Automation Notes

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TECHNOCRAT AUTOMATION
AUTOMATION
Definition
Allocation of human control

sequence given to technical
equipment.
MANUAL CONTROL
.
MONITORING
INLET VALVE
OUTLET VALVE
INTRODUCTION NOTES ON AUTOMATION AND P.L.C
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AUTOMATED CONTROL
INLET VALVE
L.
T
CONTROLLER
(PLC;DCS:etc)
70%
OUTLET VALVE
The automated process have a

controller which will act like a
human brain and control the
process sequence using a
program logic.
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HISTORY OF AUTOMATION
1.
MANUAL/HUMAN CONTROL
2.
HARDWIRED/ELECTRICAL
CONTROL
3.
ELECTRONIC CONTROL
4.
PROGRAMMABLE LOGIC
CONTROL
(P.L.C)
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5.
DISTRIBUTED CONTROL SYSTEM
(D.C.S)
MANUAL CONTROL
DISADVANTAGES
LOW EFFICIENCY
HIGH MAINTANCE
TIME WASTING
LOW QUALITY OF PRODUCT
FULLY DEPENDED ON HUMANS
WEAR AND TEAR
LOW ACCURACY
LESS PRECISE
HARDWIRED CONTROL
Using electrical wirings; electrical

timers;electrical counters and relay
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logics to control the process

sequence
DISADVANTAGES
Bulky wirings
Chance of short circuit
More complex
Difficult to find out faults
Maintanance
Efficiency
Installation cost is high
RELAY
Electro-mechanical switching
device.
TW0 CONTACT POINTS
I. Normally Open (NO)
II. Normally closed (NC)
DIAGRAM:
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NO
COMMON
NC
RELAY LOGICS
Circuits with electrical wirings and
relays are called relay logic wirings.
In hard wired control the relays plays
a crucial role in controlling a process.
The relay is like a switch which
switches a load ON/OFF depending on
the logic wiring; and control
sequence.
A relay have two sections
Input:
Input section has a coil; which will
energize
when it gets
an input supply.
Output:
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Output section has three contacts;

1:Normally Open Contact [N.O]
2:Normally Closed Contact [N.C]
3:Common Contact[C]
N.O and N.C contact are fixed
contacts and common contact is
movable.
Common switches between N.O and
N.C.
Logic gates wiring using relay
The logic gates are:
I. NOT gate
II. AND gate
III. OR gate
IV.
V.
VI.
VII.
NAND gate
NOR gate
X-OR(EXCLUSIVE OR) gate
X-NOR(EXCLUSIVE NOR)gate
1 not gate:
NO
230V/50Hz;
1AC
MOTOR
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NC
230V/50H
z/1AC
TRUTH TABLE
S1
0
1
L
1
0
If the switch/relay (s1)is in OFF state the load will be in

ON condition; ie the relay will switch the supply to the
load through N.C contact
2 AND gate:
S1
S2
P
N
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3 OR
S1
S2
GATE
S1
S2
P
N
S1
S2
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4 Nand gate
S1
S2
P
N
S1
S2
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5 nor gate
S1
S2
P
N
S1
S2
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6 x-or gate
S1
S2
P
N
S1
S2
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7 x- nor gate
S1
S2
P
N
S1
S2
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Electronic control
Comes after the development of
transistor.
Fast switching speed.
It will work in three different
configuration:
Common emitter:- amplifier
Common base
:-switch
Common collector:-cascade
amplifier
Electronic control becomes more
common after the development of
integrated circuits like microprocessor and micro- controller.
Micro processor:- needs external
memory
Micro ctrlr
:-integrated with
memory
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disadvantages
temperature range:- 15c 23c.
limited number of inputs and
outputs.
cannot withstand to vibrations.
continuous reprogramming will
cause damages to p and cs.
work only in small voltage
ranges.
Programmable logic control (p.l.cs)

Programmable logic controllers are
new generation control sequence
which will work on the given
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program logics that are given by

the user or the operator.
Program logic means the process to
be done. (Eg:-tank level control;
boiler temperature control; etc.)
Advantages
Temperature range:- 72c-74c
Invariant to vibrations
Expand the number of i/0s
depending on the type of plc.
Re-programmable to 9999
times.
Work on both high voltage and
low voltage compare to p and
c.
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Work on both AC and DC

voltages.
Quick response.
Architecture of p.l.c
POWER SUPPLY
INPUTS FROM FIELD
230/110VAC/24VDC
24VDC/0-10VDC/4-20mA
MEMORY
PROGRAM MEMORY
OUTPUT TO FIELD
24VDC/0-10V/4-20mA
DATA MEMORY
COMMUNICATION
PORT (RS 232/RS
485..)
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EXPANSION
PORT
The main parts of a P.L.C are:1.

2.
3.
4.
5.
6.
The
The
The
The
The
The
power supply unit.

input unit.
output unit.
memory unit.
communication port.
expansion port.
Power supply
Working supply of a plc is 24VDC

Depending on power supply unit;
PLCs are divided into two:1.
Plc with smps
2.
Plc without smps
A plc with smps means ; that
the plc is manufactured with
the smps unit; ie it can
accept 230/110vac/24vdc
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A plc without smps means it

can accept only the standred
24vdc as it supply.
Input & output units

Input voltage of a plc:- 0-24vdc
:-4-20mA
:-0-10v
Input signal:- raw / unprocessed data;ie

from field.
Output signal:-processed data; ie to
field.
Basically field inputs are from sensors;
transmitters; etc..
Outputs from plc are given to relays for
switching loads.
Expansion port
Expansion port is used to expand the
number of i/os
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On the basis of expansion port the

plcs are divided into three. They
are.
1. Fixed type PLCs
P.S
INPUT
CENTRAL PROCESSING UNIT
OUTPUT
COMM
only limited number of i/os upto
128
Modular type
P.S
INPUT
CENTRAL PROCESSING UNIT
OUTPUT
COMM
E
X
P
A
N
S
I
O
N
P a g e | 22
Modular type P.L.C have the same features

of fixed type P.L.Cs the only difference
is the power of the core; ie the
controller; number of i/os.
Maximum number of i/os that can be
added to a modular type PLC:- 2048 i/os.
Rack type
Pow
er
Supp
ly
Unit
Com
mun
icati
on
port
Digi
tal
Ana
log
i/o
i/o
Rack type PLC are rack in shape.

P a g e | 23
Separate rack for each section.

Maximum i/os:- 16000
Communication port
Communication port is used to
communicate between PC and PLC(for
programs); PC and PLC (for SCADA).
PC and PLC
One of the main use of the
communication port is to communicate
between computer and the plc for
downloading programs from pc to plc
and to upload programs from plc for
further expansions.
PC and PLC
Another main advantage of the
communication port is to communicate
between PLC and SCADA.
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SCADA (Supervisory Control And Data

Acquisition) is a method used to
monitor,control,and acquire datas from
the field to the control room.
But the primary problem is that
controllig of the field is done by the PLC
which is purely a hardware and SCADA
which is purely a software in which we
can draw the graphical representatin of
the field.
To communicate between plc and scada
a serial communication protocol is
required and the communication port is
used.
Different Communication
protocols
RS 232; RS 485; RS 422
(Recommended Standred)
RJ 11;RJ 45
(Registered Jack)
PROFI BUS; PROFI NET+
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MOD BUS
FIELD BUS
Optical Fibre Communication(OFC)
Universal Serial Bus (USB)
p.l.c programming
Like computer needs programs for its
working a PLC need a program and a
programming
languages
for
its
working.
Programming make the plc work to
its control logic.
Like
our
common
computer
a
programmer needs a programming
language to program a plc.
There are mainly 5 languages to
program a plc.
Different programming languages are:-
i. Functional Block Diagram (F.B.D)

ii. Sequential
Flow
Chart
(S.F.C)
iii. Instruction List
(I.L)
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iv. Structural Text

v. Ladder Diagram
(S.T)
(L.D)
Ladder diagram
Ladder diagram is a programming
language used to program a PLC.
The program is written in the
programming
software
of
the
corresponding PLC and it is then
downloaded to the PLC through the
communication
port
using
the
required communication protocol.
The basic structure of a ladder
diagram resemblences a LADDER.
It has to vertical lines which are
known as RAILS.
Horizontal
lines
are
known
as
RUNGS.
The contacts and coils are placed on
rungs which represents inputs and
outputs in the field.
According to the ladder diagram
program the PLC control the process.
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RUNG
LEFT SIDE RAIL

RAIL
RIGHT SIDE
The ladder diagram has two vertical lines

known as rails and horizontal lines known as
rungs.
Symbols used in ladder diagram to

represent inputs and outputs are:
Normally open contact(NO)
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Normally closed contact(NC)

Output coils
SYMBOLS
NO
NC
Output coil

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Page | 1

Allocation of human control

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

The automated process have a

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

DISTRIBUTED CONTROL SYSTEM

Using electrical wirings; electrical

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

logics to control the process

Output section has three contacts;

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

If the switch/relay (s1)is in OFF state the load will be in

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

Programmable logic control (p.l.cs)

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

program logics that are given by

Work on both AC and DC

INPUTS FROM FIELD

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

The main parts of a P.L.C are:1.

power supply unit.

Working supply of a plc is 24VDC

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

A plc without smps means it

Input & output units

Input signal:- raw / unprocessed data;ie

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

On the basis of expansion port the

CENTRAL PROCESSING UNIT

CENTRAL PROCESSING UNIT

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

Modular type P.L.C have the same features

Rack type PLC are rack in shape.

Separate rack for each section.

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

SCADA (Supervisory Control And Data

i. Functional Block Diagram (F.B.D)

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

iv. Structural Text

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

LEFT SIDE RAIL

The ladder diagram has two vertical lines

Symbols used in ladder diagram to

Normally closed contact(NC)

INTRODUCTION NOTES ON AUTOMATION AND P.L.C

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