Lab Manual Industrial Automation

GOVERNMENT POLYTECHNIC, MUMBAI
INDUSTRIAL AUTOMATION - EE 11 405

LABORATRY MANUAL
ELECTRICAL ENGINEERING DEPARTMENT
Course Teacher – Dr. Mahesh S. Narkhede, LEE

Special Thanks to Mr. Avinash Dabade
(Faculty & Expert – PLC)
Industrial Automation (EE11405) Electrical Engg Dept. Government Polytechnic Mumbai
Certificate
1
Index
2
Experiment No-1
Aim: To develop ladder diagrams for ON/OFF inputs to

produce ON/OFF outputs
Objective:
1) To study fixed and modular PLC.
2) To study the ladder program for ON/OFF

input and output.
Equipments:
1) Name of PLC used _________________________________.
2) RS232 Communication cable.
3) RS Linx and RSlogix500 software.
Theory:
FixedPLC: A Fixed PLC consist of a fixed or built in
input and output sections. The I/O of a
fixed PLC is built in and not changeable.
3
There is one fixed or built in non removable screw

terminal strip containing all input signal screw
terminals connections and another screw
containing all output control signal screw
terminals.
ModularPLC:
Modular PLC does not have a terminal strip built
into the processor unit. Modular PLC’s have their I/O
points on plugin type removable units called, I/O
Modules.
PLC with modular Input and Outputs consist of
chassis ,rack, or base plate where Power supply,
CPU, and all Input Output modules are present as
separate hardware items.
Procedure:
RSLinx Software:
1) Open RSLinx software to configure the serial driver- RS232
DF1, for communication with Micrologix 1000/ 1200 PLC.
Click on Start.Click on All Programs.Click on Rockwell

Software.Click on RS Linx.
Click on Communication menu.
4
Click on Configure Drivers. Select RS232 DF1 in Available

Driver Types field. Click on Add New. Click on OK. Click on
Auto Configure button. Click on OK.Click on Close.
Again Click on Communication menu.
Click on RS Who. Select AB_DF1_1. Observe the status in Right
pan. (If PLC is not communicating with RS Linx software then it
will show cross bar on PLC.)
2)Write a Ladder Program in right pan and make sure that you
have followed the same I/O addresses as shown in fig. below.
3) Download the Ladder Program to the Micrologix 1000/ 1200

PLC and place PLC in RUN mode.
4) Make sure that all push buttons/toggle switches are physically

off, before testing the Ladder Program.
5) Test /Simulate the Ladder Program using push button / toggle

switch and by observing lamps, provided on PLC control panel.
Fig.
5
Conclusion :
We have made use of following two programming instructions of
Ladder Logic
Instruction Symbol Instruction Name
1) _______________ XIC
2) _______________ XIO
3) _______________ OTE
Performance Date Completion Date Sign
6
Experiment No-2
Aim: Basic Logic functions using Ladder Logic.
Objective: 1) To Study Fixed & Modular PLC.

2) To write Input and Output List.
3) To write the Ladder Program to satisfy the
truth table for Gates.
4) To test / simulate the ladder program.
Equipments:
1) Name of PLC used __________________________________.
Theory:
FixedPLC:
A Fixed PLC consist of a fixed or built in input and output
sections. The I/O of a fixed PLC is built in and not
changeable.
There is one fixed or built in non removable screw terminal
strip containing all input signal screw terminals
connections and another screw containing all output
control signal screw terminals.
7
ModularPLC:
Modular PLC does not have a terminal strip built into the
processor unit. Modular PLC’s have their I/O points on
plugin type removable units called, I/O Modules.
PLC with modular Input and Outputs
consist of chassis ,rack, or base plate where Power
supply, CPU, and all Input Output modules are present
as separate hardware items.
Logic: (Write down the truth tables )
1. AND Gate
Sr.No. A B Y Sr.No. SW1 SW2 Lamp

1. 0 0 0 1
2. 0 1 0 2
3. 1 0 0 3
4. 1 1 1 4
2. OR Gate
Sr.No. A B Y Sr.No. SW1 SW2 Lamp

1. 0 0 0 1
2. 0 1 1 2
3. 1 0 1 3
4. 1 1 1 4
8
3.NOR Gate
Sr.No. A B Q Sr.No. SW1 SW2 Lamp

1. 0 0 1
2. 0 1 0
3. 1 0 0
4. 1 1 0
4. XOR Gate
Sr.No. A B $O Sr.No. SW1 SW2 Lamp

1. 0 0 0
2. 0 1 1
3. 1 0 1
4. 1 1 0
Procedure:
9
RSLinx Software:
Click on Start.Click on All Programs.Click on Rockwell
Software. Click on RS Linx.Click on RS Linx. Click on
Communication menu.
Click on Configure Drivers. Select RS232 DF1 in

Available Driver Types field. Click on Add New. Click on
OK. Click on Auto Configure button. Click on OK.Click
on Close.
Again Click on Communication menu. Click on RS Who.

Select AB_DF1_1. Observe the status in Right pan. (If PLC
is not communicating with RS Linx software then it will show
cross bar on PLC.)
2) Write a Ladder Program in right pan and make sure that you
have followed the same I/O addresses as shown in Fig (A)
and Input- Output List prepared by you.
3) Download the Ladder Program to the Micrologix 1000/ 1200

PLC. And place PLC in RUN mode.
4) Make sure that all push buttons / Toggle switches are

physically off, before testing the Ladder Program.
5) Test /Simulate the Ladder Program using push button /

toggle switch and by observing Lamps, provided on PLC
control panel.
10
SW1 SW2
+24 24 DC IN0 IN1 IN2 IN3 IN4

VDC GND COM
PLC
L N E VAC OUT OUT VAC OUT OUT

VDC 0 1 VDC 2 3
Lamp
230 V AC
Figure A.
11
1.AND Gate:
2.OR Gate:
12
3.NOR Gate:
4. XOR Gate:
(Ladder Logic)
13
14
Experiment No-3
Aim: Develop a Ladder Logic for Traffic light Control System and
test it through PLC using Ton instruction.
Objective: 1) To write Input and Output List.

2) To write the Ladder Program.
3) To test / simulate the ladder program.
Equipment:
1) Micrologix 1000 PLC / Micrologix 1200 PLC.
Logic:
1. Press Start Push Button to start the function.
2. Red lamp should be ON for 25 seconds.
3. After 25 seconds Red lamp should be OFF. Then Green
lamp should be ON for 35 seconds.
4. After 35 seconds Green lamp should be OFF. Now Yellow
lamp should be ON for 15 seconds.
5. After 15 seconds Yellow lamp should be OFF. Again Red
lamp should be made ON for next 25 seconds.
6. Repeat the cycle from step 2, to autostart.
7. Press Stop Push Button to stop the function.
15
Procedure:
RSLinx Software:
Open RSLinx software to configure the serial driver- RS232 DF1,
for communication with Micrologix 1000/ 1200 PLC.
RSLOGIX500 Software:
1) Open RSLogix500 software, to design a ladder program in
RSLOGIX500 software and make sure that you have
followed the same I/O addresses as shown in Fig (A) and
Input- Output List prepared by you.
2) Download the ladder program to the Micrologix 1000/ 1200


physically off, before testing the ladder program.
4) Test /Simulate the ladder program using push button /

control panel.
16
Figure A.
NO NC
+24 24 DC IN0 IN1 IN2 IN3 IN4

VDC GND COM
PLC
L N E VAC OUT OUT VAC OUT OUT

VDC 0 1 VDC 2 3
RED GREEN YELLOW

230 V AC
17
Ladder Logic:
18
RED
GREE
N
YELLOW
RED
GREE
N
YELLOW
Figure B.
19
Conclusion:
We have made use of following programming instruction
of Ladder Logic
1) _______________ TON
2) _______________ XIC
3) _______________ XIO
Performance Completion Date Sign

Date
20
Experiment No- 4
Aim: Ladder Logic for counting the objects.
Objective:
1) To write Input and Output List.
3)To test / simulate the ladder program.
Equipments:
1) State the name of PLC used ___________________________
Logic:
1.Press Start Push Button to start the function.
2.Motor will get ON, when function starts.
3.Conveyor belt will start moving and so the objects place
on it. Sensor detects the objects and gives signal to the
counter. Counter counts the objects moving on Conveyor
belt.
4. Motor shall stop when counter counts 200 objects.
5.Press Stop Push button to stop the function.
21
Procedure:
RSLinx Software:
Open RSLinx software to configure the serial driver- RS232 DF1,
for communication with Micrologix 1000/ 1200 PLC.



control panel.
22
(Ladder Logic)
23
Start Stop Sensor

PB PB
+24 24 DC IN 0 IN 1 IN 2 IN 3 IN 4
VDC GN CO
PLC
L N E VAC
VDC
OUT
0
OUT
1
VAC
VDC
OUT
2
OUT
3
Motor
230 V AC
Figure A.
24
Sensor
Objects moving on
Conveyor Belt
Figure B. Conveyor Delivery System

Conclusion :
We have made use of following programming instruction of
Ladder Logic
1) _______________ CTU
The instruction is used in combination with sensor to count the

objects.
Performance Completion Date Sign

Date
25
Experiment No- 5
Aim: A program for Temperature Measurement.

Equipments:
Logic:
1. Use PT100 to measure the temperature of oven.
2. Assume PT100 output ( 4 to 20 ma ) is connected at input
terminal N7:33 .
3. Use SCP instruction to measure the temperature of oven.
4. Input mean to 6241 and max to 32767 with respect to 4 to
20 mA.
5. Input scale mean value to 0.
6. Input scale max value 2 to 100.
7. Assume output to be store to N7:0.
26
Procedure:
RSLinx Software:

PLC. and place PLC in RUN mode.


control panel.
27
(Ladder Program)
Heat
PT 100 er
Furnace
Figure A. Furnace Temparature Control
28
Conclusion:
Ladder Logic
1) _______________ SCP
29
Experiment No-6
Aim: To Develop a simple programmes for comparison
instructions.

Equipments:
4) Furnace along with Heater and RTD
Diagram :
Heater
Furnace
RTD
Figure :1
30
Procedure:
1) Temperature of furnace as shown in the Figure: 1 is
controlled by heater. RTD (PT100) is used to measure the
temperature of furnace.
2) Assume set point is stored in memory location N7:0.
3) Input set point = 45 ̊C.
4) Assume tolerance is stored in memory location N7:1.
5) Input Tolerance=5˚C.
6) Destination set point (effective set point) is stored at

N7:2. It will be addition of both above if we select ADD
instruction.
7) Select GRT instruction.
8) Assume process value temperature (actual temperature)

to be stored at N7:3 (source A).
9) Now alarm will be ON if actual temperature > effective

set point
31
(Ladder Logic)
32
Conclusion:
Ladder Logic
1) _______________ ADD
2) _______________ GRT
33
Experiment No - 7
Expt Name : Design of ON and OFF switch in SCADA
Equipment:
• Any IBM compatible PC with a Pentium II processor or
higher (minimum: 400MHz on a single node system,
recommended: 1.2GHz or higher).
• At least 2GB of free hard disk space.
• At least 256MB of random-access memory (RAM), 512MB
of RAM is recommended.
• Wonderware, InTouch Software
Procedure & Observation:

[1] Open the Intouch Application Manager.
[2] Create a new application named as Light On Off
[3] Create the new windows as Switch and Light
[4] In the Switch windows through wizard add fixture switch
[5] In the light window add light through wizard.
[6] Give tag names to both.
[7] Write down the expressions for green and red lights as per
the switch positions.
[8] Save and run the application
34
Fig.1 Switch-On, Light- Green Fig.2 Switch-Off, Light- Red
Output :
Conclusion:
We have made use of Intouch application Manager to design
ON and OFF switch in SCADA.
35
Experiment No - 8
Experiment Name : Calculation of Step Angle of Steeper Motor
Equipment: Stepper Motor Construction & operation Video, PC

Procedure &Observation:
[1] In a Full Step Drive mode (Fig.1 & 2), the rotor rotates
through 900 in one step, so the step angle is 900.
[2] In a Half step Drive mode (Fig.3 & 4), the rotor rotates
through 450 in one step, so the step angle is 450.
Fig. 1 Fig.2
Fig. 3 Fig.4
36
Conclusion:
The step angle of stepper motor in Fig.1 is 900 and Fig.3 & 4 is
450.
37
Experiment No - 9
Part - A
Aim : To plot characteristics of Potentiometer
Apparatus : Potentiometer, Voltmeter, Scale
Theory :
• A Potentiometer is a potential measuring device. It measures
the unknown e.m.f. or p.d. by balancing it, wholly or in part,
against a known difference of potential. There are two types
of Potentiometers
• Linear potentiometer
• Rotary Potentiometer
• Potentiometers work by having a resistive element inside.

Both end terminals are attached to it, and do not move. The
wiper travels along the strip when the knob is turned. The
closer the wiper is to the end terminal it is wired in conjunction
with, the less the resistance, because the path of the current
will be shorter. The further away it moves from the terminal,
the greater the resistance will be.
38
Circuit Diagram:
Procedure:
1) Connect DC supply to the two ends of the translation

potentiometer
2) Connect multimeter across variable arm and ground
3) Move the variable terminal in steps of 1 cm.
4) Measure the voltage across the output terminals.
5) Repeat the steps 3 and 4 till the variable terminal is at the

extreme end.
6) Plot the graph of displacement vs output voltage.
7) Calculate the sensitivity from the graph by using formula

V/
39
Observation :
Potentiometer P1 = ________ K
Supply voltage V1i = _______ V D.C.
Result:
Sensitivity of Linear Potentiometer is ---------
Part -B
Application of Potentiometer as error Detector:-
• It can also be used to measure the current flowing through a
circuit and unknown low resistance of the circuit.
• Potentiometer also can be used as error detector. When

potentiometer is used as error detector, two identical
potentiometers are used. The constant stabilized DC Supply
is connected to fixed ends of pots.
40
• The variable points are taken as output. The error voltage is

directly proportional to difference angular displacement /
linear displacement of two potentiometers. The DPM is
provided to read the error voltage between two pots.
Fig.1
Fig.2
41
Here the difference of voltage between two potentiometers is

amplified and is given to motor which is rotated by particular
angle.
Characteristics :-
Fig.3
Conclusion : Potentiometers can be effectively used as an

error detectors.
42
EXPERIMENT NO.10
AIM:- Understand and draw the Symbol sheet for different

Pneumatic and Hydraulic components .
Handdrawn
43
44
45
46
47

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GOVERNMENT POLYTECHNIC, MUMBAI

INDUSTRIAL AUTOMATION - EE 11 405

ELECTRICAL ENGINEERING DEPARTMENT

Course Teacher – Dr. Mahesh S. Narkhede, LEE

Aim: To develop ladder diagrams for ON/OFF inputs to

2) To study the ladder program for ON/OFF

There is one fixed or built in non removable screw

Click on Start.Click on All Programs.Click on Rockwell

Click on Communication menu.

Click on Configure Drivers. Select RS232 DF1 in Available

3) Download the Ladder Program to the Micrologix 1000/ 1200

4) Make sure that all push buttons/toggle switches are physically

5) Test /Simulate the Ladder Program using push button / toggle

Instruction Symbol Instruction Name

Performance Date Completion Date Sign

Objective: 1) To Study Fixed & Modular PLC.

Sr.No. A B Y Sr.No. SW1 SW2 Lamp

Sr.No. A B Y Sr.No. SW1 SW2 Lamp

Sr.No. A B Q Sr.No. SW1 SW2 Lamp

Sr.No. A B $O Sr.No. SW1 SW2 Lamp

Click on Configure Drivers. Select RS232 DF1 in

Again Click on Communication menu. Click on RS Who.

3) Download the Ladder Program to the Micrologix 1000/ 1200

4) Make sure that all push buttons / Toggle switches are

5) Test /Simulate the Ladder Program using push button /

+24 24 DC IN0 IN1 IN2 IN3 IN4

L N E VAC OUT OUT VAC OUT OUT

Performance Date Completion Date Sign

Objective: 1) To write Input and Output List.

2) Download the ladder program to the Micrologix 1000/ 1200

3) Make sure that all push buttons / Toggle switches are

4) Test /Simulate the ladder program using push button /

+24 24 DC IN0 IN1 IN2 IN3 IN4

L N E VAC OUT OUT VAC OUT OUT

RED GREEN YELLOW

Instruction Symbol Instruction Name

Performance Completion Date Sign

2) Download the ladder program to the Micrologix 1000/ 1200

3) Make sure that all push buttons / Toggle switches are

4) Test /Simulate the ladder program using push button /

Start Stop Sensor

Figure B. Conveyor Delivery System

Instruction Symbol Instruction Name

The instruction is used in combination with sensor to count the

Performance Completion Date Sign

Objective: 1) To write Input and Output List.

2) Download the ladder program to the Micrologix 1000/ 1200

3) Make sure that all push buttons / Toggle switches are

4) Test /Simulate the ladder program using push button /

Figure A. Furnace Temparature Control

Instruction Symbol Instruction Name

Performance Date Completion Date Sign

Objective: 1) To write Input and Output List.

2) Assume set point is stored in memory location N7:0.

3) Input set point = 45 ̊C.

4) Assume tolerance is stored in memory location N7:1.

6) Destination set point (effective set point) is stored at