NETTUR TECHNICAL TRAINING FOUNDATION

WORK INSTRUCTION
FOR
AUTOMATION LAB II

S4 P1
 SUBJECT CONTENT
Sl.No TOPICS Hrs.

1.1 Familiarisation of PLC System

1.2 Familiarisation of Basics Function

1.3 Basic Logic Function

6H

1.4 Basics of Timer and Counter

1.5 Application of PLC using Timer and Counter

GENERAL SAFETY RULES

Cleanliness

Cleanliness is very important aspect while doing any kind of work. It has been
scientifically proven that a clean working environment enhances your work out put.As
soon as you reach your work place clean it and arranges all the equipments onyour
table in a proper manner so that all your equipment is easily accessible.

Equipment check

Before starting your experiment make sure that your equipments are present on
the table and check if all their knobs and push buttons are in good condition and fixed
properly on the equipment. Then you should check if the equipments are in proper
condition or not. If the equipments are not ok make arrangements to send the
equipments for maintenance as soon as possible

Component check

Before starting your experiment make sure that components are present on the
table. Then you should check if the components are in good condition using aCRO/multi
meter. If they are in good condition fix them properly on the bread board.

Behavior

1. Do not run in the laboratory.

2. No yelling, no loud noises or no swearing allowed.
3. Do not engage in horseplay of any kind.
4. Do not operate any electronic devices without permission.

Safety check

The most important factor of working with electronics is safety, not only for
yourself, but also for everyone around you .Check if your table mounted sockets are in
good condition and none of them are loosely fixed .If required then make adequate
arrangements to fix them . Follow all safety guide lines.
 All sensible people take interest in their health and safety. Electricity cannot be
seen, heard or smelt. But it is very rapid in action and its effect may be fatal.

An electric current flowing through the body causes electric shock. The degree of
shock depends upon the current flowing (which depends on the voltage) and the
electrical resistance of the body, factor that varies in different persons and is much
reduced if the skin is wet.

Shocks are possible from voltages as low as 15V and 20-25V may cause pain.
Shocks are usually not fatal below about 70V AC. The normal mains supply 0f 240V
AC and currents of 25-30mA or more are the most common cause of serious and fatal
shocks. A current passing through the body causes contraction of muscles. This may
result in the person being unable to let go of the equipment.

The voltage supplies encountered in electronic equipment in general range from

voltages as low as 10V to as high as 25KV or more, thus great care should be
exercised.

The designations of voltages of different ranges are as follows:

Low Tension (L.T) - Below 250V

Medium Tension (M.T) - 250 - 650V

High Tension (H.T) - 650 – 3000V

Extra High Tension (E.H.T) - Above 3000V

When working on high voltages, it is prudent to use only one hand, the safest
place for the other being in your pocket. If a shock is received it is then across your
hand or between fingers, which is not usually serious. Do not hold the chassis or the
frame of test equipment with one hand whilst probing live conductors with the other; any
shock received is now between hands and is much more serious because the current
passes near the heart. Always work on a rubber mat, never on a concrete floor (a good
conductor to earth). Floor covering in a workshop should be made of an insulating
material & benches constructed of insulating material.

E.g.wood, Formica or leno tops. Also the bench top should be covered with an insulator.
Effects of Electricity on the Human Body

The brain via very small electrical impulses controls all muscles .When an
external electrical current of value greater than that generated by brain passes through
the body; it effectively takes over control of the muscles

There are 3 major consequences of these:

1. First a current passing through the heart (which is itself a muscle) may cause it to
cease its pumping action, the commands from the brain being overwhelmed. Thus, a
person suffers from a cardiac arrest.

2. The second consequence may be that a person becomes stuck to the live conductor.
This occurs when a person touches a live conductor with his hand and the polarity is
such that the signal to the muscles in the hand is effectively saying contract. The hand
now grabs the conductor and the person is unable to let go, ever though they may try to
do so; the small let go command from the brain being totally swamping. Left in contact
with the conductor, heat is generated and the person may receive severe burns,
especially if the voltage is very high (>50V).

3. The third consequence may be that, on touching the live conductor the polarity ofthe
current commands in the muscle in the arm to reflex. The person appears tothrow
himself or herself from the conductor, although he/she has no control over thisaction. A
danger with this is that there are no guarantees where the person will land& serious
physical injury may result.

In both second and third cases, cardiac arrest could occur if the current takes
path through the heart and the value of current is high enough.

General rule is: Current Kills, voltage burns

 A current of less than one amp is enough to kill a person & many safety cutouts
are designed to trip at 30mA. (0.03 Of 1 Amp).The greatest electrical shock hazard for
electronic service engineers is on when working on live equipment that has a high
voltage DC source (found in TV‟s , microwaves & large audio amplifiers) especially if
the current path is around the chest. Main supplies have an earth terminal which is
connected to the neutral pole at the power station.

Recommended first aid action

Symptoms Action

Shock Move casualty as little as possible. Loosen all tight cloths (belts, Ties,
(suffered by etc.). If possible lay him/her down and raise legs overhead Level. Keep
Most casualty warm with blankets or coats. Reassure Casualty. Send for
casualties) medical help.
Burns Immerse burnt areas in cold water. Treat for shock. Do not remove burnt
clothing. Do not apply oil or grease to burns. Cover burns with clean dry
cloth. Arrange for medical help if burns are severe
Cuts and Small cuts and grazes should be washed in running water and
Grazes addressing applied. Applying pressure to the wound should stop more
severe bleeding of deep cuts. Treat for shock. Call for medicinal
assistance.
Bruising Applying ice bag or damp cloth until the pain stops

Falling Make causality lie still. Check for obvious injuries. If necessary treat for
shock. If in doubt call for medical help.
Contact Wash affected area with water. Cover with dry dressing. Get casualty to
with hospital
chemicals
Contact Remove casualty from gas – laden or oxygen – deficient area. Loosen
with tight clothing. Apply resuscitation, if breathing has stopped.
toxic fumes

It is clearly essential that prompt action be taken in the case of severe electric
shock.
The following procedure must be adopted.

1. Do not touch the casualty with hands.

2. Switch off supply.
3. If this is not possible, pull the casualty away from contact using insulating material,
i.e. a scarf, piece of wood, newspaper etc.
4. If heart or breathing or both have stopped, apply resuscitation and cardiac massage
until the casualty recovers.
5. Treat for burns.
6. Check for other injuries, treat as necessary.
7. Treat for shock.
8. Call for medical assistance.

Note: If possible, get a third person to call for medical help as soon as the casualtyis
discovered.

Methods of resuscitation:

Cardiopulmonary resuscitation (CPR)Place victim flat on back of a hard surface

A. Open the airway, if unconscious and not breathing

B. Breathing. Look, listen and feel for breathing. If not breathing give mouth tomouth
resuscitation.

C. Close nostrils with fingers and blow into mouth. Make sure there is no air leakand
the chest expands. Give 2 normal breaths.

D. Perform chest compressions

E. Place both hands on the lowest third of breastbone. Depress sternum 1½-
1inches at a rate of 80 compressions per minute. Alternate 2 breaths. Check
pulse after 1 minute and every 3 minutes.
 Expt No: 1.1 Familiarisation of PLC System

AIM:

To Familiarize on the PLC System.

THEORY:
PLC System has the four major units as follows,

1) Central Processing Unit (CPU)

CPU is the “brain” of the system, which has three subparts:

a) Microprocessor
The computer center that carries out mathematical and logical operations.
b) Memory
The area of the CPU in which data and information is stored and retrieved. Holds the system
software and user program.
c) Power supply
The electrical supply that converts alternating current (AC)line voltage to various operational
DC values (24V & 5V). It is necessary for the processor and the circuits in the input and output interface
modules.

PM
Programmer/monitor

CPU
Microprocessor
Output

Input Memory
Module

Module

Power Supply
ysupply
Rack and Chassis

Overall PLC System

 2) Programmer Monitor

 The programmer/monitor (PM, programming equipment) is a device used to communicate with the
circuits of the PLC
 A programming device is used to enter the desired program into the memory of the processor
 Hand-held terminals, industrial terminals, and personal computers exist as PM devices

3) I/O Modules
 The I/O (Input/Output) module forms the interface by which field devices are connected to the
controller
 Input devices such as pushbuttons, limit switches, and sensors are hardwired to the input module
terminals
 Output devices such as motor starters, solenoid valves, and indicator lights are hardwired to
the output module terminals

4) Rack and chassis

The PLC parts are mounted on the rack and the CPU, PM, and modules are mounted on the enclosures

RESULT:

The study of basic PLC functions is done successfully.

 Expt No.1.2 Familiarisation of Basic PLC Function

AIM:
To Familiarise on the basic PLC functions.

THEORY:

The three core functions available with all PLCs are timers, counters and memory registers.

1. Register Basics
Introduction to Register
Memory locations that provide temporary storage of data, instructions, information
and numerical values associated with timers and counters.
General characteristics of Registers
 Registers are found in two locations within the PLC CPU

 The microprocessor has internal registers, most of which are not directly accessible by

the user

 Accumulator registers, data registers, index registers, condition code registers, scratch pad
registers, and instruction registers—all work to temporarily store data.

Holding Registers
A holding, or working, register (HR) “holds” the contents of a calculation, arithmetic or
logic. Conceptually, it is in the “middle” of the CPU, as shown in fig.

Input Working or output

registers holding registers
registers
Specific Specific
inputs outputs
8-12 100-1000 8-12
Typically Typically Typically
I/O Registers:
Input Registers: Single and Group
 The input register has basically the same characteristics as the holding register, except

that it is readily accessible to the input module’s terminals or ports

 The number of input registers in a PLC is normally one-tenth that of holding registers

Output Registers: Single and Group

 The output register has basically the same characteristics as the holding register,

except that it is readily accessible to the output module’s terminals or ports

 The number of output registers is normally equal to the number of input registers

2. Timer
Timers are used to operate devices for certain period of time. PLC contains different types of
timers they are,
A. ON delay timer (TON)
B. OFF delay timer (TOFF)
C. Pulse timer (TP)
3. Counters
Counter instructions are used to keep track of events. A counter instruction compares an
accumulated count value to a preset value to determine when the desired count has been
reached.
Counters can be used to start an operation when a count is reached or to prevent an operation
from occurring until a count has been reached.
Types of counters are
A. Up Counter (CU)
B. Down Counter (CD)
C. Up-Down Counter (CUD)

RESULT:

The study of basic PLC functions is done successfully.

Expt No.1.3 Basic Logic Function
AIM:

To design a program for the following,

(a) AND, OR, and NOT gate.

(b) NAND and NOR gate.

(C) EX OR and EX NOR gate.

APPARATUS REQUIRED:

1. Siemens S7 200 PLC

2. Step 7 Microwin software

3. RS 485 communication cable

4. Personal computer with WINDOWS OS

THEORY:

i. AND Gate:

In AND gate logic when both inputs are high the output will be high and for all
the inputs the output will be low.

ii. OR Gate:

In OR gate the output will be high if all the input or anyone of the input is high
and will be low when both outputs are low.

iii. NOT Gate:

The output of the NOT gate is inverted so this gate is called inverter gate.

The output of this gate will be high when the input is low and vice versa.
 iv. NAND Gate:

1. NAND gate is the combination of AND and NOT gate.

2. The output of the NAND gate is low only when both inputs are high

v. NOR Gate:

1. NOR gate is a combination of OR and NOT gate.

2. The output of NOR gate is high only when both the inputs are low.

vi. EX-OR Gate:

1. In EX-OR gate logic the output is high when the input is an odd multiple of
one‟s.

2. In remaining all conditions the output is low.

vii. EX-NOR Gate:

1. EX-NOR Gate is a combination of EX-OR gate and NOT gate.

2. In EX-NOR gate logic the output will high when both the inputs are same

3. In remaining all conditions the output is low.

PROCEDURE:

1. Design the ladder diagram in STEP 7 MICROWIN application software

2. Upload the program to the PLC

3. Execute the program by using input switches in the input module

RESULT:

Thus the program for AND, OR, NOT, NAND, NOR, EX-OR, EX-NOR are
designed and executed.
 Implementation Of Gates Using PLC (Expt No. 1.3)
1) AND GATE:

Input 1
TRUTH TABLE Output
Input 2

Input 1 Input 2 Output

0 0 0
0 1 0
1 0 0
1 1 1
LADDER DIAGRAM

2) OR GATE:
Input 1
Output
Input 2
TRUTH TABLE
Input 1 Input 2 Output
0 0 0
0 1 1
1 0 1
1 1 1
 LADDER DIAGRAM

3) INVERTER or NOT GATE:

Input Output
TRUTH TABLE
Output
Input
1 0
0 1

LADDER DIAGRAM
 4) NOR GATE:
Input 1
Output
Input 2

TRUTH TABLE Input 1 Input 2 Output

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

LADDER DIAGRAM

5) NAND GATE:

Input 1
Output
Input 2
Input 1 Input 2 Output
TRUTH TABLE 0 0 1
0 1 1
1 0 1
1 1 0
LADDER DIAGRAM

6) EX-OR GATE:

Input 1
TRUTH TABLE Output
LADDER Input 2 DIAGRAM
Input 1 Input 2 Output
0 0 0
0 1 1
1 0 1
1 1 0
7) EX-NOR GATE:

Input 1
Output
Input 2
TRUTH Input 1 Input 2 Output TABLE
0 0 1
0 1 0
1 0 0
1 1 1

LADDER DIAGRAM
 Expt No.1.4 Basics of Timer and Counter
AIM:
To study on the basics of timer and counters.

THEORY:
Timers:
PLC’s have timers as built-in devices. Timers count fractions of seconds or seconds using the
internal CPU clock.
Timers behave like relays with coils, when energized result in the closure or opening of contacts
after some preset time.

There are different forms of timers that can be found with PLC’s
On-delay timers:
These are timers which come ON after a particular time delay
Off-delay timers:
These timers are ON for a fixed period of time before turning off
Pulse timer:
This timer switches on or off for a fixed period of time
Retentive pulse timer:
These timers gets on when they receive a single pulse and remains in ON state
till it get reset. Eg. Stop watch

Counters:
Counters are provided as built-in elements in PLC’s and allow the number of occurrences of
input signals to be counted.
A counter is set to some preset number value and, when this value of input pulses has been
received, it will operate its contacts. Thus normally open contacts would be closed,
normally closed contacts opened
Types Of Counters are,
Up Counter:
Up counter is an increment counter, it counts “up” with each off-to-on transition
Input.
Down Counter:
The down counter is a decremental counter, it will count down or decrease by 1 each time the
counted event occurs.
Up-Down Counter:
Up-Down counter do both the function of Up and Down counters

i) Timer Circuit
(ii) Counter Circuit

RESULT:

Thus the study of basic timer and counter circuits are verified and executed.
Expt No.1.5 Application of PLC Using Timer and Counter
AIM:

To design a program for following condition,

A) Start 3 machines consequently after 3 seconds.
B) To design a ladder diagram when a sensor had sensed 5 bottles the
machine should ON.

APPARATUS REQUIRED:

1. Siemens S7 200 PLC

2. Step 7 Microwin software

3. RS 485 communication cable

4. Personal computer with WINDOWS OS

THEORY:

1 .To start three machines consequently three timers are connected one by one the
address of the first timer is given as the input of the second timer by using a
normally open switch.

2. To stop the timer a normally close switch is connected to the input of timer.

3. Counters are used in PLC’s to count the number of parts. Here we are using UP
COUNTER for counting the number parts.

4. The input I1.0 will be a proximity sensor to sense number of object. As the sensor
senses the parts the counter starts counting and when the counter reaches 5 the
output gets ON.

5. The normally open switch I1.1 is used to reset the counter. By providing a NO
switch with the address of output the counter resets automatically.

PROCEDURE:

1. Design the ladder diagram in STEP 7 MICROWIN application software

2. Upload the program to the PLC

 3. Execute the program by using input switches in the input module

A) Timer Circuit B) Counter Circuit

RESULT:

Thus the program for controlling the motor using timer and Up Counter function is
designed and executed.