Shri

Automation in Process Control

Dr S. R. Desai
B.M.S.C.E.
Automation in Process
Control
(Part-1)

Dr S. R. Desai

B.M.S.C.E.
Introduction
What is automation ?

Automation is the conversion of a work process, a procedure or equipment to automate rather than
human operation or control.

Automation is the use of logical programming commands and mechanized equipment to replace the
decision making and manual command-response activities of human beings.
• Does not simply transfer human functions to machines, but involves a deep reorganization of the work process,
• Both the human and the machine functions are redefined.

Evolution:
• Understand the historical perspective on the evolution of control systems implementation philosophy and hardware elements.
• Early automation relied on mechanical and electromechanical control devices; during the last 40 years, however, the computer
gradually became the leading vehicle of automation.
• Modern automation is usually associated with computerization.
Automation
Production cycle
 Industrial Process
3 main flows determining an industrial process
- material, energy and information flow
ENERGY MATERIAL
FLOW FLOW

INFOR
MATIO
N
FLOW

INDUSTRIAL PROCESS

Objective of plant automation is to identify information flow and

control material and energy flow as desired in optimum way.
What is Automation?
Automation is
delegation of
human control Sensors for
sensing the input Transmitters for
functions to parameters (RTD, transmitting the
technical Thermocouple, raw signal in
Pressure, Flow, electrical form
equipment for Level, etc)
increasing
productivity,
better quality, Control system
Output devices /
which includes
reduced cost & PLC, DCS, PID &
actuators like
drives, control
increase safety PC based
valves.
controllers
in working
conditions
Process
Physical process is a series of actions, operations, changes, or functions
that takes place within, bringing about changes or producing an output or a
result.
• It is also a sequence of interdependent operations or actions which, at every stage,
consumes one or more inputs or resources to convert them into outputs or results to reach
a known goal or the desired end result.

Broadly divided into three categories

• • Natural processes - presented by or produced by nature. Ex : human body

• • Self-regulated processes - not natural but do not need external assistance for
• regulation. Ex : domestic geyser
• • Industrial processes - systematic series of physical, mechanical, chemical,
• or similar kinds of operations that produce a result.
• Ex: factories manufacturing goods
 Industrial Process

Technically, all industrial processes can be broadly

classified into three levels
• Application : any industrial process can be either manufacturing
that creates physical values to deliver goods/products as per
specification or utilities that deliver services as per requirement.
• Operational : Regarding operation, any application process can
be continuous, discrete, or batch.
• Physical : All processes are physically classified as either localized
or distributed (even geographical).
 Industrial Process
Application
• Manufacturing process
• Process plants: Chemical, cement, power generation, fertilizer, cement, etc.
• Factories: Engineered products, automobiles, assembly lines, etc.
• Utility process
• Civic utilities: Water distribution, power distribution, gas distribution, water/sewage treatment, etc.
• Backbone utilities: Power transmission, water transmission, oil/gas pipelines, etc

Operational : Regarding operation, any application process can be continuous, discrete, or batch.
Typical examples are
• • Continuous: Process plants, distribution of power, water, gas; treatment plants, etc.
• • Discrete: Factories, assembly lines, etc.
• • Batch: Pharma, food, beverage, etc.

Physical : All processes are physically classified as either localized or distributed (even
geographical). Typical examples are
• • Localized: Process plants, factories, electrical substations, pump stations, etc.
• • Distributed: Distribution of water, power, and gas; transmission of water, power, gas, etc.
Types of Process -Operational

Batch
Process
Types of
Continuous
Process Process
(Operational)
Discrete
Manufacturing
Batch process
Continuous process
Discrete manufacturing
 Dairy Industry

Sequential, batch, short continuous, or semi-continuous

operations
Automotive Industry
Pulp and paper industrial process
Pulp and paper industrial process
What is Automation?
Automation is
delegation of
human control Sensors for
sensing the input Transmitters for
functions to parameters (RTD, transmitting the
technical Thermocouple, raw signal in
Pressure, Flow, electrical form
equipment for Level, etc)
increasing
productivity,
better quality, Control system
Output devices /
which includes
reduced cost & PLC, DCS, PID &
actuators like
drives, control
increase safety PC based
valves.
controllers
in working
conditions
Basic elements of an automated system
Types of Automation System

• Fixed automation
Automated • Programmable
production automation
systems classified • Flexible automation
into three basic
types
Types of Automation System

FIXED AUTOMATION
• A system in which the sequence of processing (or assembly) operations is
fixed by the equipment configuration.
• Operations in the sequence are usually simple.
• It is the integration and coordination of many such operations into one
piece of equipment that makes the system complex.

Typical features of fixed automation

• High initial investment for custom–Engineered equipment
• High production rates
• Relatively inflexible in accommodating product changes

Examples : mechanized assembly and machining transfer lines

Types of Automation System

PROGRAMMABLE AUTOMATION
• In this the production equipment is designed with the capability to change the sequence
of operations to accommodate different product configurations.
• The operation sequence is controlled by a program, which is a set of instructions coded so
that the system can read and interpret them.
• New programs can be prepared and entered into the equipment to produce new products

Typical features of programmable automation

• High investment in general-purpose equipment
• Low production rates relative to fixed automation
• Flexibility to deal with changes in product configuration
• Most suitable for batch production.
Examples : Numerically controlled machine tools and industrial robots
Types of Automation System
FLEXIBLE AUTOMATION
• It is an extension of programmable automation.
• Capable of producing a variety of products (or parts) with virtually no time lost
for changeovers from one product to the next.
• No production time lost while reprogramming the system and altering the
physical setup (tooling, fixtures, and machine setting).
• Can produce various combinations and schedules of products instead of requiring
that they be made in separate batches.

Typical features of flexible automation

• High investment for a custom-engineered system.
• Continuous production of variable mixtures of products.
• Medium production rates.
• Flexibility to deal with product design variations.
Automation in Production system
Types of Automation System
Summary: Types of Automation
PLANT AUTOMATION
PLANT AUTOMATION

• To identify the information

Basic flow, and to manipulate the
material and energy flows of a
objective given process in a desired,
optimal way.
PLANT AUTOMATION

• Production volume enhancement

• Production cost reduction
• Productivity increase
• Product quality improvement
Most common

• Optimal production flexibility

benefits

• Optimal production scheduling

• Optimal use of available facilities
• Inventory control
• Market competitivity
• Humanization of work place
• Environmental pollution control
• Production reliability
• Plant safety
Factors contributed to development of modern automation
Advances in microprocessor, memory, and related VLSI technology

Developments in intelligent semiconductor sensors and fiber-optic sensors

Implementations of programmable controllers

Standardization of modular hardware and software for process control

Advancements in computer technology

Emergence of powerful interactive graphics for human interface

Standardization of data communication links and networks

Adoption of a whole range of methods of modern control and system theory (model building, estimation
theory, optimal, adaptive, self-tuning control, etc.) For modelling, simulation, design of control systems
Developments in artificial intelligence
Layers/levels of an automation system.
Automation Pyramid
Industrial Revolution
Evolution of communication technology
PLANT AUTOMATION
Classical Approaches to Plant Automation

Direct Manual Process Control Modular Presentation of a Control Loop

Direct Manual Process Control

At the very beginning industrial plants were supervised and

controlled manually.

Plant operator placed in the close vicinity of the plant itself

Plant operator supervised the plant based on indications of local

instruments, installed on the field
 Direct Manual Process Control

Development of process instrumentation, such as sensors for measuring of main process

variables (temperature, pressure, level, flow, etc.)

Mechanical, pneumatic, and hydraulic controllers in the 40s directly contributed to the
gradual plant automation.

This trend continued through 50s, when also electric instruments for process control were
introduced, leading to the centralized plant supervision and control

Introduction of standards for signal transmission, both for pneumatic and electronic
instrumentation elements

Modularization of the plant automation systems in terms of compatible sensors, transducers,

transmitters, controllers, actuators, indicators, recorders, etc. became a reality
COMPUTER-BASED PLANT AUTOMATION CONCEPTS
• Pioneering era 1958 to 1964
• Centralized computer era 1965 to 1970
• Minicomputer era 1971 to 1975
• Distributed control era since 1975

• During the initial period, the computers used were much too large,
slow, expensive, and unreliable.
• Had to be used in supervisory mode only, for calculation of optimal
set-point values for installed conventional controllers.
• Two different approaches emerged
Operator guidance mode
 Set-point control mode.
Operator Guidance Mode for Plant Control
Set-Point Control Mode (SPC)
Basic DDC Configuration
Benefits of DDC as compared to the conventional control

Easy configuration, re-configuration, and parametrization of control loops

Easy self-tuning of controller parameters

Simple introduction of new control loops

Possibility of realization of advanced control algorithms

Model-based calculation of optimal set-point values for all control loops available

Comprehensive data acquisition and presentation

Drawbacks of digital control when using a single
centralized computer
Low fail-safety of the system: the failure of the
computer causes failure of all digital
control loops

Higher investment, maintenance, and personnel

costs, including the programming costs

Overloads of CPU and difficulties in programming

when process computer had to handle some
process automation functions in addition to DDC
Overview of a Dual-Computer System for DDC
Operating modes

Computer mode (C), also called DDC mode, in which the

computer performs control function of the loop

Automatic mode (A), or Controller mode, in which the

analog back-up controller controls the plants

Manual mode (M), or open-loop

Back-up Concept of DDC
 Recap till now…
• The evolution concerns the heart of any control system which is how information flow and decision
making advanced.
Roughly speaking, one can identify the following development stages :
• pioneering era 1958 to 1964
• centralized computer era 1965 to 1970
• minicomputer era 1971 to 1975
• distributed control era since 1975
• Pneumatic Implementation:
- In the early implementation of automatic control systems, information flow was accomplished by
pneumatic transmission
- Computation was done by mechanical devices using bellows, spring etc.
- The pneumatic controller has high margin for safety since they are explosion proof.
- Two fundamental problems associated with pneumatic implementation:
• Transmission: the signals transmitted pneumatically (via air pressure) are slow responding and
susceptible to interference.
• Calculation: Mechanical computation devices must be relatively simple and tend to wear out
quickly.
 Electron analog implementation
- Electrons are used as the medium of transmission in his type of implementation
mode.
- Computation devices are still the same as before.
- Electrical signals to pressure signals converter (E/P transducers) and vice verse
(P/E transducers) are used to communicate between the mechanical devices and
electron flow.

The primary problems associated are:

• Transmission: analog signals are susceptible to contamination from stray fields, and signal
quality tends to degrade over long transmission line.

• Calculation: the type of computations possible with electronic analog devices is still limited
 Digital Implementation
- Transmission medium is still electron, but the signals are transmitted as
binary numbers.
- Digital signals are far less sensitive to noise.
- The computational devices are digital computers.
- Digital computers are more flexible because they are programmable.
- They are more versatile because there is virtually no limitation to the
complexity of the computations it can carry out.
- Possible to carry out computation with a single computing device, or with
a network of such devices.
- Many field sensors naturally produce analog voltage or current signals.
For this reason transducers that convert analog signals to digital signals
(A/D) and vice verse (D/A) are used as interface between the analog and
digital elements of the modern control system.
Need of Process Computers

Plant size and No of operators

parameter increase increase on floor

Self regulation and re-

adjusting of set point
Sequential process of controller required,
example – chemical
plant

Data logging and

Optimal process
material balance
control
sheet
Computer based plant automation concept
• Digital computer has long been real alternative of analog control
• Initially they were unreliable, slow, bulky and too expensive
• First RW-300 computer based plant controlled online polymerization
unit in Texas on March 12, 1959
• Centralized computer era :- 1965-1970
• Minicomputer era:- 1971- 1975
• Distributed computer era :- Since 1975
• Being unreliable, they had to be used in Operator Guidance Mode
and Set-point Control Mode
Computers in Process Control
• In small processes such as laboratory prototype or pilot plants,
the number of control loops is relatively small. An inexpensive
and straightforward way to deal with the systems is to configure
a network of personal computers for data acquisition and
control.
Computers in Process Control
• Main computer linked directly to the process in two-way
channels.
• Other local computers are linked to the main computer and are
also connected to the process through one-way or two-way
links.
Computers in Process Control
• These local computers can be interconnected.
• Each of the local computers has a video display and a specific
function. For example, some local computers are dedicated for data
acquisition only, some for local control only and some other for both
data acquisition and local control. The main computer could have a
multiple displays.
Computers in Process Control
• All computers operate with a multitasking operating system. They
would be normally configured with local memory, local disk storage,
and often have shared disk storage with a server.
Computers in Process Control
Closed Loop Control
Operator guidance mode
Set-Point Control mode
Layers/levels of an automation system
Layers/levels of an automation system
Layers/levels of an automation system
Automation functions
Hierarchical system for manufacturing automation
DATA ACQUISITION SYSTEM
DATA ACQUISITION SYSTEM

Block Diagram
DATA ACQUISITION SYSTEM

DAS with Conditioning and conversion for each i/p

DATA ACQUISITION SYSTEM

Computer Automated Process Control

DATA ACQUISITION SYSTEM

More Automated version of DAS

Distributed Control System (DCS)
• Relay based control system can’t control Continuous process
• DCS designed for Continuous process control
• To fill the gap of Discrete and batch process PLC introduced by
General Motor
• High speed microcomputer introduced in 1972 using
semiconductor technology
• In 1975 Honeywell introduced first DCS with PLC and DDC
control facilities.
Distributed Control System (DCS)

• DCS is powerful and flexible integrated control system that supply

data acquisition , advance process control and monitoring , batch
control capacities.
• Plant operator monitor and manipulates set point of process from
central control room
• Operator views the process information on CRT screen and
Control through keypad
• BASIC function of DCS
• Data collection ( analog and digital )
• Generate output signal to actuator
• Plant GUI
• Remote location control
Advantages of the DCS

The computer can record and store a very large amount of data

The data can be displayed in any way the user requires

Thousands of sensors over a wide area can be connected to the system

The operator can incorporate real data simulations into the system

Many types of data can be collected from the RTUs

The data can be viewed from anywhere, not just on site

Disadvantages of the DCS

The system is more complicated than the sensor to panel type

Different operating skills are required, such as system analysts and programmer

With thousands of sensors there is still a lot of wire to deal

The operator can see only as far as the PLC

Leading DCS providers

The leading DCS providers include

• Yokogawa : CS 3000 , CS 5000 (Earlier Centum Excel, Micro Excel)

• Honeywell : TDC 3000

• Fisher - Rosemant - Delta V

• ABB - Freelance 2000

• Moore - APACS

• Fox boro - I/A series

Direct Digital control (DDC)
Advantage of Direct Digital control (DDC)
Easy configuration, reconfiguration and parameterization of process loop

Self tuning of controller parameter

Simple introduction of new control loop

Possible to go for few advance control algorithm

Model based calculation

Comprehensive data acquisition and presentation

Disadvantage of Direct Digital control (DDC)
Low fail safety : failure of all digital loop

Higher investment

Higher Maintenance cost

High Programming cost

Overload of CPU

Not possible for High level process control

PLC
What is PLC ?

A special form of microprocessor-based controller

• Designed for use in an industrial environment

• Uses memory for the internal storage of user-oriented instructions
• Uses specific functions such as logic, sequencing, timing, counting
and arithmetic and etc.
• Digital or analog inputs and outputs,
• Suitable for types of machines or processes
What is PLC?

Hardware interface for input sensors and final output control element of the
field.

The field I/p include element like limit switches, sensors, push button and the
final control elements like actuator, solenoid/control valves, drives, heaters etc.

PLC Senses the input through I/P modules, Processes the logic through CPU and
memory and gives output through output module
Leading PLC providers

• Rockwell Automation : Allen Bradley (Micrologix, SLC, PLC,

Control Logix)

• Siemens ( S7 200, S7 300 , S7 400)

• Grouppe Schneider : Modicon ( Nano, Micro, Premium, Quantum)

• GE Fanuc : Versa, Series 90-30, 90-70

• OMRON

• Mitsubishi Electric
PLC Origin
• Developed to replace relays in the late 1960s
• Costs dropped and became popular by 1980s
• Now used in many industrial designs
PLC History
• Introduction of PLC.
1960

• Introduction of CPU in the PLC.

1970

• Introduction of Communication abilities in PLC.

1973

• Standardization in PLC Communication.

1980

• Modernization of Protocols for PLC.

1990
Selection of PLC
PLC Siemens S7-300
Advantages of using PLCs
• Highly reliable
• Highly versatile (universal applicability)
• Simple troubleshooting
• Simple installation
• Quick modification of the program (highly flexible)
• Capable of tasks not possible with relays before:
• Calculation
• Information exchange
• Text and graphic display
• Data processing
• Networking
• Low space requirement
• Low power consumption
• High processing speed
• No moving parts, hence no wear and tear
Disadvantages of using PLCs

• High initial cost ( for a simple process )

• Sensitive to dust, high temperature and high humidity

• Repair must be made by a qualified personnel

PLC

Siemens S7-300
PLC

Typical I/O modular housings

PLC
PLC
Siemens S7-300

• Signal Modules (SM)

• Digital input modules: 24V DC, 120/230V AC
• Digital output modules: 24V DC, Relay
• Analog input modules: Voltage, current, resistance, thermocouple
• Analog output modules: Voltage, current
• Interface Modules (IM): The IM360/IM361 and IM365 make
multi-tier configurations possible.
PLC
• Dummy Modules (DM): The DM 370 dummy module reserves a slot for a
signal module whose parameters have not yet been assigned.
• It can also be used, for example, to reserve a slot for installation of an interface
module at a later date.
• Function Modules (FM): Perform special functions
• Counting
• Positioning
• Closed-loop control
• Communication Processors (CP): Provide the following networking
facilities:
• Point-to-Point connections
• PROFIBUS
• Industrial Ethernet.
International Standard for PLC
International Standard for PLC
• The IEC 1131 standards were developed to be a common and open framework for
PLC architecture, agreed to by many standards groups and manufacturers.
• They were initially approved in 1992, and since then they have been reviewed as
the IEC-61131 standards.
• The main components of the standard are:
• IEC 61131-1 Overview
• IEC 61131-2 Requirements and Test Procedures
• IEC 61131-3 Data types and programming
• IEC 61131-4 User Guidelines
• IEC 61131-5 Communications
• IEC 61131-6 Functional Safety
• IEC 61131-7 Fuzzy control
• IEC 61131-8 Guidelines for the application and implementation of
programming languages
Conventional automation in
comparison to
programmable automation.
PLC- Before and After

• Simple troubleshooting

• Simple installation

• Low space requirement

• No moving parts, hence no wearing

parts
PLC- Block Diagram
PLC
PLC
PLC
PLC-Types
PLC
PLC

Typical micro-PLC wiring diagram

PLC

Typical discrete input module wiring diagram

PLC

Wiring diagram of a typical discrete output module

PLC
PLC
PLC
PLC
PLC
A Simple Example
PLC- Electromagnetic Control Relays
PLC -The Decision Makers: AND, OR and NOT
PLC - The Decision Makers: AND, OR and NOT
PLC - The Decision Makers: AND, OR and NOT
PLC – Ladder Diagram : Example
Control relay used to control two pilot lights

With the switch open, coil CR is de-energized.

• The circuit to the green pilot light is completed
through the normally closed contact, so this light will be on.
• At the same time, the circuit to the red pilot light is opened
through the normally open contact, so this light will be off.

With the switch closed, the coil is energized.

• The normally open contact closes to switch the red
pilot light on.
• At the same time, the normally closed contact opens to
switch the green pilot light off.
PLC : Symbols –O/P control devices
PLC
PLC –PLC Operation
PLC - PLC program scan cycle.
PLC- PLC program scan cycle.
PLC - PLC program scan cycle.
PLC - PLC program scan cycle.
PLC - The I/O Section
PLC - Discrete I/O Modules
Common Ratings for Discrete I/O Interface Modules
PLC - Discrete AC input module

Simplified diagram
PLC - Discrete AC output module

Simplified diagram
PLC : DC I/O modules - interfacing with current-source or current sink devices

Sinking and sourcing inputs

Sinking and sourcing outputs

PLC - Discrete I/O Module Specifications

• NOMINAL INPUT VOLTAGE

• INPUT THRESHOLD VOLTAGES
• NOMINAL CURRENT PER INPUT
• AMBIENT TEMPERATURE RATING
• INPUT ON/OFF DELAY
• OUTPUT VOLTAGE
• OUTPUT CURRENT
• INRUSH CURRENT
• SHORT CIRCUIT PROTECTION
• LEAKAGE CURRENT
• ELECTRICAL ISOLATION
PLC - Analog I/O Module Specifications

• CHANNELS PER MODULE

• INPUT CURRENT/VOLTAGE RANGE(S)
• OUTPUT CURRENT/VOLTAGE RANGE(S)
• INPUT PROTECTION
• RESOLUTION
• INPUT IMPEDANCE AND CAPACITANCE
• COMMON-MODE REJECTION
PLC- AC Input/output module
Two basic types of analog input modules
- voltage sensing
- current sensing

Analog voltage input modules are available in two types:

- unipolar
- bipolar.
PLC- AC Input/output module
Two basic types of analog input modules
- voltage sensing
- current sensing

Sensor and analog module supplied power.

Current sensing input modules typically accept analog data over

the range of - 4 mA to 20 mA, but can accommodate signal
ranges of – 20 mA to 120 mA.
 PLC
Programming
Contactors and Starters
Manually Operated Switches
• Manually operated switches are controlled by hand.
• toggle switches, pushbutton switches, knife switches, and selector switches.
Mechanically Operated Switches
Sensors
Sensors
Sensors
Sensors
Valve Actuator
 PLC -Schematic diagram of latching relay

(a) relay tripped and power circuit open (b) relay set-latched and power circuit closed.
Latching Relays
PLC Program: Mixer process control problem
PLC Program: Ex-Mixer process control problem

PLC ladder logic program

Process control relay ladder diagram.
PLC- Working of Relays
When Switch not pressed
PLC- Working of Relays
When Switch Pressed
PLC- Seal in Circuit
When Start PB pressed and released
PLC- Control Processes

Sequential control process

• certain operations be performed in a specific order.

Combination control process

• certain operations be performed without regard to the
order in which they are performed.
Automatic control process.
• Maintaining desired set pint at the output
PLC- Control Processes

Sequential control process

• certain operations be performed in a specific order.
PLC- Control Processes

Combination control process

• certain operations be performed without regard to the
order in which they are performed.
PLC- Control Processes

Automatic control process.

•Maintaining desired set pint at the output
PLC Program: Sequential Control process

Conveyor Belt Control

PLC Program: Sequential Control process
PLC Program: Sequential Control process
PLC Program: Seal in Circuit
 PLC Program: Control level of water in tank
The modes of operation are to be programmed as follows:
OFF Position —The water pump will stop if it is running and
will not start if it is stopped.
Manual Mode —The pump will start if the water in the
tank is at any level except low.
Automatic Mode —If the level of water in the tank reaches
a high point, the water pump will start so that water can be
removed from the tank, thus lowering the level.
- When the water level reaches a low point, the pump will
stop .
Status Indicating Lights —Water pump running light
(green)
- Low water level status light (red)
- High water level status light (yellow)

Process shown is to be used to control the level of water in a storage tank by turning a discharge pump on or off.
PLC Program: Liquid level Control in tank
PLC Program: Ex-Mixer process control problem
PLC Program: Sequential Control process
1.Start PB is to start the process.
Automatic surface grinding process 2.At initial, Job in sensor should be in ON
condition and job out sensor should be in
OFF condition.
3.When job in sensor detects object for
surface grinding should turn on conveyor
motor to move the object.
4.When rough sensor detects object,
conveyor motor should turn OFF and
Rough grinding motor should turn ON for
20s. After the process, Conveyor motor
should turn ON automatically.
5.When fine sensor detects object,
conveyor motor should turn OFF and Fine
grinding motor should turn ON for 20s.
After the process, Conveyor motor should
turn ON automatically till job out sensor
turn ON.
6.Packing sensor should turn ON, when
job out sensor ON.
PLC Program: Sequential Control process
PLC Program: Sequential Control process
PLC Program: Motor Control
Timers
Timers
PLC Timers
> Time settings can be easily changed.
> Numbers used in a circuit can be
PLC timers offer several advantages over increased or decreased through the use of
their mechanical and electronic programming rather than wiring changes.
counterparts. > Timer accuracy and repeatability are
extremely high because its time delays are
generated in the PLC processor.

+ On-delay timer (TON)

Three different PLC timer types: + Off-delay timer (TOF)
+ Retentive timer on (RTO)

There are also many other timing

configurations, all of which can be derived
Most common is On-delay timer
from one or more of the basic time-delay
functions.
PLC Timers -Timer commands

• TON (Timer On Delay) —Counts time-based intervals when the

instruction is true.
• TOF (Timer Off Delay) —Counts time-based intervals when the
instruction is false.
• RTO (Retentive Timer On) —Counts time-based intervals when
the instruction is true and retains the accumulated value when
the instruction goes false or when power cycle occurs.
• RES (Reset) —Resets a retentive timer’s accumulated value to
zero.
PLC Timers
PLC Timers
• On-delay timer- NOTC The operation of the circuit can be
summarized as follows:
• With S1 initially open, TD coil is de-
energized so TD1 contacts are open and
light L1 will be off.
When S1 is closed TD coil is energized and
the timing period starts. TD1 contacts are
delayed from closing so L1 remains off.
• After the 10 s time-delay period has
elapsed, TD1 contacts close and L1 is
switched on.
• When S1 is opened, TD coil is de-
energized and TD1 contacts open instantly
to switch L1 off.
PLC Timers
• On-delay timer- NCTO The operation of the circuit can be
summarized as follows:
• With S1 initially open, TD coil is de-
energized so TD1 contacts are closed
and light L1 will be on.
• When S1 is closed, TD coil is
energized and the timing period starts.
TD1 contacts are delayed from opening
so L1 remains on.
• After the 10 s time-delay period has
elapsed, TD1
contacts open and L1 is switched off.
• When S1 is opened, TD coil is de-
energized and TD1 contacts close
instantly to switch L1 on.
PLC Timers
• OFF-delay timer- NOTO
The operation of the circuit can be summarized
as follows:
• With S1 initially open, TD coil is de-energized
so TD1 contacts are open and light L1 will be off.
• When S1 is closed, TD coil is energized and TD1
contacts close instantly to switch light L1 on.
• When S1 is opened, TD coil is de-energized and
the timing period starts.
• After the 10 s time-delay period has elapsed,
TD1contacts open to switch the light off.
PLC Timers
The operation of the circuit can be
• OFF-delay timer- NCTC summarized as follows:
• With S1 initially open, TD coil is
de-energized so TD1 contacts are
closed and light L1 will be on.
• When S1 is closed, TD coil is
energized and TD1 contacts open
instantly to switch light L1 off.
• When S1 is opened, TD coil is de-
energized and the timing period
starts. TD1 contacts are delayed
from closing so L1 remains off.
• After the 10 s time-delay period
has elapsed, TD1 contacts close to
switch the light on.
PLC Timers
• Several quantities are associated with the timer instruction:
• The preset time represents the time duration for the timing circuit. For
example, if a time delay of 10 s is required, the timer will have a preset of 10 s.
• The accumulated time represents the amount of time that has elapsed from
the moment the timing coil became energized.
• Every timer has a time base. Once the timing rung has continuity, the timer
counts in time-based intervals and times until the preset value and accumulated
value are equal or, depending on the type of controller, up to the maximum time
interval of the timer.
Timers can be programmed with several different time bases: 1 s, 0.1 s, and 0.01
s are typical time bases.
If a programmer entered 0.1 for the time base and 50 for the number of delay
increments, the timer would have a 5-s delay
(50 * 0.1 s= 5 s).
The smaller the time base selected, the better the accuracy
of the timer.
PLC Timers - On-Delay Timer
Figure shows an example of the on-delay timer instruction. The information to be entered
includes:
• Timer number —This number must come from the timer file. In the example shown, the
timer number is T4:0, which represents timer file 4, timer 0 in that file. The timer address
must be unique for this timer and may not be used for any other timer.
• Time base —The time base (which is always expressed in seconds) may be either 1.0 s or
0.01 s. In the example shown, the time base is 1.0 s.
• Preset value —In the example shown, the preset value is 15. The timer preset value can
range from 0 through 32,767.
• Accumulated value —In the example shown, the accumulated value is 0. The timer’s
accumulated value normally is entered as 0, although it is possible to enter a value from 0
through 32,767. Regardless of the value that is preloaded, the timer value will become 0
whenever the timer is reset.
 PLC Timers - On-Delay Timer
The timer is activated by input switch A.
• The preset time for this timer is 10 s, at which
time output D will be energized.
• When input switch is A is closed, the timer
becomes true and the timer begins counting and
counts until the accumulated time equals the
preset value; the output D is then energized.
• If the switch is opened before the timer is timed
out, the accumulated time is automatically reset
to 0.
• This timer configuration is termed nonretentive
because any loss of continuity to the timer causes
the timer instruction to reset.
• This timing operation is that of an on-delay timer
because output D is switched on 10 s after the
switch has been actuated from the off to the on
position.
 PLC Timers - On-Delay Timer
Figure shows the timing diagram for the
ondelay timer’s control bits. The sequence of
operation is as follows:
• The first true period of the timer rung shows the
timer timing to 4 s and then going false.
• The timer resets, and both the timer-timing bit
and the enable bit go false. The accumulated value
also resets to 0.
• For the second true period input A remains true
in excess of 10 s.
• When the accumulated value reaches 10 s, the
done bit (DN) goes from false to true and the
timertiming bit (TT) goes from true to false.
• When input A goes false, the timer instruction
goes false and also resets, at which time the control
bits are all reset and the accumulated value resets
to 0
 PLC Timers - On-Delay Timer
Figure shows an application for an on-delay timer
that uses an NCTO contact. This circuit is used as
a warning signal when moving equipment, such
as a conveyor motor, is about to be started.
• According to the hardwired relay circuit diagram,
coil CR is energized when the start pushbutton PB1 is
momentarily actuated.
• As a result, contact CR-1 closes to seal in CR coil,
contact CR-2 closes to energize timer coil TD, and
contact CR-3 closes to sound the horn.
• After a 10-s time-delay period, timer contact TD-1
opens to automatically switch the horn off.
• The ladder logic program shows how an equivalent
circuit could be programmed using a PLC.
• The logic on the last rung is the same as the timer
timing bit and as such can be used with timers that
do not have a timer-timing output.
 PLC Timers - On-Delay Timer
Figure shows how a series of motors can be started
automatically with only one start/stop control station. The
operation of the circuit can be summarized as follows:
• According to the relay ladder schematic, lube-oil pump
motor starter coil M1 is energized when the start
pushbutton PB2 is momentarily actuated.
• As a result, M1-1 control contact closes to seal in M1,
and the lube-oil pump motor starts.
• When the lube-oil pump builds up sufficient oil
pressure, the lube-oil pressure switch PS1 closes.
• This in turn energizes coil M2 to start the main drive
motor and energizes coil TD to begin the time delay
period.
• After the preset time-delay period of 15 s, TD-1 contact
closes to energize coil M3 and start the feed motor.
• The ladder logic program shows how an equivalent
circuit could be programmed using a PLC.
 PLC Timers - Off-Delay Timer
The off-delay timer (TOF) operation will keep the output
energized for a time period after the rung containing the
timer has gone false.
If logic continuity is lost, the timer begins counting time-
based intervals until the accumulated time equals the
programmed preset value.
The operation of the circuit can be summarized as follows:
• When the switch connected to input I:1/0 is first closed,
timed output O:2/1 is set to 1 immediately and the lamp
is switched on.
• If this switch is now opened, logic continuity is lost and
the timer begins counting.
• After 15 s, when the accumulated time equals the preset
time, the output is reset to 0 and the lamp switches off.
• If logic continuity is gained before the timer is timed
out, the accumulated time is reset to 0. For this reason,
this timer is also classified as nonretentive.
 PLC Timers - Off-Delay Timer

Figure illustrates the use of an off-delay timer

instruction used to switch motors off sequentially at
5 second intervals.
• Timer preset values for T4:1, T4:2, and T4:3 are set
for 5s, 10s, and 15 s, respectively.
• Closing the input switch SW immediately sets the
done bit of each of the three off-delay timers to 1,
immediately turning on motors M1, M2, and M3.
• If SW is then opened, logic continuity to all three
timers is lost and each timer begins counting.
• Timer T4:1 times out after 5 s resetting its done bit
to zero to de-energize motor M1.
• Timer T4:2 times out 5 s later resetting its done bit
to zero to de-energize motor M2.
• Timer T4:3 times out 5 s later resetting its done bit
to zero to de-energize motor M3.
 PLC Timers -Off-Delay Timer
Figure shows how a hardwired off-delay timer
relay circuit with both instantaneous and timed contacts.
The operation of the circuit can be summarized as
follows:
• When power is first applied (limit switch LS open),
motor starter coil M1 is energized and the green
pilot light is on.
• At the same time, motor starter coil M2 is deenergized,
and the red pilot light is off.
• When limit switch LS closes, off-delay timer coil
TD energizes. As a result, timed contact TD-1 opens to
deenergize motor starter coil M1, timed contact
TD-2 closes to energize motor starter coil M2,
instantaneous contact TD-3 opens to switch the
green light off, and instantaneous contact TD-4
closes to switch the red light on.
The circuit remains in this state as long as limit switch LS1
PLC Timers - Examples
Figure shows a program that uses both the
ondelay and the off-delay timer instruction. The
process involves pumping fluid from tank A to
tank B. The operation of the process can be
summarized as follows:
• Before starting, PS1 must be closed.
• When the start button is pushed, the pump
starts. The button can then be released and the
pump continues to operate.
• When the stop button is pushed, the pump
stops.
• PS2 and PS3 must be closed 5 s after the
pumpstarts. If either PS2 or PS3 opens, the
pump will shut off and will not be able to start
again for another 14 s
 PLC Timers -Retentive Timer

A retentive timer accumulates time whenever the device receives

power

Maintains the current time when power is removed from the

device.

When the timer accumulates time equal to its preset value, the
contacts of the device change state.

Loss of power to the timer after reaching its preset value does
not affect the state of the contacts.

The retentive timer must be intentionally reset with a separate

signal for the accumulated time to be reset and for the contacts
of the device to return to its nonenergized state.
PLC Timers -Retentive Timer
• Figure illustrates the action of a motor-driven,
electromechanical retentive timer used in some appliances.
• The shaft-mounted cam is driven by a motor.
• Once power is applied, the motor starts turning the shaft and
cam.
• The positioning of the lobes of the cam and the gear reduction
of the motor determine the time it takes for the motor to turn
the cam far enough to activate the contacts.
• If power is removed from the motor, the shaft stops but does
not reset.
 PLC Timers -Retentive Timer

The timer will start to pushbutton PB1 is closed.

• If the pushbutton is closed for 3 seconds and then opened for 3 seconds, the timer accumulated value will
remain at 3 seconds.
• When the time pushbutton is closed again, the timer picks up the time at 3 seconds and continues timing.
• When the accumulated value (9) equals the preset value (9), the timer done bit T4:2/DN is set to 1 and the pilot
light output PL is switched on.
• Whenever the momentary reset pushbutton is closed the timer accumulated value is reset to 0.
PLC Timers -Retentive Timer
To start the machine, the operator turns SW on.
• Before the motor shaft starts to turn, the bearings
are supplied with oil by the pump for 10 seconds.
• The bearings also receive oil when the machine is
running.
• When the operator turns SW off to stop the
machine, the oil pump continues to supply oil for
15 seconds.
• A retentive timer is used to track the total running
time of the pump. When the total running time is 3
hours, the motor is shut down and a pilot light is
turned on to indicate that the filter and oil need to
be changed.
• A reset button is provided to reset the process
after the filter and oil have been changed.
PLC Timers - Examples
Figure shows an equivalent PLC program of
the hardwired sequential time-delayed
motor-starting circuit.
Two programmed on-delay timers are
cascaded together to obtain the same logic
as the original hardwired timer relay
circuit.
Note that the output of timer T4:1 is used
to control the input logic to timer T4:2.
Two timers can be interconnected to form
an oscillator circuit.
The oscillator logic is basically a timing
circuit programmed to generate periodic
output pulses of any duration.
PLC Timers - Examples

> Figure shows the program for an

annunciator flasher circuit.
> Two internal timers form the oscillator
circuit, which generates a timed, pulsed
output.
> The oscillator circuit output is
programmed in series with the alarm
condition.
> If the alarm condition (temperature,
pressure, or limit switch) is true, the
appropriate output indicating light will flash.
> Note that any number of alarm conditions
could be programmed using the same
flasher circuit
 PLC Timers : Ex -Mixer process control problem

Inputs
•Cycle START
•Cycle STOP
•Low level
switch
•Level material
A
•Level material
B

Outputs
•Cycle ON
•Inlet valve 1
•Inlet valve 2
•Agitator motor
•Outlet valve
PLC Timers : Sequential Control process
1.Start PB is to start the process.
Automatic surface grinding process 2.At initial, Job in sensor should be in ON
condition and job out sensor should be in
OFF condition.
3.When job in sensor detects object for
surface grinding should turn on conveyor
motor to move the object.
4.When rough sensor detects object,
conveyor motor should turn OFF and
Rough grinding motor should turn ON for
20s. After the process, Conveyor motor
should turn ON automatically.
5.When fine sensor detects object,
conveyor motor should turn OFF and Fine
grinding motor should turn ON for 20s.
After the process, Conveyor motor should
turn ON automatically till job out sensor
turn ON.
6.Packing sensor should turn ON, when
job out sensor ON.
PLC Timers - Examples

The ladder logic circuit of Figure illustrates a control of a set of

traffic lights in one direction.
The operation of the program can be summarized as follows:
• Transition from red light to green light to amber light is
accomplished by the interconnection of the three TON timer
instructions.
• The input to timer T4:0 is controlled by the T4:2 done bit.
• The input to timer T4:1 is controlled by the T4:0 done bit.
• The input rung to timer T4:2 is controlled by the T4:1 done bit.
• The timed sequence of the lights is:
Red—30 s on
Green—25 s on
Amber—5 s on
• The sequence then repeats itself.
The chart shows the timed sequence of the lights for two-
directional control of traffic lights.
 PLC : Artificial fishpond water level monitoring system

Inputs
•L0 –L3 -Level Sensor

Outputs
•Feeding pump :- Q0.0
•Drainage pump 1 :-
Q0.1
•Drainage pump 2 :-
Q0.2
•Alarm lamp :- Q0.3
Counters
PLC Counters

Types:

- Mech/Elec

- Up/Down/Up-Down counter

- Coil formatted/ Block formatted

PLC Counters
PLC Counters
PLC Counters -UP
PLC Counters - UP
PLC Counters - UP
The operation of the program can be
summarized as follows:
• Counter C5:2 counts the total number of
cans coming off an assembly line for final
packaging.
• Each package must contain 10 parts.
• When 10 cans are detected, counter C5:1
sets bit B3/1 to initiate the box closing
sequence.
• Counter C5:3 counts the total number of
packages filled in a day. (The maximum
number of packages
per day is 300.)
• A pushbutton is used to restart the total
part and package count from zero daily.
PLC Counters – UP - DOWN
• Up Down-Counter
PLC Counters –DOWN

Parking garage counter.

PLC Counters –Ex: Parking Garage Counter

Parking garage counter.

PLC Counters ––Ex: Parking Garage Counter

Parking garage counter.

PLC Counters Ex: Cutting objects

24-hour clock program.

PLC Counters Ex: Length measurement
PLC Counters Ex: In-process Monitoring
PLC ––Ex: Count objects on a conveyor belt
PLC Cascading Counters

Cascading counters for extremely large counts.

PLC Cascading Counters

24-hour clock program.

PLC Cascading Counters Ex: Automatic Stacking Program

.
PLC Cascading Counters Ex: Motor lock-out program
Coming up
next…
Data Manipulation Instructions
Sequencer and Shift Register
Instructions
 Distributed
Control Systems
Functional Safety
Human Machine
Interface in
Automation
Human Machine
Human Machine
Happy Learning