(An Imprint of Laxmi Publications Pvt. Ltd.)

ADVANCED INDUSTRIAL AUTOMATION AND ITS APPLICATIONS (PLC, HMI, SCADA, VFD & SERVO)

Ravindra Sharma

Advanced Industrial Automation and its Applications

ADVANCED INDUSTRIAL AUTOMATION AND ITS APPLICATIONS (PLC, HMI, SCADA, VFD & SERVO)

Ravindra Sharma B.E. (Electrical & Electronics) Director, AutoSys Indore

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Dedicated To My PARENTS (Shri R.N.SHARMA & Smt GULAB SHARMA) & My TEACHER Shri R.L.SHUKLA

Content 1. Introduction of Automation

1



1

1.1 What is Automation?



3.6 Description of Some of the Best PLC 3.7 Description of Power Supply

Brands

63



1.2 Types of Automation

1





1.3 Advantages of Automation

3

4. PLC Programming Languages



1.4 Components of Industrial Automation

3



4.1 Types

of

Languages

Used

71

74 in

PLC

Programming 74

2. Introduction of Various Controllers

4



4



4.2 Description of Ladder Diagram (LD)

4.3 Description of Functional Block Diagram 79

2.1 Micro Controllers

74



2.2 Programmable Logic Controller (PLC)

4





2.3 Distributed Control Systems (DCS)

6



4.4 Description of Structured Text

80

4.5 Example of CFC

80



2.4 PAC

14





2.5 RTU

14

5. Logic Gate Programming in PLC

81



2.6 Machine Automation Controller (MAC) 16



5.1 AND Gate

81



2.7 Comparison between RTU and PLC

18



5.2 OR Gate

82



2.8 Comparison between PLC and DCS

19



5.3 NOT Gate

82

2.9 Comparison between PLC & PAC

20



5.4 X-OR Gate

82



2.10 Difference between PLC & PC

20



5.5 X-NOR Gate

83



2.11 Advantages of PLC Over Relay Wired



5.6 NAND Gate

83

System 21



5.7 NOR Gate

84

5.8 Multiplexer

84





2.12 PLC Advantages

21





2.13 Leading Brands of PLC

22



2.14 Areas of Application of PLC

22

6. Various Programming Concepts in PLC 86

6.1 PLC Scan Cycle

86

3. Programmable Logic Controller(PLC)

24



6.2 Flag/Memory Bit/Internal Relay bit

88



3.1 Block Diagram of PLC

24



6.3 Interlocking

91



3.2 Classification of PLC

25



6.4 Trigger/Pulse Instruction

93



3.3 Description of PLC Components

27



6.5 Set-Reset/Latch-Unlatch

95



3.4 Description of Various Input Devices

32



6.6 Latching without Set/Reset Instruction 98



3.5 Description of Various Outputs

50



6.7 Practice Session with Different Examples 98

vii

viii 7. Timers 106



11.3 Schneider Twido Series PLC System Bits 178



7.1 Introduction

106



7.2 Timers Types

107



11.4 Mitsubishi PLC Memory Bits

179

111



11.5 Mitsubishi PLC Memory Word

179

8. Counters

128

12. Jump and Subroutine Instruction

180



8.1 Introduction

128



12.1 Jump Instruction

180



8.2 Types of counter

128



12.2 Subroutine Instruction

183



8.3 Example Based on Counter

133



8.4 High-Speed Counter (HSC)

140

13. Master Control Reset (MC/MCR) Instruction 186

9. Memory Registers

143

14. Shift and Rotate Instruction

189



143



14.1 Shift Instruction

189

14.2 Rotate Instruction

190



7.3 Timer Based Practice Question

9.1 Introduction



9.2 Number System

143





9.3 Various Conversions

145

15. Stacking Instruction

192



9.4 Types of Memory Storage Systems in PLC,

16. Servo Motor

198



16.1 Servo Motor Theory

198



16.2 Servo Motor Working Principle

198



16.3 Servo Motor Control

200



16.4 Continuous Rotation of Servo Motors 201



16.5 Application of Servo Motor

Shown in Table 9.1.

147



9.5 Register Addressing Format

148



9.6 Memory Mapping

148

10. Analog Programming

151



10.1 Determine

how

to

Convert

Physical

Quantity

151

10.2 Determine how to Connect the Sensor to the PLC



159

10.3 Determine how the Analog Value is Represented in the PLC



161

10.4 Determine how the Value should be Scaled? 162



10.5 Practice

Problems

of

Analog

Input

Programming 169

10.6 Analog Output Programming



10.7 Practice

Problems

of

Analog

173 Output

Programming 174

10.8 Trigonometric Functions

175



10.9 Exponential Function

175

202

17. Field Bus

203



17.1 What is Serial?

204



17.2 What is RS-232?

205



17.3 What is RS-422?

206



17.4 What Is RS-485?

207



17.5 How do RS-232, RS-422, and RS-485 Compare? 207



17.6 What is Handshaking?

208



17.7 Industrial Protocols

210

18. PLC Redundancy/Failsafe Operation

213



18.1 Types of PLC Redundancy

214



18.2 Tips for Higher Reliability in PLC Control 18.3 Failsafe Wiring and Programming

Systems 214



10.10 Logarithmic Function

175





10.11 Logical Function

175

19. PID Controller

219

177

19.1 PID Controller

219

11. System Bit/Special Memory Bit

11.1 Siemens S7-200 Series PLC System Bits 177



11.2 Siemens

S7-200 Series PLC System

Words 178

215

20. Human Machine Interface (HMI) /Man Machine Interface (MMI)

235



235

20.1 How HMI Works?

ix

20.2 Introduction of HMI

235

22. Motors

254



20.3 Typical Applications

236



254



20.4 HMI Functionality

238



20.5 HMI Softwares

238

23. Motor Starters



20.6 Features of HMI

238

21. SCADA (Supervisory Control and Data



22.1 Motors

259

23.1 Full Voltage Starting Method (For up to

5 HP Motor)

259



23.2 Reduced Voltage Starting Method

261

Acquisition)

244



23.3 Solid State Controller

268



21.1 How SCADA Software Works?

244

24. Electric Drives

270



21.2 Introduction of SCADA

245



24.1 Introduction

270



21.3 Subsystems of SCADA

247



24.2 Features of AC Drive

272



21.4 Benefits of SCADA

248



24.3 Block Diagram of VFD

273



21.5 Applications of SCADA

248



24.4 Torque and Speed Characteristics of VFD



21.6 Functions of SCADA System

249



21.7 Scada Software

249



24.5 VFD Wiring and Programming



21.8 Examples of SCADA

250

Appendix 282

274

Index

274

321

Foreword Automation, whether it is home or industry, has drawn the significant attention of electrical engineers in the past 20 years. Automation in a process or control hastens the production along with precision in the products and error-less processes, which are the demands of the fast moving world. In my view, ancient manual process or control has been overtaken by modern Automation Industry. Automation is achieved by controllers along with power devices at one side and user interface at other side. Programmable Logic Controllers (PLCs) are one of the widely used controllers in motion industry. They have profoundly contributed in Industrial Automation. Apart from PLC, HMI and SCADA have made user interfacing easier and simpler. Drives and Servos are already known as workhorse of the industry. All the above mentioned three parts of automation are covered at a single platform as a book. This book will be very helpful for a beginner who wants to make his career in Industrial Automation. The book will also be useful for a professional individual as a guide which can be used on the automation field. I personally feel, this book can be used as a handbook of Industrial Automation and that will serve the purpose of its writing. I would like to appreciate the intention of the author to write such a book and bring it in public. The author has been working in the field of Automation for the past 10 years, and that experience poured off in the book, will certainly help the readers get a deep insight of Industrial Automation. The first edition of the book as well as upcoming editions of the book should set a benchmark for the automation industry and encourage the students to work in the field of Automation which may lead to country's growth. Thanks Amit Kumar Gupta Senior Research Fellow and Project Engineer Applied Power Electronics Laboratory Department of Electrical Engineering Indian Institute of Technology (IIT) Bombay Powai, Mumbai-76

x

Preface The idea of writing this book came in my mind when I was a student and was willing to read a book on Industrial Automation which could cover all the automation related topics. Many times, I went to several book shops and libraries to search for such kind of book, especially of an Indian author, but I could not find a single one. In the past nine years, I studied and learned many things in Industrial Automation by reading e-books and user manuals of various PLC manufacturers. I would say, I learned more by working on various automation live projects simultaneously. Now I am aspiring to share my knowledge and experience with upcoming engineers in the form of this book so that they can find a ready book with an easier language on Industrial Automation. Reading of a book is a good practice but material whatever you study should be interesting and in readable language. I have tried to write each and every chapter with very easy language and tried to make it interesting with lots of pictures of every product which is being covered in respective chapter. This book covers various components of Industrial Automation Like PLC, HMI, SCADA, VFD and Servo. Each component is discussed with the depth of theory as well as its practical implementations. Most of the books available in the market cover a particular brand of PLC for explaining the programming and wiring. I have tried to use several PLC brands Like ABB, Siemens, Mitsubishi, Allen-Bradley, Delta, Messung etc. to explain the programming and wiring. Book contents are enriched with PLC wiring, programming, interfacing and troubleshooting. The specialty of this book is that all kinds of Sensors, switches and related equipment are described in detail. I have tried to explain beautifully about the analogue programming section which is hardly available in the literature. This book is best suited for all the categories of readers; whether an engineering student, engineering faculty, working professional, site engineer and those who are working in electrical maintenance field or automation projects. It can also be useful for a hobbyist who wants to understand automation and would like to work on its application. I have also included basic but important fundamentals of electrical engineering like various electrical symbols, PLC programming cable diagrams, HMI cable diagrams, PLC program upload and download procedure of various PLC brands and motor selection criteria, so that readers could

xi

xii get all the important contents in the book only. Readers can use this book as a handbook of Industrial Automation. I do not claim credit for any original work and I wish to acknowledge the readers to all the standard text-books, reference books, e-books and various PLC manufacturers' manual, application note or any other literature from where I compiled the contents on Industrial Automation, just with a motive of providing a single platform to the readers to study Automation. At the end, I would like to share that my wife Mrs. Khushboo Sharma supported me and played an active role in writing this book. She continued to be like my next hand during the journey of preparing this book. For any query and suggestion please write to me at ravindra@autosysindore. com, improvements will be done in next print/edition. —Author

1

CHAPTER

Introduction of Automation

1.1  WHAT IS AUTOMATION? The word “Automation” came from a greek word automata, which means self guided system. In hindi it’s meaning “swachaalit”. Automation control systems are implemented in certain processes to reduce human operation and failure. Usually, PLC, computers and automation software are used to implement automation technology in a manufacturing company. For example in the electronics sector, automation plays a crucial role; the production of electronic components or even consumer electronics demands a high level of automation. For a successful business activity in a sector with strong global competition and international standards, a manufacturer is seeking for cost reduction and the increase of productivity, flexibility and quality. A high level of automation allows a producer to easily switch the production flow and the manufacturing process from one product to another. Industrial automation also provides a high level of safety as human errors can be minimized. Automation affects the productivity in following aspects:

• Increasing production by avoiding manual delays. • Improving productivity by achieving the optimum efficiency of the machine. • Avoiding reprocessing and improving the product quality. • Automation improves the power saving possibilities and hence the cost of product goes down. • By avoiding manual error it improves the quality of product and hence productivity.

1.2  TYPES OF AUTOMATION

• Home Automation.  Office Automation • Printer

2

Advanced Industrial Automation and its Applications

• Scanner • Data record maintenance

 Mall Automation • Elevators • Escalators • Automatic light control • Metering  Building Automation • Fire alarm system • Smoke sensor • Audio door phone station • Automatic door opening and closing • CCTV etc  School/Colleges Automation • Enterprise Resource Planning systems • Automatic attendance • Library Automation etc. • Industrial Automation  Process Automation  Factory Automation Process Automation means where the process is continuous and it cannot be stopped. Industries come under process automation are:



• Steel Industries • Cement Industries • Pharmaceutical Industries • Textile Industries • Sugar Industries • Rubber Industries • Food Industries • Plastic Industries • Refineries • Power Plants

Factory Automation means where the process is not need to be continuous. Process can stopped in between. Industries come under factory automation are:

• Automobile Industries • Packaging Industries • Machine manufacturing Industries etc.

1.3  ADVANTAGES OF AUTOMATION

• Elimination of human error. • Cleaner Technology. • Consistency of product. • Minimize Energy consumption. • Easy diagnosis of fault. • Reduction in Resource (Chemicals, water, energy etc.) • Reduce manpower. • Data collection and consolidation. • Effective application for Complex tasks. • Self Trending and Report generation. 1.4  COMPONENTS OF INDUSTRIAL AUTOMATION

For developing a typical automation systems following things are required as shown in Fig. 1.1.

• Controller (PLC) • Input Devices (Sensors, Switches etc.) • Output Devices (Valves, Motors, Drives etc.) • Display Devices (HMI & SCADA)

Fig. 1.1 We will understand all components of automation with details in next chapters; basically this book is dedicated in all above components like PLC, HMI, SCADA, VFD, Servo Motor, input devices and output devices. It is covered the theory and practical aspects of each component in details.

Chapter 1

3

Introduction of Automation

ADVANCED INDUSTRIAL AUTOMATION AND ITS APPLICATIONS (PLC, HMI, SCADA, VFD & SERVO)

Ravindra Sharma

ABOUT THE BOOK This Modern Industrial World is getting fully enriched with the only and only single term i.e. Automation, especially process industries have promptly accepted the change of Industrial Automation. PLC (Programmable Logic Controller), HMI, SCADA, VFD & SERVO are the key components of Industrial Automation. This book has been prepared to impart the complete knowledge of PLCs, HMI, SCADA, VFD & SERVO. It is divided into 24 chapters, where the first one explains the Automation; the second is briefing on various controllers; PLC is detailed from chapter 3 to chapter 19, covering—classification, inputs/outputs, languages, logic gates, programming concepts, Timers, counters, Analog Programming, Memory Registers, Various PLC Instructions, PID controller, Industrial Protocols, PLC redundancy & Fail safe wiring, Servo Motors, etc. Chapter 20 has the detailed about HMI, Chapter 21 represents SCADA, Chapters 22 & 23- MOTOR, Motor Starters and the last Chapter 24 is about Electrical Drives. This book will find the acceptance among the Engineering Students and Professional Engineers working in the Industry, where they can use it as a guide. It will play a key role, for those who wish to learn about the Automation, as it serves the purpose of SELF-LEARNING. ABOUT THE AUTHOR Ravindra Sharma, is currently working as a Director in an ISO 9001:2008 certified company, “AutoSys Indore”. He has completed his BE in Electrical & Electronics Branch from Medicaps Institute of Technology and Management Indore. He has about four years of teaching experience in engineering colleges. He also possesses over a decade of experience in the field of Industrial Automation. His research interest is in the area of Industrial Automation with the motive of grooming the innovative engineers towards the modern Industrial Automation World. He yields an expertise in providing support to the engineers for handling the engineering automation projects. He has undertaken many Industrial Automation workshops in various Engineering Institutions and Industries for which he is rewarded many times. He has explored techniques to learn PLC, Drives & HMI practically by Introducing Automation Lab Training Kits. Recently, he has involved in latest technological development like IOT, IIOT, Smart Sensors, Robotics, Cloud Computing, Data Logger and various Industry 4.0 Projects.

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