A Laboratory Manual for

INDUSTRIAL AUTOMATION
(22534)
Semester- V
Scheme- I

Diploma in Electronics Engineering Group

(EJ/IS)

Bharati Vidyapeeth Institute of Technology,

Navi Mumbai.
 Bharati Vidyapeeth Institute of Technology
Navi Mumbai

Certificate

This is to certify that, Mr./ Ms. ………………………………………………….

Roll No. ……………… of Fifth Semester of Diploma in Electronics Engineering

Group of Bharati Vidyapeeth Institute of Technology, Navi Mumbai (Inst. code:

0027) has satisfactorily completed the term work in the subject INDUSTRIAL

AUTOMATION (22534) for the academic year 20…….to 20……. as

prescribed in the MSBTE curriculum.

Place: ……………………... Enrollment No. : …………………

Date: ………………………. Exam. Seat No. : ………………….

Subject Teacher Head of the Department Principal

Sign:

Name:

Seal of
Institution
 LIST OF EXPERIMENTS AND PROGRESSIVE ASSESSMENT FOR TERM WORK D-3

ACADEMIC YEAR 20 - 20

Course Code :- Sub & Code :

Name of Candidate : Enrollment No : Roll No :

Marks : Max : Min : Name of Staff-

Dated
Date of Date of Assess Sign of
Sr. Page
Title of Experiment Performa Submissi ment teacher
No No
nce on Marks with
Remark
Identify various parts and front panel status indicators
1
of the given PLC.
Use PLC to test the START STOP logic for two inputs
2
and one output.
Develop /Execute a ladder program for the given
3
application using following:- timer, counter,
comparison, logical, arithmetic instruction.

Measure temperature of the given liquid using RTD or

4
Thermocouple and PLC.
Develop/ test ladder program to blink LED/lamp.
5

Develop/ test ladder program for sequential control

6
application of lamps/ DC motors.
Develop/ test ladder program for traffic light control
7
system.
Develop/ test ladder program for pulse counting using
8
limit switch/proximity sensor.
Develop/ test ladder program for automated car parking
9 system.

Develop/ test ladder program for automated elevator

10 control.

Develop/ test ladder program for rotating stepper motor

11 in forward and reverse direction at constant speed.
 Use various functions of SCADA simulation editors to
12 develop simple project.

Total marks out of 120

Marks out of 25

Name and Signature of Student Name and Signature of Staff

Assessment Scheme

Performance Indicators Weightage

Process Related (10 Marks) (40%)
1 Simulating various parameters within appropriate 20%
range satisfactorily
2 Tabulate results independently 20%
3 Product Related (15 Marks) 60%
4 Interpretation of result 20%
5 Conclusions 20%
6 Practical related questions 20%
Total(25Marks) 100%
 Experiment No. : 1
Title: Identify various parts and front panel status indicators of the given PLC.

Apparatus: PLC trainer kit

Procedure :
1. Visit laboratory and study the trainer kit.
2. Read the user manual before operating the trainer kit.
3. Follow the rules and safety precautions.
4. Identify the scope of subject for career development.

Concept structure:
Observations:

Front Panel Function

Status indicators

Parts of PLC Function

Power supply

I/O modules

Processor

Programming device

Status indicators Mode

Green light

Red light

Conclusion:
 In industries _______________ (automation/manual) processes are preferred to achieve
higher productivity and accuracy.
Questions:
1. State the meaning of automation.
2. State the need of automation in industry.
3. List PLC programming languages.
4. State advantages of PLC.
5. List any four PLC brands available in market.
6. Explain rails and rungs related to PLC.

Space for Answers

 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 2
Title: Use PLC to test the START STOP logic for two inputs and one output.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Ladder diagram:

Explanation:

Observations:

Sr . Case Motor status (ON/OFF)

no.
1. START (NO) button is pushed

2. STOP (NC) button is pushed

Result:
When start button is pushed:
__________________________________________________________________
__________________________________________________________________
When stop button is pushed:

__________________________________________________________________
__________________________________________________________________

Conclusions:
1. When START (NO) switch is pushed, motor will be ______ (ON/OFF).
2. When STOP (NC) switch is pushed, motor will be ______ (ON/OFF).
3. When START (NO) switch is released after push, motor remain ______ (ON/OFF).

Questions:
1. Draw a ladder diagram to switch PLC output high if any of the three inputs is high.
2. Draw logic symbols for NO and NC switches.
3. Draw the circuit for ON/OFF control of motor.
4. List different manually operated switches.
5. What is relay.
6. State the meaning of ladder rung.
7. Draw electrical symbols used to represent switches: NO push button and NC push button.

Space for Answers

 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 3
Title: Develop /Execute a ladder program for the given application using following:- timer,
counter, comparison, logical, arithmetic instruction.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Ladder diagram:

TIMER :

Ladder Diagram Waveform

COUNTER
COUNTER :

Ladder Diagram Waveform

COMPARISON:
Ladder Diagram

LOGICAL: A
COMPARISON: LOGICAL
Ladder Diagram Ladder Diagram

Conclusion:

Questions :
1. List types of timers.
2. List types of counters.
3. Give different comparison instruction.
4. Draw format of logical instructions.
5. List different arithmetic instructions.
Space for Answers
 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 4
Title: Measure temperature of the given liquid using RTD or Thermocouple and PLC.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Concept structure:

Temperature Temperature condition Action taken by PLC

0C to 64.9C Heater ON and cooler OFF
65C Lower cut off Both heater and cooler are OFF
70C Upper cut off Both heater and cooler are OFF
70.1C to 100C Heater OFF and cooler ON

Problem statement :
 Temperature controller will start when START switch is closed.
 Temperature shall be maintained between 60 C to 70C.
 When the temperature is less than 60C the heater is turned ON and cooler is OFF.
 When the temperature is greater than 70C the heater is turned OFF and cooler is ON.
 Temperature range is 0C to 100C.
Ladder diagram:

Explanation:
Observations:

Sr. Value of Temperature when Temperature when

no. temperature heater is cooler is
ON OFF ON OFF
1
2
3
4

Conclusion:
1. When the measured temperature is less than lower cut off temperature then
_______________ (heater/cooler) is ON.
2. When the measured temperature is greater than higher cut off temperature then
_______________ (heater/cooler) is ON.

Questions:
1. State need of temperature controller in various industries?
2. List advantages of temperature controller using PLC.
3. List comparing instruction of PLC.
4. List out types of continuous and discontinuous controller.
5. List out various type of temperature transducer used for measurement of temperature.

Space for Answers

 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 5
Title: Develop/ test ladder program to blink LED/lamp.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Ladder diagram:

Explanation:
Observations:
1. ON time of LED is ____ seconds and OFF time of LED is ____ seconds.

Conclusions:
1. On-delay timer counts time based intervals when the rung condition is __________
(true/false).
2. Off-delay timer counts time based intervals when the rung condition is __________
(true/false).

Questions:
1. Draw ladder diagram to make LED ON after 15 seconds when switch is pressed.
2. What is the preset bit in PLC timer indicate?
3. State the meaning of ON delay timer and OFF delay timer in PLC.
4. State the range of preset in PLC timer.
5. State function of accumulator with reference to PLC timer.
6. How the retentive PLC timer works?

Space for Answers

 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 6
Title: Develop/ test ladder program for sequential control application of lamps/ DC motors.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Concept structure: Sequential ON-OFF of lamps:

It is specific way of On-Off control of the lamps. Two lamps need to be controlled sequentially
one after another. Two pushbutton switches and two lamps are required for this control. When
START button is pressed, lamp 1 will glow and after 10 seconds lamp 2 glows and lamp 1 will
become off. One on delay timer (Ton) is used for generating a delay.

Ladder diagram:
Explanation:

Observations:
Readings for timer bits

Timer address

Time base

Preset

Accumulator

Conclusions:
1. The processes that demand certain operations to be performed in a specific order need
_______________ control (sequential/combination/automatic).
2. If lamp 2 glows after turning ON lamp 1, then the type of control process involved is
_______________ (sequential/combination/automatic).

Questions:
1. Draw logic symbols for PLC timers.
2. List two applications of timer.
3. Explain timer instruction of PLC.
4. State the PLC timer that needs reset instruction.
5. What are numerical limits for typical 16-bit timers?
6. Give applications of retentive timer.

Space for Answers

 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 7
Title: Develop/ test ladder program for traffic light control system.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Concept structure: Traffic Light Control

Traffic light is an arrangement of three colour lights. It is used for controlling the traffic at road
junctions by providing a particular sequence of these lights. Different colour lights used are Red,
Green and Amber (or Yellow). The red light indicates ‘STOP’, green light indicates ‘GO’ and
amber light indicates ‘WAIT’ for red or green.

Timers are devices that count increments of time. Traffic lights are one example where timers are
used. In this example timers are used to control the length of time between signal changes. The
lights in a traffic signal go through a sequence: Red,green,amber, Red,green,amber etc.

When an ON/OFF switch is turned on and a START button is momentarily pressed, the red
signal (R) lights for 30 seconds, then turns off and the green (G) lights for 25 seconds, then turns
off and the Amber (A) turns on for 5 seconds and then turns off and back to the red. On the
opposite street, the red light (R’) is on during the time the light on the other street is either green
or amber. Transition from red to green to amber is accomplished by cascading timer circuits. The
sequence then repeats itself.
Ladder Diagram:
Explanation:

Observations:
Red light will be ON for

Green light will be ON for

Amber light will be ON for

Conclusions:
1. ______ number of timers are used in the ladder diagram of this experiment.

Questions:
1. When is the enable bit of timer instruction true?
2. When does the done bit of timer change state?
3. When is the output of a programmed timer energized?
4. How RES instruction in relation with retentive PLC timer works?
5. How accumulated count of programmed timer energized?

Space for Answers

 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 8
Title: Develop/ test ladder program for pulse counting using limit switch/proximity sensor.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Ladder diagram :
Explanation :

Observations:

Sr. no. Switch positions Up Counters LED Status

(starts/stops) (ON/OFF)
1 SW ‘A’ pressed 10 times

2 SW ‘B’ pressed

Conclusion :
1. The PLC counters range from ____________________ (C0 to C250/ C0 to C255).

2. Maximum value of reset in PLC counters is ______________

Questions:
1. Develop a ladder diagram that will latch ON an output B 20 seconds after input A has
been turned ON. After A is pushed, there will be a 10 second delay until A can have any
effect again. After A has been pushed 3 times, B will be turned OFF.
2. List applications of PLC counters.
3. What the reset bit in PLC counter indicates?
4. State the function of accumulator with reference to PLC counter.
5. How Up Down counter works?
6. State range of presser in PLC counter.

Space for Answers

 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 9
Title: Develop/ test ladder program for automated car parking system.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Concept structure:

 If parking space is available, hence system allow to enter car for parking.
 If no space is available for parkng hence system does not allow to enter new car.

Problem Statement :
Design automated parking system for following specification

1. Automated parking system allow to park 6 car in parking zone.

2. Automated parking system allow to maintain maximum 6 car is to park. When the
number of car is less than 6 then system allow to enter new car and is number of car
parked in parking zone is 6 then display parking full message and does not allow to enter
new car.
3. When one of the car is moved out then allow to enter new car in parking zone
Ladder diagram :

Explanation
Observation:

Sr.no. No. of car in parking zone Status of display (full/empty)

1 2
2 6
3 4
4 9

Conclusion:
1. If the automated parking system indicates message full means space _________________
(available/not available) for parking.
2. When system indicate message empty then it allows to enter car ___________ (equal/less
than/greater than) number of car.

Questions:
1. Explain the need of automated parking system.
2. List various parking mechanism used for parking system.
3. Draw block diagram of parking system.
4. What is a counter?
5. List various types of counter.
6. Explain various counter term related to PLC(i.e. CTU,DN,CU,CTD and preset)

Space for Answers

 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 10
Title: Develop/ test ladder program for automated elevator control.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Concept structure: Elevator System

An elevator is one of the important aspects in electronics control module in automotive
application using programmable logic controller to control the circuit and building the elevator
model. Hall Effect sensor is used for the elevator position. DC Motor is used to control the up
and down movement of the elevator car. Push buttons are used to call the elevator car. The
elevator position is described by using the display unit.
Ladder Diagram :
Explanation :

Conclusion :
1. A hall effect sensor is transducer that varies its output _____________ (voltage/current)
in response to a magnetic field.
2. An elevator is a type of _____________ ( vertical/horizontal) transport equipment that
efficiently moves people or goods between floors of a building.

Questions:
1. Explain the need of elevator system.
2. List various components of elevator system.
3. Why hall effect sensor used in elevator system?
4. What is overflow bit of an up counter set?
5. What is underflow bit of an up counter set?
6. List two applications of PLC up down counter.

Space for Answers

 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 11
Title: Develop/ test ladder program for rotating stepper motor in forward and reverse direction
at constant speed.

Apparatus: PLC software, NO and NC switches.

Procedure :
1. Load the RS Logix software to the PC.
2. Open the RS Logix software.
3. Switch On the PLC trainer.
4. Open the New project and draw the ladder logic program.
5. Compile the program.
6. Run the Program.
7. Give force and observe the output.

Concept structure:
Ladder diagram : (Forward Direction)

Explanation:
Ladder diagram : (Reverse Direction)

Explanation:
Observation:

Clockwise motion:

Step Terminal 1a Terminal 2a Terminal 1b Terminal 2b

1
2
3
4
1

Anticlockwise motion:

Step Terminal 1a Terminal 2a Terminal 1b Terminal 2b

1
2
3
4
1

Conclusion:
 The time delay controls the _____________ (speed/direction) of stepper motor.

 The stepper motor rotates ____________ (in step/ continuously).

Questions:
1. Explain operating principle of stepper motor.
2. Define step angle.
3. Define scanning cycle.
4. Define speed of execution.
5. List out four industrial applications of stepper motor.
6. Compare DC motor and stepper motor.
Space for Answers
 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)
 Experiment No. : 12
Title: Use various functions of SCADA simulation editors to develop simple project.

Apparatus: Ellipse software

Theory :
SCADA is an acronym that stands for Supervisory Control and Data Acquisition. SCADA refers
to a system that collects data from various sensors at a factory, plant or in other remote locations
and then sends this data to a central computer which then manages and controls the data.

Definition of SCADA: A collection of equipment that will provide an operator at remote

location with enough information to determine the status of a particular piece of a equipment or
entire substation and cause actions to take place regarding the equipment or network.

What is SCADA?

How : By collecting Information from plant / Load centre bend reducing it to the EMS

Where : Control Centre. Both at Plant and Load

Why : To gather Information as here (voltage, current, frequency, power, circuit breaker status)
and To perform online actions

Functions of SCADA:

The important functions of an SCADA are listed below

1. Data Acquisition
2. Information Display
3. Supervisory Control
4. Alarm Processing
5. Information Storage and Reports
6. Sequence of Event Acquisition
7. Data Calculation
8. Special RTU Processing/Control

Typical SCADA system:

Components of SCADA:
 Marks obtained Dated sign. Of Teacher
Process Related(10) Product Related(15) Total(25)