Introduction of SOFCON  Sofcon a Channel Partner of Rockwell Automation

in India.  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

Sofcon offers various courses 0 PLC Course Contents 0 Digital Electronics Basics 0 PLC Fundamentals 0 PLC Hardware & Architecture 0 Source & sink Cencepts 0 Wiring Different field Devices to PLC

SCADA Course Contents 0 Introduction to SCADA Software 0 Creating new SCADA project 0 Creating & editing elementary graphic display 0 Attaching controls to graphic objects 0 Real time & historical trends Using alarms &

events 0 Application of scripts Communication with PLC 0 Communication with excel

AUTOMATION 0 Automation is a step beyond mechanization. 0 Automation is the use of control systems

and information technologies to reduce the need for human work in the production of goods and services.

Automation Components 0

Sensor for sensing physical conditions

0 Transmitters 0Control Systems 0Output Devices

Automation : Typical installation . . . . SCADA Software Communication Cable

Control Hardware Control Field Cabling

Junction Box Field Cabling

Sensors Placed in the field

Back

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 to the PLC memory. Its purpose is to monitor crucial process parameters and adjust process operations accordingly.

 It controls output devices based on the status of inputs and a written program. Originally developed to directly replace relays used for discrete control. It performs functions as

FUNCTIONS

•

On/Off

Control

Timing

Counting

Sequencing

Arithmetic

Data Handling

ADVANTAGES PLC Saves

By

Material cost

Reduced wiring & associated errors

Installation cost

Less space

Troubleshooting

No moving parts - rugged

Labor cost

Possibility of reprogramming

Value added benefits Reliability Flexibility Advanced Function Communication Speed Diagnostics

APLLICATIONS Any application in any industry that requires electrical control Packaging Material Handling Power Generation Security Systems Paint Lines

Bottling & Canning Machining HVAC/ Building Automation Automated Assembly Water treatment

Industry Cement Metals

Automobile Paper

Chemicals F&B

Plastics

Various Brands of PLCs Allen Bradley USA Siemens Modicon

Mitshubishi Japan GE Fanuc USA Omron Japan

ARCHITECTURE Programming/ Communication Device

Input Circuits

Central Processing Unit (U)

Output Circuits

Memory Optical isolation

program data

Power supply

Optical isolation

INPUTS PLC system consists of Inputs 1) Inputs - Discrete - On/Off type o o o o o o

Pushbuttons Switches Limit Switches Selector Switches Proximity sensors Photo - electric sensors

2) Inputs devices - Analog o

Resistance Temp. Detectors

o

Thermo - couple

Input Circuits

Input Modules

9

10

- 24 Volts

COM

24 Volt DC System A/D conversion

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 Input Terminal block Module this is where 1 2 wires from the 3 field devices are 4 Field device connected 5 6 this is 7 showing a + 24 8 simple switch Volts

To PLC

Input Modules

Switch 24V DC

Pressur e

Temperatur e 0-10V DC

OUTPUTS PLC system consists of Outputs o o o o o o o

Solenoids Relays - AC or DC powered ors Motor Starters Indication Lights Valves Alarms

Output Circuits

Output Modules Output Module

D/A Conversion

From PLC

1 2 3 4 5 6 7 8 9 10 COM

Terminal block this is where wires from the field devices are connected Field device -Motor starter, controlling an AC motor.

Output Modules The output module operates in opposite manner from input module

Valve 0-10V

Fan 120V AC

Light 24V DC

Processor, Controller, or U  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

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

PLC SCAN

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 PLC Scan time in normal applications is 1 ms to 2 ms & in bigger applications 100 ms to 200 ms

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 the system of PLC The 16-bit word is more common

Types of Memory It is divided into two parts :

1)The memory is for

storage of program i.e. ladder logic 2)The storage memory is used to store information such as input/ output status timers, or counters

Programming Languages 0 Ladder Diagram (LD) 0 Functional block Diagram (FBD) 0 Structured Text (ST) 0 Instruction List (IL) 0 Sequential Functional Chart (SFC)

Ladder Basics Ladder 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 U interprets it as True condition If s/w Open at this add U interprets it as False condition

If s/w Open at this add U interprets it as True condition If s/w Closed at this add U interprets it as False condition

CONTROL CONTROL SIGNAL IN1 SIGNAL IN2

OUTPUT

0

0

0

0

1

0

1

0

0

1

1

1

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 parallel combination of normally open switches. Truth Table Control signal CONTROL OUTPUT IN1

SIGNAL IN2

0

0

0

0

1

1

1

0

1

1

1

1

Hardware Over View of MicroLogix 1000

MicroLogix 1000 is a packaged controller containing a power supply, input circuits, output circuits, and a processor.

Data Files in Micrologix 1000

Basic Components of a PLC Network Interface System Most PLCs have the ability to communicate with other devices. The PLC will communicate to the other devices through a network interface.

PLC

Network interface module

Network connecting other devices

Typical PLC Application Solenoid 1

Motor

Solenoid 2

Ingredient A

Ingredient B

Sensor 1

Sensor 2

Solenoid 3

Programming a PLC – Conveyor example Photoeye 2

Motor 1

Light 1

Photoeye 1

PLC Programming Software

Supervisory Control and Data Acquisition (SCADA) Systems 0 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

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,

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 37

DEVICE CONNECTIVITY Every manufacturer have there one way communication or follow different protocols. SCADA S/W should have connectivity to different h/w used in automation

Benefits of SCADA 0 Standard frame for application 0 Rich functionality (50 - 100 p-yrs investment) 0 Reliability and Robustness (very large installed

base, mission critical processes) 0 Limited specific development 0 Technical and maintenance 0 ….. Etc

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PCaPAC'2000 - DESY

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Development Tools 0 Project editor 0 Graphics editor 0 Configuration through parameter templates 0 Scripting language 0 Most processing tools based on IEC 1131 0 Batch configuration according to S88.1 0 Driver Development Tool Kit

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PCaPAC'2000 - DESY

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Configuration of SCADA Systems

Data Server

Data Server

PLC’s Field Bus

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PCaPAC'2000 - DESY

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PLC

Configuration nd of SCADA Systems 2

Programs

Communication Processor

•Analog-Input •Value-AI-0 •Value-AI-1 •Analog-Output •Value-AO-0 •Value-AO-1

SCADA

Mapping

•Analog-Input •Vacuum_VALUE •Pressure_VALUE •Analog-Output •Valve_1_OUT •Heater_1_OUT

Field Bus

Play 42

THAT’S IT FROM THE PRESENTATION AREA U O Y K N A H T

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