CONTENTS

Topic Page No.

Certificate 1
Candidate’s Declaration 2

Contents 3

CHAPTER 1 INTRODUCTION 4-8

1.1 Automation 4
1.2 PLC introduction 5
1.3 History of PLC 5
1.4 Advantages 7

CHAPTER 2 TRAINING WORK 8-25

2.1 Inside A PLC 8

2.2 PLC Operations 11
2.3 PLC Programming 13
2.4 Contacts and Coils 16
2.5 Timers And Counters 19
2.6 Memory Designs 21
2.7 Communication 23
2.6 Programmable Controllers and Networks
25

CHAPTER 3 RESULTS AND DISCUSSIONS 26-31

3.1 Motor Starter Examples 26

3.2 Motor Starter Examples with PLC 27
3.3 PLC Operation
28
3.4 Tank Used to Mix Two Liquid 30
3.5 Human Machine Interference 31

CHAPTER 4 CONCLUSION AND FUTURE SCOPE

4.1 Conclusion 32
4.2 Future Scope
32 APPENDIX
 Program-1-10 UP and DOWN Counter 33
Water Level Indicator 34

CHAPTER 1-INTRODUCTION

1.1 Automation

Automation is the use of control systems such as computers to control industrial machinery and
process, reducing the need for human intervention. In the scope of industrialization, automation
is a step beyond mechanization. Whereas mechanization provided human operators
with machinery to assist them with physical requirements of work, automation
greatly reduces the need for human sensory and metal requirements as well.
Processes and systems can also be automated.

Automation impacts

●It increases productivity and reduces cost.

●It gives emphasis on flexibility and convertibility in the manufacturing process. Manufacturers
are increasingly demanding the ability to easily switch from product A to
manufacturing product without having to completely rebuild the production lines.

●Automation is often applied primarily to increase quality in the manufacturing

process, where automation can increase quality substantially.

●Automation reduces power consumption and reduces man power requirement.

●Automation improves production quality.

●Automation provides safer working conditions

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1.2 Programmable Logic Controller (PLC)

A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control

system that continuously monitors the state of input devices and makes decisions based upon
a custom program to control the state of output devices. Almost any production line, machine
function, or process can be greatly enhanced using this type of control system. However, the
biggest benefit in using a PLC is the ability to change and replicate the operation or process
while collecting and communicating vital information. Another advantage of a PLC system is
that it is modular. That is, you can mix and match the types of input and Output devices to best suit
your application.

1.3 History of PLCs

●The first Programmable Logic Controllers were designed and developed by Modicon as a relay
re-placer for GM and Landis.

●These controllers eliminated the need for rewiring and adding additional hardware for each new
configuration of logic.

●The new system drastically increased the functionality of the controls while reducing the
cabinet space that housed the logic.

●The first PLC, model 084, was invented by Dick Morley in 1969.

●The first commercial successful PLC, the 184, was introduced in 1973 and was designed by
Michael Greenberg.

 The Hydramatic Division of the General Motors Corporation specified the design
criteria for the first programmable controller in 1968

Their primary goal

 To eliminate the high costs associated with inflexible, relay-controlled systems.

• The controller had to be designed in modular form, so that sub-assemblies could be

removed easily for replacement or repair.
• The control system needed the capability to pass data collection to a central system.
• The system had to be reusable.

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• The method used to program the controller had to be simple, so that it could be easily
understood by plant personnel.
• 1968  Programmable concept developed

• 1969  Hardware CPU controller, with logic

• instructions, 1 K of memory and 128 I/O

• points

• 1974  Use of several (multi) processors within a

• PLC - timers and counters; arithmetic

• operations; 12 K of memory

• and 1024 I/O points

• 1976  Remote input/output systems introduced

• 1977  Microprocessors - based PLC introduced

• 1980  Intelligent I/O modules developed

• Enhanced communications facilities

• Enhanced software features

• (e.g. documentation)

• Use of personal microcomputers as

• programming aids

• 1983  Low - cost small PLC’s introduced

• 1985 on  Networking of all levels of PLC, computer

and machine using SCADA software.

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1.4 Advantages of PLCs

PLCs not only are capable of performing the same tasks as hard-wired control, but are also
capable of many more complex applications. In addition, the PLC program and electronic
communication lines replace much of the interconnecting wires required by hard-wired control.
Therefore, hard-wiring, though still required to connect field devices, is less intensive.
This also makes correcting errors and modifying the application easier. Some of the
additional advantages of PLCs are as follows:

●Smaller physical size than hard-wire solutions.

●Easier and faster to make changes.

●PLCs have integrated diagnostics and override functions.

●Diagnostics are centrally available.

●Applications can be immediately documented.

●Applications can be duplicated faster and less expensively

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 CHAPTER 2- TRAINING WORK

2.1Inside A PLC

The Central Processing Unit (CPU), contains an internal program that tells the PLC
how to perform the following functions:· Execute the Control Instructions contained in the
User's Programs. This program is stored in "non-volatile" memory, meaning that the program will not
be lost if power is removed· Communicate with other devices, which can include I/O Devices,
Programming Devices, Networks, and even other PLCs.· Perform Housekeeping activities such
as Communications, Internal Diagnostics, etc.

Figure 2.1:-Inside a PLC

THE CPU

The microprocessor or processor module is the brain of a PLC system. It consists of the
microprocessor, memory integrated circuits, and circuits necessary to store and retrieve
information from memory. It also includes communications ports to other peripherals, others
PLC’s or programming terminals. Today’s processors vary widely in their capabilities to control
real world dvices. Some controls as few as 6 inputs and outputs (I/O) and others 40,000 or more.
One processor can control more than one process or manufacturing line.
Processors are often linked together in order to provide continuity throughout the
process. The number of inputs and outputs PLCs can control are limited by the overall capacity
of the PLC system hardware and memory capabilities. The job of the processor is to monitor

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status or state of input devices, scan and solve the logic of a user program, and control on or off
state of output devices.

RAM

RAM or Random Access Memory is a volatile memory that would lose its
i n f o r m a t i o n i f p o w e r w e r e removed. This is why some processor units incorporate a
battery back-up. The type of RAM normally used is CMOS or Complementary Metal Oxide
Semiconductor. CMOS RAM is used for storage of the user's program (ladder logic diagrams) and storage
memory.

ROM

ROM or Read Only Memory is a non-volatile type of memory. This means you don't need an
external power source to keep information. In this type of memory, information can be
read, but not changed. For this reason the manufacture sometimes calls this firmware. It is
placed there for the internal use and operation of processor units.
EEPROM
EEPROM or Electrically Erasable Programmable Read Only Memory is usually an add-on
memory module that is used to back up the main program in CMOS RAM of the processor. In many cases, the
processor can be programmed to load the EEPOROM’s program to RAM if RAM is lost or corrupted.

Input Module
There are many types of input modules to choose from. The type of input module used is depend
ent uponwhat real world input to the PLC is desired. Some examples of inputs are limit switches, 
electric eyes, andpushbuttons. DC inputs, such as thumbwheel switches, can be used to enter inte
ger values to bemanipulated by the PLC. DC input cards are used for this application. Since most 
industrial power systemsare inherently noisy, electrical isolation is provided between the input a
nd the processor. Electromagneticinterference (EMI) and Radio Frequency Interference (RFI) ca
n cause severe problems in most solid statecontrol systems. The component used most often to pr
ovide electrical isolation within I/O cards is called anoptical isolator or optocoupler. The wiring 
of an input is not complex. The object is to get a voltage at aparticular point on the card. Typicall
y there are 8 to 32 input points on any one input module. Each pointwill be assigned a unique ad
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dress by the processor. Analog input modules are special input cards that useanalog to digital con
version (A to D) to sense variables such as temperature, speed, pressure, and position.The extern
al device normally is connected to a controller (transducer) producing an electrical signal theanal
og input card can interpret. This signal is usually 4 to20 Ma or a 0 to 10 volt signal.

Output Module
Output modules can be for used for ac or dc devices such as solenoids, relays, contractors, pilot l
amps, andLED readouts. Output cards usually have from 6 to 32 output points on a single modul
e. The output devicewithin the card provides the connection from the user power supply to the lo
ad. Usually silicon controlledrectifiers (SCR), triac, or dry contact relays are use for this purpose. 
Individual outputs are rated most oftenat 2 to 3 amperes. Output cards, like input cards have elect
rical isolation between the load being connectedand the PLC. Analog output cards are a special t
ype of output modules that use digital to analog conversion(D to A). The analog output module c
an take a value stored in a 12 bit file and convert it to an analog signal.Normally this signal is 0 -
10 volts dc or 4 to 20 Ma. This analog signal is often used in equipment such asmotor operated v
alves and pneumatic position control devices.

Figure 2.2:-Block Diagram of PLC Operation

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2.2 PLC OPERATION
There are four basic steps in the operation of all PLCs : which continually take place in a repeati
ng loop.

•Input Scan

•Program Scan

•Output Scan

•Housekeeping

Figure 3.1:-PLC operation cycle

•Input Scan : Detects the state of all input devices that are connected to the PLC

•Program Scan : Executes the user created program logic.

•Output Scan : Energizes or de energize all output devices that are connected to the PLC.

•Housekeeping : This step includes communications with programming terminals, internal diagn
osticsetc...

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CHECK INPUT STATUS: First the PLC takes a look at each input to determine if it is on 
or off. In other words, is the sensorconnected to the first input on? Then the second input? Then t
he third and so on…. It records this data into its memory tobe used during the next step.

EXECUTE PROGRAM: Next the PLC executes your program one instruction at a time. M
aybe the program says that if the first input was on then it should turn on the first output. Since it 
already knows which inputs are on/off from theprevious step it will be able to decide whether the 
first output should be turned on based on the state of the firstinput. It will store the execution res
ults for use later during the next step.

UPDATE OUTPUT STATUS: Finally the PLC updates the status of the outputs. It
updates the outputs based on which inputs were on during the first step and the results of
executing your program during the second step. Based on the example in step 2 it would now
turn on the first output because the first input was on and your program said to turn on the first
output when this condition is true.

After the third step the PLC goes back to step one and repeats the steps
continuously. One scan time is defined as the time it takes to execute the 3 steps listed above

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2.3 PLC PROGRAMMING

Ladder diagram (LD)

Ladder diagram is a graphic programming language derived from the circuit diagram of directly
wired relay controls. The ladder diagram contains contact rails to the left and the right of the
diagram; these contact rails are connected to switching elements (normally open / normally
closed contacts) via current paths and coil elements.

Function block diagram (FBD)

In the function block diagram, the functions and function blocks are repre
s e n t e d   g r a p h i c a l l y   a n d interconnected into networks. The function block diagram
originates from the logic diagram for the design of electronic circuits.

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Sequential function chart (SFC)

The sequential function chart is a language resource for the structuring of sequence-
oriented control programs. The elements of the sequential function chart are steps,
transitions, alternative and parallel branching. Each step represents a processing status of
a control program, which is active or inactive. A step consists of actions which, identical to the
transitions, are formulated in the IEC 1131-3 languages. Action themselves can again
contain sequence structures. This feature permits the hierarchical structure of a
control program. The sequential function chart is therefore an excellent tool for the design and
structuring of control programs.

Instruction list (IL)

Statement list is a textual assembler-type language characterized by a simple machine model

(processor with only one register). Instruction list is formulated from control instructions
consisting of an operator and an operand.

LD Part_TypeA
OR Part_TypeB
AND Part_present
AND Drill_ok
ST Sleeve_in
With regard to language philosophy, the ladder diagram, the function block diagram
and instruction list have been defined in the way they are used in today’s PLC technology.
They are however limited to basic functions as far as their elements are concerned. This
separates them essentially from the company dialects used today. The competitiveness of these
languages is maintained due to the use of functions and function blocks.

Structured text (ST)

Structured text is high-level language based on Pascal, which consists of

expressions and instructions. Instructions can be defined in the main as : Selection
instructions such as IF...THEN...ELSE etc., repetition instructions such as FOR, WHILE etc. and
function block invocations.

Sleeve_in := (Part_TypeA OR Fig. B5.7: Part_TypeB) AND Part_present AND Drill_ok;

12
Structured text enables the formulation of numerous applications, beyond pure function
technology, such as algorithmic problems (high order control algorithms etc.) and data handling
(data analysis, processing of complex data structures etc.).

LADDER LOGIC

Ladder Logic, or Ladder Diagrams is the most common programming language used to program a PLC.

Ladder logic was one of the first programming approaches used in PLCs because it borrowed
heavily from the Relay Diagrams that plant electricians already knew. The symbols used in Relay Ladder
Logic consists of a power rail to the left, a second power rail to the right, and individual
circuits that connect the left power rail to the right. The logic of each circuit (or
rung) is solved from left to right. The symbols of these diagrams look like a ladder - with two
side rails and circuits that resemble rungs on a ladder. The picture above has a single circuit or "rung" of
ladder.

•If Input1 is ON (or true) - power (logic) completes the circuit from the left rail to
the right rail - andOutput1 turns ON (or true).

•If Output1 is OFF (or false) - then the circuit is not completed and logic does not
flow to the right – and Output 1 is OFF.

There are many logic symbols available in Ladder Logic - including Timers, Counters, Math,
and Data Moves- such that any logical condition or control loop can be represented in Ladder
Logic. With just a handful of basic symbols - a Normally Open Contact, Normally Closed
Contact, Normally Open Coil, Normally Closed Coil, Timer, Counter - most logical conditions can be
represented.

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2.4 CONTACTS AND COILS

With just the Normally Open Contact and Normally Open Coil - a surprising array of basic
logical condition scan be represented.

Normally Open Contact

This can be used to represent any input to the control logic - a switch or sensor, a
contact from an output, or an internal output. When "solved" the referenced input is examined for an
ON (logical 1) condition. If it is ON, the contact will close and allow power (logic) to flow from
left to right. If the status is OFF (logical 0), the contact is Open, power (logic) will NOT flow
from left to right.

Normally Open Coil

This can be used to represent any discrete output from the control logic. When "solved" if the logic to the
left of the coil is TRUE, the referenced output is ON (logical 1).

Solving a Single Rung

Suppose a switch is wired to Input1, and a light bulb is wired through Output1 in such a way that
the light is OFF when Output1 is OFF, and ON when Output1 is ON. W h e n I n p u t 1 i s O F F
(logical 0) the contact remains open and power cannot flow from left to
r i g h t . Therefore, Output1 remains OFF (logical 0).When Input1 is ON (logical 1) then the
contact closes, power flows from left to right, and Output1 becomes ON (the light turns ON).

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Another set of basic contacts and coils that can be used in Ladder Logic are the Normally Closed
Contact and the Normally Closed Coil. These work just like their normally open counterparts -
only in the opposite.

When "solved" the referenced input is examined for an OFF condition. If the status is OFF
(logical 0)power (logic) will flow from left to right. If the status is ON, power will not flow.

When "solved" if the coil is a logical 0, power will be turned on to the device. If logical 1, power
will beOFF

The AND Rung

The AND is a basic fundamental logic condition that is easy to directly represent in Ladder
Logic. Suppose a switch is wired to Switch1, a second switch is wired toSwitch2, and a light
bulb is wired through Light1 in such a way that the light is OFF when Light1 is OFF, and ON
when Light1 is ON. In order for Light1 to turn ON, Switch1 must be ON, AND Switch2 must be ON. If
Switch1 is OFF, power (logic) flow from the left rail, but stops at Switch1. Light1 will be OFF
regardless of the state of Switch2.If Switch1 is ON, power makes it to Switch2. If Switch2 is OFF,
power cannot flow any further to the right, and Light1 is OFF. If Switch1 is ON, AND Switch2 is ON -
power flows to Light1 solving its state to ON.

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The OR Rung

The OR is a logical condition that is easy to represent in Ladder Logic. Suppose a switch is wired to
Switch1, a second switch is wired to Switch2, and a light bulb is wired throughLight1 in such a way that the light
is OFF when Light1 is OFF, and ON when Light1 is ON. In this instance, we want to the light to turn ON if either
Switch1 OR Switch2 is ON.

If Switch1 is ON - power flows to Light1 turning it ON.

If Switch2 is ON - power flows through the Switch2 contact, and up the rail to Light1 - turning it ON.

If Switch1 AND Switch 2 are ON - Light1 is ON.

The only way Light1 is OFF is if Switch1 AND Switch2 are OFF

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2.5 Timers and Counters

Many times we will want to take action in a control program based on more than the
states of discrete inputs and outputs. Sometimes, we will want to turn something on after a
delay, or count the number of times a switch is hit. To do these simple tasks, we will need Timers &
Counters.
Simple Timers (TIM)
A timer is simply a control block that takes an input and changes an output based on time. There
are two basic timer types we will deal with initially (there are other advanced timers,
but we will start with the basics first) - On-Delay Timer and the Off-Delay Timer.

On-Delay Timer

This timer takes an input, waits a specific amount of time, then turns ON an output
(or allows logic to flow after the delay).

Off-Delay Timer

This timer takes turns ON an output (or allows logic to flow) and keeps that output ON until the
set amount of time has passed, then turns it OFF (hence off-delay)
Simple Counter (CNT)
A counter simply counts the number of events that occur on an input. There are two basic types of counters- Up
counter and a Down counter.

Up Counter

As its name implies, whenever a triggering event occurs, an up counter increments

the counter.

17
Down Counter

Whenever a triggering event occurs, a down counter decrements the counter

2.6 Memory Designs

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VOLATILE.

A volatile memory is one that loses its stored information when power is removed.
Even momentary losses of power will erase any information stored or programmed on a volatile
memory chip.
Common Type of Volatile Memory

RAM(Random Access Memory(Read/Write)

Read/write indicates that the information stored in the memory can be retrieved or read, while
write indicates that the user can program or write information into the memory.
The words random access refer to the ability of any location (address) in the memory to be
accessed or used. Ram memory is used for both the user memory (ladder diagrams) and storage
memory in many PLC’s.
RAM memory must have battery backup to retain or protect the stored program.
Several Types of RAM Memory:
1.MOS
2.HMOS
3.CMOS
The CMOS-RAM (Complimentary Metal Oxide Semiconductor) is probably one of the most
popular. CMOS-RAM is popular because it has a very low current drain when not being
accessed (15microamps.), and the information stored in memory can be retained by as little as
2Vdc.

NON-VOLATILE

Has the ability to retain stored information when power is removed, accidentally or intentionally.
These memories do not require battery back-up.
Common Type of Non-Volatile Memory

ROM( Read Only Memory)

Read only indicates that the information stored in memory can be read only and cannot be
changed. Information in ROM is placed there by the manufacturer for the internal use and
operation of the PLC.
Other Types of Non-Volatile Memory

PROM(Programmable Read Only Memory)

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Allows initial and/or additional information to be written into the chip.
PROM may be written into only once after being received from the PLC manufacturer;
programming is accomplish by pulses of current.
The current melts the fusible links in the device, preventing it from being reprogrammed. This
type of memory is used to prevent unauthorized program changes.

EPROM(Erasable Programmable Read Only Memory )

Ideally suited when program storage is to be semi-permanent or additional security is needed to

prevent unauthorized program changes.
The EPROM chip has a quartz window over a silicon material that contains the electronic
integrated circuits. This window normally is covered by an opaque material, but when the
opaque material is removed and the circuitry exposed to ultra violet light, the memory content
can be erased.
The EPROM chip is also referred to as UVPROM.

EEPROM(Electrically Erasable Programmable Read Only Memory)

Also referred to as E2PROM, is a chip that can be programmed using a standard programming
device and can be erased by the proper signal being applied to the erase pin.
EEPROM is used primarily as a non-volatile backup for the normal RAM memory. If the
program in RAM is lost or erased, a copy of the program stored on an EEPROM chip can be
down loaded into the RAM.

2.7 Communications

There are several methods to communicate between a PLC and a programmer or even between two PLCs.
Communications between a PLC and a programmer (PC or Hand held) are provided by the
makers and you only have to plug in a cable from your PC to the programming port on the PLC.
This communication can be RS232; RS485 or TTY. Communication between two PLC’s can be
carried out by dedicated links supplied/programmed by the makers (RS232 etc.) or via outputs from
one PLC to the inputs on another PLC. This direct link method of communication can be as simple as,
if an output on the first PLC is on then the corresponding input on the second PLC will be
on and then this input is used within the program on the second PLC. If a word of
input/outputs (16 bits) are used then numerical data can be transferred from one PLC to the other
(refer back to the section on numbering systems).There are many other methods of

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communication between PLCs and also from PLC to PC. Refer to the manuals
supplied with the PLC that you are using for full details on communications

Common Uses of PLC Communications Ports

Changing resident PLC programs - uploading/downloading from a supervisory controller

(Laptop or desktop computer).

Forcing I/O points and memory elements from a remote terminal.

Linking a PLC into a control hierarchy containing several sizes of PLC and computer.

Monitoring data and alarms, etc. via printers or Operator Interface Units (OIUs).

Serial Communications

PLC communications facilities normally provides serial transmission of information.

Common Standards

RS 232
Used in short-distance computer communications, with the majority of computer hardware and
peripherals.

Has a maximum effective distance of approx. 30 m at 9600 baud.

Local Area Network (LAN)

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Local Area Network provides a physical link between all devices plus providing overall data
exchange management or protocol, ensuring that each device can “talk” to other machines and
understand data received from them.

LANs provide the common, high-speed data communications bus which interconnects any or all
devices within the local area.

LANs are commonly used in business applications to allow several users to share costly software
packages and peripheral equipment such as printers and hard disk storage.

RS 422 / RS 485

Used for longer-distance links, often between several PCs in a distributed system. RS 485 can
have a maximum distance of about 1000 meters.

2.8 Programmable Controllers and Networks

Dedicated Network System of Different Manufacturers

Manufacturer Network
Allen-Bradley Data Highway
Gould Modicon Modbus
General Electric GE Net Factory LAN
Mitsubishi Melsec-NET
Square D SY/NET
Texas Instruments TIWAY

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 CHAPTER 3 RESULTS AND DISCUSSIONS

3.1 Motor Starter Example :

First consider a hardwired approach. The following line diagram illustrates how a normally
open and a normally closed pushbutton might be connected to control a three-phase AC
motor. In this example, a motor starter coil (M) is wired in series with a normally open,
momentary Start pushbutton, a normally closed, momentary Stop pushbutton, and normally closed
overload relay (OL) contacts.

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 Figure 3.1:-Motor Stator Circuit
Momentarily pressing the Start pushbutton completes the path for current flow and energizes the
motor starter (M). This closes the associated M and Ma (auxiliary contact located in the motor
starter) contacts. When the Start button is released, current continues to flow through the Stop button
and the Ma contact, and the M coil remains energized. The motor will run until the normally closed Stop
button is pressed, unless the overload relay (OL) contacts open. When the Stop button is pressed, the
path for current flow is interrupted, opening the associated M and Ma contacts, and the motor stops

3.2 Motor Starter Examples with PLC :

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This motor control application can also be accomplished with a PLC. In the following example, a
normally open Start pushbutton is wired to the first input (I0.0), a normally closed Stop
pushbutton is wired to the second input (I0.1), and normally closed overload relay contacts (part
of the motor starter) are connected to the third input (I0.2). These inputs are used to control
normally open contacts in a line of ladder logic programmed into the PLC.

Figure 3.2:-Motor Stator With PLC

Initially, I0.1 status bit is a logic 1 because the normally closed (NC) Stop Pushbutton is closed.
I0.2 status bit is a logic 1 because the normally closed (NC) overload relay (OL) contacts are
closed. I0.0 status bit is a logic0, however, because the normally open Start pushbutton has not
been pressed. Normally open output Q0.0contact is also programmed on Network 1 as a sealing
contact. With this simple network, energizing output coil Q0.0 is required to turn on the motor.

3.3 The Operation

25
When the Start pushbutton is pressed, the CPU receives a logic 1 from input I0.0.
This causes the I0.0contact to close. All three inputs are now a logic 1. The CPU
sends a logic 1 to output Q0.0. The motor starter is energized and the motor starts.

Figure 3.3:-Motor Start with NO PUSH Button

The output status bit for Q0.0 is now a 1. On the next scan, when normally open contact Q0.0 is solved, the
contact will close & output Q0.0 will stay on even if the Start pushbutton is released.

26
 Figure 3.4:-Latch Established

When the Stop pushbutton is pressed, input I0.1 turns off, the I0.1 contact opens, output coil Q0.0 de-energizes,
and the motor turns off.

Figure 3.5:-Motor Stop with NC PUSH Button

3.4 Water Level Indicator

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 MOTOR
A
FS

C
TIMER

Figure 3.6:-Water Tank Example

A tank is used to mix two liquids. The control circuit operates as follows:

1. When the start button is pressed, solenoids A and B energize. This permits the two liquids to
begin filling the tank.

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2. When the tank is filled, the float switch trips. This de-energizes solenoids A and B and starts
the motor used to mix the liquids together.

3. The motor is permitted to run for one minute. After one minute has elapsed, the motor turns
off and solenoid C energizes to drain the tank.

4. When the tank is empty, the float switch de-energizes solenoid C.

5. A stop button can be used to stop the process at any point.

6. If the motor becomes overloaded, the action of the entire circuit will stop.

7. Once the circuit has been energized it will continue to operate until it is manually stopped.

3.4 Human Machine Interface

A Human Machine Interface or HMI is the apparatus which presents process data to a human operator, and
through which the human operator controls the process.

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An HMI is usually linked to the SCADA system's Database and software programs,
to provide trending, d i a g n o s t i c d a t a , a n d m a n a g e m e n t i n f o r m a t i o n s u c h a s
s c h e d u l e d m a i n t e n a n c e p r o c e d u r e s , l o g i s t i c information, detailed schematics for a
particular sensor or machine, and expert-system troubleshooting guides.

The HMI system usually presents the information to the operating personnel graphically, in the
form of a mimic diagram. This means that the operator can see a schematic
representation of the plant being controlled. For example, a picture of a pump connected to
a pipe can show the operator that the pump is running and how much fluid it is pumping through
the pipe at the moment. The operator can then switch the pump off. The HMI software will show
the flow rate of the fluid in the pipe decrease in real time. Mimic diagrams may consist of
line graphics and schematic symbols to represent process elements, or may consist of
digital photographs of the process equipment overlain with animated symbols.

The HMI package for the SCADA system typically includes a drawing program that the
operators or system maintenance personnel use to change the way these points are
represented in the interface. The sere presentations can be as simple as an on-screen traffic
light, which represents the state of an actual traffic light in the field, or as complex as a multi-
projector display representing the position of all of the elevators in a skyscraper or all of the trains on a
railway.

CHAPTER 4 CONCLUSION AND FUTURE SCOPE

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4.1Conclusion
Future of PLC in industrial automation has been rising since 1947 and most of the industries
including automation are using PLCs and install control systems to reduce the manual labor and
improve the precision and efficiency. PLCs are very popular because of their precision.

4.2 Scope of PLC Programming

PLCs are continuously growing and evolving to be the best option for a variety of industrial
automation applications. Scope of plc programming is increasing rapidly because of greater
programming flexibility and ease, scalability, more memory, smaller sizes, very high-speed
(gigabit) Ethernet, and built-in wireless features. PLCs are getting benefits from USB technology
and thus make it easier than ever before to get online, program, and monitor your control
systems. PLC programming will evolve, and with the availability of smaller micro and mini USB
connectors, you can expect to see this option on more of the smaller PLCs. In the future, PLCs
will continuously evolve while adapting technology enhancements in communications,
hardware, and software.

Future Scope of industrial automation

Future scope of industrial automation would be good enough as every technology is involved
with automation techniques. It is the use of various control devices such as PC’s, DCs, and PLCs
to control various operations of an industry without significant intervention from humans and to
provide automatic control performance. In industries, there would be a set of technologies that
are implemented to get the desired performance or output, making the automation systems most
essential for industries. On the other hand, industrial automation involves usage of advanced
control strategies such as cascade controls, control hardware devices and other instruments for
sensing the control variables etc.

Appendix

1-10 UP and DOWN Counter

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 Figure 1:-UP DOWN Counter

Water Level Indicator

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Figure 2:-Water Level Indicator

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