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Introduction of SOFCON
Sofcon a Channel Partner of Rockwell Automation inIndia.
It offers Turn-key Automation projects, solutions &
services to power, chemical, pharma, cement, energy,
food, water management etc. industries for over 02
decades.
Sofcon India Pvt. Ltd (Training Wing of Sofcon Group)
is committed to Strengthen practical Knowledge of
Engineers / Working Professionals / Technicians
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Sofcon offers various courses
0 PLC Course Contents
0 Digital Electronics Basics
0 PLC Fundamentals0 PLC Hardware & Architecture
0 Source & sink Cencepts
0 Wiring Different field Devices to PLC
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SCADA Course Contents
0 Introduction to SCADA Software
0 Creating new SCADA project
0 Creating & editing elementary graphic display0 Attaching controls to graphic objects
0 Real time & historical trends Using alarms & events
0 Application of scripts Communication with PLC
0 Communication with excel
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AUTOMATION
0 Automation is a step beyond mechanization.
0 Automation is the use of control systems and
information technologies to reduce the need forhuman work in the production of goods and services.
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Automation Components
0 Sensor for sensing physical
condit ions0 Transmitters
0Control Systems
0Output Devices
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Sensors Placed in the field
Automation : Typical instal lation . . . .
Junction Box
F ield Cabling
Control Panel
Control Hardware
SCADA Software
Communication Cable
F ield Cabling
Back
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Programmable Logic
Controllers A PLC is a solid state / industrial computer that performs
discrete or sequential logic in a factory environment.
It was originally developed to replace mechanical relays,
timers, counters.
A sequence of instructions is programmed by the user to thePLC memory. Its purpose is to monitor crucial process
parameters and adjust process operations accordingly.
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FUNCTIONS It controls output devices based on the status of inputs and a user
written program.
Originally developed to directly replace relays used for discrete
control.It performs functions as
On/Off Control
• Timing Counting
Sequencing Arithmetic
Data Handling
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PLC SavesMaterial cost
Installation cost
Troubleshooting
Labor cost
ByReduced wiring & associated errors
Less space
No moving parts - rugged
Possibility of reprogrammingValue added benefits
Reliability
Flexibility
Advanced Function
Communication
Speed
Diagnostics
ADVANTAGES
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Packaging Bottling & Canning
Material Handling Machining
Power Generation HVAC/ Building AutomationSecurity Systems Automated Assembly
Paint Lines Water treatment
Industry Cement Automobile Chemicals Plastics
Metals Paper F&B
APLLICATIONSAny application in any industry
that requires electrical control
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Various Brands of PLCs
Allen Bradley USA
Siemens Germany
Modicon France
Mitshubishi Japan
GE Fanuc USA
Omron Japan
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Programming/
CommunicationDevice
Central
Processing
Unit (CPU)
Input
Circuits
Output
Circuits
Memory
program data
Power supply
Optical isolation Optical isolation
ARCHITECTURE
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INPUTSPLC system consists of Inputs
Input
Circuits
1) Inputs - Discrete - On/Off type
o Pushbuttons
o Switches
o
Limit Switcheso Selector Switches
o Proximity sensors
o Photo - electric sensors
2) Inputs devices - Analog
o Resistance Temp. Detectors
o Thermo - couple
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Input Modules
1
23
4
56
7
8
9
10
COM
A / D c o
nv er si on
To PLC
Terminal block - this is
where wires from the
field devices are
connected
Field device - this isshowing a simple
switch
Input Module
24 Volt
DCSystem
+ 24 Volts
- 24 Volts
The input module performs tasks
electronically as:
oDetermines the presence or absence of
input
oConverts input single to a DC level use
able PLC
oProvides Electronic isolation B/w input
signal & PLC
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Input Modules
Pressure
4-20 mA
Temperature
0-10V DCSwitch
24V DC
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PLC system consists of Outputs
OutputCircuits
o Solenoids
o Relays - AC or DC powered
o Contactors
o Motor Starters
o
Indication Lightso Valves
o Alarms
OUTPUTS
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Output Modules
Fan
120V ACLight
24V DC
Valve
0-10V DC
The output module operates in oppositemanner from input module
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Processor, Controller, or CPU
Stores the control program and data in its memory
Reads the status of connected input devices
Performs Arithmetic and Logical Operations
Executes the control program
Commands connected outputs to change state based on program execution
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WORKING OF PROCESSOR
For any execution of program processor has to scan
the entire program
Scan cycle consist of:- Input Scan
Program Scan
Output Scan
Housekeeping
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PLC SCAN
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Facts about scan cycle
Scan Cycle Depends upon No of I/Os More I/Os More scan time Application Decides the Scan time of a
PLCScan time in normal applications is 1 msto 2 ms & in bigger applications 100 ms to
200 ms
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MEMORY
The processor consists of memory locations known as
words
Each word can store binary data
The number of bits that a word can store depends on thesystem of PLC
The 16-bit word is more common
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Programming Languages
0 Ladder Diagram (LD)
0 Functional block Diagram (FBD)
0 Structured Text (ST)0 Instruction List (IL)
0 Sequential Functional Chart (SFC)
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Ladder BasicsLadder is widely used language & is close to Electrical
basics. In 50-60% places in a ladder: NO, NC
or (XIC, XIO in case of Allen Bradley) are used.
If s/w closed at this add CPUinterprets it as True condition
If s/w Open at this add CPUinterprets it as False condition
If s/w Open at this add CPUinterprets it as True condition
If s/w Closed at this add CPUinterprets it as False condition
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CONTROLSIGNALIN1
CONTROLSIGNAL IN2
OUTPUT
0 0 0
0 1 0
1 0 0
1 1 1
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OR Gate, Relay and PLC Equivalent Boolean Expression is written as: Y = A + B
In an OR gate, the output is high if any one or all of the inputs
are high. Therefore the OR gate is equivalent to a parallelcombination of normally open switches. Truth Table
Controlsignal IN1
CONTROLSIGNAL IN2
OUTPUT
0 0 0
0 1 1 1 0 1
1 1 1
ar ware ver ew o
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ar ware ver ew oMicroLogix 1000
MicroLogix 1000 is a packaged controller containing a power
supply, input circuits, output circuits, and a processor.
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Data Files in Micrologix 1000
B i C t f PLC
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Basic Components of a PLC
SystemNetwork Interface
Most PLCs have the ability to communicate with other devices. The
PLC will communicate to the other devices through a network interface.
Network connecting other devices
Network
interface
module
PLC
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Typical PLC Application
Motor Solenoid 1 Solenoid 2
Solenoid 3
Sensor 1
Sensor 2
Ingredient A Ingredient B
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Programming a PLC – Conveyor
example
Light 1Photoeye 2 Photoeye 1
Motor 1
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PLC Programming Software
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Supervisory Control and Data
Acquisition (SCADA) Systems0 SCADA systems
0 used to monitor and control a plant or equipment in
industries
such as:
0 telecommunications, water and waste control, energy,
oil and gas refining and transportation
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PURPOSE
A SCADA SYSTEM
Gathers information from Remote Terminal Units
(RTUs) and/or (PLCs), and the central host and the
operator terminals(such as where a leak on a pipeline
has occurred).
Transfers the information back to a central site, then
alerts the home station that a leak has occurred
carries out necessary analysis and control,
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What do SCADA Provide?
Dynamic Process Graphics
Basic SCADA functionality Real time &historical trend
Alarms
Recipe Management
Security
Report Generation
Logging, Archiving
Device connectivity
Data base connectivity
Interfaces to H/W and S/W Interfaces to ERP- and Expert-Systems
Development Tools
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Configuration
of SCADA Systems
9 - 12 Oct. 2000 PCaPAC'2000 - DESY 41
Field Bus
Data Server PLC’s Data Server
C fi ti
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Configuration
of SCADA Systems 2nd
42
PLC Programs
Communication
Processor
•Analog-Input
•Value-AI-0
•Value-AI-1
•Analog-Output
•Value-AO-0
•
Value-AO-1Field Bus
•Analog-Input
•Vacuum_VALUE
•Pressure_VALUE
•Analog-Output
•Valve_1_OUT
•
Heater_1_OUT
Mapping
SCADA
Play
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THAT’S IT FROM THE
PRESENTATION AREA
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