List of Experiments

1. Simulate analog and digital function blocks

2. Study, understand and perform experiments on timers and counters

3. Logic implementation for traffic Control Application

4. Logic implementation for Bottle Filling Application

5. Tune PID controller for heat exchanger using DCS

6. Implementation of Logic Gates

7. Develop a ladder program for DOL Starter

8. Develop an application using On-Delay Timer

9. Develop an application using On-Delay Timer

10. Study of PID controller instruction for a pilot plant

 Experiment No. 1

Aim: Simulate analog and digital function blocks

Apparatus Required: Virtual Lab

Theory: In the previous experiment the hardware and software associated with Distributed

Control System is discussed. In this experiment the software and programming concept

is discussed.

There are several programming languages used for logic development.

The IEC 61131 standard part3 specifies these languages as:

• Ladder Logic (LD)

• Structured Text (ST)

• Instruction List (IL)

• Sequential Flow Charts (SFC)

• Functional Block Diagram (FBD)

Generally in DCS Functional Block Diagram (FBD) is used for programming and Sequential

Flow Charts (SFC) is preferred for batch control applications.

Functional Block Diagram (FBD) Basics:

This language basically is a graphical language wherein the users are allowed to program

elements in the form of blocks. The blocks then can be wired together like electrical circuits. It

describes a function between input and output variables.

It is a graphical method of programming DCS. Functional algorithms and control strategies for a
particular plant can be implemented by FBD. The control modules are treated as unique entity in

DCS system. Each function block contains specific algorithm such as AI, AO, DI, DO, PID and

the parameters required for the algorithm. Function blocks ranges from simple input conversion

block to a complex control strategy.

Generally available Function blocks are:

1. Input/ Output (I/O)

2. Math

3. Logical

4. Timer/ Counter

5. Analog Control

6. Advanced control

A Typical Function block –

The description of the various parameters associated with this block:

 Definition name: This is the name by which the block is identified in the library.

 Usage name: This name can be user defined as per his/her convention.

 Parameters: These are part of the function block available for standard connection.

 Execution number: The number by which the function block is executed.

Following functions blocks are generally available in the libraries.

1. Input Output library

Analog Input

Analog Output

Discrete Input
Discrete Output

Pulse Input

2. Math Library

Add

Comparator

Divide

Multiply

Subtract

Absolute value

Integrator

3. Logical Library

And

Or

Condition

Not

Negative Edge Trigger

Positive Edge Trigger

Multiplexer

De multiplexer

4. Timer / Counter Library

On Delay Timer

Off Delay Timer

Counter

Retentive Timer

Timed Pulse

5. Analog Control Library

Input Selector

Limit

PID

Ratio

Ramp

Filter

Scalar

Signal Characterizer

Signal Generator

Signal Selector

Splitter

Let us discuss about the commonly used Input/ Output library function blocks.

Analog Input function Block –

Analog Input (AI) Function Block accesses a single Analog measurement value and its

status on the AI channel. In manual mode, when AI block is configured, input has to be in

engineering units as well as output is indicated in engineering units on the screen. In

automatic mode, output of the block will reflect process variable value. Input to the block
 could be 4-20mA or digitally communicated variable from HART based transmitter.

Analog Output function Block –

Analog output (AO) function block assigns any output value to a field devices like control

valve through a specific AO channel. In manual mode, the output parameter value can be

set manually. In automatic mode, OUT is set automatically based on set point and process

variable value in engineering units. A feedback can also be set for the output parameter.

Discrete (digital) Input (DI) Function Block –

The Discrete Input (DI) Function blocks accesses a single digital input value with its status

between two states of the field devices. The block gives processed physical input for other

function blocks. In automatic mode, Process variable is copied to output which can be
either 0 or 1. In manual mode, the digital input can be toggled manually and output follows

the same.

Discrete (digital) Output (DO) Function Block –

Digital Output block takes value from the process and writes it to specific digital output

channel. One can confirm physical output operation by configuring a hardware discrete

input to it. In automatic mode, when the signal from process changes the output of the

block which will be connected to AO channel which in turn connects to field outputs e.g a

solenoid valve, changes.

Logical Library:

Commonly used logical blocks under logical library are described here
AND Function Block:

AND function block is used as an AND operator. For 2 input AND gate if both the inputs

are high the output of the function block is high.

The function block and the truth table is as given below:

OR Function Block:

OR function block is used as an OR operator. For 2 input OR gate if any one inputs is high,

the output of the functions block is high. The function block and the truth table is as given

below:
NOT Function Block:

NOT function block is used as NOT operator, wherein if the input to the block is high or

active the output is opposite i.e. low and vice versa. The function block and the truth table

are as given below:

Procedure:

The procedure for using simulator is as follows:

Click on the link provided under simulator tab to open the simulator. You need to configure the

required logic.

Part 1: Understanding the operation of AI and AO function block

Step 1: First left click on AI block available under IO tab. Drag this block to required position

preferably left side and vertically at center.

2. Now left click on AO block. Drag it and put it next to AI block.

3. Take the cursor to the color dot at the output side of AI block. Move it by left clicking and take

it to the color dot at the Input side of AO block.

4. Now click on Compile tab. If any compilation errors are there, it will be shown. Otherwise Run

tab gets activated.

5. When user clicks on Run tab, default value of AI will get displayed on wired connection.

To change the input value and observe the output change, right click on the AI block. Select edit

and enter an input value in the range 0-100. You will observe the change at the AO block output.

When you click on the block, the properties of the block gets displayed at left hand bottom corner.

To delete the connection, click on the wire question mark at the output side of the block and press

delete key.

Other options like delete, disable and configure are available on right clicking the block. For

modifying the logic, user need to first press Stop tab and enter into Configure tab.

For clearing the workspace, Clear tab is available.

Part 2: Understanding the operation of DI and DO function block

Follow same procedure as above to get the blocks in the workspace and connect DI and DO blocks.

In RUN mode, change the digital input value to 0 from1 or vice-versa and observe the effect.

Part 3: Understanding the operation of Logic function block

To configure the logic circuit, first reload the page by clicking Clear tab

1. First left click on digital input (DI) block to get it in the workspace. Repeat this

procedure for getting 2 DI blocks. They will be by default DI1 and DI2. Similarly get 1

DO block in the workspace.

2. Left click on any logic function block e.g. AND function from Logic Tab available in

the left hand panel.

3. Connect output of DI1 to one of the inputs of AND block.

Initially only one input connection is available with the logic block. As you make DI

connection with this input, another connection appears for this logic block.

Connect DI2 output to this second AND block input. Connect output of AND block to

input of DO.

4. Now click on Compile tab. If any compilation errors are there, it will be shown.

Otherwise Run tab gets activated.

5. Now change one of the inputs to AND gate by toggling DI value from 0 to 1. Observe

the DO status.

6. Change another input to AND gate in the similar manner and observe DO status.

7. Verify the AND gate truth table by changing DI status.

Similarly verify the truth tables for OR and NOT Logic Gates.

Link:

http://ial-coep.vlabs.ac.in/Expt2/AnalogDigital.html
 Experiment No. 2

Aim: Study, understand and perform experiments on timers and counters

Apparatus Required: Virtual Lab

Theory: Concept of Timer

The controller used in DCS has an inbuilt clock for its functioning. This clock is used for

executing the instruction cycle or scan cycle or in case any of important actions.

There are two types of delay required or available in the entire operation

• Logical delay

• Process delay

This internal clock is used as a reference when it is necessary to have a logical delay in the

program. Depending on number of cycles of the clock the calculation of the delay is calculated.

The base time of the delay can vary for different manufacturers e.g. 1ms, 10ms or 1s. It is based

on the crystal oscillator present in the controller whose time is taken as the reference for the

calculation.

Concept of Counter

In timer, the internal clock of the controller is considered for calculation of the delay, the same
clock can be used to calculate the external pulses of the physical world.
Suppose there is an application wherein we need to count the number of balls entering the vessel.
A limit switch as a sensor can sense the ball as it comes to the vessel. The high to low transition
at the sensor output can be counted by taking the reference of the internal clock pulse of the
controller.

TYPES OF TIMERS

Three types of timers available in DCS are on delay, Off delay and Retentive timer.

1. On Delay Timer (OND): On delay timers are preferred in most of the applications.

The example to demonstrate the function and operation of a timer is a firecracker. The firecracker

when it is lighted it takes some time to burst because of the lead present which we light. Thus after

burning the lead, which is the delay the cracker burst. Now in terms of On Delay Timer when a

high/true/active signal is given at the input, time duration specified, the output of the timer block

becomes high only after the specified time duration is elapsed.

The function block and timing diagram for On Delay Timer is shown below:

2. Off Delay Timer (OFFD): In Off Delay Timer, the output remains high until a high to

low pulse is applied at the input terminal. The output goes low after the time duration
specified has elapsed if a high to low transition is applied at input. The functional block

diagram and timing diagram of the same is shown below:

3. Retentive Timer (RET): In the above timers if the input signal changes its value back

to original, before the specified time duration is elapsed, the timer resets. It does not retain

its value. In order to overcome this problem retentive timer is used. As the name suggests,

it retains the value even if the input signal changes back to original state before time

duration has elapsed. These type of timers are used in real time clocks where retention of

time value is important. The block diagram and timing diagram of the same is shown

below:
TYPES OF COUNTERS

Two types of counters are generally used in DCS.

1. Up Counter: Up Counter counts input pulses in incremental manner i.e. it starts

counting from 0 to the value specified as preset value. When the preset value and no of

counts becomes equal the output of the counter becomes high.

2. Down Counter: Down Counter counts input pulses in decrement manner i.e. it starts

counting from the value specified in preset to 0 values. This can be done when input goes

from high to low or low to high as we select in the function block. When the preset

decrements to 0 value, the output of the counter becomes high.

Note: The up and down counter function can be implemented in same counter block. We

need to select the type as up or down counting.The input signal form in which counting is

to be done i.e. from low to high or from high to low is also selectable.

The block diagram of counter and its timing diagram:

Procedure:

The procedure for using simulator is as follows:

Part 1: Understanding the operation of On Delay Timer and Off Delay Timer

1. From the panel at left side, click on IO tab and click on DI.

2. Use left click and drag the DI block at center location in the workspace.

3. Take TON block available under TIMERS tab by clicking on it. Put this block next to

DI block.

4. Next to TON block, take DO block to observe On delay timer operation. Follow the

procedure mentioned in step 1.

5. Connect the output of DI block to input of TON block and output of TON block to input

of DO block.

6. Rightt click on Timer block and configure it. Enter required delay (preset value by which

the output is to be delayed) in terms of milli seconds. e.g. For a delay of 1 second, require

preset value is 1000.

7. When configuration is done, click on Compile tab to activate the Run tab. Run the logic

now.

8. To start the Timer operation, Change the DI value. You need to toggle the input value

by using right click.

9. Observe the accumulated timer value. When it becomes equal to preset value, the timer

output and the Do block output is set to 1.

10. Change the DI value to 0 again and observe the output status.

11. To observe the operation of off delay timer, first click on Stop tab. Go to compile mode.

You need to replace the TON block with TOFF Timer block.

12. Right click on TON block. Select and delete the block. Form panel, select TOFF block

available under Timer tab.

13. Repeat steps 5 to 9.

The output of Off delay timer is set to 1 without any delay, when DI is set to 1. But when

DI is changed back to 0, the timer operation starts, delay is provided and the output is

changed to 0 or Off state.

Link:

http://ial-coep.vlabs.ac.in/Expt3/TimersCounters.html
 Experiment No. 3

Aim: Logic implementation for traffic Control Application

Apparatus Required: Virtual Lab

Theory: Previous three experiments cover the basic hardware and software information along

with the functions block available in DCS. This information can be applied for logic

development in specific application. Traffic light control is one common example where

timer function can be used.

Consider the traffic lights situation as shown below.

There are two lamp posts as shown in the diagram. Consider a case where the lamp R1

is off.As the lamp R1 is off,lamp G2 will be on to allow the traffic from south to north.
The lamp on-off sequence is as follows.

For implementing this logic using function blocks, on delay times can be used.

Solution Hint:

For starting the Traffic Control System in auto mode use Pulse Input Block.

For the lamps, Digital Output blocks can be used.

Procedure:

The procedure for using simulator is as follows:

One of the possible solutions implemented using EMERSON DELTA V DCS is shown

below. Refer to the procedure in experiments 3 related to timer and counter function

implementation. Configure the logic as shown below and see the result. You can also try

different logic to get the results.

Instead of PIN block used in the solution, make use of DI block available in simulator.
The lamp G2 is on when system is started. When 25 sec time is elapsed (indicated by OND

Timer block), lamp Y2 is switched on and G2 is switched off.

OND block is used to switch on lamp R2 and switch off lamp Y2 after a delay of 5 sec.

The lamp R2 is kept on for 30 sec and after this delay the cycle is repeated.

Another OND block with logical AND block is used to implement this. To get negated

output status NOT block is used. This is the logic for one lamp post. In the similar manner

it can be implemented for another lamp post.

Link:

http://ial-coep.vlabs.ac.in/Expt4/TrafficControl.html
 Experiment No. 4

Aim: Logic implementation for Bottle Filling Application

Apparatus Required: Virtual Lab

Theory: At this stage we are aware of various function blocks available in the dcs library. In the

traffic control application we have seen how on delay timers (OND block) are used.

Let us see another example for logic development. The P & I diagram for bottle filling

plant is shown here.

To start the process, command is given by the field operator as well as from the control room i.e.

through DCS. The Conveyor belt starts running when conveyor motor (CM) is switched on. The
bottles are kept manually on the conveyor belt. When bottle is reached below the filling solenoid

valves (SV); detected by a limit switch (BP), CM stops.

The filling process starts by opening SV, when the bottle is raised up by raising the platform by

pneumatic cylinder. The time required to raise the bottle is 5 seconds.

Upto 90% filling takes place through solenoid valve (coarse) and remaining 10% (100% full

condition) by opening solenoid valve (fine).

Bottle 90% full condition is sensed by proximity switch (coarse). Bottle 100% full condition is

sensed by another proximity switch (fine). When bottle is full SV should become off and the count

is displayed. When SV is closed, CM runs again till next bottle is detected by BP switch and the

cycle repeats.

Procedure: One of the possible solutions implemented using EMERSON DELTA V DCS is

presented here. Try to analyse this logic and implement it using simulator.

Link: http://ial-coep.vlabs.ac.in/Expt5/BottleFilling.html
 Experiment No. 5

Aim: Tune PID controller for heat exchanger using DCS

Apparatus Required: Virtual Lab

Theory: Distributed control systems are used for controlling plants which are physically as well
as functionally distributed. This control system is preferred when number of analog control loops
to be controlled is more than discrete control. One of the analog schemes used as basic control
strategy is PID control. The theory behind PID control is discussed here.

On-Off Control: Discrete Control

As the name suggests this strategy is preferred for on –off type applications. This is a simplest
form of control. Chattering of contacts for final control element is major problem but it can be
avoided by addition of dead zone. Precise control is not possible due to addition of dead zone.
Mostly all domestic applications as Water Geyser, Electric iron, Electric Ovens are controlled
using on-off control strategy.

PID: Continuous Control

There are 3 basic actions in PID.

• Proportional

• Integral

• Derivative

Proportional mode: - In this mode the controller output varies linearly with respect to the error.

The equation for P mode is

m = Kp * e + Po
Where,

m is the controller output.

Kp is the gain of controller

e is the error in %

Po is the proportional Bias. (Value of m at e =0)

Due to addition of proportional bias, positive as well as negative errors are handled. Generally Po

is set at 50% to handle equal positive and negative error range. Higher is the gain lower is the band

to control.

Integral mode: - Integral mode is used to remove the offset produced due to P mode. Offset can

either be positive and negative. Equation for Integral mode is

Where,

Ti is the integral time setting and t is the time.

When this action is used alone due to integral effect the action becomes too slow. When

combined with Proportional, the action may go into saturation which is called as Reset Windup.

To overcome this, controller output is limited at lower and higher end. This is called as Anti reset

windup. But due to addition of Integral action Offset is nullified.

Derivative mode:-This action is used to increase the speed of response of slow processes. It

anticipates the rate of change of error and takes the control action.

Equation for Derivative mode is

Where,

Td is the derivative time .

Set Point can be achieved quickly by using D mode. In noisy environment. this action is not used

as the output goes into saturated

condition. Even for constant error D action provides no correction, hence not preferred alone. It

is always combined with P action.

Composite controller, i.e. P, I and D adds advantages of all the three modes.

The Equation for the combined controller is

Loop tuning time can be optimized by using proper combination of PB, Ti and Td

One of the analog control functions available in DCS is ‘PID’. Let us look at various configurable

parameters available for this block.

The process parameter analog value (PV) is given as input to the block at IN terminal. The remote

analog set point is provided to CAS IN terminal in case of Cascade Control. In case of

feedforward control input is given to FF terminal. In case of manual mode, input value is given

to SIMULATE terminal. For auto/manual bumpless transfer or to avoid rest windup, the FB OUT
is connected back to FB IN of the same or another block. This keeps the track of changes made

in manual mode and adjusts the controller output prior to the control mode is changed from

manual to auto.

Let us see how PID function is used for controlling heat exchanger.

The piping and Instrument diagram for the heat exchanger with a boiler unit along with system

details are shown here.

This pipe in pipe type heat exchanger uses the steam produced by an electrically fired boiler which

raises water temperature. The feed water pump for boiler is mounted on the base frame of the unit

and pumps water into the boiler. To avoid scale formation and to reduce maintenance treated water

is used. Heat released by operating heaters is utilized for heating water in the shell. Insulation of

shell is done with glass wool to prevent heat losses. The steam pressure is controlled by means of

a pressure switch at 4.5 Kg/cm2. PT-100 sensors used monitor the temperature at the inlet and
outlet . The inlet water flow is measured with a magnetic flow, while the steam pressure is

monitored using HART (Highway Addressable Remote Transducer) based pressure transmitter.

The objective is to maintain water outlet temperature. The variables associated are

The photograph of the system is show below.

 Experiment No. 6

Aim: Implementation of Logic Gates

Apparatus Required: Virtual Lab

Theory: Basics of Digital Electronics and Boolean Algebra:

Digitization is a process where continuous analog signal is converted into a finite number

of discrete states. These states are well separated so that noise does not create errors.

The resulting digital signal has following advantages:

1. storage over arbitrary periods of time.

2. flawless retrieval and reproduction of the stored information
3. flawless transmission of the information

Some information is essentially digital. Hence it is natural to process and manipulate such

information using purely digital techniques. Examples are numbers and words. The

drawback to digitization is that a single analog signal (e.g. a voltage which is a function of

time, like a stereo signal) needs many discrete states, or bits, in order to give a satisfactory

reproduction.
Logic

What can a digital circuit do?

The simplest task we can think of is a combinational type of logic decision. For example,

we can design a digital electronic circuit to make an instant decision based on some

information. Here we emphasize “instant” in the decision making process. That means,

the process has no time delay, is used to determine temperature.

X = It is a sunny day? Yes

Y = Is it Sunday or holiday? Yes

Action Z = Go for shopping

The rule is Z = X and Y. The circuit is a simple AND gate

Truth Tables:
Boolean algebra:

Logic can also be expressed in algebraic form.

e.g.Truth Table for AND gate:

Boolean algebra Simplification:-

Basic Laws:

Theory:

Introduction

Each manufacturer of PLC systems has own style of writing the instructions. Different PLCs has

different instruction sets but even some common basic instructions are shared by all the PLCs. All

manufacturers give different software packages for programming PLCs. Ladder is most commonly

used programming language. Prior to PLCs, relay logic was used in industry. Ladders were

developed to mimic or imitate relay logic.

Relay Logic / Instructions

A relay is simple magnetic device which acts as a control switch.

When the switch is on, current will flow through the coil on iron piece. This iron core acts an

electromagnet and due to the magnetic field upper contact gets attracted towards lower one and

circuit gets completed, allowing current to flow from load.

Ladder Programming

Ladder diagram is popular language of programming the PLCs. Ladder diagram shows the

sequence of the logic execution which is presented diagrammatically. In ladder diagram,

there are two vertical lines generally called as Phase (positive) or neutral. Rungs which

show current flow in horizontal direction are the sequence in which the logic executes. The

Analogous to relay, ladder has two main symbols which are contacts and output coil.

Generally each rung has inputs (contacts) on left hand side and outputs (coil) on the right

hand side. These contacts and coils are called as bits of the relays. Each input and output

are individual bit in I/O files. An instruction in ladder instructs PLCs how to respond to the

bits in I/O files which are stored in the memory. Input contacts are the condition area, the

conditions must be fulfilled to change the status of the output coils.

Most commonly used relay instructions used in PLC programming are as shown in the

table below.

Link: http://plc-coep.vlabs.ac.in/exp2/simulator2.html

Procedure: Important steps for developing Ladder using Simulator

Please follow the steps so as to understand the procedure for developing ladder logic for

various logical gates.

1. Prior to starting of the development of ladder diagram following steps needs to be

understood:

a. Understand the problem statement like test the logic for OR gate, AND Gate etc.

b. Develop the logic on paper and validate the logic by considering various cases
c. Prepare the truth table and test the logic using all valid cases

d. Go to simulator icon and click on the “Simulator” button

e. The PLC simulator will be opened in new window

2. The procedure for writing the ladder diagram in the work space is as follows

a. The screen shot for the first window will appear like this.

Add a new rung by clicking on the 'Add Rung' icon. The window will appear like this:
b. Place the contacts as per the requirement by left clicking the appropriate contact shown at

the top side. In the example demonstrated below one normally contact and one coil is placed as

shown the figure.

C. Right click on the contact or coil and you can give tag name like “start”, “stop” etc. Please

ensure that the tag numbers are true replica of process connections. Similarly give tag name to
coil like “motor”, “Lamp” etc. The final ladder will look like this.

d. Please note that the tag names are case sensitive and if you are using them in circuit as bit

make sure that the correct tag name appears.

e. Click the Compile button so the ladder will be ready for running. For testing the logic you

need to click on Run. Both sides of the rung will become green and this is the indication of run

mode. Please not that in run mode you can't make changes in the ladder. For modifications user

has to go to development mode.

f. By right clicking on the contact toggle the state of contact. Check the output contact status.
g. Please remember the ladder contacts or the state of the inputs and outputs are always in de-

energised state. The de-energised is that state wherein the contacts are in non-active state.

h. You can once again toggle the contact and the output state will change. To add any contact

you will have to go to development mode. Click on the rung and add contacts.

i. To delete any contact or output right click on the contact and press “delete”, the contact will

be deleted.

j. You can add seven elements in series and 5 elements in parallel.

k. To add element in parallel click on the node near contact where you wish to add parallel

branch. Select the branch and click on the '+' sign to complete the loop. The screen will appear

as shown below.
l. Repeat the procedure and verify your logic.

m. Similarly you can check the logic for OR, NOR, and NAND gates. Validate the truth tables

and confirm the results.Lab Integration Kit 1.0.0 Released

 Experiment No. 7

Aim: Develop a ladder program for DOL Starter

Apparatus Required: Virtual Lab

Theory: One method of starting electric motors is using direct on line (DOL) or across the

line starter. In this method full line voltage is applied to the motor terminals. This is

simplest type of motor starter. An electrical wiring diagram for single phase DOL starter

is shown below.

A DOL motor starter contains fuse and over load relay (OLR) for protection purpose. The

starter can be contain momentary contact or maintained contact push buttons. The example

considered here is momentary contact push buttons. For starting purpose normally open

(NO) push button is preferred whereas normally closed (NC) push button is used to stop

the motor.
The excessive supply voltage drop causing high inrush current is the criteria to limit the

use of DOL starter. Conveyor motors, water pumps are the applications where DOL starters

are used.

Procedure

Problem Statement: To start a motor using DOL starter. The simple P&I; diagram for this

problem is as below.

Listing of Input and Output devices:

Inputs: PB1- To start the motor

PB2- To stop the motor

Output: M1- Motor

Sequence of Events :

1. When Start push button (PB1) is pressed, Motor (M1) has to start.

2. If Start pushbutton (PB1) is released and Stop pushbutton (PB2) is not pressed,

Motor (M1) should remain on.

2. When Stop push button (PB2 is pressed, Motor (M1) has tol stop.

3. If stop push button is released and start is not pressed (released) motor shouldl

remain off.

The Boolean equation to represent this sequence is

The ladder diagram to implement these equations is shown below.

As the momentary contact push buttons are used here, the condition of PB1 is maintained

through contact of coil C1. This contact is called as latching contact.

The same sequence of event can be executed by using latch and unlatch instruction in the following

way.
Procedure:

1. The Latch and unlatch instructions are used for holding the output status.

2. The tag name of latch and unlatch output bit must be same.

3. Once you toggle the input bit for the latch; even if you release it by toggling once

again, the output bit remains latched.

4. To unlatch the output you will have to toggle the input bit in the unlatch rung and

the output will be de-energised.

Execute the following ladder on simulator and observe the output status:

You can develop ladder for a DOL “Direct On Line” starter using these instructions.

You can also develop the logic using start and stop push buttons as explained under theory tab.

observe the output status at different input conditions.

Link: http://plc-coep.vlabs.ac.in/exp3/simulator3.html
 Experiment No. 8

Aim: Develop an application using On-Delay Timer

Apparatus Required: Virtual Lab

Theory: LC timers instruction is used to activate or deactivate a device after a preset interval

of time.

Types of Timers available are:

On-Delay timer (TON)

Off-Delay timer (TOF)

Retentive timer on (RTO)

On-Delay Timer (TON)

It is used when an action is to begin a specified time after the input becomes true.

Consider an example wherein a certain step in the manufacturing process is to begin 30 seconds

after a signal is received from a limit switch. The 30 seconds delay is the ON-delay timer’s

preset value.

The figure below shows a symbolic representation of the timer.

The instruction mainly includes three status bits namely EN, TT, DN. Their significance is as

follows:
Enable (EN) Bit: - The enable bit indicates the TON instruction is enabled

Timer-Timing (TT) Bit: -The timing bit indicates that a timing operation is in process.

Done (DN) Bit: -The done bit changes state whenever the accumulated value reaches the preset

value.

Accumulator (ACC) Bit: -The accumulated value specifies the number of milliseconds that

have elapsed since the TON instruction was enabled.

Preset (PRE) Bit: - The preset value specifies the value (1msec units) which the accumulated

value must reach before the instruction sets the .DN bit.

The figure shows the timing diagram which illustrates the functioning of all the bits in sequence.

The following example, after running, will illustrate the function of each bit
Before toggling the Start, all the lamps namely Lamp_1, Lamp_2 and Lamp_3 are OFF.

After the Start is toggled, Lamp_1 and Lamp_2 are ON. This implies the Timer_1 is enabled and

its timer timing bit is activated. After the delay i.e. preset value of the timer, Lamp_1 and Lamp_3

are ON and Lamp_2 will be OFF.

Procedure:

In this experiment the on delay timer will be tested for its functionalities using Simulator.

Following bits of the

timer are to be observed.

Initialising bit “ON” in this case.

Enable bit “T_en”

Done bit “T_dn”

Timer timing bit “T_tt”

Preset value needs to be entered by the user.

While configuring the timer thedefault time is 1 mS. Select appropriate preset value as per the

need of the application. The screen shot of the configured timer will appear like this.
To test the EN, DN, and TT bits;configure the timer by right clicking anywhere on the timer

block. Submit tag and preset value.

Add new rung to test the timer status or to energies the output. You can also test the

cascading of the timer using these bits. Observe the tag name for timer DN bit. See

following screen shot to observe the output bit status when delay is over.

Observe the bit status in Run mode when input a is toggled again.

Link: http://plc-coep.vlabs.ac.in/exp4/simulator4.html
 Experiment No. 9

Aim: Develop an application using On-Delay Timer

Apparatus Required: Virtual Lab

Theory: The timer concept and details of on delay timers with its terminology is discussed in

the previous experiment. Let us learn about Off-Delay Timer (TOF).

OFF-Delay Timer:

Consider an example where the contents of a storage tank are to transfer to further process.

When the low level is detected by level switch the outlet valve is to be closed. To allow entire

contents to drain out, sometime delay is needed as the level switch is installed slightly above

the tank bottom level. This can be achieved by using off delay timer.

Consider an example that, there is a Low level switch to a tank, and we have to close the drain

valve of the tank after 5 second delay when low level is reached. In this case this 5 seconds

delay can be given using off delay timer as we have to close the drain valve after delay.

The figure below shows a symbolic representation of the off delay timer.

The instruction mainly includes three status bits namely EN, TT, DN. Their significance is as

follows:
EN-Enable Bit: - The enable bit indicates the TOF instruction is enabled.

TT-Timer-Timing Bit: - The timing bit indicates the timing operation is in process.

DN- Done Bit: - The done bit changes state whenever the accumulated value reaches the preset

value.

ACC- Accumulator Bit: - The accumulated value specifies the number of milliseconds that have

elapsed since the TOF instruction was enabled.

Pre-Preset Bit: - The preset value specifies the value (1msec units) which the accumulated value

must reach before the instruction clears the DN bit.

The figure shows the timing diagram which illustrates the functioning of all the bits in sequence.

The timing diagram illustrates the functioning of all the bits in sequence.

The following example, will illustrate the function of each bit of Off Delay Timer after

downloading the ladder and taking the PLC in run mode.

For low to high transition of start bit, timer will start lamp 3 will glow, as T1.DN,bit is

high. When the start bit is toggled again i.e from high to low, the delay is provided and

after 5 seconds delay lamp3 will be off.

Procedure: Implement the operation using Simulator.

 The configuration of off delay timer is same as 'on delay timer'.

 A typical difference can be observed in the operation (in Run mode).

 When the q bit is energised the output DN bit goes high. The timer starts only after

toggling the initialisation bit again.

 Implement the operation using Simulator. To test the EN, DN, and TT bits; configure the

timer. The same tag name is to be used in the new rung to test the status or to verify the

output status. You can also test the cascading of the timer using these bits.

Link: http://plc-coep.vlabs.ac.in/exp5/simulator5.html
 Experiment No. 10

Aim: Study of PID controller instruction for a pilot plant

Apparatus Required: Virtual Lab

Theory: Programmable logic controller were originally designed to implement discrete or

logical control. But it has limited capability of handling analog input and outputs as well

as analog control. PID control is available in PLC as a function. The theory behind PID

control is discussed here.

In this experiment students are expected to study all features of the PID block available in

PLC, in simulation mode without considering any process application.

As the name suggests this strategy is preferred for on –off type applications. This is a simplest

form of control. Chattering of contacts for final control element is major problem but it can be

avoided by addition of dead zone. Precise control is not possible due to addition of dead zone.

Mostly all domestic applications as Water Geyser, Electric iron, Electric Ovens are controlled

using on-off control strategy.

PID: Continuous Control

There are 3 basic actions in PID.

• Proportional

• Integral

• Derivative

Proportional mode: -

In this mode the controller output varies linearly with respect to the error.

The equation for P mode is

m = Kp * e + Po

Where:

m is the controller output.

Kp is the gain of controller

e is the error in %

Po is the proportional Bias. (Value of m at e =0)

Due to addition of proportional bias, positive as well as negative errors are handled.

Generally Po is set at 50% to handle equal positive and negative error range. Higher is the

gain lower is the band to control.

Integral mode: -Integral mode is used to remove the offset produced due to P mode. Offset

can either be positive and negative.

Equation for Integral mode is

Where,

Ti is the integral time setting and t is the time.

When this action is used alone due to integral effect the action becomes too slow. When

combined with Proportional, the action may go into saturation which is called as Reset Windup.

To overcome this, controller output is limited at lower and higher end. This is called as Anti reset

windup. But due to addition of Integral action Offset is nullified.

Derivative mode:-This action is used to increase the speed of response of slow processes. It

anticipates the rate of change of error and takes the control action. Equation for Derivative mode

is

Where,

Td is the derivative time .

Set Point can be achieved quickly by using D mode. In noisy environment. this action is not

used as the output goes into saturated condition. Even for constant error D action provides no

correction, hence not preferred alone. It is always combined with P action.

Composite controller, i.e. P, I and D adds advantages of all the three modes.

The Equation for the combined controller depends on how P, I, D blocks are combined. There

are two commonly used configurations, Non-interacting and Parallel.

The equation for non-interacting controller is

Parallel PID controller algorithm:

The equation for parallel algorithm is

Loop tuning time can be optimized by using proper combination of PB, Ti and Td

The process parameter analog value (PV) is given as input to the block. Various settings such

direct or reverse action, Proportional band setting, Set point value, Proportional band,
Proportional gain, Derivative gain, Integral gain etc. are configurable parameters available in

PID function.

Procedure:

1. Add a new to rung.

2. Click on PID tab to insert PID function block in the rung.

3. The screen will appear as follows.

4. Now right click anywhere on PID function block to configure the block.
5. Once you configure the tags, you can set the action, PID mode, type of PID etc.

The screen will be as follows

6. Click on Configure tab. Now you can set the tuning parameters and submit the

same. See the following screen shot.

 7. Now go to run mode and observe the PID output.

Repeat steps 3 to 7 for various configurations and different tuning parameters

Link: http://plc-coep.vlabs.ac.in/exp8/simulator8.html