LAB MANUAL

MCT-334L Industrial Automation

Department of Mechanical, Mechatronics & Manufacturing Engineering

B.Sc. Mechatronics & Control Engineering Program
University of Engineering & Technology Lahore (Faisalabad Campus)
 INDUSTRIAL AUTOMATION LABORATORY

LIST OF EXPERIMENTS

EXP. NO. EXPERIMENT TITLE

1 Introduction to Industrial Automation and PLCs

2 Orientation to PLC Software (Fatek)

Introduction to:
 Memory Structure
3
 Ladder Logic Programming Elements
 PLC Programming

Use of advanced Instructions:

 Comparison Instructions
4
 Mathematics (Addition, Subtraction, Comparison etc.)
 Data Handling

5 Introduction to Set, Reset Coils and Latching

6 Introduction to Timers

7 Introduction to Counters

8 Design Ladder Diagram for Traffic Module

9 Design Ladder Diagram for Tank Filling / Draining Control Module

10 Design Ladder Diagram for Vehicle Parking Module

11 Design Ladder Diagram for Bottling Plant Module

12 Design Ladder Diagram for Apple Packing Module

13 Design Ladder Diagram for Tank Level and Pump Control Module

14 Connecting Real Sensors and Actuators with PLC

 Lab No. 01
Introduction to Industrial Automation and PLCs
Name: _____________________________

Registration # _______________________

Date: _______________________

Objective:
 To become familiar with Industrial Automation & PLCs.

Introduction:
Industrial Automation:

Automation takes a step further mechanization that uses a particular machinery mechanism aided
human operators for performing a task. Mechanization is the manual operation of a task using powered
machinery that depends on human decision making. Automation replaces the human involvement with
the use of logical programming commands and powerful machineries.

Industrial Automation is the replacement with computers and machines to that of human thinking.
The word Automation gives the meaning ‘self dictating’ or ‘a mechanism moves by itself’ that derived
from the Greek words ‘Auto’ and ‘Matos’ where ‘auto’ means self while ‘Matos’ means moving. In a
brief, industrial automation can be defined as the use of set technologies and automatic control devices
that results the automatic operation and control of industrial processes without significant human
intervention and achieving superior performance than manual control. These automation devices
include PLCs, PCs, PACs, etc. and technologies include various industrial communication systems.

Advantages of Automation System:

 To increase productivity
 To provide optimum cost of operation
 To improve product quality
 To reduce routine checks
 To raise the level of safety
Types of Industrial Automation Systems:
1) Fixed or Hard Automation:

This type of automation is employed to perform

fixed and repetitive operations in order to achieve
high production rates. It uses special purpose or
dedicated equipment to automate the fixed sequence
assembling or processing operations. Once it is
employed, it is relatively hard to change or vary the
product design. Therefore, it is inflexible in
providing product variety, but increases the
efficiency with higher production rate and reduces
unit cost.
Fig 1.1: Fixed Automation

2) Programmable Automation

In this automation, a specific class of product

changes and also assembling or processing
operations can be changed with the modification of
control program in the automated equipment. This
automation is best suited for batch production
process where product volume is medium to high.
But in this, it is hard to change and reconfigure the
system for a new product or sequence of operations.
Therefore, new product or reconfigure of sequence
of operations requires a long setup.

Fig 1.2: Programmable Automation

3) Flexible or Soft Automation

This automation system provides the automatic

control equipment that offers a great flexibility for
making changes in the product design. These
changes can be performed quickly through the
commands given in the form of codes by the human
operators. This automation allows the manufacturers
to produce multiple products with different ranges
as a combined combination process rather than
separate. Some of the examples of this automation
system are automatic guided vehicles, automobiles,
and multipurpose CNC machines.

Fig 1.3: Flexible Automation

PLCs:
Programmable Logic Controllers (PLCs) are small industrial computers with modular components
designed to automate customized control processes. PLCs are often used in factories and industrial
plants to control motors, pumps, lights, fans, circuit breakers and other machinery. To understand the
purpose of PLCs better, let’s look at a brief history of PLCs.

History:
Industrial automation began long before PLCs. In the early to mid-1900s, automation was usually done
using complicated electromechanical relay circuits. However, the amount of relays, wires and space
needed to create even simple automation was problematic. Thousands of relays could be necessary to
automate a simple factory process and if something in the logical circuit needed to be changed then it
will be very difficult.

In 1968 the first programmable logic controller came along to replace complicated relay circuitry in
industrial plants. The PLC was designed to be easily programmable by plant engineers and technicians
that were already familiar with relay logic and control schematics. Since the beginning PLCs have
been programmable using ladder logic which was designed to mimic control circuit schematics. The
ladder diagrams look like control circuits where power is flowing from left to right through closed
contacts to energize a relay coil.

Fig 1.4: Ladder Logic Example

As we can see in Fig 1.4 ladder logic looks like simple control circuit schematics where input sources
like switches, push-buttons, proximity sensors, etc. are shown on the left and output sources are shown
on the right. The ability to program complicated automated processes with an intuitive interface like
ladder logic made the transition from relay logic to PLCs much simpler for many in the industry.

Although, the first PLCs were very limited in their memory and speed capabilities, they quickly
improved over the years. The presence of PLCs helped simplify the design and implementation of
industrial automation.

Working of PLC:
A programmable logic controller is a specialized computer used to control machines and processes. It
therefore shares common terms with typical PCs like central processing unit, memory, software and
communications. Unlike a personal computer though the PLC is designed to survive in a rugged
industrial atmosphere and to be very flexible in how it interfaces with inputs and outputs to the real
world.

The components that make a PLC work can be divided into three core areas.
1) The power supply and rack
2) The central processing unit (CPU)
3) The input/output (I/O) section
PLCs come in many shapes and sizes. They can be so small as to fit in your shirt pocket while more
involved controls systems require large PLC racks. Smaller PLCs (a.k.a. “bricks”) are typically
designed with fixed I/O points. For our consideration, we’ll look at the more modular rack based
systems. It’s called “modular” because the rack can accept many different types of I/O modules that
simply slide into the rack and plug in.

Fig 1.5: PLC

1) The Power Supply and Rack

The rack is the component that holds everything together. Depending on the needs of the control
system it can be ordered in different sizes to hold more modules. Like a human spine the rack has a
backplane at the rear which allows the cards to communicate with the CPU. The power supply plugs
into the rack as well and supplies a regulated DC power to other modules that plug into the rack. The
most popular power supplies work with 120 VAC or 24 VDC sources.
2) The CPU:

The brain of the whole PLC is the CPU module. This module
typically lives in the slot beside the power supply. The CPU
consists of a microprocessor, memory chip and other integrated
circuits to control logic, monitoring and communications. The
CPU has different operating modes. In programming mode, it
accepts the downloaded logic from a PC. The CPU is then placed
in run mode so that it can execute the program and operate the
process.

Since a PLC is a dedicated controller it will only process this one

program over and over again. One cycle through the program is
called a scan time and involves reading the inputs from the other
modules, executing the logic based on these inputs and then
updated the outputs accordingly. The scan time happens very
quickly (in the range of 1/1000th of a second). The memory in
the CPU stores the program while also holding the status of the
I/O and providing a means to store values.
Fig 1.6: CPU Cycle
3) I/O System:

Inputs:

Input devices can consist of digital or analog devices. A digital input card handles discrete devices
which give a signal that is either on or off such as a pushbutton, limit switch, sensors or selector
switches. An analog input card converts a voltage or current (e.g. a signal that can be anywhere from
0 to 20mA) into a digitally equivalent number that can be understood by the CPU. Examples of analog
devices are pressure transducers, flow meters and thermocouples for temperature readings.

Outputs:

Output devices can also consist of digital or analog types. A digital output card either turns a device
on or off such as lights, LEDs, small motors, and relays. An analog output card will convert a digital
number sent by the CPU to its real world voltage or current. Typical outputs signals can range from
0-10 VDC or 4-20mA and are used to drive mass flow controllers, pressure regulators and position
controls.

Programming a PLC:
In these modern times a PC with specially dedicated software from the PLC manufacturer is used to
program a PLC. The most widely used form of programming is called ladder logic. Ladder logic uses
symbols, instead of words, to emulate the real world relay logic control, which is a relic from the PLC's
history. These symbols are interconnected by lines to indicate the flow of current through relay like
contacts and coils. Over the years the number of symbols has increased to provide a high level of
functionality.
The completed program looks like a ladder but in actuality it represents an electrical circuit. The left
and right rails indicate the positive and ground of a power supply. The rungs represent the wiring
between the different components which in the case of a PLC are all in the virtual world of the CPU. So
if you can understand how basic electrical circuits work then you can understand ladder logic.

In this simplest of examples, a digital input (like a button connected to the first position on the card)
when it is pressed turns on an output which energizes an indicator light.

Fig 1.7: Ladder Logic

The completed program is downloaded from the PC to the PLC using a special cable that’s connected
to the front of the CPU. The CPU is then put into run mode so that it can start scanning the logic and
controlling the outputs.

Conclusion:
 Lab No. 02
Orientation to PLC Software (Fatek)
Name: _____________________________

Registration # _______________________

Date: _______________________

Objective:
 To become familiar with FATEK WinProladder Software.
 To implement Logic Gates (AND, OR, NOT, NAND, NOR, XOR, XNOR) using Ladder logic
in FATEK PLC.

Equipment and Components:

 FATEK FBS 14 MA
 FATEK WinProladder Software
 PC
Introduction:
FATEK FBS-14-MA PLC:
The FATEK FBS Series PLC is a new generation of micro PLC
equipped with excellent functions comparable to medium or
large PLC, with up to five communication ports. The maximum
I/O numbers are 256 points for Digital Input (DI) and Digital
Output (DO), 64 words for Numeric Input (NI) and Numeric
Output (NO). The Main Units of FBS are available in three
types: MA (Economy Type), MC (High-Performance Type),
and MN (High-Speed NC Type). With the combination of I/O
point ranges from 10 to 60, a total of 17 models are available.
Fifteen DI/DO and 19 NI/NO models are available for
Expansion Units/Modules. With interface options in RS232,
RS485, USB, Ethernet, CANopen, Zigbee and GSM, the
communication peripherals are available with 15 boards and
modules. FATEK FBS 14 MA indicates economy type PLC
having 14 in/out ports, 8 inputs and 6 outputs ports.
Fig 2.1: FATEK FBS-14-MA
FATEK WinProladder Software:
It provides the connection for PLC and PC with varieties. Among the connections, there are hardware
connection, Modem connection and Internet connection. For every different connection, WinProladder
provide a session name to associate the setting of the communication parameters, such as port no.,
baud rate, IP address etc. With this feature can alleviate the user from the burden of the memorizing.
It provides the on-line program editing capability. After modify the ladder program can send the RUN
command immediately without to re-download the program to PLC. With this feature can reduce the
application development time dramatically comparing with other PLC without this feature.

Fig 2.2: WinProladder Operational Window

(Functions toolbar) is the collection of functions included in the applications software, presented in
different categories. When the user selects any of the categories in the above function’s toolbar, a list
of additional selectable functions will be displayed for the user to select.

(Tools bar) In the process of the design of a project, it is often convenient to provide a toolbar with
the most commonly used functions included in it for the user to directly select, which can prove to be
much faster and more convenient that having to find the function through the functions toolbar.

(Component tray) allows the user to easily select the components and command functions that they
need to use without having to search for what they want through the functions toolbar, which is faster
and more convenient.

(Status bar) displays information on the status of the current application, such as whether the
application is connected, whether it is in execution or has been disconnected, and the current location
of the cursor, etc., allowing the user to know the status of the current application at all times.
Logic Gates:

i) Not Gate:
In this logic gate, the output is high if the input is
low and vice versa. The symbol and truth table for
this gate are shown.

ii) OR Gate:
In this Logic gate, the output is high if one of the
input is high. If both the inputs are low, then the
output is low. The symbol and truth table are
shown.

iii) AND Gate:

In this Logic gate, the output is high if either one
of the input is high. If both the inputs are low, then
the output is low.

iv) NAND Gate:

In NAND gate the output is low only if all its inputs are
high otherwise output will be high. Its output is
complement of an AND gate. The symbol and truth table
for this gate are shown.

v) NOR Gate:
In this Logic gate, the output is low if one of the input
is high. If both the inputs are low, then the output is
high. The symbol and truth table for this gate are shown

vi) XOR Gate:

In XOR gate output is high when the one input is high
and other is low otherwise the output will be low.

vii) XNOR Gate:

In XOR gate output is low when the one input is high and
other is low otherwise the output will be high.
Procedure:
 Run WinProladder software.
 Select [File]  [New Project] from the function toolbar, the [New Project] window appeared, as
is shown in Fig 2.3.
 Enter “EXAMPLE1” into the [Project Name] field.
 Click on the Edit button to enter the PLC model type selection screen and selected FBs14MA
model type.

Fig 2.3: New Project Window

 Click ok button, and the following screen will appear:

Fig 2.4: Working Window

 Then create ladder logic using a contact (label X0) for fan button and a coil (Label Y0) for fan:

Fig 2.5: Ladder Logic

 Then select [PLC]  [Simulation] from the function toolbar.

 Then selected [PLC]  from the function toolbar.
 Then turn ON the Fan button (X0) and insert the PLC simulation below:

Fig 2.6: Simulation of Ladder Logic

 Then add an output Light (Y1) in ladder logic to indicate the switching of Fan. If the fan is ON,
the light should be ON and vice versa. Insert the PLC simulation below:

Fig 2.7: Ladder Logic

 Then select [PLC]  [Simulation] from the function toolbar.

 Then selected [PLC]  from the function toolbar.
 Then turn ON the Fan button (X0) and insert the PLC simulation below:

Fig 2.8: Simulation of Ladder Logic

 Create Ladder Logic for NOT gate, verify all the outputs using different inputs & insert the PLC
simulation below:

Fig 2.9: Ladder Logic for NOT Gate

 Create Ladder Logic for OR gate, verify all the outputs using different inputs & insert the PLC
simulation below:

Fig 2.10: Ladder Logic for OR Gate

 Create Ladder Logic for NOR gate, verify all the outputs using different inputs & insert the PLC
simulation below:

Fig 2.11: Ladder Logic for NOR Gate

 Create Ladder Logic for AND gate, verify all the outputs using different inputs & insert the PLC
simulation below:

Fig 2.12: Ladder Logic for AND Gate

 Create Ladder Logic for NAND gate, verify all the outputs using different inputs & insert the PLC
simulation below:

Fig 2.13: Ladder Logic for NAND Gate

 Create Ladder Logic for XOR gate, verify all the outputs using different inputs & insert the PLC
simulation below:

Fig 2.14: Ladder Logic for XOR Gate

 Create Ladder Logic for XNOR gate, verify all the outputs using different inputs & insert the PLC
simulation below:

Fig 2.15: Ladder Logic for XNOR Gate

Conclusion:
 Lab No. 03
Introduction to Memory Structure, Ladder Logic
Programming Elements & PLC Programming
Lab No. 04
Use of advanced Instructions:
Comparison Instructions, Mathematics (Addition, Subtraction,
Comparison etc.) & Data Handling
Name: _____________________________

Registration # _______________________

Date: _______________________

Objective:
 To become familiar about memory elements.
 To perform various arithmetic operations using memory elements.
 To become familiar with use of comparators in PLCs.
Equipment and Components:

 FATEK FBS 14 MA
 FATEK WinProladder Software
 PC
Introduction:
Registers in PLC:
In a PLC there are several registers. Each data register can store a binary word of usually 8 or 16 bits.
The number of bits determines the size of the number that can be stored. The binary system uses only
two symbols, 0 and 1. Thus we might have the 4-bit number 1111.

Arithmetic function in PLC:

Almost all PLCs have simple ladder diagram Arithmetic operations as add (ADD), subtract (SUB),
divide(DIV), multiply(MUL), square root(SQRT), average(MEAN), Negation(NEG) &
Absolute(ABS).
Some arithmetic operations used in WinProladder are described below and shown in Fig 4.1.

Fig 4.1: Arithmetic Function

Addition (+):
Performs the addition of the data specified at Sa and Sb and writes the results to a specified register D
when the add control input "EN" =1 or from 0 to 1(P instruction). If the result of addition is equal to 0
then set FO0 to 1. If carry occurs (the result exceeds 32767 or 2147483647) then set FO1 to 1. If
borrow occurs (adding negative numbers resulting in a sum less than -32768 or -2147483648), then
set the FO2 to 1. All the FO statuses are retained until this instruction is executed again and overwritten
by a new result.

Fig 4.2: Addition Block

Subtraction (-):
Performs the subtraction of the data specified at Sa and Sb and writes the results to a specified register
D when the subtract control input "EN" =1 or from 0 to 1(P instruction). If the result of subtraction is
equal to 0 then set FO0 to 1. If carry occurs (subtracting a negative number from a positive number
and the result exceeds 32767 or 2147483647), then set FO1 to 1. If borrow occurs (subtracting a
positive number from a negative number and the resulted difference is less than -32768 or -
2147483648), then set FO2 to 1. All the FO statuses are retained until this instruction is executed again
and overwritten by a new result.

Fig 4.3: Subtraction Block

Multiplication (*):
Performs the multiplication of the data specified at Sa and Sb and writes the results to a specified
register D when the multiplication control input "EN" =1 or from 0 to 1(P instruction). If the product
of multiplication is equal to 0 then set FO0 to 1. If the product is a negative, then set FO1 to 1.

Fig 4.4: Multiplication Block

Division (/):
Performs the division of the data specified at Sa and Sb and writes the quotient and remainder to
registers specified by register D when the division control input "EN" =1 or from 0 to 1 (P instruction).
If the quotient of division is equal to 0 then set FO0 to 1. If the divisor Sb=0 then set the error flag
FO1 to 1 without executing the instruction.

Fig 4.5: Division Block

Increment (+1):
Adds 1 to the register D when the increment control input "EN" =1 or from 0 to 1 (P instruction). If
the value of D is already at the upper limit of positive number 32767 or 2147483647, adding one to
this value will change it to the lower limit of negative number -32768 or -2147483648. At the same
time, the overflow flag FO0 (OVF) is set to 1.

Fig 4.6: Increment Block

Decrement (-1):
Subtracts 1 from the register D when the decrement control input "EN" =1 or from 0 to 1 (P
instruction). If the value of D is already at the lower limit of negative number -32768 or -2147483648,
subtracting one from this value will change it to the upper limit of positive number 32767 or
2147483647. At the same time, the underflow flag FO0 (UDF) is set to 1.

Fig 4.7: Decrement Block

Average (MEAN):
When operation control "EN" = 1 or from 0 to 1(P instruction), add the N successive 16-bit or 32-bit
(D instruction) numerical values starting from S, and then divided by N. Store this mean value
(rounding off numbers after the decimal point) in the register specified by D. While the N value is
derived from the content of the register, if the N value is not between 2 and 256, then the N range error
"ERR" will be set to 1, and do not execute the operation.

Fig 4.8: Average Block

Square root (SQRT):

When operation control "EN" = 1 or from 0 to 1(P instruction), take the square root (rounding off
numbers after the decimal point) of the data specified by the S field, and store the result into the register
specified by While the S value is derived from the content of the register, if the value is negative, then
the S value error flag "ERR" will be set to 1, and do not execute the operation.

Fig 4.9: Square root Block

Negation (NEG):
When operation control "EN" = 1 or from 0 to 1(P instruction), negate (i.e. calculate 2's complement)
the value of the content of the register specified by D, and store it back in the original D register. If the
value of the content of D is negative, then the negation operation will make it positive.

Fig 4.10: Negation Block

Absolute (ABS):
When operation control "EN" = 1 or from 0 to 1(P instruction), calculate the absolute value of the
content of the register specified by D, and write it back into the original D register.

Fig 4.11: Absolute Block

Comparator function in PLC:

Comparator is a device for comparing
something measurable with a reference or
standard. Some of the most often used
instructions in PLC programming
are comparator operations. A bit has only two
possible values of one or zero, true or false and
based on these limited values We can easily
demand the desired command for a PLC output.
Some Comparator operations used in
WinProladder are described below and shown in
Fig 4.12. Fig 4.12: Comparator Function
Comparison (CMP):

Compares the data of Sa and Sb when the compare control input "EN" =1 or from 0 to 1(P instruction).
If the data of Sa is equal to Sb, then set FO0 to 1. If the data of Sa>Sb, then set FO1 to 1. If the data of
Sa<Sb, then set FO2 to 1. If the data of Sa < Sb, then set the FO2 to 1.

Fig 4.13: Comparison Block

Zone Compare (ZNCMP):

When operation control "EN" = 1 or from 0 to 1 (P instruction), compares S with upper limit SU and
lower limit SL. If S is between the upper limit and the lower limit (SL≦S≦SU), then set the inside
zone flag "INZ" to 1. If the value of S is greater than the upper limit SU, then set the higher than upper
limit flag "S>U" to 1. If the value of S is smaller than the lower limit SL, then set the lower than lower
limit flag” S<L" as 1. The upper limit SU should be greater than the lower limit SL. If SU<SL, then
the limit value error flag "ERR" will set to 1, and this instruction will not carry out.

Fig 4.14: Zone Compare Block

Procedure:
 First run WinProladder software.
 Select [File]  [New Project] from the function toolbar, the [New Project] window will appear.
 Enter project name into the [Project Name] field.
 Then click on the Edit button to enter the PLC model type selection screen and select FBs14MA
model type. Click ok button, and the working screen will appear.
 Apply increment operation on two registers D0 and D1 and insert the PLC simulation below:
 Assign value 4 at D0 and 2 at D1.

Fig 4.15: Increment Function

 Apply the sum operation on D0 & D1 and store their sum in D21 and insert the PLC simulation
below:

Fig 4.16: Sum Function

 Apply the subtraction operation on D0 & D1 and store their sum in D22 and insert the PLC
simulation below:

Fig 4.17: Subtract Function

 Apply the multiplication operation on D0 & D1 and store their sum in D100 and insert the PLC
simulation below:

Fig 4.18: Multiplication Function

 Apply the division operation on D0 & D1 and store their sum in D23 and insert the PLC simulation
below:

Fig 4.19: Division Function

 Apply the mean operation on D0 & D1 and store their sum in D24 and insert the PLC simulation
below:

Fig 4.20: Mean Function

 Apply the square root function on D0 & D1 and store their sum in D25 and insert the PLC
simulation below:

Fig 4.21: Square Root Function

 Apply the negative function on D0 and store their sum in D26 and insert the PLC simulation below:

Fig 4.22: Negate Function

 Apply the absolute function on D0 and store their sum in D27 and insert the PLC simulation below:

Fig 4.23: Absolute Function

 Apply Comparator operation on D0 & D1 and insert the PLC simulation below:

Fig 4.24: Comparator Function

 Apply Zone Compare operation on D0. Set the upper limit of zone to 10 and lower limit 2. Insert
the PLC simulation below:

Fig 4.25: Zone compare Function

 Setup Master reset to reset the stored values in all registers and insert the PLC simulation below:

Fig 4.26: Master reset

Conclusion: