PREPARED BY: CHANDRA MOHAN MITTALI E D, NOIDA

AUTOMATION AND PANELLING

BASIC DESCRIPTION ABOUTPANELLING

COMPONENTS IN PANELLING

EXTERNAL VIEW OF PANEL

INTERNAL VIEW OF PANEL

MAIN INCOMER MCCB: MCCB is known as molded case circuit breaker. Molded case circuit breaker (MCCB) is mainly used in electric power system with rated frequency of AC50Hz, rated voltage up to 690V and rated current up to 800A to distribute electric power. Moreover, these are also used to protect the line and equipment from being damaged due to overload, short circuit and under voltage. It can also be used to control infrequent motor operation. The protection specialty of the electronic tripper and the intelligent tripper is accurate and convenient. It Operates on three phase supply.•Product Specifications:Standard: IS 13947 & IEC 947 •Voltage Rating: 240/415 V•Frequency: 50 Hz•Breaking Capacity: 10 KA-25 KA•Current Rating: 32 A- 250 A.

MCBMCB: MCB is Known as Miniature Circuit breaker. Miniature circuit breakers (MCBs) are fitted as protection units in place of fuses. They have the advantage that they can be manually reset without having to replace wire as in the case of the traditional fuse. The MCBs have either a button or lever that can be flicked to reset it. “MCB’S BREAKING CAPACITY IS UPTO 16 KA” The MCB tripping is an indication either that the circuit has been overloaded or that a short circuit has occurred somewhere in the system. Depending on their type they can rated for different applications –

B type - General Domestic Consumer Unit useC type - Motor RatedAnd others - Inductive, Capacitance, Reactive loads, etc.

Available in 1,2,3,4 Poles in both incoming and outgoing Supplies.

STANDARD CURRENT RATINGThe commonly-available preferred values for the rated current are 6 A, 10 A, 13 A, 16 A, 20 A, 25 A, 32 A, 40 A, 50 A, 63 A, 80 A and 100 A (Renard series, slightly modified to include current limit of British BS 1363 sockets). The circuit breaker is labeled with the rated current in amperes, but without the unit symbol "A". Instead, the ampere figure is preceded by a letter "B", "C" or "D" that indicates the instantaneous tripping current, that is the minimum value of current that causes the circuit-breaker to trip without intentional time delay (i.e., in less than 100 ms), expressed in terms of In:

MPCB The MPCBs may be combined with a magnetic contactor to provide 2 component combination starters and with the addition of an overload relay. They generally provide contacts to indicate The Motor Protection Circuit Breakers (MPCBs) provide short circuit protection, overload protection, and motor position (Trip, Not Tripped) and also axillaries contacts normally open closed - Operational range usually from 0.11 A to 100 A and this is usually adjustable from the front of the unit as opposed to MCB which are generally set. They are also more expensive.

Current rating: .11A to 100A.

Features: 1) In 2,3,4 pole2)Specially installed for high load protection of motor To avoid burning of motor. 3) Needs three phase supply for operation.

RELAYSThere are 5 types of relays which are used normally in practice:1)Simple relay2)Overload relay3)Control relay4)Interposing relay5)Double change over relay

A relay is an electrically operated switch. Current flowing through the coil of the relay creates a magnetic field which attracts a lever and changes the switch contacts. The coil current can be on or off so relays have two switch positions and most have double throw (changeover) switch contacts as shown in the diagram.

EXPLANATION

INTERPOSING RELAYInterposing Relay is special type of relay which is used to provide the isolation between two electrical components.

For example: A plc operates on the 24V dc supply whereas a contactor operates on 120V ac, so an Interposing relay operates in such a condition that it provides 24V dc to PLC for operation & 120V ac to contactor for holding. It has 2 NO contacts And 2 NC contacts.

Double Changeover Relay Module •Jumpers for "common +ve" or "common -ve" mode operation. Spare jumper given on pcb. Option for screw less / screw terminal connection. Din rail mounting.

RELAYS BASIC

CHOOSING A RELAYYou need to consider several features when choosing a relay: •Physical size and pin arrangement If you are choosing a relay for an existing PCB you will need to ensure that its dimensions and pin arrangement are suitable. You should find this information in the supplier's catalogue.

•Coil voltage The relay's coil voltage rating and resistance must suit the circuit powering the relay coil. Many relays have a coil rated for a 12V supply but 5V and 24V relays are also readily available. Some relays operate perfectly well with a supply voltage which is a little lower than their rated value.

•Coil resistance The circuit must be able to supply the current required by the relay coil. You can use Ohm's law to calculate the current:

DIFFERENCE B/W MANUAL AND AUTO CONTROL

ELECTRICAL SYMBOLSLanguage has been developed in order to transfer ideas and information. In order to understand the ideas and information being communicated, an understanding of the language is necessary. The language of controls consists of a commonly used set of symbols which represent control components.

Contact Symbols : Contact sym bols are used to indicate an open or closed path of current flow. Contacts are shown as normally open (NO) or normally closed (NC). Contacts shown by this symbol require another device to actuate them.The standard method of showing a contact is to indicate the circuit condition produced when the actuating device is in the de-energized state. For example, in the following illustration a relay is used as the actuating device. The contacts are shown as normally open, meaning the contacts are open when the relay is de-energized. A complete path of current does not exist and the light is off.

NORMALLY OPEN CONTACTNorm ally Open Contact: In a control diagram or schematic, symbols are usually not shown in operated state.

Example shown in the energized or operated state. However, for the purposes of explanation in this text, a contact or device shown in a state opposite of its normal state will be highlighted. For example, in the following illustration the circuit is first shown in the de-energized state. The contacts are shown in their normally open (NO) state. When the relay is energized, the contacts close, completing the path of current and illuminating the light. The contacts have been highlighted to indicate they are now closed. (This is not a legitimate symbol. It is used here for illustrative purposes only.)

NORMALLY CLOSED CONTACT Normally Closed Contact In the following illustration the contacts are shown as normally closed (NC), meaning the contacts are closed when the relay is de-energized. A complete path of current exists and light is on. When the Relay is energized, the contacts open & light is off.

EXAMPLE:

SWITCH SYMBOLS Switch symbols : These are also used to indicate an open or closed path of current flow. Variations of this symbol are used to represent limit switches, foot switches, pressure switches, level switches, temperature-actuated switches, flow switches, and selector switches. Like contacts, switches require another device or action to change their state. In the case of a manual switch, someone must manually change the position of the switch.

Pushbutton Symbols: There are two basic types of pushbuttons: Momentary and Maintained. A normally open momentary pushbutton closes as long as the button is held down. A normally closed momentary pushbutton opens as long as the button is held down. A maintained pushbutton latches in place when the button is pressed.

LIGHT SYMBOLS

SWITCH SYMBOLS

HOW TO READ PANEL DRAWINGTo understand the drawing of panel we must under stand line diagrams.One should know how to read the line diagrams.

Line Diagrams The method of expressing the language of control symbols is a line diagram, also referred to as a ladder diagram. Line diagrams are made up of two circuits, the control circuit and the power circuit. Electrical wires in a line diagram are represented by lines. Control-circuit wiring is represented by a lighter-weight line, and power-circuit wiring is represented by a heavier-weight line. A small dot or node at the intersection of two or more wires indicates an electrical connection

Line diagrams show the functional relationship of components and devices in an electrical circuit, not the physical relationship. For example, the following illustration shows the physical relationship of an indicator light and a pushbutton.

The following illustration shows the physical relationship of an indicator light and a pushbutton:

PLC HISTORY PLC development began in 1968 in response to a request from an US car manufacturer (GE). The first PLCs were installed in industry in 1969.

Communications abilities began to appear in approximately 1973. They could also be used in the 70′s to send and receive varying voltages to allow them to enter the analog world.

What does ‘PLC’ mean?

A PLC (Programmable Logic Controllers)  is an industrial computer used to monitor inputs, and depending upon their state make decisions based on its program or logic, to control (turn on/off) its outputs to automate a machine or a process.

PLC HARDWAREHardware Components of a PLC SystemProcessor unit (CPU), Memory, Input/Output, Power supply unit, Programming device, and other devices.

Central Processing Unit (CPU)CPU – Microprocessor based, may allow arithmetic operations, logic operators, block memory moves, computer interface, local area network, functions, etc.CPU makes a great number of check-ups of the PLC controller itself so eventual errors would be discovered early.

System BussesThe internal paths along which the digital signals flow within the PLC are calledbusses.The system has four busses:- The CPU uses the data bus for sending data between the different elements,- The address bus to send the addresses of locations for accessing stored data,- The control bus for signals relating to internal control actions,- The system bus is used for communications between the I/O ports and the I/O unit.

PLC HARDWARE CONTD.MemorySystem (ROM) to give permanent storage for the operating system and the fixed data used by the CPU.RAM for data. This is where information is stored on the status of input and output devices and the values of timers and counters and other internal devices. EPROM for ROM’s that can be programmed and then the program made permanent.I/O SectionsInputs monitor field devices, such as switches and sensors.Outputs control other devices, such as motors, pumps, solenoid valves, and lights.Power SupplyMost PLC controllers work either at 24 VDC or 220 VAC. Some PLC controllers have electrical supply as a separate module, while small and medium series already contain the supply module.Programming DeviceThe programming device is used to enter the required program into the memory of the processor.The program is developed in the programming device and then transferred to the  memory unit of the PLC.

PLC OPERATIONInput RelaysThese are connected to the outside world. They physically exist and receive signals from switches, sensors, etc. Typically they are not relays but rather they are transistors.

Internal Utility RelaysThese do not receive signals from the outside world nor do they physically exist. They are simulated relays and are what enables a PLC to eliminate external relays.There are also some special relays that are dedicated to performing onlyone task.

CountersThese do not physically exist. They are simulated counters and they can be programmed to count pulses.Typically these counters can count up, down or both up and down. Since they are simulated they are limited in their counting speed.Some manufacturers also include highspeed counters that are hardware based.

PLC OPERATION CONTD.TimersThese also do not physically exist. They come in many varieties and increments.The most common type is an on-delay type.Others include off-delay and both retentive and non-retentive types. Increments vary from 1ms through 1s.

Output RelaysThese are connected to the outside world. They physically exist and send on/off signals to solenoids, lights, etc.They can be transistors, relays, or triacs depending upon the model chosen.

Data StorageTypically there are registers assigned to simply store data. Usually used as temporary storage for math or data manipulation.They can also typically be used to store data when power is removed from thePLC.

INTRODUCTION TO PLC’S RS Logix 500 Series

PLC PROCESSOR CAT. NO.

I/O CAT NO.

MICROLOGIX 1000

1761 -

MICROLOGIX 1100

1763 1762

MICROLOGIX 1200

1762 1762

MICROGIX 1400 1766 1762MICROLOGIX 1500

1764 1769

RS LOGIX 500 SERIES

SLC 500 1747 1746SLC 5/01 1747 1746SLC5/02 1747 1746SLC 5/03 1747 1746SLC 5/04 1747 1746SLC 5/05 1747 1746

RS LOGIX 5000 SERIESCOMPACT LOGIX L23

1769 1769

COMPACT LOGIX L32

1769 1769

COMPACT LOGIX L35

1756 1756

COMPACT LOGIX L52

1756 1756

PLC COMMUNICATION• Extension modules

PLC I/O number can be increased through certain additional modules by system extension through extension lines. Each module can contain extension both of input and output lines.Extension modules can have inputs and outputs of a different nature from those on the PLC controller. When there are many I/O located considerable distances away from the PLC an economic solution is to use I/O modules and use cables to connect these, over the long distances, to the PLC.

• Remote I/O connectionsWhen there are many I/O located considerable distances away fromthe PLC an economic solution is to use I/O modules and use cables toconnect these, over the long distances, to the PLC.

• Remote PLCsIn some situations a number of PLCs may be linked together with a master PLC unit sending and receiving I/O data from the other units.

COMMUNICATIONCablesTwisted-pair cabling, often routed through steel conduit. Coaxial cable enables higher data rates to be transmitted and does not require the shielding of steel conduit.Fiber-optic cabling has the advantage of resistance to noise, small size and flexibility.

Parallel communication•Parallel communication is when all the constituent bits of a word aresimultaneously transmitted along parallel cables. This allows data to be transmitted over short distances at high speeds. Might be used when connecting laboratory instruments to the system.•Parallel standardsThe standard interface most commonly used for parallel communication is IEEE-488, and now termed as General Purpose Instrument Bus (GPIB).Parallel data communications can take place between listeners , talkers , and controllers. There are 24 lines: 8 data (bidirectional), 5status & control, 3 handshaking, and 8 ground lines

COMMUNICATION MODESSerial communication•Serial communication is when data is transmitted one bit at a time. A data word has to be separated into its constituent bits for transmission and then reassembled into the word when received. Serial communication is used for transmitting data over long distances. Might be used for the connection between a computer and a PLC.•Serial standardsRS-232 communications is the most popular method of plc to external device communications. RS 232 is a communication interface includedunder SCADA applications. Other standards such as RS422 and RS423are similar to RS232 although they permit higher transmission rates and longer cable distances.•  RS-232 devices has two types of protocols: DF1 –When we use 2,3,5 no. pins of serial port. RS-485-When pins above 5 are used in serial port.

MODES CONTD. ASCIIASCII is a human-readable to computer-readable translation code(each letter/number is translated to 1′s and 0′s). It’s a 7-bit code, so we can translate 128 characters (2^7 is 128).

ProtocolsIt is necessary to exercise control of the flow of data between two devices so what constitutes the message, and how the communication is to be initiated and terminated, is defined. This is termed the protocol.One device needs to indicate to the other to start or stop sending data.Interconnecting several devices can present problems because of compatibility problems.In order to facilitate communications between different devices the International Standard Organization (ISO) in 1979 devised a model to be used for standardization for Open System Interconnection (OSI).

CABLES USED FOR COMMUNICATIONPM02:Use to communicate plc & laptop.

NC13: Use to communicate HMI & Laptop.

CP3: Use to communicate Plc & Modem.

NC21: Use to communicate HMI & plc.

ETHERNET: Use for programming.

HM02: Use to communicate plc & Panel view.

NULL cable: consists of one port male and other port female.

C10: communicate RJ-45 with RJ-45.

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