COMPANY PROFILE

ECI SYSTEM PRIVATE LIMITED

About ECI
ECI is “A CONTROL AUTOMATION SOLUTION PROVIDER”,
specialized in providing total engineering solution for vertical industries. Started its
inception from 2005, having its head office at Coimbatore. This company provides
sales and service of control panels, AC/DC motors, AC servo drives and applications
of PLC, HMI, and SCADA. This company provides solution for industrial
automations and make the manufacturing process faster.

MISSION
Our mission is to provide world-class standards and best of products and
solutions through an unmatched understanding of our partner’s business and goals.
We are dedicated to crafting total systems solutions that benefit both our customers
and our suppliers, helping all to become more successful. It is our continued mission
to build value for our partners by achieving operational excellence and unrivaled
customer satisfaction.

VISION
Our Vision is to go from an entrepreneurial company to an enduring, great
organization by the end of the decade without losing the simplicity and agility of a
small company. Our goal is to be more significant to our customers and manufacturers
combined through the strength of our customers’ satisfaction and by consistently
providing superior systems and service solutions.

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Products
Industrial control and sensing device

 Switching Relays
 Measuring & Monitoring
 Relays for 1PH/3PH
 Timers , Counters
 Power supplies
 Level controllers
 Photo electric sensors
 Temperature controllers
 Proximity sensors
 Encoders
 PLC panels
 Drive panels
 PCC & MCC panels
 Control desks
 Junction boxes
 Cable harness
 Installation & commissioning / EPC /AMC

Factory automation solutions

 Programmable logic controller (PLC)
 Motion controls including
 Inverter / variable frequency drives
 HMI / Programmable Terminals / SCADA

Applications solutions
 Vision sensor for quality inspection
 Safety light curtains
 RFID

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DAY 1
On the first day of our internship, we went to ECI SYSTEM PRIVATE
LMT unit -1 which is situated garden retreat , 15km from Coimbatore On the day, we
have been explained about all departments of the company ,and various machines,
manpower, various products and it applications, customers of the company. Then we
visited all the departments of the company and learnt the infrastructural facility of the
company

MANUFACTURING FACILITY
ECI takes great pride in understanding the requirements of clients and provide
them with the perfect electrical solution.

 Quality Assurance-quality and innovation is our forte and we stand by it at

every stage of production. We believe in operational excellence and excellent
design. We strive to satisfy our clients with the right product, prompt delivery
and right price
 R&D Facility-The manufacturing facility of the company comprises of a
full-fledged R&D wing that is Recognised by the Department of Scientific &
Industrial Research, Government of India
 Clients – our products are used by the following companies TNPL, INDIAN
OIL, PRICO, WIPRO, HATSUN, ROOTS, LNT, and CRAFTSMAN.

DAY 2

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ASSEMBLY DEPARTMENT
On the second day, we visited the ASSEMBLY DEPARTMENT. We have
been briefed about the junction boxes manufacturing for ZF COMPANY to control
wind mill motors and for CRAFTSMAN to control crane movement.

JUNCTION BOX
A Junction box is an electrical box that contains terminal blocks. TB1 and
TB2 both combine together to form a complete junction box. It acts as an intermediate
between field devices and control panel.

SPECIFICATIONS
The specified types of junction boxes used by ZF company is

 EH811
 EH0941(WT19)
 EH829

1. EH811 have two terminal blocks TB1 and TB2 .It has three layers and four pin
connectors.
2. EH0941 – It is a press type TB. The PLC used is costly and four different modules
such as bus coupler (for communication, DI8-digital input and RTD – temperature.
The default IP used for bus coupler is 192.168.0.3. Quattro size TB is used here. The
blue cable is used for indicating power and Red cable is used for indicating control.
3. EH829- TB1 of EH829 has six pin connector and TB2 has 24 pin connector

Fig.1. Junction Box Terminal Connecters

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 A terminal block (also called as connection terminal or terminal connector) is
a modular block with an insulated frame that secures to or more wires together it
consists of a clamping component and a conducting strip. A typical simplest terminal
block is an image (2) below

Terminal block has two types of connections

 Press type
 Screw type

Screw terminal blocks are those that have a screw as the method for holding a
cable or wire. It is more common to see screws have flat-head fittings, and these types
of terminals are often found in situations in which voltage and current demands will
be moderate (domestic/commercial wiring

Press terminal blocks are those that have a press as the method for holding a
cable or wire. It is more common to see the press have push head fittings and these
types of terminal are often found in situations in which voltage and current demands
will be moderate

Fig.2. Screw
Type and Press Type Terminal

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DAY -3
On the third day, we learnt about the various cables and lugs that are used in
control panels.

CABLE:
Control cables are used to connect instrument transformers, coils of circuit
breakers and contactors, control switches, meters, protection devices and other control
and monitoring equipment. Control cables have conductors in copper, insulation and
outer sheath in PVC and they may have up to 150 cores.

LUGS:
Device that connects the cable to the device terminals that simplifies the
assembly of personnel, maintenance, and repair processes. A cable lug or connector is
used when a permanent connection is required, but a direct one is inconvenient or
impossible to achieve.

FERRULE:
Ferrules are identification labels provided for every wire terminations in an
instrument, equipment, or electrical/instrumentation control panels. These tube-
shaped sleeves can be inserted easily on each individual wire in a multi-core cable.

TYPES OF LUGS:
 Ring type lug
 U type lug
 Pin type lug
 Boot lace type lug
 Ring Type Lug

These type of lugs are used in blot & nuts plotted areas. In MCB, MCCB,
ACB, OCB and the electrical panel areas we use this type of connectors.

Ring type
 Lug sizes: 1, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 90, 120 (Diameter of the hole
is depends on bolt size such as 8 or 10
 Available insulation colors: Red, yellow, blue and black

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 Fig.3 (a) Ring Type Lug

U Type Lug:
 These type of lugs are used in the relays, timer, and contactor and MCB
areas.
 U type cable lug sizes: 1, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 90, 120
 Available insulation colors: Red, yellow, blue, black and white.

Fig.3 (b) U Type Lug

Pin Type Lug
 Pin type of lugs are used in Terminal blocks.
 Pin type cable lug sizes: 1, 2.5, 4, 6, 10, 16, 25, 35, 50, 70, 90, 12
 Available insulation colors: Red, yellow, blue and black.

Fig.3 (c) Pin Type Lug

DAY -4
On the fourth day, we learnt about the relays, its kinds and function in control
panel that are manufactured in ECI SYSTEMS.

RELAYS:

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  Relay are electrically operated switches that open and close the circuits by
receiving electrical signals from outside sources.
 Relay works on the principle of electromagnetic induction. When the
electromagnet is applied with some current, it induces a magnetic field around
it.

On this day we visited the relay manufacturing department. Generally ECI

uses general purpose relays to transfer the electricity for high voltage or high
frequency applications. ECI offers also general purpose miniature relays with LED
indication and 3 poles. It is ideal for power and sequence control, instrumentation,
industrial controls and automation systems. It is highly durable and reliable. The
relays with 5/10 Amps are used in UPS, inverters, voltage stabilizers, process control
systems, instrumentation, automation system, vending machine, machine tools and
textile machineries. 10 16 Amp relays are elegant, sturdy and lightweight. They are
great for air conditioners. As per client demand, we offer them with AC and DC coils.

Fig.4. General Purpose Relay

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 ECI also uses control relay to control several input output voltage supplies. It
is ideal for Control & Relay Panel (CRP) solution is designed to control several
feeders, through medium voltage indoor and outdoor switchgear in a primary
distribution substation. It is typically deployed when associated switchgear does not
have space to accommodate the protection, control, and monitoring needs of a

substation.

Fig.5. Control Relay

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DAY-5
One the fifth day, we have studied about the contactors in the control
panel. This company uses for industrial and automation purpose.

CONTACTORS
The contactor is an electrical component that serves to connect or
disconnect AC power. Contactor or often also called the relay contactor we can find
on the electric control panel.

Unlike general-purpose relays, contactors are designed to be directly

connected to high-current load devices. Relays tend to be of lower capacity and are
usually designed for both normally closed and normally open applications. Devices
switching more than 15 amperes or in circuits rated more than a few kilowatts are

usually called contactors

Fig.6. Contactors

TYPES OF CONTACTORS

Serial no Current (A) Contactors Application

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 1. 120A A9 Emergency
breaking system

900A L3 Main source

2.

3. 500A AD5A Pumping system

CONTACTORS USED IN ECI:

This is an electromagnetic type contactor and it can operate automatically. It
requires a small amount of control circuit to turn on and off the load. Therefore, the
operation of this contactor is safe compared to manual contactor. This is the most
used contactor in industrial applications.

Table 1: Current rating of contactors

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DAY-6
SWITCHES
On the sixth day, we learnt about the switches. There are many type of
switches used in control panel such as MCB, MCCB, MPCB. All these switches
protect the devices from the over load and short circuit. Based on the need and usage
the switch installation will vary.

MCB
MCB- Miniature Circuit Breaker
MCB is an automatic switch that opens when excessive current flows through
the circuit. It can be reclosed without any manual replacement. In the case of a fuse,
once it has been operated, it must be replaced or rewired, depending on the type of the
MCB. Hence, fuse is known as one of the sacrificial devices.

Fig.7. Miniature Circuit Breaker (MCB)

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MCCB
MCCB – Molded case circuit Breaker
MCCB stands for Molded Case Circuit Breaker. It is another type of electrical
protection device which is used when load current exceeds the limit of a miniature
circuit breaker. The MCCB provides protection against overload, short circuit faults
and is also used for switching the circuits.

Fig.8. Molded case circuit Breaker (MCCB)

MPCP

MPCP- Motor protection circuit breaker

A motor protection circuit breaker, or MPCB, is a specialized electromechanical

device that can be used with motor circuits of both 60 Hz and 50 Hz. It has several
functions that allow it to provide a safe electrical supply for motors:

 Protection against electrical faults such as short circuits, line-to-ground faults and
line-to-line faults. The MPCB can interrupt any electrical fault that is below its
breaking capacity.

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 Motor overload protection, when a motor draws electric current above its
nameplate value for an extended period of time. Overload protection is normally
adjustable in MPCBs.
 Protection against phase unbalances and phase loss. Both conditions can severely
damage a three-phase motor, so the MPCB will disconnect the motor in either
case as soon as the fault is detected.
 Thermal delay to prevent the motor from being turned back on immediately after
an overload, giving the motor time to cool down. An overheated motor can be
permanently damaged if it is turned back on.
 Motor Circuit Switching – MPCBs are normally equipped with buttons or dials for
this purpose.
 Fault Signaling – Most models of motor protection circuit breakers have a LED
display that is turned on whenever the MPCB has tripped. This is a visual
indication for nearby personnel that a fault has occurred and the electric motor
must not be connected again until the fault is addressed.
 Automatic Reconnection – Some MPCB models allow a cool down time to be
input in case there is an overload, after which the motor will restart automatically.
 Electric motors are expensive equipment, so the role of the motor protection
circuit breaker is very important. If a motor is not protected correctly, it may be
necessary to carry out costly repair works or even replace the equipment
completely. An electric motor that is adequately protected with an MPCB will
have a much longer service life.

Fig.9. Motor protection circuit breaker (MPCP)

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APPLICATIONS OF MPCP:
 Rooftop air conditioners, chillers, compressors, heat pumps and cooling
towers.
 Extraction and injection fans, as well as air handling units.
 Water pumping systems.

OTHER CIRCUIT
MPCP
BREAKERS

It breaks the circuit depend upon the MCB,MCCB,ETC which also used to
properties of the machine protect the circuit against over voltage

Which can used to be manual or

These are used in various applications
automatically to industries
 Elevators and other Hoisting devices.
 Industrial conveyor belts and other machinery used in manufacturing process

DIFFEENCE BETWEEN MPCP AND OTHER CIRCUIT

BREAKERS

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DAY- 7
On this seventh day we learnt about SMPS used in control panels to provide
fixed power supply to PLC

SMPS

In ECI, SMPS is used to provide constant power supply to PLC (24V dc)
inside the control panel. SMPS – SWITCH / SINGLE MODE POWER SUPPLY

The full form of SMPS is Switched Mode Power Supply also known as Switching
Mode Power Supply. SMPS is an electronic power supply system that makes use of a
switching regulator to transfer electrical power effectively.

WORKING PRINCIPLE OF SMPS

In the SMPS device, the switching regulators are used which switches on and
off the load current to maintain and regulate the voltage output. Suitable power
generation for a system is the mean voltage between off and on. Unlike the linear
power supply, the SMPS carry transistor switches among low dissipation, full-on and
full-off phase, and spend much less time in high dissipation cycles, which decreases
depleted strength.

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 Fig.10. Inside of SMPS

BENEFITS OF SMPS
 The switch-mode power source is small in scale.
 The SMPS is very lightweight.
 SMPS power consumption is typically 60 to 70 per cent, which is ideal for
use.
 SMPS is strongly anti-interference.
 The SMPS production range is large.
 Limitations of SMPS
 The complexity of SMPS is very large.
 The production reflection is high and its control is weak in the case of SMPS.
 Use of SMPS can only be a step-down regulator.
 In SMPS, the voltage output is just one

Fig.11. SMPS

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DAY – 8
On the eighth day, we panel learnt about the control panels, function and its
area of the uses.

CONTROL PANEL:
An electrical control panel is an enclosure, typically a metal box or plastic
molding which contains important electrical components that control and monitor a
number of mechanical processes.

TYPES OF CONTROL PANEL

There are three types of electrical control panels.

 Power control center (PCC Panel)

 Motor Control center (MCC Panel)
 Automation Panel (SCADA PLC Panel)

MOTOR CONTROL PANELS:

Motor control panels come in a variety of shapes and sizes, but all serve the
same purpose: to provide power and control for electric motors. The most common
type of motor control panel is the starter panel, which houses the starter and
associated controls for an electric motor.

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 Fig.12. Motor Control Panels

POWER CONTROL PANEL:

PCC is an electrical control panel is a combination of electrical devices which
use electrical power to control the various mechanical functions of industrial
equipment or machinery. An electrical control panel includes two main categories:
panel structure and electrical components.

Fig.13. Power Control Panels

AUTOMATION CONTROL PANELS:

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 Automation control panels can perform both simple and complex processes by
employing relays, timers, sensors, starters, and controllers. The main advantage of
automation control panels is that they provide more control over the industrial
equipment in a facility.

Fig.14. Automation Control Panel

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DAY -9
On the ninth day, we learnt about the about the overview of the PLC. ECI uses
the Siemens Manufactured PLC’S.

PROGRAMMABLE LOGIC CONTROLLER:

PLC-Programmable Logic Controller is industrial computer control that
continuously monitors the state of input devices and makes decision based upon the
custom program to control the state of output devices

USES

 PLC’s are often used in factories and industries to control motors, pumps,
lights, circuit breakers and machine.
 Digital computer used for automation of typical industrial electromechanical
process such as controls of machinery, factory assembly conveyors,
amusement riders.

TYPES OF PLC

 Relay output
 Transistor output
 TRIAC output

BRANDS OF PLC

 Siemens
 ABB
 Omron
 GE Fanuc
 Medicon
 AB
 Delta

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  Phoenix
 Hitachi

CPU FAMILY:

 S7-1200
 ET200
 S7200
 S7300
 S7400
 1500

PROGAMMING LANGUAGES:
 LD – Ladder Diagram
 FBD – Function Block Diagram
 SFC- Sequential Function Chart
 ST – Structured Text
 IL- Instruction list

PLC HARDWARE:
The hardware components of a PLC system are CPU, Memory, Input/Output,
power supply unit and programming device. Below is a diagram of the overview of
PLC
 CPU -Keeps checking the PLC controller to avoid errors. They perform
functions including logic operations, arithmetic operations, computer interface
and many more.

 I/O section – Input keeps a track on field devices which includes sensors,
switches.

 Memory – Fixed data is used by the CPU. System (ROM) stores the data
permanently for the operating system. RAM stores the information of the

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 status of input and output devices, and the Values of timers, counters and other
internal devices.

 O/P Section Output has a control over the other devices which includes
motors, pumps, lights and solenoids. The I/O ports are based on Reduced
Instruction Set Computer (RISC).
 Power supply-Certain PLCs have an isolated power supply. But, most of the
PLCs work at 220VAC or 24VDC. Programming device-This device is used
to feed the program into the memory of the
 Processor. The program is first fed to the programming device and later it is
transmitted to the PLC’s memory.
 System Buses – Buses are the paths through which the digital signal flows
internally of the PLC. The four system buses are:

 Data bus is used by the CPU to transfer data among different elements
 Control bus transfers signals related to the action that are controlled
internally.
 Address bus sends the location’s addresses to access the data
 System bus helps the I/O ports and I/O units to communicate with each
other.
ADVANTAGES:
 PLC’S can be programmed easily which can be understood clearly well.
 They are fabricated to survive vibrations, noise, humidity, temperature.
 The controller has the input and output for interfacing

DISADVANTAGES:
 It is tedious job when replacing or bringing any changes to it.
 Skillful work force is required to find its errors
 Lot of efforts is put to connect the wires
 The holdup time is usually indefinite when any problem arises

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 Fig.15. PLC Hardware

DAY – 10
On the tenth day, we learnt About the Ladder Logic using NO, NC, and
Timers. ECI system uses SIEMENS TIA portal V17.

LADDER PROGRAM:

Ladder logic has evolved into a programming language that represents a

program by a graphical diagram based on the circuit diagrams of relay logic hardware.
Ladder logic is used to develop software for programmable logic controllers (PLCs)
used in industrial control applications. The name is based on the observation that
programs in this language resemble ladders, with two vertical rails and a series of
horizontal rungs between them. While ladder diagrams were once the only available
notation for recording programmable controller programs, today other forms are
standardized in IEC 61131-3 (For example, as an alternative to the graphical ladder
logic form, there is also a language more like C called Structured text within the IEC
61131-3 standard).

RUNG AND RAILS:

PLC Rung Input:

If you are designing an electrical circuit in ladder logic rung, input instruction can
be used in two different forms like,

 –[ ]– Normally Open contact (NO)

 –[\]– Normally Closed Contact (NC)

PLC Rung Output:

The rung output contains output instructions in the form of an actuator or coil. In
ladder logic rung, PLC outputs represent in two ways.

 –( )– Normally Inactive (NO) Coil

 –(\)– Normally Active (NC) Coil

PLC RAILS:

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 The two vertical lines are called the PLC Rail or Power Rail. Power rail is used to
provide the power source for each rung that makes a complete circuit. It can connect
with AC or DC source.

 The left vertical line represents the positive rail (consider as the phase).
 The right vertical line represents the negative rail (consider as the neutral).

Fig.16. RAILS AND RUNG

MEMORY ADDRESS:
Memory address use to stimulate the logics. Memory address is used in input
as well as in output. Memory address helps to identify components.

 M0-0 Word - 8 bit (M0.0 to M0.7)

 MW0- 0 Word - 16 bit ( MW0.0 to MW0.15)
 MD0- Double word -32 bit (MD0.0 to MD0.31)
 MB0 - Byte - 64 bit ( MB0.0 TO MB0.63)

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 Fig.17. Logic Using Memory Address

DAY -11
On the eleventh day, we learnt about the ladder using on timer, off timer and
arithmetic operations (add, subtraction, multiplication, division).

TIMERS IN LADDER LOGIC:

A timer is a PLC instruction measuring the amount of time elapsed following
an event. The accuracy and repeatability of the timer are extremely high because the
PLC processor generates delays. A timer starts counting at time-based intervals and
continues until the accumulated value equals the preset value. When the accumulated
value is equal to the preset time, the output will be energized. Then the timer sets the
output.

There are two main types timer code in the Ladder logic
 Timer ON
 Timer OFF

TIMER ON:
An “on-delay” timer activates an output only when the input has been active for
a minimum amount of time.
 The timer starts operating, when the rung is turned ON.
 When the rung is on, the timer starts counting until the preset value is equal to
the accumulated value.
 The timer starts counting when the rung is turned ON, the counting of
accumulated value will be shown at the ET rung on the timer logic.
 The preset value is given at the timer box, it can be changed.
 Whenever the rung is ON, the ET bit starts counting until the count equal the
preset value.

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 Fig.18. Ladder Logic for Timer ON

TIMER OFF:
This timer instruction differs from the on-delay type in that the timing function
begins as soon as the instruction is deactivated, not when it is activated.

 The off-delay timer works normally for logic true. When the rung is turned
ON the system works as the same.
 But when the rungs turn false, which means when the rung is false the output
will no get turn immediately.
 The timer starts counting, until when the accumulated value is equal to the
preset value.
 When the switch is turned OFF, the instrument continues it state for a period
given at the ET line. And turn off the instrument after a delay.

Fig.19. Ladder Logic for Timer OFF

ARITHMETIC OPERATIONS IN LADDER LOGIC:

ADDITION:
Fig.20 shows an additional example in ladder logic. It shows two operators A
and B of integer data types. The variable A is located at address MW2 and variable B
is located at address MW4 while the result is stored in variable RES which is located
at address MW6. All of these variables are of type integer and size one word or 32

27
bits. The figure show simulation results on the PLC simulator and shows the RES
variable holds summation of A and B.

Fig.20. Addition Ladder Logic

SUBTRACTION:
Fig.21 shows a subtraction example in ladder logic. It shows two operators A
and B of integer data types. The variable A is located at address MW2 and variable B
is located at address MW4 while the result is stored in variable RES which is located
at address MW6. All of these variables are of type integer and size one word or 32
bits. This image shows the simulation results after enabling the subtraction by switch
or the “SUB” command contact. The Res variable now reflects the results of

subtraction.variables

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 Fig.21. Subtraction In Ladder Logic

DAY -12
On the twelfth day, we learnt about the Arithmetic operations ( Mul , div) and
Comparators (Equal comparator operator, Equal comparator operator , greater- than
comparator) in ladder logic.

PLC PROGRAMMING – I ARITHMETIC IN LADDER LOGIC

MULTIPLICATION :
Fig.22 shows an example for performing the multiplication process. First, the
“MUL” is selected and two input operators of multiplications are given and output.
The simulation result shows the RES variable holds the result of multiplication of the
input operators

Fig.22. Multiplication In Ladder Logic

DIVISION:
Fig. 23 shows an example for performing the Division process. The “DIV” is
selected as an instruction to be executed and two input operators of division are
provided and output. The simulation result shows the RES variable holds the result of
the division of the input operators.

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 Fig.23. Division In Ladder Logic

MOD :
Fig.24 shows an example for performing the MOD function process. The MOD
function determines the remainder of the division process, in this example we are
dividing 25 by 10 which gives 2, and the remainder of 5. “MOD” function firstly is
selected as an instruction to be executed and two input operators of MOD function are
provided and output. The simulation result shows the RES variable holds the
remainder of the division of the input operators.

Fig.24. Mod in Ladder Logic

COMPARATORS IN LADDER LOGIC:

There are many comparator operations like equal (==), not equal (<>), less
than (<), greater than (>), less than or equal (<=), greater than or equal (>=). All these
comparator operations might be used in different logic scenarios while writing a
ladder logic.

EQUAL COMPARATOR OPERATOR:

The equal operator is used to check if two operands are equal or not. The
input operands’ datatype could be any. The datatype could be an array or structure of
elements of the basic datatypes.

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 Fig.25. Equal Comparator Logic

NOT EQUAL COMPARATOR OPERATOR:

This operator is used to compare two operands. When they are not equal it
produces positive RLO with High logic and when they are equal it returns false or “0”

Fig.26. Not Equal Comparator Logic

GREATER – THAN COMPARATOR :

The greater than comparator operator is used for checking if operand 1 is greater
than operand 2 or not. The ladder logic program that utilizes greater than comparator
operation in which two operands of the integer data type are compared using the
greater-than operator. The first operand is at memory location MW4 and the second
operand is at memory location MW2.

Fig. 27. Greater – Than Comparator Logic

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DAY – 13
On the thirteenth day , we learnt about the comparator ( Less-than
comparator, Greater-than or equal comparator, Less-than or equal comparator) and
counters.

PLC PROGRAMMING - II
COMPARATORS IN LADDER LOGIC:
LESS THAN COMPARATOR OPERATOR:
The less than comparator operator is used for checking if operand 1 is less
than operand 2. The ladder logic program that utilizes less than comparator operation
“A<B” in which two operands of the real data type are compared using the less-than
operator. The first operand is at memory location MD8 and the second operand is at
memory location MD12.

Fig.28. Less– Than Comparator Logic

GREATER THAN OR EQUAL COMPARATOR OPERATOR:

The ladder logic program that uses greater-than or equal “>=” operator. The
output shows true when the two operands are equal.

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 Fig.29. Greater Than Or Equal Comparator

LESS THAN OR EQUAL COMPARATOR:

The ladder logic program that uses less than or equal “<=” operator. The
output shows true when the two operands are equal.

Fig.30. Greater Than Or Equal Comparator

COUNTER IN LADDER LOGIC:

A PLC Counter is a function in PLC programming that is used to measure
things like how many times an event has happened in a process or how many times a
product has been produced.

INPUTS:
 CU – Count Up Input
 CD – Count Down Input
 S – Set Input for presetting counter
 PV – Value for presetting counter
 R – Reset Input

OUTPUTS:
 Q – Status of Counter
 CV – Current counter value
 CV_BCD – Current counter value in BCD coded

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There are Two types of counters

 Up counter
 Down counter

UP COUNTER:
In this counter, each time a trigger input signal has been received at (CU), the
counter counts up until reaching the preset value (PV) to energize output . The
counter has three inputs: the trigger command, the reload command, and the preset
value to set to what number the maximum counter is going to count up. Furthermore,
it has two outputs: the counter output which is turned to true when the counter reaches
the PV values, and the current value (CV) which tells the current value at any time to
whom the counter reaches.

Fig. 31. Up Counter Logic

DOWN COUNTER:
In this counter, the two functions of the count up and count down can be
combined in one block. Each rising edge of a trigger input signal has been received at

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(CD), the counter counts down. And each time it receives a command trigger signal at
(CU), it counts up and so on till it reaches the PV values. At then the counter output is
energized. As shown in figure 5, the counter has five inputs: the trigger command for
counting down (CD), the trigger command for count up (CU), the reload command to
reload to the PV value, the reset command to reset to zero, and the preset value to set
to what number the initial value from whom the counter starts counting up or down.
Furthermore, It has three outputs: the counter down output (QD) which is turned to
true when the counter reaches zero, the counter up output (QU) which goes to true
when the counter reaches the PV value, and the current value (CV) which tells the
current value at any time to whom the counter reaches.

Fig. 31. Down Counter Logic

HUMAN MACHINE INTERFACE:

The hardware or software through which an operator interacts with a controller.
An HMI can range from a physical control panel with buttons and indicator lights to
an industrial PC with a color graphics display running dedicated HMI software.

HMI CONTROL PANELS:

 HMI is the acronym for Human Machine Interface which, simply put, is an
interface between a user and a machine. HMI is a term specific to

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 manufacturing and process control systems. An HMI provides a visual
representation of the status of a control system with real-time data acquisition.
 HMI’s can also act as the centralized control unit for manufacturing lines as
they are usually equipped with non-volatile memory containing data recipes,
can execute event logging and event triggering, and can provide video feed for
status monitoring.
 For a manufacturing line to be integrated with an HMI, it must first be
connected to a Programmable Logic Controller (PLC) or Motion Controller. It
is the PLC/Motion Controller that takes the information from the machine
sensors and converts it into Boolean algebra to communicate with the HMI.
From factories to extreme remote locations, IndustLabs HMI control panels
enable customers to easily connect, monitor and control processes across a
diverse range of industries that include manufacturing, oil and gas and

water/wastewater.

Fig.32. HMI Screen

SCADA: .
Supervisory control and data acquisition (SCADA) is a system of software and
hardware elements that allows industrial organizations to:
 Control industrial processes locally or at remote locations
 Monitor, gather, and process real-time data
 Directly interact with devices such as sensors, valves, pumps, motors, and
more through human-machine interface (HMI) software
 Record events into a log file

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 SCADA systems are crucial for industrial organizations since they help to
maintain efficiency, process data for smarter decisions, and communicate system
issues to help mitigate downtime.

The basic SCADA architecture begins with programmable logic controllers

(PLCs) or remote terminal units (RTUs). PLCs and RTUs are microcomputers that
communicate with an array of objects such as factory machines, HMIs, sensors, and
end devices, and then route the information from those objects to computers with
SCADA software. The SCADA software processes, distributes, and displays the data,
helping operators and other employees analyze the data and make important
decisions.

For example, the SCADA system quickly notifies an operator that a batch of
product is showing a high incidence of errors. The operator pauses the operation and
views the SCADA system data via an HMI to determine the cause of the issue. The
operator reviews the data and discovers that Machine 4 was malfunctioning. The
SCADA system’s ability to notify the operator of an issue helps him to resolve it and
prevent further loss of product.

Fig. 33. Block Diagram of SCADA

INTERFACING OF PLC , HMI AND SCADA :
 SCADA is most easily understood as the central database that stores and
controls your operations at large.
 This communicates with the PLC, which is how the system functions and
communicates within the operational environment.

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  If there is an HMI, it might come in the form of a screen, buttons, levers, or a
keyboard, thus allowing humans to interact with the SCADA-PLC system.
 Some examples include factory machines, computers, and vehicles.
 In industrial manufacturing, HMIs are essential in delivering information to
the operator.
 The PLC system can identify any issues within the SCADA system, and
through the HMI, present it to the human operator so the problem can be fixed.

Fig.34. Interfacing Block Diagram

SENSORS:
When you write logic in a PLC that initiates motion, ysou want to be certain
that the motion you are expecting actually occurs. This is where sensors come into
play. Sensors provide indication to the PLC, robot, or other controller that some
physical event has taken place.

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TYPES OF SENSOR THAT ARE USED IN ECI :
1. LIMIT SWITCHES
2. PROXIMITY SENSORS
3. PHOTOELECTRIC SENSORS
4. ROTARY ENCODERS
5. VISION SYSTEM
6. SAFETY LIGHT CURTAINS

LIMIT SWITCH:
 Limit switch is an electromechanical switch that operates by any physical
force or the movement of a machine.
 These switches are very helpful in detecting the absence or presence of an
object, counting, detecting speed, detecting movement range, travel limit,
positioning, etc.
 These switches include three terminals NO (Normally Open), NC (Normally
Open) & Common.
 The controlling of this switch can be done by different factors like
temperature, position, and pressure.
 This switch is mainly designed to operate only once a fixed limit is achieved,
and it is generally activated through contact by using an object like a cam

Fig.35(a). Limit Switch Symbol

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 Fig.35(b). Limit Switch Sensor

PROXIMITY SENSORS:
Proximity sensors – sometimes referred to as proximity switches – are sensors
that are used in industrial automation and other applications. What distinguishes them
from other sensors is that they can sense objects without having to touch them.
Because they don’t have to physically interact with the objects they detect, proximity

sensors often have no moving parts.

Fig.36. Proximity Sensors

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PHOTOELECTRIC SENSORS:
 Photoelectric sensors, also known as photo eyes, emit a beam of light that is
used to detect the presence or absence of items and equipment or changes in
surface conditions.
 When the emitted light is interrupted or reflected by the object, the change in
light patterns is measured by a receiver and the target object or surface is
recognized.
 Photoelectric sensors are very common in industrial manufacturing fields such
as material handling, packaging, food and beverage, medical, and many
others.
 Depending on the style selected, they can be used with or without a reflector,
be self-contained, long-range, heavy-duty, or compact.
 There are many different housing and mounting options to offer a correct fit
that meets the demands of each application.
 They perform a wide variety of tasks and some of them can even be used in
harsh environments.
 There are many different styles of photoelectric sensors, but really only four
basic technologies: through-beam, reflective, diffuse, and background
suppression.

Fig.37. Photoelectric Sensor

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ROTARY ENCODER SENSOR:
 A rotary encoder is a type of position sensor, they measure rotary movements
and displacement and can either be absolute or incremental. A rotary encoder
is an electromechanical feedback device used to provide information on
position, speed, count or direction.
 Rotary encoders are incredibly diverse and are used across many different
industries. Some industries which they are used within regularly are;
o Packaging
o Food and beverage
o Printing
o Textiles
o Mobile vehicle
o Aerospace
o Material Handling
o Robotics
o Lift Industry
o Automation
 Rotary Encoders are sensors that detect position and speed by converting
rotational mechanical displacements into electrical signals and processing
those signals. Sensors that detect mechanical displacement for straight lines
are referred to as Linear Encoders.

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 Fig.38. Rotary Encoder Sensor

VISION SYSTEM SENSOR :

With vision systems, manufacturers receive a constant stream of information by
capturing images of specific manufacturing process functions. From the data gathered,
the vision system can make decisions, generally pass/fail, on operations needing an
analysis.This allows companies to:

 Improve efficiencies
 Eliminate unproductive processes
 Increase uptime
 Identify out-of-specification products
 Reduce costs

Fig.39. Vision System Sensors

SAFETY LIGHT CURTAINS SENSOR:

 Photon Controls Electronic safety light curtain sensor is designed to provide
maximum safety to the operator working in danger zone.

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 Safety Light curtain works on modulated infrared beam principal with latest
technique of synchronized cyclic scanning thru microcontroller programming.
 Light curtains differ from other photoelectric sensors in that they have self-
monitoring circuitry.
 In the event of a fault in their operation, this circuitry sends an automatic stop
signal, ensuring that the connected device will not function unless an effective
safeguard is present.

Fig.40. Safety Light Curtain Sensor

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 REPORT

At the end of our internship in ECI SYSTEMS PRIVATE LIMITED, we were

assembled at the conference hall and we presented the observed data’s of the training
to the authorities concerned

The HR of ECI SYSTEMS gave us a full details about the PLC available in
their company. The HR helped us to recollect the important data’s about the
organization and hence we had a better understanding about the products and
compiled a report and submitted to the organization.

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 CONCLUSION

The internship has been an excellent and rewarding experience. We have been
able to meet and network with any people in industry. We have acquired important
skills and knowledge reputed of an industry. Thughout the industry training, we found
that several things are important. These are

 Technical skills: Its necessary to have in depth knowledge in basis and one
Must know how to apply that in applications
 Critical and analytical thinking: To organize our tasks and assignment, we
need to analyze our problems and assignment, and to formulate a good
solution to the problem
 Time management: Time management allows us to do our assignment
efficiently and meet our schedules. Schedules avoid time wastage and allows
us to plan ahead, and gaining more as a result
 Goal management: It is better to sub divided the goals to a few achievable
tasks, so that we will be gaining more confidence by accomplishing those
tasks
 Colleague managements: Communicating and sharing is much needed in the
working environment. Therefore, working together as a team is easier in
reaching our targets, rather than operating individually

This internship gave us wide knowledge about the technical details of the meters
and products manufactured by the ECI SYSTEMS PRIVATE LIMITED. These
companies provided us the real working environment. In a nutshell, this internship has

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helped us in building many skills and it lies at stepping stones to our success in our
future career

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