils, registers, timers and other items can be monitored
to determine proper operation.
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2.1.6 System Block Diagram

A Programmable Controller is a specialized computer. Since it is a computer, it has all the basic
component parts that any other computer has; a Central Processing Unit, Memory, Input Interfacing and
Output Interfacing. The system block diagram will show us how different PLC components are inter
linked to form a system which can monitor, control and process runtime data/status variations on work
floor.

Figure 2-5| PLC System Block Diagram

The Central Processing Unit (CPU) is the control portion of the PLC. It interprets the program
commands retrieved from memory and acts on those commands. In present day PLC's this unit is a
microprocessor-based system. The CPU is housed in the processor module of modularized systems.

2.2 PLC Software Handling

2.2.1 Software Installation
1) Double click on “WPL-Soft setup”.
2) Click on “Next”.
3) Accept terms and conditions then click on “Next”.
4) Click on “Next” select “Destination Folder” and then click on “Next”.
5) Click on “Install” for installation.
6) After installation click on Finish button.
7) Now you can use WPL-Soft.

2.2.2 Software Operations

 To make a program in PLC there is a very big need to handle related software. Different function
in software are used to make executions.
 These are the main steps to be followed to execute any program in PLC or simulation.

Select WPL Soft 2.45: (Click on software icon on desktop to open it)
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Select New Page: (Click on new document to make create your work file)
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Select Model: (Select the model from dialog box)

Select PLC model ES2: (Select ES2 model in which we have to write the program)
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Select input device: (Click on the load NO contact to load the input device)
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Select input number: (Select the number of your input device from X0 – X7)

Select output device: (Click on Output Coil to load output device)

Select output number: (Select the number of your output from Y0 – Y7)
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Compile: (To compile your program click on CODE)

Simulator mode: (Click 0n simulator to monitor your program in absence of PLC)

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Online mode: (Click online mode to check the status of your program)

Run: (if program is stopped than click on Run to execute the program)
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Set on: (To make on your input device in absence of PLC right click on input device in
online mode and click on Set on option)

Set off: (To make off your input device in absence of PLC right click on input device in
online mode and click on Set off option)
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Save file: (Click on save option, select file destination and press OK to save a file)

Write to PLC: (To burn the program in PLC click on write to PLC)
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2.3 Basic PLC Programming

2.3.1 Load Normally Open and Close Contacts
The following table displays list of WPL Soft symbols their description, command, and
memory registers that are able to use the symbol.
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LD Instruction

1.1.1.1. Explanation:
The LD instruction is used to load NO contact which connects to left side bus line or starts a new
block of program connecting in series or parallel connection.

1.1.1.2. Program Example:

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LDI Instruction:

Explanation:
The LDI instruction is used to load NC contact which connects to left side bus line or starts a new block
of program connecting in series or parallel connection.

Program Example:

2.3.2 Output coil and End instruction

Explanation:

Output the program evaluation results before OUT instruction to the designated device.

Status of Coil Contact

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Program Example:

Explanation:

END instruction needs to be connected at the end of program. PLC will scan from address 0 to END
instruction and return to address 0 to scan again.

2.3.3 Load Rising-Edge & Falling-Edge Pulse Contacts

Similar to LD instruction, LDP and LDF instructions only act at the rising edge or falling edge when the
contact is ON, as shown in the figure below.
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2.3.4 SET & RESET Command

Explanations:
When the SET instruction is driven, its designated device will be ON and latched whether the SET
instruction is still driven. In this case, RST instruction can be applied to turn off the device.

Program example:

Ladder Diagram:

Instruction: Operation:
LD X0 Load NO contact X0
ANI Y0 Connect NC contact Y0 in series
SET Y1 Drive Y1 and latch the status

Explanations:

Device status when RST instruction is driven:

Device Status
S, Y, M Coil and contact are set to OFF.
T, C Current value is cleared. Associated contacts or coils are reset.
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D, E, F The content is set to 0.

Status of designated devices remains the same when RST instruction is not executed.
Program example:
Ladder diagram:

Instruction: Operation:
LD X0 Load NO contact X0
RST Y5 Reset contact Y5

2.3.5 Alternate Command (ALT)

Explanation:
 The status of D is alternated every time when the ALT instruction is executed.
 When ALT instruction is executed, ON/OFF state of D will be switched which is usually
applied on switching two operation modes, e.g. Start/Stop.
 This instruction is generally used in pulse execution mode (ALTP)

Program Example:
When X0 goes from OFF to ON, Y0 will be ON. When X0 goes from OFF to ON for the
second time, Y0 will be OFF.
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2.3.6 Arithmetic Commands (16-Bit & 32-Bit)

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2.4 PLC Wiring and Symbols

2.4.1 Basic Electric Wiring Symbols
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We shall begin with a study of the fundamental components used in electrical machine controls and
their ladder diagram symbols. It is important to understand that the material covered in this chapter is by
no means a comprehensive coverage of all types of machine control components. Instead, we will
discuss only the most commonly used ones. Some of the more exotic components will be covered in
later chapters.

Control Transformers:

Fuses:

Push button:

Mushroom Head Pushbutton:

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Selector Switches:

Limit Switches:

Indicator Lamps:

Relays:
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2.4.2 Need of JIC Symbols

To standardize electrical schematics, the Joint International Committee (JIC) symbols were developed,
these are shown in below Figures:
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2.4.3 Symbols used in PLC Programming

Figure 2.4.3.1 Normally Open Contact Figure 2.4.3.2 Normally Close Contact

Figure 2.4.3.3 Positive Transition-Sensing Contact Figure 2.4.3.4 Negative Transition-Sensing Contact
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Figure 2.4.3.5 Normally Open Coil Figure 2.4.3.6 Normally Close Coil

Figure 2.4.3.7 Set Latch Coil Figure 2.4.3.8 Reset Latch Coil

Figure 2.4.3.9 Positive Transition Sensing Figure 2.4.3.10 Negative Transition-Sensing Contact

2.4.4 Relay Wiring

1) Mount relay base on channel strip carefully.

2) First of all attach 24 V DC supply at point 13 and 14 of relay base.
3) Attach live or neutral wire to any normally open point i.e. 8, 7, 6 and 5 of the relay base.
4) Attach second live or neutral wire to any corresponding normally close point i.e. 12, 11, 10, 9 of the
relay base.
5) Attach all the relays to the relay base.
6) Turn on the power supply to check the working of relays.
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7) Before installing relay bases make sure that all power connections are off and do check for remaining
capacitor back current to avoid spark.
8) Be careful in making corresponding connections i.e. same connection on both side of relay.
9) Keep the numbering of relay pins in mind while attaching them.

2.4.5 Timer Wiring

Above timer has 8 terminals

1) 2 and 7 are used to energize the coil

2) 1 and 8 are common terminal
3) 4 and 5 are normally close terminal
4) 3 and 6 are normally open terminal
5) Before installing timer base make sure that all power connections are off and do check for
remaining capacitor back current to avoid spark.
6) Be careful in making corresponding connections i.e. same connection on both side of timer.
7) Keep the numbering of timer pins in mind while attaching them.
8) Mount timer base on channel strip carefully.
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9) Connect 24 V DC supply at point 2 and 7 of timer base.

10) Connect live or neutral wire to any common terminal i.e. 1 and 8 that you want to control through
timer
11) For ON Delay take out wire from any corresponding normally open point i.e. 3 and 6 of the timer
base.
12) For OFF Delay take out wire from any corresponding normally close point i.e. 4 and 5 of the
timer base.
13) Set time by rotating the dial
14) Place the timer to the timer base.
15) Turn on the power supply to check the working of timer.

2.4.6 Concept of Sourcing and Sinking

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2.4.7 PLC Wiring

2.4.8 Proximity Sensors and Limit Switches Wiring

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3 Basic Logic Design

3.1 Number System
A familiarity with number system is quite useful when working with programmable controllers, since
a basic function of these devices is to represent, store, and operate on numbers, even when
performing the simplest of operation.

The following statements apply to any number system:

 Every number system has a base or radix.

 Every system can be used for counting.
 Every system can be used to represent quantities or codes.
 Every system has a set of symbols.
The number system usually encountered while using programmable controllers are base 2, base 10,
base 8 and base 16. These systems are called Binary System, Decimal System, Octal System and
Hexadecimal System respectively.

3.1.1 Decimal Number System

The decimal number system is composed of 10 numerical or symbols. These 10 symbols are
0,1,2,3,4,5,6,7,8,9; using these symbols as digit of a number we can express any quantity. The
decimal system, also called base-10 system because it has 10 digits, has evolved naturally as a result
of a fact that people have 10 fingers. In fact, the word digit id derived from the Latin word for
“Finger”.

Figure 3-6.1 Representation of the decimal number

3.1.2 Octal Number System

Octal numbers therefore have a range of just “8” digits, (0, 1, 2, 3, 4, 5, 6, and 7) making them a
Base-8 numbering system and therefore, q is equal to “8”. The subscript 8 is used to identify a
number expressed in octal. For example, an octal number is expressed as: 2378.
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MSB Octal Number LSB

88 87 86 85 84 83 82 81 80

16M 2M 262k 32k 4k 512 64 8 1

Figure 3-1.2.1 Representation of the octal number system

Decimal 3-bit Binary Octal

0 000 0

1 001 1

2 010 2

3 011 3

4 100 4

5 101 5

6 110 6

7 111 7

8 001 000 10 (1+0)

9 001 001 11 (1+1)

Figure 3.1.2.2 the relationship between decimal, binary and octal numbers

3.1.3 Binary Number System

In binary number system there are only two symbols or possible digital values 0 and 1. Even so, this
base-2 system can be used to represent any quantity that can be represented in decimal or other
number system. In general though, it takes a greater number of binary digits to express given decimal
quantity.
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Figure 3-7| LSB & MSB in 8-bit Binary Number System

Figure 3-8| Representation of Binary Number System

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3.1.4 Hexadecimal Number System

One common way of overcoming this problem is to arrange the binary numbers into groups or sets
of four bits (4-bits). These groups of 4-bits uses another type of numbering system also commonly
used in computer and digital systems called Hexadecimal Numbers.

Figure 3-9| Hexadecimal String

Being a Base-16 system, the hexadecimal numbering system uses 16 (sixteen) different digits with
a combination of numbers from 0 through to 15. The numbers from 0 to 9 and the capital
letters A to F to represent its Binary or Decimal number equivalent, starting with the least
significant digit at the right hand side.

Decimal 4-bit Binary Hexadecimal

0 0000 0

1 0001 1

2 0010 2

3 0011 3

4 0100 4

5 0101 5

6 0110 6

7 0111 7

8 1000 8

9 1001 9
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10 1010 A

11 1011 B

12 1100 C

13 1101 D

14 1110 E

15 1111 F

16 0001 0000 10 (1+0)

17 0001 0001 11 (1+1)

Figure 3-10| the relationship between decimal, binary and hexadecimal

Using the original binary number from above 1101 0101 1100 11112 this can now be converted into
an equivalent hexadecimal number of D5CF which is much easier to read and understand than a
long row of 1’s and 0’s that we had before.

So by using hexadecimal notation, the numbers can be written with fewer digits and much less
likelihood of an error occurring. Similarly, converting hexadecimal based numbers back into binary
is simply the reverse operation.

MSB Hexadecimal Number LSB

168 167 166 165 164 163 162 161 160

4.3G 2.6G 16M 1M 65k 4k 256 16 1

Figure 3-11| Representation of a Hexadecimal Number

3.1.5 Binary Coded Decimal Number System

In the BCD numbering system, a decimal number is separated into four bits for each decimal digit
within the number. Each decimal digit is represented by its weighted binary value performing a direct
translation of the number. So a 4-bit group represents each displayed decimal digit from 0000 for a zero
to 1001 for a nine.
So for example, 35710 (Three Hundred and Fifty-Seven) in decimal would be presented in Binary Coded
Decimal as:
35710 = 0011 0101 0111 (BCD)
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In other words, the BCD is a weighted code and the weights used in binary coded decimal code
are 8, 4, 2, and 1, commonly called the 8421 code as it forms the 4-bit binary representation of the
relevant decimal digit.

Binary Power 23 22 21 20

Binary Weight: 8 4 2 1

Figure 3-12| BCD Representation of a Decimal Number

The relationship between decimal (denary) numbers and weighted binary coded decimal digits is given
below.

Decimal Number BCD 8421 Code

0 0000 0000

1 0000 0001

2 0000 0010

3 0000 0011

4 0000 0100

5 0000 0101

6 0000 0110

7 0000 0111

8 0000 1000

9 0000 1001

10 (1+0) 0001 0000

11 (1+1) 0001 0001

… …

20 (2+0) 0010 0000

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21 (2+1) 0010 0001

Figure 3-13| Truth Table for Binary Coded Decimal

We can see that 8421 BCD code is nothing more than the weights of each binary digit, with each
decimal (denary) number expressed as its four-bit pure binary equivalent.

Figure 3-14| Binary, Decimal, Octal and Hexadecimal Numbers

3.2 One’s and Two’s Complement

The one’s and two’s complements of a binary number are operations used by programmable controllers,
as well as computers, to perform internal mathematical calculations. To complement a binary number
means to change it to a negative number.

For example, to subtract the number 20 from the number 40, first complement 20 to obtain –20, and
then perform an addition.

3.2.1 One’s Complement

Let’s assume that we have a 5-bit binary number that we wish to represent as a negative number. The
number is decimal 23, or binary:

(10111)2

There are two ways to represent this number as a negative number. The first method is to simply place a
minus sign in front of the number, as we do with decimal numbers:
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– (10111)2

This method is suitable for us, but it is impossible for programmable controllers. To represent negative
numbers in computer language one’s complement is used.

First, the one’s complement method places an extra bit (sign bit) in the most significant (left-most)
position and lets this bit determine whether the number is positive or negative.

(0 10111)2

The negative representation of binary 10111 is obtained by placing a 1 in the most significant bit
position and inverting each bit in the number (changing 1s to 0s and 0s to 1s). So, the one’s complement
of binary 10111 is:

(1 01000)2

If a negative number is given in binary, its one’s complement is obtained in the same fashion.

(–15)10 = (1 0000)2

(+15)10 = (0 1111)2

3.2.2 Two’s Complement

In the one’s complement, all bits are inverted; but in the two’s complement, each bit, from right to
left, is inverted only after the first 1 is detected. Let’s use the number +22 decimal as an example:

(+22)10 = (0 10110)2

It’s two’s complement would be:

(–22)10 = (1 01010)2

Note that in the negative representation of the number 22, starting from the right, the first digit is a
0, so it is not inverted; the second digit is a 1, so all digits after this one are inverted.

If a negative number is given in two’s complement, its complement (a positive number) is found in
the same fashion:

(–14)10 = (1 10010)2

(14)10 = (0 01110)2

Again, all bits from right to left are inverted after the first 1 is detected. Other examples of the
two’s complement are shown here:

(+17)10 = (0 10001)2 (–17)10 = (1 01111)2

(+1)10 = (0 00001)2 (–1)10 = (1 11111)2

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3.3 Conversions

Figure 3-15| Conversions from binary, octal, decimal, and hex number system to other number systems.

3.4 Gray Code

3.4.1 Definition
A numerical code used in computing in which consecutive integers are represented by binary numbers
differing in only one digit. The reflected binary code (RBC) also known as Gray code.

The Gray code shown in Table 1 to represent digital data that have been converted from analog data.

Decimal Binary Gray Code

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0 0000 0000
1 0001 0001
2 0010 0011
3 0011 0010
4 0100 0110
5 0101 0111
6 0110 0101
7 0111 0100
8 1000 1100
9 1001 1101
Figure 3-16| Decimal to Binary and Grey Codes

3.4.2 Applications
 Today, Gray codes are widely used to facilitate error correction in digital communications such
as digital terrestrial television and some cable TV systems.
 In binary when move from one number to another, one or more than one bit change but in case
of Gray Code only one bit change after each transfer so the chance of error is reduce which
shows in above table.
 A typical application of the Gray code is the representation of analog data by a continuous
change in the angular position of a shaft. The shaft is partitioned into segments, and each
segment is assigned a number. If adjacent segments are made to correspond with the Gray‐code
sequence, ambiguity is eliminated between the angle of the shaft and the value encoded by the
sensor.

Figure 3-17 4-bit Gray Code used for Shaft-angle encoding

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3.5 Logic Gates

Since Boolean functions are expressed in terms of AND, OR, and NOT operations, it is easier to
implement a Boolean function with these type of gates. Factors to be weighed in considering the
construction of other types of logic gates are

1) The feasibility and economy of producing the gate with physical components
2) The possibility of extending the gate to more than two inputs
3) The basic properties of the binary operator, such as commutativity and associativity
4) The ability of the gate to implement Boolean functions alone or in conjunction with other
gates.

3.5.1 Types of Logic Gates

AND Gate:

Boolean Expression of AND Gate:

C= A . B

Truth Table:

Figure 3-18| AND Gate IC and Its Internal Structure:

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OR Gate
Boolean Expression of OR Gate:

Y = A +B

Truth Table:

OR Gate IC and Its Internal Structure:

Figure 3-19\ OR Gate IC and Its Internal Structure:

NOT Gate

Boolean Expression of NOT Gate: X =X

Truth Table:

Input Output
0 1
1 0

NOT Gate IC and Its Internal Structure:

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Figure 3-20|Not gate IC and Pin Configuration

NAND Gate

Boolean Expression of NAND Gate:

Y=A .B

Truth Table:

NAND Gate IC and Its Internal Structure:

Figure 3-21\ NAND Gate IC and Pin Configuration

NOR Gate
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Boolean Expression of NOR Gate:

X =A + B

Truth Table:

NOR Gate IC and Its Internal Structure:

Exclusive-NOR Gate:

Boolean Expression of XNOR Gate:

Output =XY + X Y

Truth Table:

XNOR Gate IC and Its Internal Structure:

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Figure 3-22| XNOR Gate IC and pin configuration

Exclusive-OR Gate

Boolean Expression of XOR Gate:

Output= A B+ A B

Truth Table:

Input A Input B Output

0 0 0
0 1 1
1 0 1
1 1 0

XOR Gate IC and Its Internal Structure:

Figure 3-23| XOR Gate IC and Pin Configuration

3.5.2 Universal Gates

NAND and NOR are universal gates any function can be implemented using only NAND or only NOR
gates. How can we prove this?

Proof for NAND gates

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Any Boolean function can be implemented using AND, OR and NOT gates. So if AND, OR and NOT
gates can be implemented using NAND gates only, then we prove our point.

Implement NOT using NAND

Implementation of AND using NAND

Implementation of OR using NAND

3.6 Boolean Algebra

3.6.1 Definition

In mathematics and mathematical logic, Boolean algebra is the branch of algebra in which the values
of the variables are the truth values true and false, usually denoted 1 and 0 respectively.
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3.6.2 Laws of Boolean Algebra

Boolean Equivalent Boolean Algebra

Description
Expression Switching Circuit Law or Rule

A in parallel with
A+1=1 Annulment
closed = "CLOSED"

A in parallel with
A+0=A Identity
open = "A"

A in series with
A. 1 = A Identity
closed = "A"

A in series with
A. 0 = 0 Annulment
open = "OPEN"

A in parallel with
A+A=A Idempotent
A = "A"

A in series with
A. A = A Idempotent
A = "A"

NOT A
NOT A = A Double Negation
(double negative) = "A"

A in parallel with
A+A=1 Complement
NOT A = "CLOSED"

A in series with
.A=0 Complement
NOT A = "OPEN"

A in parallel with B =
A+B = B+A Commutative
B in parallel with A

A in series with B =
A.B = B.A Commutative
B in series with A

A+B = A.B invert and replace OR with AND de Morgan’s Theorem

A.B = A+B invert and replace AND with OR de Morgan’s Theorem

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A brief description of the various Laws of Boolean are given below with A representing a variable
input.

Annulment Law – A term AND with a “0” equals 0 or OR with a “1” will equal 1.

A. 0 = 0 A variable AND with 0 is always equal to 0.

A + 1 = 1 A variable OR with 1 is always equal to 1.

Identity Law – A term OR with a “0” or AND with a “1” will always equal that term.

A + 0 = A A variable OR with 0 is always equal to the variable.

A . 1 = A A variable AND with 1 is always equal to the variable.

Idempotent Law – An input that is AND or OR with itself is equal to that input.

A + A = A A variable OR with itself is always equal to the variable.

A . A = A A variable AND with itself is always equal to the variable.

Complement Law – A term AND with its complement equals “0” and a term OR with its complement
equals “1”.

A . A = 0 A variable AND with its complement is always equal to 0.

A + A = 1 A variable OR with its complement is always equal to 1.

Commutative Law – The order of application of two separate terms is not important.

A . B = B. A The order in which two variables are AND makes no difference.

A + B = B + A The order in which two variables are OR makes no difference.
Double Negation Law – A term that is inverted twice is equal to the original term. A = A A
double complement of a variable is always equal to the variable.

de Morgan´s Theorem – There are two “de Morgan´s” rules or theorems,

Two separate terms NOR together is the same as the two terms inverted (Complement) and AND for
example, A+B = A. B.

Two separate terms NAND together is the same as the two terms inverted (Complement) and OR for
example, A.B = A +B.

Other algebraic Laws of Boolean not detailed above include:

Distributive Law – This law permits the multiplying or factoring out of an expression.

A(B + C) = A.B + A.C (OR Distributive Law)

A + (B.C) = (A + B).(A + C) (AND Distributive Law)
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Absorptive Law – This law enables a reduction in a complicated expression to a simpler one by
absorbing like terms.

A + (A.B) = A (OR Absorption Law)

A(A + B) = A (AND Absorption Law)

Associative Law – This law allows the removal of brackets from an expression and regrouping of the
variables.

A + (B + C) = (A + B) + C = A + B + C (OR Associate Law)

A(B.C) = (A.B)C = A . B . C (AND Associate Law)

3.6.3 Boolean-Algebra Functions

Using the information above, simple 2-input AND, OR and NOT Gates can be represented by 16 possible
functions as shown in the following table.

Function Description Expression

1. NULL 0

2. IDENTITY 1

3. Input A A

4. Input B B

5. NOT A A

6. NOT B B

7. A AND B (AND) A.B

8. A AND NOT B A.B

9. NOT A AND B A.B

10. NOT AND (NAND) A.B

11. A OR B (OR) A+B

12. A OR NOT B A+B

13. NOT A OR B A+B

14. NOT OR (NOR) A+B

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15. Exclusive-OR A.B + A.B

16. Exclusive-NOR A.B + A.B

3.7 Variable Reduction Using DE Morgan’s Laws

3.7.1 Boolean and DE Morgan Theorem
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Example:
Simplify the following Boolean expression and note the Boolean or De Morgan’s theorem used at each
step. Put the answer in SOP form.

Solution:

Example:
Simplify the output function F2. Be sure to note the Boolean or DE Morgan’s theorem used at each step.
Put the answer in SOP form.
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Solution:

Practice Problem:

3.8 Variable Reduction using Karnaugh’s Maps

3.8.1 Introduction

The Karnaugh map was invented in 1953 by Maurice Karnaugh a telecommunications engineer at Bell
Labs.
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3.8.2 Rules for K-Maps

 Each cell with a 1 must be included in at least one group.

 Try to form the largest possible groups.
 Try to end up with as few groups as possible.
 Groups may be in sizes that are powers of 2: 2 0 = 1, 2 1 = 2, 2 2 = 4, 2 3 = 8, 2 4 = 16, ...
 Groups may be square or rectangular only (including wraparound at the grid edges). No
diagonals or zig-zags can be used to form a group.
 The larger a group is, the more redundant inputs there are:

 A group of 1 has no redundant inputs.

 A group of 2 has 1 redundant input.
 A group of 4 has 2 redundant inputs.
 A group of 8 has 3 redundant inputs.
 A group of 16 has 4 redundant inputs.

3.8.3 Two Variable K-Map

Figure 3-24| Example map

Example:

Direct from truth table: Y = A’B’ + A’B + AB’

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3.8.4 Three Variable K-Map

 Extreme ends of same row are adjacent

Example:

3.8.5 Four Variable K-Map

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 Four corners adjacent

Example:

4 Timers and Counters

4.1 Introduction to Timers
 The most commonly used process control device after coils and contacts is the timer.
 Timing mechanisms which activate a switch, are sometimes also called "timers".
 PLC Timers are generally used for delaying an event from taking place, or to delay a
device from shutting off either on an on transition or an off transition.
 A timer which counts upwards from zero for measuring elapsed time is often called a
stop-watch.
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 A device which counts down from a specified time interval is more usually called a timer.

4.2 Timer Instruction

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4.3 Timer Resolution

 100ms
 10ms
 1ms

4.4 Types of Timers

There are two fundamental types of timers.

4.4.1 ON-Delay Timer

An on-delay timer will wait for a set time after a line of ladder logic has been true before turning
on, but it will turn off immediately.

ON-delay means output ON after some delay and retentive timer has ability to accumulate its value
even input switch is turn off.

An ON delay retentive timer program shown in Figure below.

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In Delta PLC retentive timers are:

 100ms Timer: T250 ~ T255

 10ms Timer: T240 ~ T245
 1ms Timer: T246 ~ T249

Consider the example of an old car. If you turn the key in the ignition and the car does not start
immediately, that is an on-delay.

4.4.2 OF-Delay Timer

An off-delay timer will turn on immediately when a line of ladder logic is true, but it will delay
before turning off.

OFF-delay means output off after some delay and retentive timer has ability to accumulative its
value even input switch is turns off.

An off delay retentive timer program shown in Figure below.

Consider the example of an old car. If you turn the key to stop the engine but the engine doesn’t
stop for a few seconds that is an off delay.
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 TON - Timer ON
 TOF - Timer OFF
 RTO - Retentive Timer ON
 RTF - Retentive Timer OFF

4.5 Time Arithmetic Instruction

4.5.1 Time Addition Instruction
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4.5.2 Time Subtraction Instruction

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4.6 RTC Instructions

4.6.1 Time Read Instruction
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4.6.2 Time Write Instruction

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4.6.3 Hour Meter Instruction

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4.7 Introduction to Counters

A counter is a special function included in the PLC program language that allows the PLC to increment
or decrement a number each time the control logic for the rung switches from false to true.

A typical counter is shown in Figure

4.8 Counters Instruction

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4.9 Types of Counters

4.9.1 Up Counter
 Counter which is used for up counting.
 In Delta ES2 16-bit counter are up counters.
 Range of up counter in Delta PLC ES2 are (C0 to C199).

4.9.2 Up/Down Counter

 Counter that can count up and down in both directions.
 In Delta ES2 32-bit counter are up/down counters.
 Range of up/down counters in Delta PLC ES2 are ( C200 to C255)

4.9.3 High Speed Counter

 The counter used for the counting of high speed pulses (e.g. Encoder pulses) is called
high speed counter.
 In Delta PLC ES2 high speed counter are 32-bit up/down counters.
 Range of up/down counters in Delta PLC ES2 are ( C231 to C255)

5 Advance PLC Programming

5.1 Move Instructions
5.1.1 MOV Instruction
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5.1.2 SMOV Instruction

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5.1.3 FMOV Instruction

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5.1.4 BMOV Instruction:

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5.2 Rotation Instructions

5.2.1 Rotation Right Instruction
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5.2.2 Rotation Left Instruction

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5.2.3 Rotation Right with Carry Instruction

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5.2.4 Rotation Left with Carry Instruction

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5.3 Bit-Wise Data Control

5.3.1 Bit Shift Right Instruction
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5.3.2 Bit Shift Left Instruction

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5.3.3 BOUT Instruction

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5.3.4 BSET Instruction

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5.3.5 BRST Instruction

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5.3.6 BON Instruction

5.3.7 SUM Instruction

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5.4 Coding Instructions

5.4.1 Decoder Instruction
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5.4.2 Encoder Instruction

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5.4.3 7-Segment Decoder Instruction

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5.4.4 Exchange Instruction

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5.5 Comparison Instructions

5.5.1 CMP Instruction
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5.5.2 ZCP Instruction

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5.5.3 Contact Type Comparison

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5.5.4 Logic Contact Operation

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5.6 Matrix
5.6.1 Matrix AND Instruction
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5.6.2 Matrix OR Instruction

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5.6.3 Matrix XOR Instruction

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5.6.4 Matrix XNOR Instruction

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5.6.5 Matrix Inverse Instruction

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5.7 Floating Point Instructions

5.7.1 Move Floating Point Data Instruction
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5.7.2 Floating Point Square Root Instruction

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5.7.3 Floating Point Compare Instruction

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5.7.4 Floating Point Zone Compare Instruction

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5.8 Trigonometry Instruction

5.8.1 Sine Instruction
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5.8.2 Cosine Instruction

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5.8.3 Tangent Instruction

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5.8.4 Arc Sine Instruction

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5.8.5 Arc Cosine Instruction

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5.8.6 Arc Tangent Instruction

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5.8.7 Degree to Radian Instruction

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5.8.8 Radian to Degree Instruction

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5.9 STL and RET Instruction

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5.10Interrupts
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5.11Subroutine Call Instructions

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5.12Conditional Jump Instruction

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5.13MC and MCR Instruction

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6 Sensors
6.1 Introduction to Sensors
Sensor is a device whish detect or measure the physical quantity (temperature, pressure etc.) and
covert the data into electrical signal.

A transducer converts one physical parameter into another. The fuel level sending unit in an
automobile fuel tank is a transducer because it converts a liquid level to a variable resistance,
voltage, or current that can be indicated by the fuel gauge.

Feedback elements are those elements of a control system which regulate the output of the system
with respect to the difference between the reference and the instantaneous output of the system to
generate progressive or compensatory response, called error signal, which is processed for the
system to generate a regulated response.
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Figure 6-25| Basic Control Circuit Block Diagram of a Closed Loop Feedback System

6.2 Types of Sensors

6.2.1 Two Wire Sensor

6.2.2 Three Wire Sensor

6.2.3 Four Wire Sensor

6.3 Discrete Sensors

6.3.1 Inductive Proximity Sensor
Inductive proximity sensors operate on the principle that the inductance of a coil and the power losses in
the coil vary as a metallic (or conductive) object is passed near to it.
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Because of this operating principle, inductive proximity sensors are only used for sensing metal objects.
They will not work with non-metallic materials.

Figure 6-27| Inductive Proximity Sensor Working

Figure 6-28| Inductive Proximity Sensor internal

Figure 6-26| Sample Inductive Proximity Sensors structure

When a metallic object (steel, iron, aluminium, tin, copper, etc.) comes near to the face of the sensor, as
shown in Figure 6.3-2, the alternating magnetic field in the target produces circulating eddy currents
inside the material. To the oscillator, these eddy currents are a power loss.

As the target moves nearer, the eddy current loss increases which loads the output of oscillator. This
loading effect causes the output amplitude of the oscillator to decrease.

Figure 6-29| Variations in response to the absence or presence of an object in the vicinity of the inductive sensor

Small diameter sensors (approximately ¼” in diameter) have typical sensing ranges in the area of 1mm,
while large diameter sensors (approximately 3" in diameter) have sensing ranges in the order of 50mm
or more.

6.3.2 Capacitive Proximity Sensor

The principle of operation of the sensor is that an internal oscillator will not oscillate until a target
material is moved close to the sensor face.

The target material varies the capacitance of a capacitor in the face of the sensor that is part of the
oscillator circuit.
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Figure 6-30| Sample Capacitive Proximity Figure 6-31| Internal Structure of a capacitive proximity
Sensors Sensor

There are two types of capacitive sensor

In the dielectric type of capacitive sensor, there are two side-by-side capacitor plates in the sensor face.
For this type of sensor, the external target acts as the dielectric.
As the target is moved closer to the sensor face, the change in dielectric increases the capacitance of the
internal capacitor, making the oscillator amplitude increase, which in turn causes the sensor to output an
“on” signal.
Dielectric type capacitive proximity sensors will sense both metallic and non-metallic objects.
However, in order for the sensor to work properly, it is best if the material being sensed has a high
density. Low density materials (foam, bubble wrap, paper, etc.) do not cause a detectable change in the
dielectric and consequently will not trigger the sensor.

The conductive type of sensor operates similarly; however, there is only one capacitor plate in the
sensor face. The target becomes the other plate. Therefore, for this type of sensor, it is best if the target
is an electrically conductive material (usually metal or water-based).

Figure 6-32| Operating Principle of Capacitive Proximity Figure 6-33| Working of Capacitive proximity
Sensor sensor

Conductive type capacitive proximity sensors require that the material being sensed to be an electrical
conductor. These are ideally suited for sensing metals and conductive liquids.
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For example, since most disposable liquid containers are made of plastic or cardboard, these sensors
have the unique capability to “look” through the container and sense the liquid inside. Therefore, they
are ideal for liquid level sensors.

6.3.3 Photo Sensor

A photoelectric sensor, or photo eye, is an equipment used to discover the distance, absence, or
presence of an object by using a light transmitter, often infrared, and a photoelectric receiver. They are
largely used in industrial manufacturing.

Working Principle

A beam of light is emitted from the light emitting element and is received by the light receiving element

Reflective Model

Both the light emitting and light receiving elements are contained in a single housing. The sensor
receives the light reflected from the target.

Thru-beam Model

The transmitter and receiver are separated. When the target is between the transmitter and
receiver, the light is interrupted.
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Retro-reflective Model

Both the light emitting and light receiving elements are contained in same housing. The light
from the emitting element hits the reflector and returns to the light receiving element. When a target is
present, the light is interrupted.

6.3.4 Motion Sensor

A motion detector is a device that detects moving objects, particularly people. Following are the types of
motion sensors

Passive infrared (PIR)

Passive infrared (PIR) sensors are sensitive to a person's skin temperature through emitted black body
radiation at mid-infrared wavelengths, in contrast to background objects at room temperature. No
energy is emitted from the sensor, thus the name passive infrared.
Microwave
In this sensor a continuous wave of microwave radiation is emitted, and phase shifts in the reflected
microwaves due to motion of an object toward (or away from) the receiver result in a heterodyne signal
at a low audio frequency.
Ultrasonic
An ultrasonic transducer emits an ultrasonic wave (sound at a frequency higher than a human ear can
hear) and receives reflections from nearby objects.
Tomographic motion detector
These systems sense disturbances to radio waves as they pass from node to node of a mesh network.
They have the ability to detect over large areas completely because they can sense through walls and
other obstructions.
Gesture detector
Photo-detectors and infrared lighting elements can support digital screens to detect hand motions and
gestures with the aid of machine learning algorithms.
6.4 Temperature Sensing Devices
Switches and relays are the simplest type of sensors that can help system regulating its output.
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6.4.1 Bimetallic Switch

The bi-metallic switch is a discrete (ON-OFF) sensor that takes advantage of the fact that as materials
are heated they expand, and that for the same change in temperature, different types of material expand
differently. The switch is constructed of a bi-metallic strip.

Figure 6-34| Bimetallic Switch Contraction and working

The bi-metallic strip consists of two different metals that are bonded together. The metals are chosen
so that their coefficient of temperature expansion is radically different.

Since the two metals in the strip will be at the same temperature, as the temperature increases, the
metal with the larger of the two coefficients of expansion will expand more and cause the strip to
warp.

If we use the strip as a conductor and arrange it with contacts as shown in Figure 6.5-1 we will have
a bi-metallic switch. Therefore, the bi-metallic strip acts as a relay that is actuated by temperature
instead of magnetism.

In most bi-metallic switches, a spring mechanism is added to give the switch a snap action. This
forces the strip to quickly snap between its two positions which prevents arcing and pitting of the
contacts as the bi-metallic strip begins to move between contacts.

Figure 6-35| Bimetallic Switch with snap action

6.4.2 Thermocouple

Thermocouples provides analog temperature information. They are extremely simple, very rugged,
repeatable, and very accurate.

The operation of the thermocouple is based on the physical property that whenever two different
(called dissimilar) metals are fused (usually welded) together, they produce a voltage. The
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magnitude of the voltage (called the See beck voltage) is directly proportional to the temperature
of the junction.

For certain pairs of dissimilar metals, the temperature-voltage relationship is linear over a small
range, however, over the full range of the thermocouple, linearization requires a complex
polynomial calculation. The temperature range of a thermocouple depends only on the two types
of dissimilar metals used to make the thermocouple junction.

There are six types of thermocouples that are in commercial use, each designated by a letter.
These are listed in the table below. Of these, the types J, K and T are the most popular.

Figure 6-36| Different Types of Thermocouples

Wiring a thermocouple with off the shelf copper hookup wire will create additional junctions and
accompanying voltage and temperature measurement errors.

For example, if we wish to use a type-J thermocouple, we must also purchase type-J wire to use
with it, connecting the iron wire to the iron side of the thermocouple and the constantan wire to the
constantan side of the thermocouple.

It is not possible to connect a thermocouple directly to the analog input of a PLC or other
controller. The reason for this is that the Seebeck voltage is extremely small (generally less than 50
millivolts for all types).
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In addition, since the thermocouples are non-linear over their full range, compensation must be
added to linearize their output. Therefore, most thermocouple manufacturers also market electronic
devices to go with each type of thermocouple that will amplify, condition and linearize the
thermocouple output.

6.4.3 RTD
 Resistance thermometers, also called resistance temperature detectors (RTDs),
are sensors used to measure temperature.
 Many RTD elements consist of a length of fine wire wrapped around a ceramic or glass
core but other constructions are also used.
 RTD wire is a pure material, typically platinum, nickel, or copper.
 RTDs work on a basic correlation between metals and temperature. As the
temperature of a metal increases, the metal's resistance to the flow of electricity
increases

 Platinum resistance thermometers (PRTs) offer excellent accuracy over a wide

temperature range (from –200 to +850 °C). ... The most common type (PT100) has a
resistance of 100 ohms at 0 °C and 138.4 ohms at 100 °C.

 There are also PT1000 sensors that have a resistance of 1000 ohms at 0 °C.

6.4.4 Temperature Gauges

Temperature Gauge is a device used to indicate the temperature of an item being monitored.

Common methods of measuring temperature include bimetallic strip (the bending of which increases
with temperature) and the thermocouple which produces an electronic voltage that depends on
the temperature.
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6.5 Pressure Sensing Devices

Force on unit area is called pressure

6.5.1 Pressure Switches

A pressure switch is a form of switch that closes an electrical contact when a certain set
fluid pressure has been reached on its input.

The switch may be designed to make contact either on pressure rise or on pressure fall.

Figure 37Temperature gauge

Figu

6.5.2 Pressure Sensors

Pressure sensor is a device for pressure measurement of gases or liquids. Pressure sensor usually
acts as a transducer, it generates a signal as a function of the pressure imposed.
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Pressure sensors can be classified in terms of pressure ranges they measure, temperature ranges of
operation, and most importantly the type of pressure they measure.

6.5.3 Pressure Gauges

A pressure gauge is a fluid intensity measurement device.

OR Instruments used to measure and display pressure in an integral unit are called pressure gauges
or vacuum gauges. A manometer (not to be confused with manometer) is a good example, as it uses
a column of liquid to both measure and indicate pressure.

The amount of uncoiling that occurs is proportional to the pressure inside the bourdon tube.
Mechanical pressure gauges are connected directly to the process fluid being measured (i.e. oil). As the
process fluid pressure changes the pressure on the bourdon tube also changes which in turn moves the
pointer on the gauge.
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6.5.4 Solenoid Valves

"A solenoid valve is an electromechanical actuated valve to control the flow of liquids and
gases."

The magnetic field exerts a force on the plunger. As a result, the plunger is pulled toward
the center of the coil so that the orifice opens. This is the basic principle that is used to open
and close solenoid valves.

When a normally open solenoid valve is not powered, the plunger is down, which means that a flow
is allowed through the valve. Once the coil on the plunger is energized, however, the magnetic field
causes the plunger to rise. This effectively seals the valve, preventing the gas or liquid from flowing
through.

A 2-way, normally closed, solenoid valve has 2 pipe connections, an inlet called the cavity port and
an outlet called the body orifice port. When the valve is energized the plunger opens allowing media
to flow through the valve in the cavity port and out the body orifice port. Turn off the power.

Solenoid valves are commonly used at the inlet of day tanks for flow control. A normally
closed valve is used for normal day tank fill. A normally open valve is sometimes used in series to
activate as high level stop valve.

6.6 Water Level Sensor

6.6.1 Float Switch

The liquid level float switch is a simple device that provides a discrete output. As illustrated in Figure
6.6.1, it consists of a snap-action switch and a long lever arm with a float attached to the arm.
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Figure 6-39| Horizontally fixed type Float Switch labeled

Figure 6-38| Float Switch Schematic Diagram diagram

Figure 6-40|Hanging type Float Switch based upon metallic ball and a micro-switch (limit Switch)

As the liquid level rises, the lever arm presses on the switch’s actuator button. Coarse adjustment of the
unit is done by moving the vertical mounting position of the switch. Fine adjustment is done by
loosening the mounting screws and tilting the switch slightly (one of the mounting holes in the switch is

elongated for this purpose), or by simply bending the lever arm. The electrical symbols for the float
switch are shown in Figure 6.6-4.

Figure 6-41| Discrete Output Float Switches Symbols

The N/O switch on the left closes when the liquid level rises, and the N/C switch on the right opens as
the liquid level rises.

6.7 Encoder
An optical encoder is an electromechanical device which has an electrical output in digital form
proportional to the angular position of the input shaft. It is used to measure the angular position
and RPM of the machine.
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6.7.1 Slotted Disk and Opto-Interrupter (Simple Rotary Encoder)

Although angular position and RPM of the machine can be measure by using optical encoder,but
one relatively inexpensive method to accomplish this is to use a simple slotted disk and Opto-
interrupter.

This device is constructed of a circular disk (usually metal) mounted on the machine shaft as
shown in Figure 6.7-1.

A small radial slot is cut in the disk so that light from an emitter will pass through the slot to a photo-
transistor when the disk is in a particular angular position. As the disk is rotated, the photo-transistor
outputs one pulse per revolution.

Generally, the slotted disk is painted flat black or is black anodized to keep light scattering and
reflections to a minimum.

The slotted disk system can be used to initialize the angular position of a machine. The process of
initializing a machine position is called homing and the resulting initialized position is called the home
position.

To do this, the PLC simply turns on the machine’s motor at a slow speed and waits until it receives a
signal from the photo-transistor.

If the slotted disk is used to measure rotating speed, there are two standard methods to do this.

1. In the first method, the PLC starts a retentive timer when it receives a pulse from the
photo-transistor. It then stops the timer on the next pulse. The rotating speed of the
machine in RPM is then S rpm = 60 / T, where T is the time value in the timer after the
second pulse. This method works well when the machine is rotating very slowly (<<1
revolution per second) and it is important to have a speed update on the completion of
every revolution.
2. In the second method, we start a long timer (say 10 seconds) and use it to enable a counter
that counts pulses from the photo-transistor. When the timer times out, the counter will
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contain the number of revolutions for that time period. We can then calculate the speed
which is Srpm = C * 60 / T, where C is the value in the counter and T is the preset (in
seconds) for the timer used to enable the counter.

7 Analog Handling
7.1 A/D Module
A/D module is used to convert analog signal into discrete signal.

7.1.1 External Wiring

 When performing analog input, please isolate other power wirings.

 When the A/D module is connected to current signals, make sure you short-circuit “V+” and
“I+” terminals.
 If the noise is too significant, please connect FE to the grounding terminal.
 Please connect the terminal on both the power module and A/D module to the system earth
point and ground the system contact or connect it to the cover of power distribution cabinet.
 If the ripples at the loaded input terminal are too significant that causes noise interference on
the wiring, connect the wiring to 0.1 ~ 0.47μF 25V capacitor.

7.1.2 A/D Conversion

 In industrial automation, many measuring units are transmitted by analog signals. The most
frequently adopted range for the signals are voltage -10V ~ 10V and current -20mA ~
20mA.
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 To use the analog signals as the parameters for PLC operations, you have to convert them
into digital values first.
 For example, the voltage -10V ~ 10V is first converted into values -32,000 ~ +32,000 by an
A/D module, and the PLC will read/write the control registers (CR) in the A/D module. The
signals sent back to the PLC for operations will be digital K-32,000 ~ K32,000
 DVP04AD-E2 analog signal input module receives external 4 points of analog input signals
(voltage or current) and converts them into 16-bit digital signals.
 The Main Processing Unit (MPU) can read/write the data in the module by using
FROM/TO instructions or D9900~D9999 in the program.
 You can select voltage input or current input by the wiring. Range for voltage input: ±10V
(±32,000). Range for current input: ±20mA (±32,000).

7.1.3 Module Specification

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7.1.4 CR (Control Register)

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7.2 TO and FROM Instruction

7.2.1 TO Instruction
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7.2.2 FROM Instruction

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7.3 D/A Module

D/A module is used to convert discrete signal into analog signal.

7.3.1 External Wiring

 When performing analog output, please isolate other power wirings.

 If the ripples at the loaded input terminal are too significant that causes noise interference on
the wiring, connect the wiring to 0.1 ~ 0.47μF 25V capacitor.
 Please connect the terminal on both the power modules and DA to the system earth point and
ground the system contact or connect it to the cover of power distribution cabinet.
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7.3.2 D/A Conversion

 In industrial automation, many control signals are analog signals. The most frequently
adopted range for the signals are voltage -10V ~ 10V and current 0 ~ 20mA. Therefore, the
data in the PLC have to be converted into analog signals for controlling the peripheral
devices.
 For example, data -32,000 ~ 32,000 in the PLC are converted into voltage -10V ~ 10V by a
D/A module. The output voltage can therefore be used for controlling the peripheral analog
devices.
 DVP02DA-E2 (DVP04DA-E2) analog signal output module receives four groups of 16-bit
digital data from the PLC and converts the digital data into four points analog output signals
(voltage or current).
 You can select voltage output or current output by the wiring. Range for voltage output: -10V
~ 10V (-32,000 ~ 32,000). Range for current output: 0 ~ 20mA (0 ~ 32,000).

7.3.3 Module Specification

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7.3.4 CR (Control Register)

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7.4 PT Module
7.4.1 External Wiring

 Wiring for analog input should adopt cables of PT100 / PT1000 temperature sensor or double
shielded cable and should be separated from other power cables that may cause interference.
 Apply 3 wires for PT100 / PT1000. If a 2 wires sensor is applied, please short-circuit I+ and I-
terminals.
 Connect FE with terminal for noise suppression.
 Connect the terminal on both power module and DVP04PT-E2 to the system grounding point
then ground the point or connect it to the cover of power distribution cabinet.

7.4.2 Temperature Conversion

Platinum temperature sensor is highly accurate and stable.

Quality of linearity between -200°C and 600°C is fairly good.

The temperature coefficient of PT100 temperature sensor is more significant at low temperature -
200°C ~ -100°C while it becomes small at high temperature, i.e. 300°C ~ 500°C.

The quality of linearity is good at middle temperature 100°C ~ 300°C.

The resistance of PT100 is 100Ω at 0°C, which is taken as the standard for a metallic temperature
sensor.
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In order to reduce self-heating, a working current that is too big should be avoided in the
application of PT100 temperature sensor. Generally, we confine the rated current to be below
2mA.

The self-heating of 1mW on PT100 will cause a temperature variation of 0.02°C ~ 0.75°C.

Reducing the current through PT100 will reduce the temperature variation as well. However, if
the current is too small, PT100 will be interfered by noise easily. Therefore, it is appropriate to
confine the current between 0.5mA and 2mA.

DVP04PT-E2 temperature measurement module is able to receive 4 points of platinum

temperature sensors (PT100 3-WIRE 100Ω 3850 PPM/°C (DIN 43760 JIS C1604-1989)/ NI100 /
PT1000 / NI1000) and convert them into 16-bit digital signals.

The data in DVP04PT can be read/written by using FROM/TO instructions or D9900 ~ D9999 in
the program

. You can select the temperature to be displayed in Celsius (°C) or Fahrenheit (°F). Resolution of
temperature in Celsius: 0.1°C and in Fahrenheit: 0.18°F.

7.4.3 Module Specification

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7.4.4 CR (Control Register)

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8 Human Machine Interface (HMI)

8.1 Introduction and Types of HMI
There has been some sort of interface involved in the past either in the form of mechanical control panel
or numeric control panel, or computer aided numeric control.

But today we have the latest state of the art human machine interfaces (HMI) based on graphic LED
displays with or without multi-touch feedback assistance.

This graphical user interface or simply GUI help user to get the details of various processes going on
inside a machine/ plant and help observing as well as changing the runtime environment variables of the
system.

Figure 8-42| an HMI of Mitsubishi Electric

Some basic types of HMIs that use in industries are as follows.

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 LED HMI
 LCD Displays
 PLCs with integrated Touch-Screen HMI
 Monitor based HMI

Figure 8-43| Touch Screen HMIs of Delta

There can be several reasons to install an HMI on a system some areas

 Display machine faults

 Display machine status
 Allow the operator to start and stop cycles
 Monitor part counts
 Process monitoring
 Remote parameter variations
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Figure 8-44| Configuration of HMI in an operational machining system

8.2 Software Installation and Communication Setting

8.2.1 Software Installation
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8.2.2 Communication Setting

RS-485
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8.3 Meter and Gauges

Purpose: To monitor the analog values on screen of HMI we draw the meters on the
screen. We can draw three type of meter on the screen 180°, 300° and 360°.

Task: -
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Description:

→ Element → Meters

→ Meters → Meter (1)

→ Meters → Meter (2)

→ Meters → Meter (3)

8.4 Multistate Indicators

Purpose: To monitor the status of 0utput we use indicators. On HMI we can use simple
indicator, range indicator and multistate indicator.

Task:

Description: -

→ Element → Indicator

→ Indicator → Simple indicator

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→ Indicator → multistate indicator

→ Indicator → Range indicator

8.5 Numeric and Alphabet Entry

To give input we can draw the numeric and Alphabet entry..

Task:

Description:

→ Element → Input and output

→ Input → Draw numeric entries

→ output → Draw numeric display.

8.6 Numeric and Alphabet Display

Purpose: In display we can draw and monitor the numeric type display, character
display, date display, time display, day of week display, pre-stored message and moving
sign type of display.
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Task: -

Description: -

→ Element → Display

→ Display → Draw all type of display

8.7 Slider and Moving Signs

Purpose: We can set graphic on HMI screen to monitor the movement. We can set state
graphic, animated graphic, dynamic line, dynamic rectangle, dynamic ellipse, and real
image type of movements.

Task: -
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Description: -

→ Element → Graphic

→ Graphic → Draw all type of graphic

8.8 History Graph and Table

It is a Graphical representation of data. History graph is used to store and display the address values
read during a specific time period.

Double Click on Graph

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Go to option Select History Buffer setup

Graph Properties
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8.9 Alarms
Go to option Select Alarm setup

Set number of Alarms

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8.10HMI Passwords
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Go to option Select Passwords

9 Link Devices
9.1 Variable Frequency Drive (VFD)
9.1.1 Introduction to VFD
Variable Frequency Drive or VFD is the way that enables controlling of the speed of induction motor by
applying varying frequency of AC supply voltage.

By controlling the output AC frequency, it is possible to drive the motor at different speed based on the
requirements.

These are adjustable speed drive largely used in industrial applications such as pumps, ventilation
systems, elevators, machine tool drives etc.

It is essentially an energy saving system. Therefore the first requirement is to generate sine wave with
different frequency for VFD.

9.1.2 VFD Wiring

Note that the terminals represented by and are denoted for main and control circuits, respectively.

a. Wiring diagram for 1/2~5 HP (200V class)/1~5HP (400V class)

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9.1.3 Acceleration and Deceleration Time

Acceleration time is the time required by output frequency from zero Hz to the maximum
frequency.

Deceleration time is the time required from maximum frequency dropped to 0 Hz.
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Usually use the frequency setting signal rise and fall to determine the acc/dec time. It needs to
restrict the rise rate of the frequency in acceleration during the electric motor start period in order
to prevent over-current, and limit the frequency decrease rate in order to prevent over-voltage
during deceleration period.

Acceleration time setting requirements: limits the speed up current below the VFD's over-current
capacity, make the over current speed loss don't cause the VFD drives tripped.

The deceleration time set point is to prevent smoothing circuit voltage excessive, make
regeneration overvoltage don't cause the variable frequency drive tripped.

Following functions are used for the setting of acceleration and deceleration time in VFD.

A. F_018: Base frequency of acc./dec. with range 0.01~400.00 Hz

B. F_019: Primary acceleration time with range 0.0~3200.0 seconds

C. F_020: Primary deceleration time with range 0.0~3200.0 seconds

D. F_021: Acceleration time of speed level 1 with range 0.0~3200.0 seconds.

E. F_022: Deceleration time of speed level 1 with range 0.0~3200.0 seconds

F. F_023: Acceleration time of speed level 2 with range 0.0~3200.0 seconds

G. F_024: Deceleration time of speed level 2 with range 0.0~3200.0 seconds

H. F_025: Acceleration time of speed level 3 with range 0.0~3200.0 seconds.

I. F_026: Deceleration time of speed level 3 with range 0.0~3200.0 seconds

J. F_027: Secondary acceleration time with range 0.0~3200.0 seconds

K. F_028: Secondary deceleration time with range 0.0~3200.0 seconds

L. F_029: S-curve acceleration/deceleration time with range 0.0~5.0 seconds

a. Multiple acc./dec. times are the time duration in which output

frequency is form 0 to base frequency (F_018). Multiple level command can control the multiple
speed level and acc./dec. time of multiple speed level.

b. The acceleration/deceleration times of jog speed and speed level 4~7 are the same as those of
main speed

c. Secondary acc./dec. times have the higher priority. Multiple function input terminals can be
programmed to enable secondary acc/dec. The timing chart is shown in figure below.
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d. If the stop signal is generated, the command of inhibiting acc./dec. is useless.

Note: that there are 4 types of STOP signal described as followings: (1) If F_001=0 or 2, FWD and REV
are either open or close simultaneously.

(2) If F_001=1, FWD is open.

(3) If F_003=1, press STOP.
(4) If start command is generated by keypad, press STOP.
e. The acceleration/deceleration times of S curve acceleration/deceleration are set for smooth running,
for example, to avoid the drop of object in transmission line or shock of elevator.
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9.1.4 Speed Control

Variable Frequency Drive is used to control the speed of motor as it is required in industries. To run motor
at different speed following setting is required in VFD.

9.1.5 FWD / REV Operation

To run motor in forward and reverse direction following parameter setting is required.

 Select “3” in F001 to run in forward direction.

 Select “4” in F001 to run in reverse direction.
 Select “1” in F002 for frequency command by keypad.

Function:
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9.1.6 Parameter Lock

F_092 : Lock of parameters:

0: Parameters are changeable. Max. Frequency cannot over 120.0Hz.

1: Parameters are locked. Max. Frequency cannot over 120.0Hz.
2: Parameters are changeable. Max. Frequency can over 120.0Hz.
3: Parameters are locked. Max. Frequency can over 120.0Hz

9.2 Servo Motor and Servo Drive

9.2.1 Introduction to Servo Drive and Servo Motor
Servomotor is also known as control motor with high torque capabilities. Their
fundamental working principle is identical to that of other electromagnetic motors. However,
their operation and structure are different.

Servomotor ratings range from a fraction of watts to hundred watts. They have high
speed response because of low inertia. Therefore, they are lesser in diameter but longer in
length. They usually operate at very low speeds or sometimes at zero speed.

They are widely used in radar surveillance and controllers, machine tools and
guidance systems computers. DC and AC, both types of servo motor (2-phase and 3-phase)
are currently used.

Servo motors is different in operational capabilities from large industrial motors in

following respects:

 High torque is produced at all speeds including zero speed.

 Servomotors can hold its static position (ie no movement).
 Servomotors do not heat up at lower speed or at static position.
 They quickly reverse its direction due to low inertia.
 They are able to accelerate and decelerate quickly.
 They can return to a specific position over again and again without any drift.
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Servo motors looks like the usual electric motors. Their main difference from industrial motors is that
more electrical wires coming out it for control as well as power.

Servo Drive is used to control the speed, torque, and direction of the servo motor. Servo which we used
in lab has model specification.

Features
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9.2.2 Servo Motor and Servo Drive Wiring

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Servo Encoder Connector

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Servo Drive Pin Configuration

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9.2.3 Servo Position and Speed Control Mode

Position Command in PT Mode
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Position Control Mode

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Selection of Speed Mode

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Speed Control Mode

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9.2.4 Servo Direction Control Mode

9.2.5 Servo Torque Control Mode
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Torque Control Mode

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9.3 PLC Link Communication

9.3.1 Data Sheet
In the table below, V means supporting PLC links, and X means not supporting PLC links.

In the table below, V means supporting function codes of PLC links, and X means not supporting.

The maximum quantity of data and station supported by DVP series PLCs are described below. In the
table below, V means supporting and X means not supporting.
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9.3.2 Communication Rates and Format

Communication Formats:
DVP series PLCs support ASCII/RTU communication. The communication formats supported by DVP
series PLCs are described below.

Communication Rates:
 Users can set a communication format for a DVP series PLC by means of D1120
(COM2)/D1109 (COM3).
 The maximum communication rate that COM3 (DVP-F485) in a DVP-EH3 series PLC supports
is 500 kbps.
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Setting a Communication Format for COM2/COM3

(1) If users want to change the communication format set for COM2/COM3, they need to write the
program shown below.
(2) After the RUN/STOP switch on a PLC is moved out of the STOP position and into the RUN
position, the PLC will detect whether M1120/M1136 is on in the first scan time. If
M1120/M1136 is on, the settings related to COM2/COM3 will be changed according to the
values in D1120/D1109.
(3) Move H86 into D1120/D1109 for ASCII mode
(4) Move H87 into D1120/D1109 for RTU mode
(5) If M1143/M1320 is off, the communication format set for COM2/COM3 is an ASCII mode.
(6) If M1143/M1320 is on, the communication format set for COM2/COM3 is an RTU mode.
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9.3.3 Communication between VFD and PLC

If M1355 is ON, M1360~M1375 (M1440~M1455) can be used to specify the stations which need
to be linked, and therefore read/write commands will be transmitted cyclically through PLC links
according to M1360~M1375 no matter how many PLCs are connected. (The master stations and
the slave stations in the examples below are DVP-EH3 series PLCs.)

A master station (A DVP-EH3 series PLC) individually exchanges sixteen pieces of data (sixteen
words) with the two slave stations (two DVP-EH3 series PLCs) manually specified through a PLC
link.

Setting Station Addresses of PLCs:

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Descri
ption of devices:
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9.3.4 Interfacing of different PLC’s

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Description of Control:

9.4 PLC Passwords

9.4.1 Limiting the Number of Failures Allowed
If there is a need to limit users who can use a PLC program, PLC Password Setting in WPLSoft
can be used.

Point to System Security on the Communication menu and click PLC Password Setting.
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A PLC password is composed of four characters at most, e.g. 1234. The Enable Limited Times
checkbox can be selected. The value selected in the box next to the Enable Limited Times checkbox
should be in the range of 2 to 255. Click OK after the setting of a password is complete.

If there is a need to unlock the PLC protected by the password set, the password needs to be typed. The
remaining number of failures allowed is the value selected in the box next to the Enable Limited Times
checkbox.

Example:
Users have to type “abcd” in the Enter Password box, select the Enable Limited Times checkbox, and
select 5 in the box next to the Enable Limited Times checkbox.
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Then users have to click OK.

The window below appears when the users want to upload/download the program protected by the
password. The password needs to be typed in the Enter Password box

After OK is clicked, the program can be uploaded/downloaded. If the number of guesses exceeds 5, the
PLC will be locked, and the program cannot be uploaded/downloaded. The users can only restore the PLC
to its default settings if they forget the password. The restoration of a PLC to its default settings is described
below.
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9.4.2 Setting a Subroutine Password

If users want to hide the subroutines in a program, they can use Subroutine Password Setting. Point to
Program Setting on the Options menu and click Subroutine Password Setting.

A subroutine password is composed of four to eight characters, e.g. 12345.

(1) A ladder diagram which is not protected by a subroutine password is shown below.

(2) If the program above is protected by a subroutine password, the ladder diagram shown in
WPLSoft will be the one shown below after the program above is downloaded and uploaded.
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Note: When the program in a PLC is read, or a program is written to a PLC, WPL-Soft does not tell the PLC
whether the subroutines in the program are unlocked. After the subroutines in a program are unlocked,
WPL-Soft will display the subroutines following FEND.

9.4.3 Setting PLC ID and Program ID

If a PLC ID is different from a program ID, a program code cannot be successfully downloaded to a PLC.

(1) Setting a PLC ID Point to System Security on the Communication menu and click
PLC ID Setting.

A PLC ID is composed of four to eight characters, e.g. 12345. Click OK after the setting of a PLC ID is
complete.
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(2) Setting a program ID

Point to Program Setting on the Options menu and click Program ID Setting.

A program ID is composed of four to eight characters, e.g. 12345. Click OK after the setting of a
program ID is complete.

Example:
Users have to open the PLC ID Setting window after they write a program.
PLC ID: ABCDE
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After the user click OK, the window which appears is the one shown below.

The users have to click Cancel in the PLC ID Setting window, and set a program ID.

Program ID: ABCDE

After a PLC ID and a program ID are set, WPLSoft will check whether the two IDs are the same if the
program needs to be uploaded/downloaded. If the PLC ID and the program ID are different, the window
shown below will appear.

Note: If users forget a password, they can restore t`he PLC used to its default settings. If a PLC is restored
to its default settings, the program in the PLC will be cleared.
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If users want to restore a PLC to its default settings, they have to click Format PLC Memory on the
Communication menu, select the Reset PLC Memory (Factory Setting) checkbox in the Format PLC
Memory window, and click OK.

9.4.4 Setting a Project Password

Users can use a project password to lock a project.

(1) Setting a project password: Point to Program Setting on the Options menu, and click Project
Password Setting

A project password is composed of four characters at most, e.g. 1234.

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(2) After users save a project which is protected by a project password, they need to click Instruction List
Mode/Ladder Diagram Mode/SFC Diagram mode and enter the project password if they want to reopen
the project.

(3) After a project password is set for a project, users can select the Synchronize Project and PLC
Password checkbox in the Transfer Setup window when the program in the project is downloaded to a
PLC. After the Synchronize Project and PLC Password checkbox is selected, the PLC password set will
be the same as the project password
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(4) After a project password is set for a project, users can select the Synchronize Project and PLC
Password checkbox in the Transfer Setup window when the program in the project is uploaded to
WPLSoft. After the Synchronize Project and PLC Password checkbox is selected, the project password
set will be the same as the PLC password.

9.4.5 Disabling the Uploading of a Program

If the uploading of the program in a PLC is disabled, the program cannot be uploaded. Note: After users
disable the uploading of a program, they cannot cancel the setting. If the users want to cancel the setting,
they have to restore the PLC used to its default settings. If the program used is restored to its default
settings, the program in the PLC will be cleared.

(1) Disabling the uploading of a program Users have to point to System Security on the Communication
menu and click Program Upload Disabled.
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After the Warning window appears, the users have to click Yes.

(2) After the users disable the uploading of the program in a PLC, Program Upload Disabled will appear
in the PLC Information window.

(3) If the uploading of a program is disabled, the window shown below will appear after Read from PLC is
clicked.
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