Ilot Te Vi Ia Week 6 7

TE_VI_SEM
ILOT6023_Industrial Automation
Module 3: Programmable Logic Controller
Software
Faculty Name : Ramakant Patil

Index
Week-6 & 7
Lecture 16 & 17 – Data transfer & program control instructions & Advanced PLC
3
instructions
Lecture 18 & 19 PID control using PLC and PLC selection for any one process
22
application
Lecture 20 – SCADA introduction, brief history of SCADA 44

Lecture 16 & 17
Data transfer & program control instructions & Advanced

PLC instructions
Data Transfer
• Data Manipulation allow the movement, manipulation or storage of data in one

data memory of PLC to another PLC or systems
• Involve the transfer of contents from one address to other
• Can address any location in the memory
• Data transfer instructions are output instructions
• Examples MOV MVM BTD FAL
4 Lecture 16 & 17 - Data transfer & program control instructions & Advanced
PLC instructions
Data Transfer concept
Data Transfer
Image Source / references: bookpetruzella pg 202
5 Lecture 16 & 17- Data transfer & program control instructions &
Advanced PLC instructions
MOV Instruction
• Used to copy the value in one register or word

to another
• This instruction copies data from source

register to destination register
MOV Instruction
6 Lecture 16 & 17 - Data transfer & program control instructions &

MVM Instruction
MVM Instruction
PLC instructions
Data Compare Instruction
• Are called input instructions
• Used to compare numerical values
• Compare instructions are:
EQU NEQ LES GRT LEQ GEQ
Compare Menu Tab
PLC instructions
EQU & NEQ Instruction
• EQU - Tests whether two values are equal.
• NEQ - Tests whether one value is not equal to

a second value
EQU & NEQ Instruction
PLC instructions
LES & GRT Instruction
• LES - Tests whether one value is less than

a second value
• GRT - Tests whether one value is greater than

a second value
LES & GRT Instruction
PLC instructions
Program Control Instructions
Allow for a greater program flexibility and efficiency in program scan
Useful to enable or disable a block of logic program
Move execution of a program from one place to another place
Program Control Menu Tab
PLC instructions
Instruction List
• JMP (Jump to Label) - Jump forward/backward to a corresponding label

instruction
• LBL (Label) - Specifies label location
• JSR (Jump to Subroutine) - Jump to a designated subroutine instruction
• RET (Return from Subroutine) - Exits current subroutine and returns to
previous condition
• SBR (Subroutine) - Identifies the subroutine program
• TND (Temporary End) - Makes a temporary end that halts program execution
• MCR (Master Control Reset) - Clears all set non-retentive output rungs between
the paired MCR instructions
• SUS (Suspend) - Identifies conditions for debugging and system
troubleshooting
PLC instructions
MCR Instruction
MCR Instruction
13 Lecture 16 & 17 - Data transfer & program control instructions & Advanced PLC
instructions
JMP Instruction
JMP Instruction
PLC instructions
….Continued
Data Transfer
https://www.youtube.com/watch?v=DcopgfEs6gg
Program Control Instruction

https://www.youtube.com/watch?v=uJZyfF-bKdA
PLC instructions
Data Handling Instructions

•Timers, counters and individual relays are all concerned with the handling of individual bits,
i.e. single on-off signal. PLC operations involve blocks of data representing a value, such blocks
being
termed words.
•Data handling consists of operations involving moving or transferring numeric information

stored in one memory word location to another word in a different location, comparing data
values and carrying out simple arithmetic operations.
•A register is where data can be stored.

Each data register can store a binary word of usually 8 or 16 bits.
The number of bits determines the size of the number that can be stored (2n–1).
•4-bit register can store a positive number between 0 and +15.

8-bit: 0 and +255.
16-bit: 0 and +65535.
16 Lecture 16 & 17 - Data transfer & program control instructions & Advanced PLC instructions
Data movement instructions

•There are typically 2 common instruction “sets“.
•The single instruction is commonly called MOV (move) copies a value from one
address to another.
•The MOV instruction needs to know 2 things:

Source – where the data we want to move is located.
Destination – the location where the data will be moved to.
•Also, the data can be moved to the physical outputs.
Data comparison
• The data comparison instruction gets the PLC to compare two data values.
• Thus it might be to compare a digital value read from some input device with a
second value contained in a register.
PLCs generally can make comparisons for:
less than (< or LESS),
equal to (= or EQU),
less than or equal to (<= or LEQ),
greater than (> or GRT),
greater than or equal to (>= or GEQ), and
not equal to ( NEQ).
18 Lecture 16 & 17 - Data transfer & program control instructions & Advanced PLC
instructions
Overflow
•Typically the memory locations are 16-bit locations. If a result is greater than the
value that could be stored in a memory location then we get an overflow.
•The plc turns on an internal relay that tells us an overflow has happened.
•We get an overflow if the number is greater than 65535
(2^16=65536).
•Depending on the plc, we would have different data in the destination location.
Some use 32-bit math which solves the problem.
•If we’re doing division, and we divide by zero the overflow bit turns on.
Arithmetic (mathematical) Instructions

PLCs almost always include math functions to carry out some arithmetic operations:
• Addition (ADD) – The capability to add one piece of data to another.
• Subtraction (SUB) – The capability to subtract one piece of data from

another.
• Multiplication (MUL) – The capability to multiply one piece of data by

another.
• Division (DIV) – The capability to divide one piece of data from another.
Continuous control (PID Instruction)
Different formats are used by different manufacturers
• MC/MCR (master control/master control reset)
•MCS/MCR (master control set/master control reset)
•MCR (master control reset).
PLC instructions
Lecture 18 & 19
PID control using PLC and PLC selection for any one process
application
PID Control using PLC.

•Continuous control of some variable can be achieved by comparing the actual
value of the variable with the desired set value and then giving an output
depending on the control law required.
•Many PLCs provide the PID calculation to determine the controller output as a
standard routine.
•All that is then necessary is to pass the desired parameters, i.e. the values of Kp,
Ki, and KD, and input/output locations to the routine via the PLC program.
23 PID control using PLC and PLC selection for any one process application

•Control instructions are used to enable or disable a block of logic program or to
move execution of a program from one place to another place.
The control instructions include:

 Master Control instruction (MC/MCR)
 Jump to label instruction (JMP)
 Label instruction (LBL)
 Jump to Subroutine instruction (JSR)
 Subroutine instruction (SBR)
 Return from Subroutine instruction (RET)
 Shift Registers
Master Control/ Master Control Reset (MC/MCR)

•When large numbers of outputs have to be controlled, it is sometimes necessary for
whole sections of program to be turned on or off when certain criteria are realized.
•This could be achieved by including a MCR instruction. A MCR instruction is an
output instruction.
•The master control instruction typically is used in pairs with a master control reset.
•Different formats are used by different manufacturers:
o MC/MCR (master control/master control reset)
o MCS/MCR (master control set/master control reset) or
o MCR (master control reset).
 The zone being controlled begins with a rung that has the first MC instruction, which
status depends on its rung condition.
This zone ends with a rung that has the second MCR instruction only.
When the rung with the first MCR instruction is true, the first MCR instruction is high and
the outputs of the rung in the controlled zone can be energized or denergized acording to
their rung conditions.
When the this rung is false, all the outputs in the zone are denrgized, regardless their
rung conditions.
 Timers should not be used inside the MC/MCR block because some manufacturers will
reset them to zero when the block is false whereas other manufacturers will have them
retain the current time state.
Counters typically retain their current counted value.
Jump Instructions
 The JUMP instructions allow to break the rung sequence and move the program
execution from one
rung to another or to a subroutine.
The Jump is a controlled output instruction.
You can jump forward or backward.
You can use multiple jump to the same label.
Jumps within jumps are possible
 There are:
1. Jump to Label.
2.Jump to subroutine
RETURN / END
A Return from Subroutine instruction marks the end of Subroutine instruction.
When the rung condition of this instruction is true, it causes the PLC to resume
execution in the calling program file at the rung following the Jump to Subroutine
instruction in the calling program.
 When a Return from Subroutine instruction is not programmed in a subroutine

file, the END instruction automatically causes the PLC to move execution back to the
rung following the Jump to Subroutine instruction.
A Jump to Subroutine instruction can be used either in a main application

program or a subroutine program to call another subroutine program.
Shift Registers
The shift register is a number of internal relays grouped together (normally 8, 16, or 32)
which allow stored bits to be shifted from one relay to another.
The grouping together of internal relays to form a shift register is done automatically by
a PLC when the shift register function is selected.
This is done by using the programming code against the internal relay number that is to
be the first in the register array.
Shift registers can be used where a sequence of operations is required or to keep track
of particular items in a production system.
The shift register is most commonly used in conveyor systems, labelling or bottling
applications, etc.
PID instruction
PID instruction
Allen Bradley instruction
Case study
Prepare a case study for following applications
1. Home Automation.
2. Elevators
3. Water Treatment
4. Food Industry
5. Bottle Filling
Case study
Food Industry application
Case study
Problem Solution
To detect burned chips light sensor are used. Light dependent resistors (LDR) are
used to detect the burned chips.
Blowers are used to throw away the burned chips from the conveyor whenever
burned chips detected.
Blowers are used to throw away burned chips from the conveyor. Here we used
two blowers, number of blowers depend on the size of the conveyor.
Time measurement is necessary for blower cycle. Here we measure time taken by
chips to reach from light source to blower.
Note:- Here we consider simple application for detecting burned chips on
the conveyor and remove them. We have taken here light source to detect
burned chips on the bases of darkness of the chips.
Case study
Reference points for case study
1. Definition or problem statement.

2. List of hardware elements/components with the justification
3. General block diagram of the system
4. Program Sequence and I/O listing
5. Ladder logic
6. Explanation of logic
7. Future scope
PLC selection criteria
The selection criteria are as listed below:
• Number of logical inputs and outputs.

• Memory
• Number of special I/O modules
• Scan Time
• Communications
• Software
Troubleshooting
The troubleshooting steps are as follows:
1. Look at the process

2. PLC status lights
HALT - something has stopped the CPU
RUN - the PLC thinks it is OK (and probably is)
ERROR - a physical problem has occurred with the PLC
3. Indicator lights on I/O cards and sensors
4. Consult the manuals, or use software if available.
5. Use programming terminal / laptop.
PLC Application Video
https://www.youtube.com/watch?v=9kWCqK7hc3c
Application of PLC
https://www.youtube.com/watch?v=02Q3cIoKa9c
Application of PLC
https://accautomation.ca/plc-programming-example-shift-register-conveyor-reject/
Application of PLC
https://accautomation.ca/tag/plc-programming-code-example/
Examples of other PLC Programming Software:
1. Allen-Bradley – Rockwell Software RSLogix500

2. Modicon - Modsoft
3. Omron - Syswin
4. GE-Fanuc Series 6 – LogicMaster6
5. Square D- PowerLogic
6. Texas Instruments – Simatic
6. Telemecanique – Modicon TSX Micro
TE_VI_SEM
ILOT6023_Industrial Automation
Module 4: Supervisory Control And Data
Acquisition System (SCADA)
Faculty Name : Ramakant Patil

Lecture 20
SCADA introduction, brief

history of SCADA
What is SCADA?
• Supervisory Control And Data Acquisition System- SCADA

- In the process industry, many enterprises are going for Manufacturing Resource
Planning (MRP) systems in the business for
* Elimination of duplicate data systems throughout the enterprise.
* To provide preventive and cost-effective maintenance scheduling.
* To provide more accurate and timely data to support the business process.
* To implement uniform business strategies.
* To minimize the effective lifetime cost of the process control system.
- To achieve the above objectives the system design is called SCADA.
- It is not a full control system but rather it focuses on the supervisory level.
- It is the software package that is positioned on the top of the hardware to which it is
interfaced.
- Hardware is PLC or any modules.
- It is a central control system that monitors and controls the complete system spread
out over a long distance.
45 Lecture 20 SCADA Introduction, Brief History of SCADA

What is SCADA?
- The bulk operations of the site is controlled automatically by Remote Terminal Unit or by
PLC.
- The host computer functions are almost restricted to basic site supervisory level
capability.
- For example, A PLC may control the flow of cooling water through part of the industrial
process, but a SCADA system may allow an operator to change the control set point for
flow and will allow alarm conditions such as loss of flow of high temperature to be
recorded and displayed.
- The feedback control loop is closed through the RTU or PLC.
- The SCADA system monitors the performance of the overall loop.
- The data are collected locally in the SCADA software database to allow trending and other
analytical work.

Historical Background
Image Source / references: powersystemautomation

Historical Background
Telemetry-based system
• The telephone wires were the key to the development of the first SCADA
system by the end of the 1950s
Mini-computers
• The minicomputers, which used 8-bit or 16-bit processors, were able to
perform the functions that were previously done by operators from the
control panels installed in each station
• The continuous development of this technology allowed the system to

offer functions like data scanning, status monitoring, alarming, and
even data display

……Continued
Microprocessors
• The development of transistors led to the appearance of

microprocessors, and furthermore, Discrete Control Systems (DCS)
were developed since then and were used to build supervisory control
systems
Radio Communication
• By the 1970s better option for Radio communication was found due to
improved industrial design

Limitations
• System engineer or operator gets various measurement information

remotely about the system. It can store data or measurement values, but
cannot control them.
• So Telemetry is very useful for analysis purpose
• Needed to cover a larger area of plant
• Monitoring at the regular interval was required
• Required up gradation with new technologies

SCADA
• The SCADA concept was developed to be a universal means of remote

access to a variety of local control modules
• This could be from different manufacturers and allowing access through

standard automation protocols.
• Using multiple means of interfacing with the plant.
• They can control large-scale processes that can include multiple sites, and
work over large distances as well as small distances.
• It is one of the most commonly used types of industrial control systems
• SCADA systems are vulnerable to cyber war/ cyber terrorism attacks.

SCADA Invention
• The term SCADA emerged in the mid-1970s
• Westinghouse and North Electric Company (USA) to develop a

supervisory control system called Visicode, which can be considered
the beginning of the SCADA systems
• The rise of microprocessors and PLCs during that decade increased

enterprises’ ability to monitor and control automated processes
• Provide an interface between the sensors and the network
• A SCADA Analyst provides formal and in-formal end-user training and

support; designs, programs, installs, and maintains application

Recent Control rooms
SCADA Control room
Image Source / references: learntechnique.com

Architecture and Block Diagram of SCADA System

• The SCADA system is used in industrial organizations, private as well as

government product manufacturers, mass traffic controlling systems, smart
travel agencies, etc.
• Level 0 (Sensors/ Actuators):

• The ground-level devices that actually interact with the physical environment
or work as technicians in a supervision system. Different types of sensors and
actuators come under this level.
• The actuator is a device that makes physical changes when an electrical or
electronic signal is applied to it.
• Level 1 (Programming Devices):

• Different types of programming devices such as PLC(Programmable Logic
Controller), and RTU (Remote Terminal Unit) come under this level. These are
the devices that directly control the ground-level devices such as sensors and
actuators. A SCADA system can be built with only local area networks or a
combination of both local and wide area networks.
• Level 2 (Local Control and HMI):

• The supervisory computers come under this level. All the programming devices
that operate the ground-level devices are connected to these computers.
Supervisory computers are those from where the SCADA software starts
working. From these computers, the actual instructions and commands are given
to do the operations. The supervisory computer may be connected to a particular
machine or multiple same types of machines or a whole manufacturing plant.
These computers are operated by machine operators, plant supervisors, and
technicians of a manufacturing plant. The main functions of these computers are
to observe and control the production, errors, etc.

• Level 3 (Coordination):
• Coordinating computers come under this level. Generally, these computers are
connected to multiple plants. So, it can help to gather data from different plants
in one place. At this level, the production planning, scheduling, and event timing
management are done by the plant in charge, managers, etc.
• Level 4 (Central Control):

• It is the top level of the SCADA System. At this level, a central computer is
connected to all the plants and machinery. Generally, this is operated and
controlled by the management team. All the data and information are collected
and stored here. Using these data and information they can take any decision.
From this computer, the management team can see all the actions and
operations, etc.

SCADA Platform
https://www.youtube.com/watch?v=nlFM1q9QPJw
https://www.youtube.com/watch?v=xvVCSYt_YsQ

Thank You

Ilot Te Vi Ia Week 6 7

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ilot Te Vi Ia Week 6 7

Uploaded by

Copyright:

Available Formats

TE_VI_SEM

Faculty Name : Ramakant Patil

Lecture 20 – SCADA introduction, brief history of SCADA 44

Data transfer & program control instructions & Advanced

• Data Manipulation allow the movement, manipulation or storage of data in one

• Involve the transfer of contents from one address to other

• Can address any location in the memory

• Data transfer instructions are output instructions

• Examples MOV MVM BTD FAL

• Used to copy the value in one register or word

• This instruction copies data from source

Image Source / references: bookpetruzella pg 202

6 Lecture 16 & 17 - Data transfer & program control instructions &

Image Source / references: bookpetruzella pg 202

• Are called input instructions

• Used to compare numerical values

• Compare instructions are:

EQU NEQ LES GRT LEQ GEQ

Compare Menu Tab

Image Source / references: bookpetruzella pg 210

• EQU - Tests whether two values are equal.

• NEQ - Tests whether one value is not equal to

EQU & NEQ Instruction

Image Source / references: bookpetruzella pg 210

• LES - Tests whether one value is less than

• GRT - Tests whether one value is greater than

LES & GRT Instruction

Image Source / references: bookpetruzella pg 212

Allow for a greater program flexibility and efficiency in program scan

Useful to enable or disable a block of logic program

Move execution of a program from one place to another place

Program Control Menu Tab

Image Source / references: bookpetruzella pg 177

• JMP (Jump to Label) - Jump forward/backward to a corresponding label

Image Source / references: bookpetruzella pg 178

Image Source / references: bookpetruzella pg 180

Program Control Instruction

Data Handling Instructions

•Data handling consists of operations involving moving or transferring numeric information

•A register is where data can be stored.

•4-bit register can store a positive number between 0 and +15.

Data movement instructions

•The MOV instruction needs to know 2 things:

•Also, the data can be moved to the physical outputs.

Arithmetic (mathematical) Instructions

• Addition (ADD) – The capability to add one piece of data to another.

• Subtraction (SUB) – The capability to subtract one piece of data from

• Multiplication (MUL) – The capability to multiply one piece of data by

Continuous control (PID Instruction)

Different formats are used by different manufacturers

• MC/MCR (master control/master control reset)

•MCS/MCR (master control set/master control reset)

•MCR (master control reset).

Continuous control (PID Instruction)

Continuous control (PID Instruction)

The control instructions include:

Master Control/ Master Control Reset (MC/MCR)

Counters typically retain their current counted value.

 When a Return from Subroutine instruction is not programmed in a subroutine

A Jump to Subroutine instruction can be used either in a main application

Allen Bradley instruction

Prepare a case study for following applications

Food Industry application