Skills for Employment Investment Program (SEIP)

COMPETENCY BASED LEARNING MATERIAL (CBLM)

FOR

CERTIFICATE COURSE IN

PROGRAMMABLE LOGIC CONTROLLER (PLC)

(LIGHT ENGINEERING SECTOR)

(STUDENT GUIDE)

Finance Division, Ministry of Finance

Government of the People’s Republic of Bangladesh

1
 Table of Contents

Contents Page
Copyright 03-03
How to Use this Competency-based Learning Material 04-04
List of Icons 06-06

Sector Specific (Common) Competencies

Module 1: Interpret Technical Drawings And Plans 09-34
Module 2: Work with Mechanical Hand Tools, Power Tools and Measuring 35-71
Devices
Module 3: Carryout Precision Checks and Measurements 72-99
Occupational Specific (Core) Competencies
Module 1: Perform Computer Operation Relevant to PLC. 100-161
Module 2: Perform Connection and Testing of Electrical Circuits 162-199
Module 3: Install Automation Instruments and Devices 200-253
Module 4: Perform PLC Programming 254-296
Module 5: Perform HMI Programming and interfacing 297-321
Module 6: Perform PLC Operations 322-388

2
Copyright

The Competency-based Learning Material (Faculty and Student Guide) for Certificate
Course in Programmable Logic Controller (PLC) is a document, aligned to its applicable
competency standard, for providing training consistent with the requirements of industry in
order for individuals who graduated through the established standard via competency-based
assessment to be suitably qualified for a relevant job.
This document is owned by the Finance Division of the Ministry of Finance of the People’s
Republic of Bangladesh, developed under the Skills for Employment Investment Program
(SEIP).
Public and private institutions may use the information contained in this competency-based
learning material for activities benefitting Bangladesh.
Other interested parties must obtain permission from the owner of this document for
reproduction of information in any manner, in whole or in part, of this Competency-based
Learning Material, in English or other language.
This document is available from:
Skills for Employment Investment Program (SEIP) Project
Finance Division
Ministry of Finance
Probashi Kallyan Bhaban (Level – 16)
71-72 Old Elephant Road
Eskaton Garden, Dhaka 1000
Telephone: +8802 551 38598-9 (PABX), +8802 551 38753-5
Facsimile: +8802 551 38752
Website: www.seip-fd.gov.bd

3
How to Use this Competency-based Learning Material

Welcome to the competency-based learning material for Certificate Course in

Programmable Logic Controller (PLC) for use in Industrial Automation. These modules
contain training materials and learning activities for you to complete in order to become
competent and qualified as Programmable Logic Control (PLC).
There are 03 (Three) modules for sector specifics competencies and 06 (Six) modules for
occupational specific competencies that make up this course which comprises the skills,
knowledge and attitudes required to become a skilled worker including:

Sector Specific (Common) Competencies:

Module 1: Interpret Technical Drawings and Plans
Module 2: Work with Mechanical Hand Tools, Power Tools and Measuring Devices
Module 3: Carryout Precision Checks and Measurements

Occupation-Specific (Core) Competencies:

Module 1: Perform Computer Operation Relevant to PLC.
Module 2: Perform Connection and Testing of Electrical Circuits
Module 3: Install Automation Instruments and Devices
Module 4: Perform PLC Programming
Module 5: Perform HMI Programming and interfacing
Module 6: Perform PLC Operations

As a learner, you will be required to complete a series of activities in order to achieve each
learning outcome of the module. These activities may be completed as part of structured
classroom activities or simulated workplace demonstrations.
These activities will also require you to complete associated learning and practice activities
in order to gain the skills and knowledge needed to achieve the learning outcomes. You
should refer to Learning Activity pages of each module to know the sequence of learning
tasks and the appropriate resources to use for each task.
This page will serve as the road map towards the achievement of competence. If you read
the Information Sheets, these will give you an understanding of the work, and why things are
done the way they are. Once you have finished reading the Information Sheets, you will
then be required to complete the Self-Check Quizzes.
The self-check quizzes follow the Information Sheets in this learning guide. Completing the
self-check quizzes will help you know how you are progressing. To check your knowledge
after completion of the Self-Check Quizzes, you can review the Answer Key at the end of
each module.
You are required to complete all activities as directed in the Learning Activity and
Information Sheet. This is where you will apply your newly acquired knowledge while
developing new skills. When working, high emphasis should be laid on safety requirements.
You will be encouraged to raise relevant queries or ask the facilitator for assistance as
required.
When you have completed all the tasks required in this learning guide, formal assessment
will be scheduled to officially evaluate if you have achieved competency of the specified
learning outcomes and are ready for the next task.

4
Approval Sheet
As a part of training, Competency Based Learning Materials (CBLMs) play an important role
which help not only trainees but also trainers to facilitate the interactive training. To develop
this CBLM, formed a team involving external experts and oriented the team headed by CEO,
LEISC-SEIP Project to analyse the tasks based on all performance criteria of the
Competency Standards(CSs) of Certificate Course in Programmable Logic Controller (PLC)
and trainees need and foster. Later on, based on task analysis, the components of CBLM
were developed with the series of consultation meeting and workshop and developed the
CBLM on Certificate Course in Programmable Logic Controller (PLC).
Finally, a validation workshop was conducted involving institutes and industry experts and
validated it on……..

Experts Involved
Industry and institutes experts who provided their valuable inputs to develop this
Competency based learning material (September -December 2023]:

S.N. Name Organization Designation

01. Mr. Md. Rafiqul Islam LEISC-SEIP Project Chief Executive Officer
Bhuiyan (CEO)
06. Engr. S.M . Shameem LEISC-SEIP Project Curriculum Development &
Ahsan Training Executive
07. Md. Zillur Rahman Siddike Consultant

Development Workshop

Competency based learning material consultation workshop participants (held on January

18, 2023):
S.N. Name Organization Designation
01. Mr. Md. Rafiqul Islam LEISC-SEIP Project Chief Executive Officer
Bhuiyan (CEO)
03 Dr. Md Waszed Ali SEIP TVET Specialist
04 Md Sirazul Islam Circle Automation BD CEO
05 Md. Raju Ahamed Motive Automation Proprietor
06 Md. Milon Hossain Instructor
07 Md.Zakiriya Estiak Bangladesh Automation Instructor
Technologies
08. Engr. S.M .Shameem Ahsan LEISC-SEIP Project Curriculum Development &
Training Executive(CDTE)
09. Md. Zillur Rahman Siddike Consultant
10. Assessment & Certificate
Engr. Md Abul Kalam Azad LEISC-SEIP Project
Executive (ACE)
11. Sacchidanand Majumder LEISC-SEIP Project LMI & Research Executive

5
Validation Workshop

Competency based learning material validation workshop participants [held on]:

S.N. Name Organization Designation

01.
03
04
05
06
07
08.

09.
10.
11.

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List of Icons:

Icon Name Icon

Module content

Learning outcomes

Performance criteria

Contents

Assessment criteria

Resources required

Information sheet

Self-check Quiz

Answer key

Activity

Video reference

Learner Job Sheet

Assessment plan

Review of competency

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 Sector-Specific (Common) Competencies

8
 Interpret Technical Drawings and Plans

After completion this module trainee will able to:

1. Select technical drawing
2. Interpret technical drawings.
3. Interpret operation & maintenance manuals

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Module 01-S: Interpret Technical Drawings and Plans

Module Content

Module Descriptor
This unit covers the knowledge, skills and attitudes required of a worker to translate
technical drawings and plans. It specifically includes the tasks of selecting technical drawing,
interpreting technical drawings and storing manuals, designs and plans.

Nominal Duration: 10 hours

Learning Outcomes:

Upon completion of the module, the trainee should be able to:

1. select technical drawing
2. interpret technical drawings.
3. interpret operation & maintenance manuals

Performance Criteria:

1.1 Drawing is selected and checked to ensure that it conforms to the job requirements.
1.2 Drawing is validated.
2.1 Drawing components, assemblies are identified.
2.2 Dimensions are identified according to job requirement.
2.3 Clearances/tolerances are checked in accordance with workplace standard.
2.4 Instructions are identified and followed accurately.
2.5 Material specifications are interpreted.
2.6 Symbols in drawing are interpreted

3.1 Operation and maintenance manuals are collected and interpreted

3.2 Operation and maintenance manuals are followed when operating and maintaining the
equipment

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 Learning Outcome 1:
Select technical drawing

Contents:
Instructions
1. Technical Drawing
2. PLC Related Diagram
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

1.1 Drawing is selected and checked to ensure that it conforms to the job requirements.
1.2 Drawing is validated.

Resources required

The following resources must be provided to students/trainees): Technical Drawing,

Diagram,PLC & HMI related Diagram

Learning Activity 1.1

Learning Activity Resources/Special Instructions/References

Select technical ▪ Information Sheet:.1.1

drawing ▪ Self-Check:.1.1
▪ Answer Sheet: 1.1

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 Information Sheet 1.1)
Select technical drawing:
Technical drawing:
Technical drawing, often known as drafting or
drawing, is the act and practice of creating
drawings that show how something works or is
built.
Technical drawing is crucial for conveying
concepts in engineering and business. People
employ well-known symbols, viewpoints, units of
measurement, notation systems, visual styles,
and page layout to make the drawings simpler to
comprehend..

Sketch:
A sketch is a hastily drawn, freehand image that
is typically not meant to be a finished piece of
art. A sketch can be used for a variety of things,
including recording what the artist observes,
developing an idea for later use, or quickly
graphically illustrating an idea, concept, or
principle. The least expensive art medium is
drawing.
.
Manual:
A manual provides instructions or guidelines on
how to perform an activity and serves as a
reference book on the activity. Different types of
manuals include: Policy manuals.

Drawing is validated:
A drawing validation process must exist to guarantee compliance with company
requirements when a drafting standard and drawing management system have been
developed. This frequently involves one or more drafters or checkers doing drawing audits
within Engineering Drawing utilizing different tools like Check Standards, Lay Walk, and so
forth. This technique can be time-consuming and expensive, especially when a lot of
drawings need to be processed quickly. There are numerous third-party tools to help with
this procedure, but the most need a significant amount of setup and an external database.
The most straightforward method might be to use a tool widely used in most GIS
applications to extract, transfer, or alter data from different file formats. The Feature
Manipulation Engine is demonstrated in this lesson (FME) can be used to verify that an
engineering design file complies with company drafting standards and audit it, lowering or
eliminating the expense of drawing validation before a project is finished.

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13
14
 Self-Check 1.1
1. What is Technical drawing
2. What is Sketch
3. What is Manual

Answer Key 1.1

1. What is Technical drawing

Technical drawing, drafting or drawing, is the act and discipline of composing drawings that
visually communicate how something functions or is constructed.
2. What is Sketch
A sketch is a rapidly executed freehand drawing that is not usually intended as a finished work
3. What is Manual
A manual provides instructions or guidelines on how to perform an activity and serves as a
reference book on the activity. Different types of manuals include: Policy manuals Procedure

Job Sheet
Job Sheet - 1
Job Perform of Technical Drawing and Plans
Procedure: 1. Collect and wear required clothing.
2. Will collect the necessary goods.
3. First, gather the necessary materials and equipment.
4. Attach the drawing paper to the drawing board.
5. Learn about electrical and electronic symbols from the
instructor.
6. Look at sample images and try drawing on paper.
7. Practice a few times.
8. At the end of work, store tools and materials in their proper
places and clean up the work area.
Personal Protective 1. Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
3. Safety Helmet 02 Pc
Materials 1. Drawing board 01 pc
2. Got the Drawing 01 pc
3. Handkerchief 01 pc
Tools and 1. Pencil 01 pc
equipment: 2. Eraser 01 pc
4. Set skier 01 pc
5. School 01 pc
6. Pencil cutter 01 pc

15
 Learning Outcome 2:
Interpret technical drawings

Contents:

Instructions
1. Technical Drawing
2. PLC Related Diagram
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM
7. Symbols
8. Drawing Components

Assessment Criteria

2.1. Drawing components, assemblies are identified.

2.2. Dimensions are identified according to job requirement.
2.3. Clearances/tolerances are checked in accordance with workplace standard.
2.4. Instructions are identified and followed accurately.
2.5. Material specifications are interpreted.
2.6. Symbols in drawing are interpreted

Resources required

The following resources must be provided to students/trainees): Drawing components,

Pencil, Eraser, and White board Marker

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Interpret technical ▪ Information Sheet:.2.1

drawings ▪ Self-Check:.2.1
▪ Answer Sheet: 2.1

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(Information Sheet 2.1)

Interpret technical drawings:

Ladder Logic Symbols – Operation and Common Uses
Typical relay logic control circuits are the source of the ladder logic symbols utilized in PLC
programming. Ladder logic programming should be simple to learn if you have a basic
understanding of electrical circuits. If not, don't panic; ladder logic is a graphical
programming language, making it simple to understand the fundamental symbols and ideas.
The input symbols and output symbols are the primary symbols used in PLC ladder logic.
Normally open contact (NO) or normally closed contact (NC) symbols are used to represent
digital inputs. While a coil symbol is used to represent digital outputs.

To define PLC digital inputs and internal logic instructions, ladder logic uses the normally
open contact (NO) and normally closed contact (NC) symbols. Switches and relay contacts
used in electrical circuits have been converted into ladder logic.

PLC digital outputs are primarily defined by a coil in ladder logic. To activate internal logic
instructions, a coil can also be employed with internal memory. Relay coils used in electrical
circuits have been transformed into the coil symbol for ladder logic.

Some of the fundamental symbols used in PLC programming include the NO and NC
connections. By examining their function and how they are frequently applied in a ladder
diagram, let's take a closer look at them and other symbols used in PLC programming.

Normally Open Contact (NO) Symbol

Operation:
If the condition is TRUE then the contact is CLOSED
and output logic flow is enabled. If the condition is
FALSE then the contact is OPEN and output logic
flow is blocked

Common Uses:
● Start Push buttons.
● Selector switches.
● Digital instrumentation.
● Internal programming.

Ladder Logic Normally Open Contact (NO)

Symbol – State Diagram

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Normally Closed Contact (NC) Symbol
Operation:
If the condition is TRUE then the contact is
OPEN and output logic flow is blocked. If the
condition is FALSE then the contact is
CLOSED and output logic flow is enabled.
The NC contact symbol operation is opposite
to the NO contact symbol

Common uses:
• Stop Push buttons.
• Fail safe instrumentation.
• Motor Thermal Overloads.
Ladder Logic Normally Closed Contact (NC) • Internal programming.
Symbol -State Diagram

Output Coil Symbol

Operation:
If the input condition is TRUE then the
output is ON. If the input condition is
FALSE then the output is OFF.

Common uses:
● Motor control.
● Actuator control.
● Indication lamps.
● Warning sirens.
● Internal programming.
● Sequence logic.

Ladder Logic Output Coil Symbol – State Diagram

One Shot Symbol– Positive Edge Detection

Operation:
If the input condition transitions from FALSE
to TRUE then the output is ON, for the time
taken to do one PLC scan.

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 Common uses:
● Counting applications.
● Math commands.
● Data Transfer commands.
● Latch output during a specific set of
conditions.

Ladder Logic One Shot Symbol (Positive Edge

Detection) – State Diagram

Set Coil Symbol

Operation:
If the input condition transitions from FALSE
to TRUE then the output is set ON. Once
the output is set ON, it stays ON, even if the
input condition goes FALSE

Ladder Logic Set Coil Symbol – State Diagram

Reset Coil Symbol

Operation:
If the input condition is TRUE then the output
is reset to OFF. If the input condition is
FALSE it has no effect on the output. The
SET and RESET coils can share the same
variable address and therefore work hand in
hand.
Common uses for Set and Reset Coil
Symbols:
● Motor and actuator outputs.
● Indication lamp and warning sirens.
● Internal programming.
● Toggle logic (flip flops).
● Complex latching logic which is set
and reset in multiple locations.

Ladder Logic Reset Coil Symbol – State Diagram

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Timer Delay On Symbol
Operation:
If the input condition is TRUE then the timer
begins. When the preset time set point has
been reached the output turns ON. If the input
condition goes FALSE, at any stage, the timer
stops and the output turns OFF as well

Common uses:
● Time delay for Warning Sirens.
● Star/Delta Motor Starters.
● Sequence start delays.
● De-bounce time delay to fix digital
instrumentation flicker.

Ladder Logic Timer Delay On Symbol– State

Diagram
Timer Delay Off Symbol
Operation:
If the input condition is TRUE then the output turns
ON. Then if the input condition goes FALSE the
timer begins. When the preset time set point has
been reached the output turns OFF. If the input
condition goes TRUE, at any stage, the timer
stops and the output turns ON as well.

Common Uses:
● Cooling Fan run on time delay.

Ladder Logic Timer Delay Off Symbol – State

Diagram

Comparison Symbols
Operation:
If the comparison between two inputs is TRUE
then the output turns ON

Common uses:
● Product Stacking and Un-Stacking
complete.
● Batching system weight set point
achieved.
● Alarm & Fault activation (Temperature,
Flow, Motor Current etc).

Math Symbols

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 Operation:
Executes the mathematical operation using the
inputs with the result written to the output

Common uses:
● Scaling of Analogue Inputs and Outputs
(Temperature, Flow, Motor Current,
Weight, Pressure etc).
● Calculating Motor Speed and Position
profiles.

Up Counter
Operation:
If the input condition transitions from FALSE to
TRUE then the counter is incremented by a value of
1. The accumulated count value is written to an
output. When the count value reaches the preset
value the done output is set TRUE. The counter is
set back to 0 by triggering the reset input.

Down Counter
Operation:
If the input condition transitions from FALSE to TRUE then
the counter is decremented by a value of 1. The
accumulated count value is written to an output. When the
count value reaches zero the done output is set TRUE. The
counter is set back to the pre-set value by triggering the
reset input.
Common uses for Up & Down Counters:
● Counting items for a stacking sequence.
● Counting items for a batching sequence.
● Counting items for a diverting conveying.
● Counting items to be queued in a conveyor line.
● Counting events for alarm and fault triggering.

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PID Closed Loop Control
Operation:
The process variable is measured via the
input and the output is adjusted to maintain
the process variable at the set point input
value. The Proportional, Integral
and Derivative input values are adjusted to
tune the performance of the PID controller.
Common uses:
● Oven Temperature control.
● Irrigation Pressure control.
● Process Flow control.
In the next section were we will fast forward
your learning of ladder logic programming by
understanding basic operating principles of
relay control circuits and also discover the
difference between relay logic and ladder
logic

PLC Ladder Diagram Symbol

Ladder Diagram Symbols Explained

The fundamental components of a ladder circuit diagram are represented by ladder diagram
symbols, which are also utilized in PLC programming. Here are a few symbols that are
included below along with their names. We also offer a symbol table where you can get a list
of all ladder symbols along with a description of each one.
Symbol Name Description
Normally Open Its operation is very simple. When the condition is
Contact (NO) true then the contact is closed and output logic flow
Symbol is enabled. When the condition is FALSE then the
contact is OPEN and output logic flow is blocked.
Normally Closed When the condition is true then the contact is OPEN
Contact (NC) and output logic flow is blocked. And when the
Symbol condition is FALSE then the contact is CLOSED
and output logic flow is enabled. The NC contact
symbol operation is nothing but just the opposite to
the NO contact symbol.
Output Coil When the input condition is true then the output is
Symbol ON. And when the input condition is false then the
output is OFF.

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 One Shot When the input condition transitions from FALSE to
Symbol– TRUE then the output is ON, for the time taken to
Positive Edge do one PLC scan.
Detection
Set Coil Symbol When the input condition transitions from false to
true then the output is set ON and once the output
is set ON, it stays ON, even if the input condition
goes FALSE.
Reset Coil When the input condition is true then the output is
Symbol reset to OFF. And when the input condition is false
it has no effect on the output. The SET and RESET
coils can share the same variable address and
therefore work hand in hand.
Timer Delay on When the input condition is true then the timer
Symbol begins. And when the present time set point has
been reached the output turns ON. If the input
condition goes FALSE, at any stage, the timer stops
and the output turns OFF as well.
Timer Delay off When the input condition is true then the output
Symbol turns ON. Then if the input condition goes false the
timer begins and when the preset time set point has
been reached the output turns OFF. If the input
condition goes TRUE, at any stage, the timer stops
and the output turns ON as well.
Greater than or When the two inputs comparison is true then output
Equal to is true otherwise false.

Less than or When the two inputs comparison is true then output
Equal to is true otherwise false.

Equal to When two inputs are equal then output are true.

Adder Adder is used to add two or more inputs.

Sub tractor Sub-tractor is used to subtract one value from the

other one.

Multiplication Multiplication block is used to multiply two or more

values.

Division Division block is used to divide two values.

PID Controller PID Controller is used to control the process value.

The process variable is measured from the primary
element (Input) and the output is manipulated to
maintain the process variable value at the set point
input value. The Proportional, Integral
and Derivative input values are tune to increase the

23
 performance of controlling. This is done according
to process requirements.
Counter Up When input is True from False then counter
increases 1 value from the last stored value. When
this stored value reaches the preset value, the
output will go True and the stored value is set again
to 0.
Counter Down When input is True from False then counter
decreases 1 value from the last stored value. When
this stored value reaches 0 value, the output will go
True and the stored value is set again to preset
value.

Self-Check 1.2

1. What is PLC and where PLC is used?

2. What is NO and NC?
3. What is Timer?
4. What is means by 16 bit Counter?
5. Which Components are used in PLC Program?

Answer Sheet 1.2

1. What is PLC and where PLC is used

PLC stands for Programmable Logic Controller. They are industrial computers used to
control different electro-mechanical processes for use in manufacturing, plants, or other
automation environments. PLCs vary in size and form factors
2. What is NO and NC?
Normally open(NO) and Normally closed (NC) are terms used to define the states of
switches, sensors or relay contacts under when its coil is not excited.
3. What is Timer?
PLC timers are internal PLC instructions that can be used to delay input and output
signals in the PLC program. These timers operate like relay timers but you cannot hold a
PLC timer in your hand and they do not need to be connected to wires to operate.
4. What is means by 16 bit Counter?
When the program is running on the plc the program typically displays the current or
"accumulated" value for us so we can see the current count value. Typically counters can
count from 0 to 9999, -32,768 to +32,767 or 0 to 65535. Why the weird numbers?
Because most plc's have 16-bit counters. We'll get into what this means in a later chapter
but for now suffice it to say that 0-9999 is 16-bit BCD(binary coded decimal) and that -
32,768 to 32767 and 0 to 65535 is 16-bit binary
5.(Which Components are used in PLC Program)?
The Hardware components of a PLC include the following: Processor, Power Supply,
Input/output Modules, and a Programming Device

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 Job Sheet
Job Sheet - 1
Job Perform of Ladder Diagram Symbols Explained
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Open the Delta PLC Program.
4. Click to New part then Selected PLC Model Ok for
solid works.
5. Select the toolbars that will use throughout drawing
6. First we will take a NO contact from make contact.
7. Then take a NC contact from the brake contact.
8. Then take the memory coil from the Output coil.
9. Then take On Delay timer from a timer coil.
10. Finally, take a coil from the output coil.)
Proper use and maintenance of equipment.
Personal protective 1. Apron 01 Pc
equipment (PPE): 2. Safety Shoe 01 Pc
Tools and equipment: 1. Computer 01 pc
2. PLC 01 pc

25
 Learning Outcome 3:
Interpret operation & maintenance manuals

Contents:

1. Technical Drawing
2. PLC Related Diagram
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM
7. Symbols
8. Drawing Components
9. Operational Manual
10. Maintenance Guide

Assessment Criteria

3.1 Operation and maintenance manuals are collected and interpreted

3.2 Operation and maintenance manuals are followed when operating and maintaining the
equipment

Resources required

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC & HMI Software, HMI

Learning Activity 3.1

Resources/Special
Learning Activity
Instructions/References

Interpret operation & ▪ Information Sheet:.3.1

maintenance manuals ▪ Self-Check:.3.1
▪ Answer Sheet: 3.1

26
(Information Sheet 3.1)
Interpret operation & maintenance manuals:
What Is an O&M Manual?
● An operation and maintenance manual, or O&M manual, is a thorough and extensive
guide that instructs maintenance personnel on how to inspect, maintain, and repair
machinery and equipment.
● A sort of technical literature known as a "operation and maintenance manual" (O&M
Manual) explains how to use a product properly and/or how to solve issues. These
are also referred to as setup manuals, installation and operation manuals, operation
and maintenance manuals, and operation manuals.

An operation and maintenance manual's primary goal is to standardize technical

procedures inside an organization in order to raise their level of quality. In addition, it
includes safety recommendations and best practices. This manual is used not just by
technicians and maintenance staff but also by managers, executives, and outside
contractors.
Benefits of an Operation and Maintenance Manual
If you still overlook the importance of creating operation and maintenance manuals, let’s
figure out how exactly they can improve the performance of your company:
● Create one repository for information.
● Avoid unplanned downtime
● Contribute to safety standards.
● Contribute to quality standards.
● Speed up learning and onboarding.

Operation and Maintenance Manual Types

Information might be kept in a single, extensive guidebook or multiple smaller manuals.
Large corporations frequently produce many sorts of operation and maintenance
manuals. There are various subsystems. Consider the scenario where various teams are
not always expected to collaborate on one another's workflow. Because of this, it is

27
possible to claim that there are many O&M manual kinds depending on the nature of the
task or activity, the functions, and the intended audience: Installation, operation, and
maintenance manuals
● Emergency procedures manuals
● HR manuals and employee handbooks
● Helpdesk manuals
● Software manuals
● Manuals for data administration
● Backup and recovery guides
● Technical assistance manuals
The main purpose of this division is to provide an employee with information in a particular
sphere and for a particular situation.
What Is Included in an O&M Manual?
Of course, O&M manuals can be quite diverse (machinery, construction, software, etc.)
and their content can be different, but here are the things that you will most probably find
in one of them:
● Information about the company
● General information: audience, terminology, the scope of a manual, etc.
● Machinery operational characteristics
● Equipment technical specifications
● Plans and maps to indicate positions of equipment pieces
● Engineering drawings of machinery and equipment
● Schedules for maintenance
● Contact information of equipment vendors
● Emergency maintenance documentation
● Safety guidelines
How to Create an Operation and Maintenance Manual?
An operation and maintenance manual requires time and work to create. It involves more
than just compiling the data into a single document. Making your manual clear, simple to
comprehend, and helpful is crucial. Let's therefore determine how to accomplish this.
Choose a Technical Writing Tool
There is undoubtedly a long list of different technical writing tools available nowadays.
Each of them is intended to address a specific issue and has advantages and downsides
of its own. Remember to pick a product that will work with your particular writing process
and satisfy your specific requirements.The Click Help Team is the best at understanding
the struggles technical writers deal with on a regular basis. Thus, we advise that you focus
on the following:
● Easy team collaboration.
● Quick update of existing topics.
● Deep analytics.
Programmable Logic Controller Maintenance Check Points
Maintenance – Preventive, Predictive, Proactive, Corrective:
“A collection of coordinated tasks known as maintenance are performed to keep a piece of
equipment in the greatest possible operating condition for the least amount of money.
Maintenance generally refers to holding a building, machine, or other structure up to a
standard that is considered acceptable.Goals of the Maintenance Program
● Maximizing production or increasing facilities availability at the lowest cost and at
the highest quality and safety standards.
● Reducing breakdowns and emergency shutdowns.
● Optimizing resources utilization.
● Reducing downtime.
● Improving spares stock control.
● Improving equipment efficiency and reducing scrap rate.
● Minimizing energy usage.

28
 ● Optimizing the useful life of equipment.
● Providing reliable cost and budgetary control.
● Identifying and implementing cost reductions.

Types of Maintenance Programs

In many places of the world, various
maintenance techniques are used. The
resources of the organization or corporation
have a major impact on the adoption of a certain
Maintenance type. Each professional must
consider the available resources before
deciding "which maintenance type is ideal for
his plant" because one maintenance strategy
may be less expensive than another.
Reactive or Corrective Maintenance
The "run it till it breaks" maintenance technique
is essentially reactive maintenance. The
equipment is not maintained in the way the
original designer intended to guarantee that the
design life is reached.

Reactive maintenance benefits have a few drawbacks as well. We can anticipate few failure
situations when working with new machinery. If we only undertake reactive maintenance, we won't
spend any money on capital projects or labor until something breaks.
Advantages of reactive maintenance
● Low cost.
● Less staff.
Disadvantages of reactive maintenance
● Increased cost due to unplanned downtime of equipment.
● Increased labor cost, especially if overtime is needed.
● Cost involved with repair or replacement of equipment.
● Possible secondary equipment or process damage from equipment failure.
● Inefficient use of staff resources
Preventive Maintenance
Preventive maintenance can be defined as follows:
"Actions carried out on a time- or machine-run-based schedule that detect, prevent, or mitigate
degradation of a component or system in order to preserve or extend its useful life by managing
degradation to an acceptable level."
The frequency of preventive maintenance may depend on the machine's operation hours or be
determined by the maintenance engineer or advised by the machine's vendor.
Advantages of Preventive maintenance
● Cost effective in many capital intensive processes.
● Flexibility allows for the adjustment of maintenance periodicity.
● Increased component life cycle.
● Energy savings.
● Reduced equipment or process failure.

29
 ● Estimated 12% to 18% cost savings over reactive maintenance program.
Disadvantages of Preventive maintenance
● Catastrophic failures still likely to occur.
● Labor intensive.
● Includes performance of unneeded maintenance.
● Potential for incidental damage to components in conducting unneeded
maintenance.
Predictive Maintenance
The definition of predictive maintenance is as follows: Measurements that can identify the
beginning of a degradation mechanism, allowing the causing stressors to be removed or
regulated before the component's physical state significantly deteriorates. Findings show
functional capabilities for the present and the future.
Advantages of predictive maintenance
● Increased component operational life/availability.
● Allows for preemptive corrective actions.
● Decrease in equipment or process downtime.
● Decrease in costs for parts and labor.
● Better product quality.
● Improved worker and environmental safety.
● Improved worker moral.
● Energy savings.
● Estimated 8% to 12% cost savings over preventive maintenance program.
Disadvantages of predictive maintenance
● Increased investment in diagnostic equipment.
● Increased investment in staff training.
● Savings potential not readily seen by management.
Proactive Maintenance
Pro-active maintenance, which employs a number of technologies to increase the
operational lifespan of equipment and essentially eliminate reactive maintenance, is the
most recent advancement in the field of predictive maintenance.

Predictive maintenance vs Proactive maintenance

Predictive maintenance uses sensors, measuring devices, and other technologies to
ascertain a machine's status.
Example: Assume that a fan had an irregular vibration that was discovered by sensing
equipment (such as a vibro-meter), and that we responded to the call to fix the fan's
current issue. Nevertheless, with proactive maintenance, we look for the root of the issue,
which could be a design issue, a weather issue, an operation issue, etc., in order to
address the real issue.
PLC Maintenance:
Backup PLC Program
When performing routine maintenance, make a duplicate of your PLC program to ensure a
somewhat current backup. This backup file can be downloaded onto a new PLC in the event that
an old PLC breaks down and needs to be replaced.
Check LED Indicators
Examine the battery and power LED indications. A low battery or possible power problems may be
indicated by the power LED indicator being off or flickering or the battery LED indicator being on or
flickering.
Replace the Battery
It's time to change the battery if the Battery OK light is flickering or illuminated. By routinely
replacing the battery, you can prevent serious issues if you lose main control power.
Check Operating Environment
To ensure that your PLC is working in the right conditions, check the temperature, humidity, and
other environmental parameters. Clean the filters in the enclosure to ensure proper airflow inside

30
the cabinet.
Check Operating Voltage
To ensure that the voltage is within the proper range and free from power spikes or "brown out"
issues, check the input voltage that is powering your PLC.
Check Program Functionality
When performing routine maintenance, make sure the system or piece of equipment being
managed is functioning properly by testing its functionality.
Keep an eye out for signs of overheated components.
Look for deformed, twisted, or discolored casings on the CPU and modules, as well as burning
smells.
Clear Dust And Check Venting
Do not let dust and filth build up on the PLC's parts. The I/O system and central processing unit are
not intended to be dust-proof. Verify that no PLC or module cooling vents are obstructed or clogged
by dirt or dust.
Ensure sure the PLC is surrounded by enough room for heat to dissipate. Circuit malfunction can
happen if heat dissipation is hindered, and conductive dust that enters the electronic boards can
result in a short circuit and potential permanent damage to the circuit board. See the Battery Status
If necessary, check the battery and replace it.
Check Connections
Ensure that all wiring, modules, plugs, sockets, terminal strips, and communication cables are
connected correctly. Consider adding a vibration detector if your PLC system is situated in a
location with frequent vibrations that could potentially loosen terminal connections. If so, perform
this check more frequently.
Identify Updates Needed
Check for any product notices, patches and upgrades and update as necessary.

Remove Unnecessary Items

Do not place anything near the PLC system, including drawings, installation guides, or other
documents. If these items are left on top of the CPU rack or other enclosures, airflow may be
obstructed, hot spots may develop, and the system may eventually fail.
Audit Parts In Use
Perform an audit to examine each portion of your PLC system and decide whether or not it needs
to be replaced.
Take Inventory Of Replacement Parts
To reduce downtime brought on by component failure; keep a supply of replacement parts on
hand. When the proper spare is on hand, a failure situation can be handled with only minutes of
downtime rather than hours or days.

Self-Check 3.1
1. What is the Operational Manual
2. What is the Advantages of reactive maintenance
3. Write down PLC Maintenance Activity

Answer Key 3.1

1. What is the Operational Manual

An operation and maintenance manual, also known as an O&M manual, is a comprehensive and
detailed document that provides maintenance employees with information on how to check,
repair, and upkeep machinery and equipment

2. What is the Advantages of reactive maintenance

31
• Low cost.
• Less staff.
3. Write down PLC Maintenance Activity
a. Backup PLC Program,
b. b. Check LED Indicators
c. Replace the Battery
d. Check Operating Environment
e. Check Operating Voltage
f. Check Program Functionality
g. Clear Dust And Check Venting
h. Check Connections
i. Identify Updates Needed
j. Remove Unnecessary Items
k. Audit Parts In Use
l. Take Inventory of Replacement Parts

32
 Job Sheet
Job Sheet - 1
Job Perform a PLC Maintenance
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Check environmental factors / operating conditions.
4. Clear debris, dust, and build up from your units.
5. Clean or replace all filters installed in enclosures.
6. Check all your connections for a tight fit, especially I/O
modules.
7. Inspect I/O devices for proper adjustments..
8. Proper use and maintenance of equipment.
Personal Protective 1. Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Tools and equipment: 1. PLC 01 pc
2. Combination Players 01 pc
3. Wire Stepper 01 pc
4. Philips Screwdriver 01 pc
5. Neon Tester 01 pc

33
 Review of Competency
:

Performance Criteria Yes No

1. Drawing is selected and checked to ensure that it  
conforms to the job requirements.

2. Drawing is validated.  

3. Drawing components, assemblies are identified.  

4. Dimensions are identified according to job  
requirement.
5. Clearances/tolerances are checked in accordance  
with workplace standard.
6. Instructions are identified and followed accurately.  
7. Material specifications are interpreted.  
8. Symbols in drawing are interpreted  
9. Operation and maintenance manuals are collected  
and interpreted
10. Operation and maintenance manuals are followed  
when operating and maintaining the equipment

Now, I feel ready to undertake my formal competency assessment.

Signed:

Date:

34
 Work with Mechanical Hand Tools, Power Tools and Measuring Devices

After completion this module trainee will able to:

1. Inspect hand tools and power tools for usability
2. Use hand tools properly and safely.
3. Operate power tools properly and safely
4. Clean/maintain hand tools and power tools after use

Module 02-S: Work with Mechanical Hand Tools, Power Tools and Measuring
Devices

35
 Module Content

Module Descriptor
This unit covers the knowledge, skills and attitudes required to work with mechanical hand
and power tools. It specifically includes the tasks of inspecting hand tools and power tools
for usability, using hand tools properly, operating power tools properly and safely and
cleaning/maintaining hand tools and power tools after use.
Nominal Duration: 10 hours

Learning Outcomes:

Upon completion of the module, the trainee should be able to:

1. Inspect hand tools and power tools for usability
2. Use hand tools properly and safely.
3. Operate power tools properly and safely
4. Clean/maintain hand tools and power tools after use

Performance Criteria:

1.1 Appropriate tools are selected.

1.2 Application of tools to job requirement is determined and demonstrated.
1.3 Usability of tools are checked and verified.
1.4 Hand tools and power tools are prepared.
1.5 Sources of power supply for power tools are identified.

2.1. Appropriate hand tool for the job is used.

2.2. Proper and safe use/operation of different hand tools is demonstrated.
2.3. Safety precautions is maintained when using hand tools.
2.4. Unsafe or faulty tools are identified and marked for repair.
3.1. Power supply outlet and electrical cord are inspected for use in accordance with
workplace safety requirements.
3.2. Proper sequence of operation is applied in using power tools to produce results.
3.3. Power tools are used safely in accordance with manufacturer’s operating
specification
4.1. Dust and foreign materials are removed from power tools in accordance with
workplace standard.
4.2. Condition of tools is checked after use.
4.3. Appropriate lubricant is applied after use and prior to storage.
4.4. Measuring devices are checked and calibrated.
4.5. Defective tools, instruments, power tools and accessories are inspected and
corrected or replaced.

Learning Outcome 1:
Inspect hand tools and power tools for usability

36
 Contents:

Instructions
7. Hardware: Hand tools & Power Tools
8. Sample product/work piece
9. Drawings and/or sketches/Diagram
10. Manual/CBLM

Assessment Criteria

1.1 Appropriate tools are selected.

1.2 Application of tools to job requirement is determined and demonstrated.
1.3 Usability of tools are checked and verified.
1.4 Hand tools and power tools are prepared.
1.5 Sources of power supply for power tools are identified

Resources required

The following resources must be provided to students/trainees):

1. White board marker
2. Flip charts
3. Hand tools
4. Portable power tools List

Learning Activity 1.1

Learning Activity Resources/Special Instructions/References

Inspect hand tools ▪ Information Sheet:.1.1

and power tools for ▪ Self-Check:.1.1
usability ▪ Answer Sheet: 1.1

Information Sheet 1.1)

Inspect hand tools and power tools for usability:
Tool

37
A tool is any physical item that can be used to achieve a goal, especially if the item is not
consumed in the process.
There are many different hand and power tools that a carpenters use on the job. Some tools
are very specific to certain types of carpentry work and may not be used by all carpenters.
Other tools are used by all carpenters.
There are two primary classifications for tools used in carpentry.
1. Hand tools
2. Power tools
a. Portable Power Tools
b. Stationery Power Tools

Hand Tools
Any tool that is not a power tool—i.e., one that is powered by manual labor rather than an
engine—is referred to as a hand tool. Power tools can be more dangerous than hand tools.
All carpenters probably utilize the common hand tools on the list below to complete their task.
The hundreds of hand tools that are accessible to PLC are much more numerous than the
few items listed below.

Power Tools
A power tool is a tool that uses additional power and a different mechanism from hand tools,
which are only used manually. Electric motors are used in the most popular kinds of power
tools.
In the furniture industry, power tools are used for a variety of tasks, including drilling, cutting,
shaping, sanding, grinding, routing, polishing, and painting.
Power tools can either be stationary or portable, where portable refers to hand-held power
equipment.

Name: Ball peen hammer Name: Cross peen hammer.

peening, or shaping metal
Used for: Used for: set small nails and pins
materials by hammering

Name: Straight peen hammer. Name: Mallet/soft hammer

used in metal work, stone
offer driving force without
Used for: work, blacksmithing or Used for:
damaging surfaces
woodworking.

38
Name: Bench vise. Name: Soft jaw.
hold an object safety and
fixture with standard, flat vise
Used for: securely so that it can be Used for:
jaws during machining
worked on

Name: Rough file Name: Medium file.

removing more quantity of
Used for: Used for: removing more metal
metal in less time

Name: Smooth file. Name: Punches

drive fasteners such as nails
and dowels, making a hole, or
removing less metal and for
Used for: Used for: forming an
giving good surface finishing
indentation/impression of the
tip on a workpiece

39
Name: Chisels. Name: Wrenches.
gripping, fastening, turning,
dressing, shaping, or working
tightening and loosening things
Used for: a solid material such as wood, Used for:
like pipes, pipe fittings, nuts
stone, or metal.
and bolts.

Name: Pliers( Cutting ) Name: Screw drivers Star

ensure even more torque can
grip, splice or cut wires, and
Used for: Used for: be applied, in mechanical
strip insulation.
production

Name: Pliers( Combinations ) Name: Pliers( Nose)

gripping, twisting, bending and Bending, re-position and
Used for: Used for:
cutting wire and cable sniping wire and cable

40
Name: Diagonal Cutting Pliers Name: Cutting Nipper
"nip" or remove small amounts
cutting wire and small pins in of a hard material, such as
Used for: areas that cannot be reached Used for: pieces of a tile, which needs to
by larger cutting tools be fitted around an odd or
irregular shape

Name: Scriber. Name: Scraper

move or remove dirt, gravel or
mark lines on work pieces,
Used for: Used for: other material from the ground
prior to machining.
surface

Name: Screw drivers Name: Surface plate

as the main horizontal
reference plane for precision
Used for: turning screws Used for:
inspection, marking out
(layout), and tooling setup

41
Name: Marking table Name: Height gauge
marking out large objects, for
checking accuracy, for height measuring the height of
Used for: Used for:
alignment and checking objects
parallelism

Name: Layout tools Name: Tap sets

laying out work pieces to create threads on components
scribe lines, center punch, such as screws, bolts, nuts
Used for: Used for:
measure lengths, and mark off and to create a threaded hole
sections, angles, and circles to screw components into

Name: Die sets. Name: Tap handle

turn taps or other small tools,
Used for: Pipe threads Used for: such as hand reamers and
screw extractors.

42
Name: Die handle Name: Hacksaw
make sure the amount of
pressure applied remains
Used for: Used for: cutting metal
uniform throughout the thread
cutting process

Name: Paint Brushes Name: Drill bits

remove material only from the
Used for: apply paint or ink Used for: edge of the hole, cutting out an
intact disc of material

Name: Tap extruder. Name: Screw Extruder.

utilizes auxiliary equipment to
Used for: Used for: produce products such as
tubing, pipes, and profiles.

43
Name: Hacksaw frame Name: Hacksaw blade.
the saw could cut into panels
cutting metal, but can also cut
of sheet metal without the
Used for: Used for: various other materials, such
length of cut being restricted
as plastic and wood
by the frame.

Name: Rivet Gun Name: Sledge Hammers

demolition jobs where high
Used for: drive rivets Used for:
force is required

Name: Sockets Name: Spanners

easy tightening and loosening provide grip and mechanical
Used for: of common fasteners, typically Used for: advantage in applying torque
nuts and bolts. to turn objects

Name: Vice grip Name: Wire Cutters

to properly cut either wire or
clamped tight and stay that cable with minimal damage to
Used for: Used for:
way while you make a cut the insulation or internal
conductors of the wire or cable

44
Name: Wood Planners Name: Hand drill machine.
helps you even out a piece of
converts and amplifies circular
wood into a board with the
Used for: Used for: motion of the crank into
exact same thickness
circular motion of a drill chuck
everywhere

Name: Hand grinding machine Name: Powered screw driver

allows you to screw and
Used for: grind work pieces Used for:
unscrew effortlessly

Name: Hand shear Name: Clamps

make quick cuts, usually in temporarily hold work securely
Used for: Used for:
smaller pieces, in place

45
Name: Jacks. Name: Soldering iron
apply great forces or lift heavy
Used for: Used for: heat solder,
loads

Name: Allen wrenches. Name: Draft punches

turning bolts and screws which Indent or create a hole through
Used for: Used for:
have hexagonal sockets a hard surface

Power tools:

46
Name: Power drills Name: Power rivet gun
create a hole in a variety of
Used for: Used for: Drive rivets
materials

Name: Hand grinders Name: Electric Air Blower

cutting, grinding, debarring, Blow away dust from every
Used for: Used for:
finishing and polishing. nook and corner

Name: Hot air gun Name: Nail Gun.

redecorating, removing
Used for: Used for: Drive nails into wood/board
flooring

Sources of power supply for power tools

47
Mains electricity and rechargeable batteries are the two
types of electricity that are most frequently used with power
tools.

Take note that 415 volt power, commonly known as "three-

phase" power, is typically used to power large industrial
machines.

Nevertheless, they don't come in the hand-held range of

power tools and utilize a different kind of power plug and
socket.

Some people refer to mains electricity as '240 volt power',

because that's the voltage that comes out of a standard
power point.

Standard power points are designed to take two-pin or

three-pin plugs. One pin connects to the active or live wire.
The opposing pin connects to the neutral wire, which
completes the circuit.

The bottom pin has no role in delivering electricity, but

connects the tool to the earth wire as a safety mechanism,
in case there is a malfunction or 'short circuit'
There are two main systems of insulation used in power
tools:

● Single insulated tools use an earth wire which is

connected to the metal casing of the tool at one
end and the earth pin of the plug at the other end.
● In the event of a fault that causes a short circuit,
the current is able to flow straight to earth without
giving the operator an electric shock.

● Double insulated tools use two layers of

insulation between the internal parts that carry a
current and the outer metal parts of the body.

For this reason, they are not connected to an earth

wire.

48
Rechargeable battery
As rechargeable batteries continue to improve in
performance and power output, an increasing variety of
'cordless' tools are coming onto the market, including
jigsaws, circular saws, planers, and even chainsaws.

However, by far the most common cordless power tool is

the drill. This is because most drills are smaller and
consume less power than the other types of tools, so their
rechargeable batteries are lightweight and relatively cheap.
Always remember to pack the battery charger when you
take cordless tools to the jobsite.

It's also a good idea to take two batteries, so you can leave
one on 'charge' while the other is in the tool.

Self-Check 1.1
1. What is Hand Tools
2. What is Power Tools
3. Write down 5 importance tools in PLC Occupations
4. what is the functions of Electric Air Blower

Answer Key 1.1

1.What is Hand Tools

A hand tool is any tool that is not a power tool – that is, one powered by hand (manual labour)
rather than by an engine. Hand tools are generally less dangerous than power tools.

2.What is Power Tools

A power tool is a tool that is actuated by an additional power source and mechanism other than

49
the solely manual labour used with hand tools. The most common types of power tools use
electric motors.

3.Write down 5 importance tools in PLC Occupations

a. Star Screwdriver
b. Flat Screwdriver
c. Combinations Pliers
d. Cutting Pliers
e. Neon Tester
4.What is the functions of Electric Air Blower

Blow away dust from every nook and corner

Job Sheet
Job Sheet - 1
Job Identify Different types of Hand tools and power tools
Procedure: 1. Collect and wear the required PPE as per specification.
2. Collect goods as per specification.
3. Learn about the use of hand tools.
4. Learn about the use of power tools.
5. Will work using tools.
6. At the end of the work, the goods and equipment will be
stored in the proper place.
7. Clean the workplace.
Personal Protective 1. Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Tools and equipment: 1. Combination pliers 01 pc
2. Cutting pliers 01 pc
3. Nose pliers 01 pc
4. Screwdriver 01 pc

50
 5. Wire stripper 01 pc
6. Pulley 01 pc
7. Crimping tools 01 pc
8. Fertilizer clip pliers 01 pc

Learning Outcome
Use hand tools properly and safely

Contents:
Instructions
1. Hardware: Hand tools
2. Sample product/work piece
3. Drawings and/or sketches/Diagram
4. Manual/CBLM

Assessment Criteria
2.1. Appropriate hand tool for the job is used.
2.2. Proper and safe use/operation of different hand tools is demonstrated.
2.3. Safety precautions is maintained when using hand tools.
2.4. Unsafe or faulty tools are identified and marked for repair

Resources required

The following resources must be provided to students/trainees):

1. White board marker
2. Flip charts
3. Hand tools

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Use hand tools properly ▪ Information Sheet:.2.1

and safely ▪ Self-Check:.2.1
▪ Answer Sheet: 2.1

51
 (Information Sheet 2.1)

Use hand tools properly and safely:

Screwdrivers
1. Screwdriver tips shall be selected to fit the screw. Sharp- edged bits will not slip as easily as ones
that are dull. Redress tips to original shape and keep them clean.
2. Do not use a screwdriver as a chisel. The tool can slip and cause a deep puncture wound.
3. Never carry a screwdriver in your pocket. If you fall, the tool could cause a serious injury.
4. Never use a screwdriver to pry anything open, there are other tools in the shop for that purpose.
5. Never strike a screwdriver with a hammer or mallet, the tips are brittle and could break and injure.
6. Make sure to use the proper screwdriver for the job; never use a slotted screwdriver for a Phillips
screw
Hammers & Mallets
1. Always inspect the hammer before use. Loose hammer heads or nails stuck in the claw might fly
off and cause injury.
2. If a hammer head is loose on the handle, immediately take it to the instructor. Redressing is not
recommended.
3. Never use a hammer to anything but unhardened nails and nail sets; use a ball-peen hammer for
still chisels and punches
4. Never strike two hammers together. The faces are very hard and a blow might cause a chip to
break off and fly out at a high speed.
5. Knuckles can be injured if you “choke up” too far on a hammer when striking a blow.
6. Unless the blow is truck squarely the hammer ma bounce off the work and cause injury.
7. Place a hammer on the bench carefully; a falling hammer can cause serious injury
8. Never use a common nail hammer to strike other metal objects.

Punches
1. Never use a punch with a mushroomed struck face or with a dull, chipped, or deformed point.
2. Punches that are bent, cracked, or chipped shall be discarded.
Chisels
1. Factors determining the selection of chisels are the materials to be cut, the size and shape of the
tool, and the depth of the cut to be made.
2. Choose a chisel only large enough for the job so the blade is used, rather than only the point or
corner.
3. Never use chisels with dull blades–the sharper the tool, the better the performance.
4. Chisels that are bent, cracked, or chipped shall be discarded.
5. Re-dress cutting edge or struck end to original contour as needed.
6. The chisel should be made heavy enough so that it will not buckle or spring when struck
Planers
1. Inspect all planer before using them. Never use dull planers.
2. All work must be clamped or put in a special jig when using the planers.
3. Never remove the blade from the planer and use it.
Saws
1. Saws should be carefully selected for the work they are to do.
2. For crosscut work on green wood, a coarse saw (4 to 5 points per inch) is to be used.
3. A fine saw is better for smooth, accurate cutting when using dry wood.

52
Saws are to be kept sharp and well set to prevent binding
Files
1. Select the right file for the job, making sure that it has a secure handle.
2. Never use a file as a pry or hammer, as chipping and breaking could result in user injury.
Allen Wrenches, Combinations Wrenches & Adjustable Wrenches
1. Select a wrench that fits properly; loose fitting wrench may slip and round off the corner of the bolt
head or nut.
2. Never hammer on a wrench to loosen a stubborn fastener, unless the tool has been designed for
this job.
3. It is dangerous practice to lengthen the wrench handle for additional leverage; use a larger wrench.
4. When using wrenches, clean grease and oil from the floor in the work area, the will reduce the
possibility of slipping and losing your balance.
5. Do not use a wrench on moving machinery.

Potential Hazards From Using Hand Tools

The following are factors contributing to hazards associated with using hand tools by
carpenter:
Hazard Factor Example of Injuries
Dangerous parts of hand tools Technician cut by sharp corner or edge
Technician cut by defective or broken parts of a tool, or
Defects in hand tools
person nearby hit by fragmented parts flying out from a tool

Hand tools slipping out from grasp Technician or person nearby injured by a tool flying out or
during work dropping from height
Technician sustaining musculo-skeletal injuries or strain
Hand tools improperly designed
injuries
Repetitive actions in use of hand Technician sustaining musculo-skeletal injuries, e.g.
tools for a prolonged period tenosynovitis

Large impact force on work pieces Broken fragments or particles flying out causing injuries to
by tools eyes or face; excessive noise causing hearing loss

Improper alignment of loads on a jack causing load

Displacement of loads from tools
displacement and injuries to workman

Self-Check 2.1
1. How you will use Screwdriver
2. How you will use files
3. How you will use saw

Answer Key 2.1

53
1. How you will use Screwdriver

Screwdriver tips shall be selected to fit the screw. Sharp- edged bits will not slip as easily as ones
that are dull. Redress tips to original shape and keep them clean.

2. How you will use files

1. Select the right file for the job, making sure that it has a secure handle.
2. Never use a file as a pry or hammer, as chipping and breaking could result in user injury.

3. How you will use saw

● Saws should be carefully selected for the work they are to do.
● For crosscut work on green wood, a coarse saw (4 to 5 points per inch) is to be used.
● A fine saw is better for smooth, accurate cutting when using dry wood.
● Saws are to be kept sharp and well set to prevent binding

54
 Job Sheet
Job Sheet - 1
Job Use hand tools properly and safely:
Procedure: 1. Collect and wear the required PPE as per specification.
2. Collect goods as per specification.
3. Learn about the use of hand tools.
4. Will work using tools.
5. At the end of the work, the goods and equipment will be
stored in the proper place.
6. Clean the workplace.
Personal Protective 1.Apron 01 Pc
Equipment (PPE):
2. Safety Shoe 01 Pc
Tools and equipment: 1. Combination pliers 01 pc
2. Cutting pliers 01 pc
3. Nose pliers 01 pc
4. Screwdriver 01 pc
5. Wire stripper 01 pc
7. Pulley 01 pc
8. Crimping tools 01 pc
9. Fertilizer clip pliers 01 pc

Learning Outcome 3:
Operate power tools properly and safely

Contents:

Instructions
11. Hardware: PLC, HMI
12. Sample product/work piece
13. Drawings and/or sketches/Diagram
14. Manual/CBLM

Assessment Criteria

3.1. Power supply outlet and electrical cord are inspected for use in accordance with
workplace safety requirements.
3.2. Proper sequence of operation is applied in using power tools to produce results.
3.3. Power tools are used safely in accordance with manufacturer’s operating
specification

55
 Resources required

The following resources must be provided to students/trainees):

1. White board marker
2. Flip charts
3. Portable power tools

Learning Activity 3.1

Resources/Special
Learning Activity
Instructions/References

Operate power tools ▪ Information Sheet:.3.1

properly and safely ▪ Self-Check:.3.1
▪ Answer Sheet: 3.1

(Information Sheet 3.1)

Operate power tools properly and safely:
SAFETY MEASURES OF POWER TOOLS
When misused, power tools can be dangerous. Depending on the type of energy they
employ, power tools can be classified as electric, pneumatic, liquid fuel, hydraulic, and
powder-actuated.
Every power tool usage should be familiar to carpenters. They should be aware of the
potential risks as well as the safety measures to mitigate such risks. Misuse injuries may
cause amputation, blindness, deafness, hearing loss, impalement, and even death.
General Safety Rules for Portable Power Tools:

 Keep your work area clean and well lit. Cluttered benches and dark
areas invite accidents.
 Do not operate power tools in explosive atmo- spheres, near
flammable liquids, gases, or dust. Power tools create sparks, which
may ignite the dust or fumes.

 Grounded tools (three pronged cords) must be plugged into a

properly grounded installed outlet. Never remove or cut off the
grounding prong or modify the plug in any way. Do not use any
adapter plugs.
 Double Insulated tools have a polarized plug (one blade is wider
than the other.) This plug will fit into an outlet only one way. Do not
change the plug in any way.
 Do not use AC only rated tools with a DC power supply.
 Store battery packs away from other metal ob- jects like paper clips,
coins, keys, nails, screws, or other small metal objects. These things

56
 can make a connection from one terminal to the
 In damp locations, only plug your tool into a Ground Fault Circuit
Interrupter (GFCI). If the work area does not have a permanent
GFCI on the outlet, use a plug-in GFCI. Wear rubber gloves and
footwear.
 Don’t use or leave power tools in the rain or wet conditions.
 Do not abuse the cord, carry the tool by its cord, or pull the cord to
unplug it. Keep the cord away from heat, oil, sharp edges or moving
parts. Replace damaged cords immediately.
 Always hold the tool by the insulated gripping surfaces. Contact with
hidden wiring or its own cord will make exposed metal parts of the
tool “live” and shock the operator.

 Rules about Extension Cords When using a power tool outside, use
an extension cord marked for outdoor use with “W-A” or “W”.
 These cords are made for outdoor use. Extension cords with 3-
prong grounding plugs must be plugged into 3-prong outlets when
using grounded tools.
 Replace damaged or worn cords immediately.

 Always read and understand the tool’s operator’s manual, tool

markings and the instructions packaged with the accessory before
starting any work.
 Stay alert, watch what you are doing and use common sense when
using a power tool.

 Use sharp blades and wheels. Damaged or dull blades could throw
teeth, posing a serious injury risk. Damaged or dull wheels can
create excessive friction, causing the wheel to warp or bind. A sharp
blade or wheel will tend to cut its way out of a pinching condition.

 Before working with an abrasive cut-off machine or dry-cut machine,

make sure the machine and its accessories are in proper working
order. Failure to do so can increase your risk of injury and result in
blade or wheel pinching, binding or stalling, and loss of control.

What should you do if you find a tool defective?

● If a tool is defective, remove it from service, and tag it clearly "Out of service for
repair".
● Replace damaged equipment immediately - do not use defective tools "temporarily".
● Have tools repaired by a qualified person - do not attempt field repairs.
Power Drill Machine/Electric Drill Machine
Drills are one of the most convenient tools for DIY projects, but like all power tools, they need to be handled
safely. Knowing how to drill correctly will help you prevent injury from flying shards of broken material or
improperly handled electricity. If you ever have a safety question that this guide does not answer, your drill's

57
manual is a good place to look next.
Things You Should Know
● Wear safety goggles or glasses that cover the sides of your eyes to protect them from flying debris.
● Drill a shallow pilot hole first. A pilot hole prevents the drill bit from slipping so you don't split or damage
the wood.
● Choose the correct drill bit to drill the final hole. Using the wrong bit can cause the bit or the material
you're drilling to break.
● Hold the drill steady and push it into the material you're drilling. If it takes more than light force to drill
the hole, you're using the wrong bit.

Step-1: Preparing to Drill:

Use protective eyewear and suitable clothing. Avoid wearing anything
too loose or wearing jewelry that might dangle as you lean over the
drill. To shield your eyes from flying debris, put on safety goggles or
glasses that cover the sides of your eyes.

Step-2: Wear ear protection if drilling regularly.

Around 90 decibels are produced by a handheld electric drill, which is
just loud enough to damage hearing over time. Hearing protection is
not required because the majority of cordless drills are quite quiet.
The loudest handheld drills produce above 100 dB, and these are
impact drills (hammer drills). It is advised to wear hearing protection
whenever using them.

Step-3: Protect your lungs when necessary:

Use face protection if the endeavor creates a lot of dust. A dust mask
only provides temporary comfort. If you drill frequently, for an
extended amount of time, or if the substance you are drilling is known
to pose a respiratory risk, use a respirator.
Each respirator has a rating for particular dangers. Ensure that the
one you choose is appropriate for your project.
Step-4: Choose the correct drill bit:
The material you are drilling or the bit itself could break if you use the
incorrect kind of bit. A general-purpose bit can be used on the
majority of wood, masonry bits can be used on stone, brick, or
concrete, HSS (high speed steel) bits can be used on the majority of
metals, and carbide or diamond-tipped bits can be used on extremely
hard, brittle surfaces like porcelain, glass, or glazed tiles. There are
many different specialized bit designs, so if you're unsure which bit to
use, consult the drill handbook or the bit manufacturer.
Step-5: Fit the drill bit firmly into the chuck.
The drill's "jaws" are clamped shut by the chuck. While the drill bit
spins, this keeps it in place. To change a drill bit, turn the chuck loose
by spinning the chuck after making sure the drill is off (and unplugged
if corded). Depending on the drill, you might be able to accomplish
this by hand or you could require a chuck key, which can be found in
a compartment on the handle or top of the drill. Retighten after
inserting the drill bit into the chuck. Before starting the drill, check that
the bit is straight and securely fastened, and take the key out.
Step-6: Preparing to Drill:
Clamp the component down securely before drilling if it is a small,
loose piece. When drilling, don't hold the component in place with just
one hand because the drill could slip and hurt you.

58
Step-7: Handle the cord safely:
When not in use, the drill's cord should never be left hanging across a
walkway. Never handle the drill's cord. Use a cordless drill instead if
you need to drill in a muddy or wet location.

Step-8: Drill a pilot hole.

In many instances, starting with a drill bit that is a little smaller than
the final hole size will yield better results. Drill a small "pilot hole" and
then finish the job with the larger bit. The drill bit won't slip as a result
of the pilot hole, which also lessens the possibility of splitting wood or
causing other damage.

Step-9: Drill with steady pressure.

Push the drill into the substance you are drilling while maintaining
stability. You're probably using the wrong bit if drilling the hole
requires more force than a light touch..

Step-10: Adjust the clutch.

Each drill features a twistable collar that can be used to change the
torque, frequently marked with a series of numbers. The drill will
apply more torque (rotational force) the higher the number. Increase
the torque if you are having problems piercing the material. Reduce
the torque if you are overdriving screws (burying them too deeply) or
if drilling too deeply could cause damage to something. Some models
display a drill bit icon to indicate the highest torque.
Step-11: Avoid overheating the drill bit.
The drill bit will experience a great deal of friction if you are drilling
through hard materials or drilling quickly. This can quickly overheat
the bit to the point where it burns the drilling material or turns red hot.
Increase drill speed only if the drill isn't running smoothly after starting
at a low speed. Stick to reasonable rates when drilling through
difficult materials or making numerous holes in any material, and take
breaks occasionally to allow the bit to cool down.
Step-12: Do not force a jammed bit through:
Don't try to force the drill bit out of the material if it becomes stuck in
the drill bit. Use manual tools to disengage the drill's plug, separate
the bit from the chuck, and remove the bit.

Hand Grinder Machine

Angle grinders are electric power tools that include removable grinding wheels that can be
used for a number of tasks around the house, including sanding, grinding, cleaning, and
cutting. Make sure you get the appropriate attachment for the work and use it properly while
using a grinder. When using a grinder, always follow safety precautions because it can lead to
injuries from the blade itself and from flying debris.
A versatile hand tool frequently used in the manufacturing sector is the grinding machine. It is
a tool used to scrape off extra surface layers. To cut, grind, and polish wood, many types of
grinders are employed.
The majority of grinders can operate at up to 13,000 revolutions per minute, and some can go
even faster. These capable tiny hand tools can quickly remove a significant quantity of material
when equipped with the right accessories.

59
5. Pick a wire brush attachment for cleaning and paint
removal jobs.:
To prevent it from moving while you work on it, secure it with a
clamp. Position the angle grinder so that the wire brush spins
away from the object you are grinding rather than into it when you
apply it to an edge. Try buzzing any accumulated dirt off of
gardening tools. Even set-on cement will function with it.
For flat surfaces, use the cup wire attachment; for nooks and
crannies, use the wheel.
6. Opt for a cutting wheel for slicing through metal,
tile, or concrete:
A cutting wheel functions similarly to a saw. When you lightly
press it against the material you want to cut through, it quickly
removes tile and metal rebar, for example.
Choose the appropriate blade type for the job you're working on.
A cut off wheel is effective and reasonably priced for metal.
Select a diamond wheel for use on concrete, tile, and masonry.
To find out what materials you can use the wheel on, read the
attachment..
7. Try a diamond tuck pointing wheel to remove
mortar:
Use this wheel to replace any loose mortar that is in your
brickwork if it has to be fixed. To get everything out, make
repeated passes with the wheel through the brickwork. Avoid
using the tool any closer than 1/8 inch from the brick (3.2 mm).
To speed up the process, choose a tuck pointing wheel that is
almost the same width as your mortar.
8. Refine edges on metal tools with a grinding wheel:
perpendicular to the blade against the edge. The grinding wheel
will turn away from the edge rather than toward it if you position it
so that it is at the same angle as the blade's edge. For a little
while, lift the wheel off. Start the grinder, and while maintaining
the proper angle, make several light passes down the blade.
Becoming too hot because doing so will make it exceedingly
brittle. Give it some time to rest if it turns black or blue.
Look for the arrow on the wheel that indicates the direction it will
spin in when it is turned on.

60
9. Put on safety gear like goggles, long sleeves, and
full-face protection:
Angle grinder risks include flying debris, including fragments that
have broken off the tool's attachments. Use safety equipment to
shield yourself from getting something in your eye. Although
safety eyewear’s are helpful, a full face shield is preferable. Use
work gloves and long sleeves as additional protection for your
hands and arms.
Put on earplugs or use noise-cancelling earmuffs to protect your
ears from the machine's deafening loudness.
While performing highly dusty tasks, such as sanding and
grinding mortar, wear a dust mask.
10. Support the tool with both hands:
Hold the handle firmly with one hand. Hold on to the dead-man
switch if your tool has one with this hand. When a tool is turned
on, a dead man's switch must be held in position continuously in
order for it to function. Hold the weight of the tool with your other
hand.
Use whichever hand seems most comfortable to grasp the
handle.
The switch on the dead man is there as a precaution. It will
automatically turn off if you unintentionally drop the grinder.
11. Let the grinder come to full speed before applying
it to the surface:
To turn it on, press the power button. Allow it to pick up speed
when cutting, grinding, or sanding to maintain your movements
fluid and consistent. For instance, the cutting disc will make a
better cut if it is running at full speed before cutting through metal
or other materials.
12. Move the angle grinder around constantly when
sanding or cleaning:
When sanding, avoid keeping the tool stationary to avoid getting
gouges. Rotate your body over the surface for a smoother finish.
If you're trying to smooth or clean a specific region, don't hold it in
place; instead, move it all over the spot until you're happy with
the results.
13. Apply the tool with light pressure when cutting or
grinding:
Leave the work to the tool. In reality, all you need to do to cut or
grind something is to hold the grinder against it. If you apply
excessive pressure, the tool could tug on the object you're
working on and kick as a result. A instrument that kicks could
cause injury.You can exert a little extra pressure when sanding.
14. Use the correct angle for the wheel attachment:
Apply the tool to the work surface at a 5°–10° angle for sanding.
Try a 15° to 30° angle for grinding; when using this attachment,
make sure you're using the flat part of the wheel.
When cutting, hold the wheel perpendicular to the item you're
cutting and use the side of the wheel to cut the piece head-on.

61
15. Keep the guard on no matter what you do:
In some tasks, the guard might get in the way, but keep it on. In
the event that the wheel or attachment breaks, it offers some
protection against flying debris. The guard will handle the blow
considerably better than your body or arms will!

16. Check the grinder has stopped spinning

completely before putting it down:
The wheel may move about on the surface you set it on if it is still
spinning in any way. If your vehicle has brakes, use them to
ensure that it is stopped. Instead, simply wait until it comes to a
complete stop.
It might begin chopping things you don't want it to or even turn
around and come back at you.
17. Unplug the tool when you're not using it:
Turning off the instrument is not sufficient to prevent accidental
activation. So that it can't turn on and hurt you or someone else,
unplug it from the wall.
When not in use, place the grinder on a table with the wheel
facing up.

18. Opt for a 4 by 4.5 in (10 by 11 cm) grinder for most

projects:
Yet, this size will work just well for a range of activities, including
the majority of the ones you'll do at home. Much larger grinders
are available for projects. Also, because it is a common size, you
can get it in most hardware stores.
A bigger instrument is also harder to handle, which increases the
risk of harm if you're not careful.
19. Choose a 5-9 amp motor if you plan on using the
grinder a while:
Try not to purchase the cheapest grinder if you plan to use it for
multiple tasks. You can purchase a higher-quality machine if you
invest a bit extra money. Choose a motor that draws between 5
and 9 amps so that it will have a little more power and possibly
operate for longer.

20. Check the RPM on accessories against the RPM on

the grinder before buying them:
There will be a maximum RPM for each accessory (rotations per
minute). Overdoing that RPM could cause the attachment to
separate, shattering into flying shards that could strike you. As a
result, the accessory's RPM must be equal to or higher than the
grinder's maximum RPM.
This will prevent you from exceeding the accessory's maximum
speed even if you turn your grinder all the way up.

62
21. Look for safety features like a wheel brake system:
If necessary, a wheel brake mechanism will instantly stop the
grinder. Also, it enables you to completely stop the grinder before
setting it down. If you can, choose a grinder with this safety
feature.
Your grinder can be made safer by using a grinding disc with
noise cancellation and a handle with vibration reduction.

Self-Check 3.1

1. Write down 2 General Safety Rules for Portable Power Tools

2. What should you do if you find a tool defective?
3. What is functions of Hand Grinder Machine

Answer Key 3.1

1. Write down 2 General Safety Rules for Portable Power Tools

● Keep your work area clean and well lit. Cluttered benches and dark areas invite
accidents.
● Do not operate power tools in explosive atmo- spheres, near flammable liquids,
gases, or dust. Power tools create sparks, which may ignite the dust or fumes.
2. What should you do if you find a tool defective?

● If a tool is defective, remove it from service, and tag it clearly "Out of service for
repair".
● Replace damaged equipment immediately - do not use defective tools "temporarily".
● Have tools repaired by a qualified person - do not attempt field repairs.
3. What is functions of Hand Grinder Machine

Angle grinders are electric power tools with detachable grinding wheels that you can apply to a
variety of jobs around your home, including sanding, grinding, cleaning, and cutting. When using a
grinder, make sure you're picking the right attachment for the job and using that attachment
correctly. Always practice safety procedures when working with a grinder, as it can cause injury,
both from the blade itself and from flying debris

63
 Job Sheet
Job Sheet - 1
Job Perform of How to use Hand Grinder Machine
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Pick a wire brush attachment for cleaning and paint
removal jobs
4. Opt for a cutting wheel for slicing through metal, tile, or
concrete:
5. Try a diamond tuck pointing wheel to remove mortar:
6. Refine edges on metal tools with a grinding wheel:
7. Put on safety gear like goggles, long sleeves, and full-
face protection:
8. Support the tool with both hands:
9. Let the grinder come to full speed before applying it to
the surface:
10. Move the angle grinder around constantly when sanding
or cleaning:
11. Apply the tool with light pressure when cutting or
grinding:
12. Use the correct angle for the wheel attachment:
13. Keep the guard on no matter what you do:
14. Check the grinder has stopped spinning completely
before putting it down:
15. Unplug the tool when you're not using it:
16. Opt for a 4 by 4.5 in (10 by 11 cm) grinder for most
projects:
17. Choose a 5-9 amp motor if you plan on using the grinder
a while:
18.Check the RPM on accessories against the RPM on the
grinder before buying them:
19.Look for safety features like a wheel brake system:
20. Proper use and maintenance of equipment.
Personal Protective 1. Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Tools and Equipment: 2. Hand Grinder Machine 01 pc

64
Learning Outcome 4:
Clean/maintain Hand tools and power tools after use

Contents:

Instructions
1. Hardware: Hand Tools/Power Tools
2. Sample product/work piece
3. Drawings and/or sketches/Diagram
4. Manual/CBLM

Assessment Criteria

4.1. Dust and foreign materials are removed from power tools in accordance with
workplace standard.
4.2. Condition of tools is checked after use.
4.3. Appropriate lubricant is applied after use and prior to storage.
4.4. Measuring devices are checked and calibrated.
4.5. Defective tools, instruments, power tools and accessories are inspected and
corrected or replaced.

Resources required

The following resources must be provided to students/trainees):

1. White board marker
2. Flip charts
3. Hand tools
4. Portable power tools
5. Lubricating materials

Learning Activity 4.1

Resources/Special
Learning Activity
Instructions/References

Clean/maintain hand ▪ Information Sheet:.3.1

tools and power tools ▪ Self-Check:.4.1
aft ▪ Answer Sheet: 4.1

er use

65
 (Information Sheet 4.1)
Clean/maintain hand tools and power tools after use:
Maintenance
Maintenance is an action carried out to retain an item in or to restore it to its functional
condition.
Regular maintenance and servicing of power tools and electric tools will help to ensure that
they operate with optimum efficiency at all times. This will not only help to keep tool operating
costs low but it can also increase tool safety and reliability.
The first thing to do in any maintenance system is to use your eyes, nose, ears, experience,
and judgment. Follow your instinct or your keen observation on an equipment when doing
maintenance.
Types of Maintenance
1. Preventive maintenance is performed in order to ensure that tools are operating
properly and efficiently.
2. Corrective maintenance is performed in order to correct a failure.
3. Emergency maintenance is necessary to put the item at hold immediately to avoid
serious consequences such as the loss of production, extensive damage of assets,
and for safety reasons
Sample checklist of tools and equipment

YES NO STORING TOOLS AND EQUIPMENT

Are the tools stored in proper storage area when not in use?
Are the defective hand power tools removed from the storage area for
repair?
Are the power equipment turned OFF when not in use or when adjustments
are needed?
Are the tools and equipment kept clean and in good working conditions?
Are the worn-out, deteriorated or poorly insulated power tools and
equipment replaced/repaired?

Procedure of Maintaining Hand Tools and Power Tools

Segregation of tools:
Procedure in segregating and Labeling Non-functional Tools and Equipment
1. Conduct an inventory of tools and equipment.
2. Record the number of non-functional tools and equipment.
3. Segregate tools that are serviceable or unserviceable.
4. Report the number of tools and equipment that are non-functional but subject for
repair.
5. Label tools and equipment which are condemnable.
6. Return tools and equipment in the tool cabinet as per operating procedures.
Cleaning
Cleaning tools is the most important task which needs to perform after a day of work, but it's
essential for keeping your tools in good shape. And it really only takes a few seconds per
tool unless you've got something really nasty on your hands. It's well-worth the time spent
doing a little cleaning to save the time spent repairing a tool.
Hand tools: Carpenters can clean most hand tools by simply wiping them down with a rag.
If they're dirty, just give them a good wash with soap and water. Just dry them well afterward.
Spritz metal with a light coat of wax and wipe with a clean rag (you really just want to leave

66
a light film on them to help keep the rust away). Wipe wooden handles with a rag dampened
with a little linseed oil.
Power tools: Power tools are a little trickier to clean. First, make sure the tool is unplugged
before you clean it. Next, you'll want to get all the dust off. An air compressor can be really
useful for that. Wipe down the surface of the tool and then lubricate any moving parts.
Machine oil is a fine choice for this, but you should also check the manual that came with the
tool to see if they have better recommendations.
Lubrication
The following features contribute to safety and economic lubricating machine tools:
1. Plates on machines clearly show the grades of lubricant, quantities and intervals are
required. The machine name, type, and model should be visible.
2. Maintain the proper level of lubrication reservoirs.
3. Suitable method of lubrication should be followed to minimize or prevent metal – to
metal contact at all times.
4. Sufficient lubricant capacity is needed to prevent overheating and thermal distortion of
machine tool structures.
5. Adequate sealing should be properly observed. Install provision for removal of
contaminant collected by the lubricant (e.g., filters).
Types of Lubricant

1. Liquid
2. Solid
3. Grease
4. Paste
● Liquid lubricant: A lanolin or natural water repellent lanolin is derived from wool
grease and a safe alternative of those common petro chemical based lubricants.
These lubricants are also preventive agents against corrosion.
● Water: It can also be used as a major component aside from other based oils.
● Vegetable oils: These are primarily derived from plants and animals.
Purpose of Lubricating:
Lubricating performs the following key functions:
• Keeps movable part apart
• Reduces friction
• Transfers heat
• Carries away contaminant and debris
• Transmits power
• Protects against wear
• Prevents corrosion
LUBRICATING PROCEDURE OF TOOLS AND EQUIPMENT
1. Read and analyze the use of preventive Maintenance Schedule form
2. Determine the types of tools and machine needed to be lubricated.
3. Fill out a requisition slip form in releasing the lubricants needed.
4. Secure a borrower’s slip from your teacher.
5. Fill out the slip form correctly intended for the needed tools.
6. Perform the task according to the prescribed schedule and the assigned machine.
7. Perform lubricating procedure.
8. Determine the parts of the machine needed to be lubricated.
9. Apply thin coat of oil on the parts for a long period of time.
10. Open the bearing cover and apply grease.
11. Apply grease on sealed bearing with the use of a grease gun.

67
Repair minor faults
1. Loose, cracked, or splintered handles. If a wooden handle is damaged, it is prone to
breaking during use, which can cause injury to you or others. If a handle is not splintered
too badly, you can probably sand it down just fine. Sand against the grain first if the
handle is really rough and then sand with the grain until it's smooth enough you can run
your hand along it without feeling any chips or splinters. Finish off with a coating of
linseed oil. However, if the handle is cracked or heavily splintered, you'll need to replace
it.
2. Mushroomed heads on tools like chisels and wedges. A mushroomed head is
exactly what it sounds like. A striking edge that should be sharp has gotten malformed
through use. If you use a tool in this condition, the head can shatter on impact.
Fortunately, you can solve this problem by keeping cutting tools sharpened. Sharpen
them whenever you notice a problem, but also plan to sharpen them every months or so
just as a habit.
3. Power tools that don't start easily. If your tool needs a couple of tries to get going or a
little "push" to get the blade spinning, don't use it. Take the time to clean and lubricate it
and if that doesn't solve the problem, get it repaired. There are some fixes you can take
on yourself, such as replacing a belt on a sander or maybe fitting in a new switch or
power cord. But if you're not 100% sure you're up to the repair, take it to a pro.
4. Frayed insulation or exposed wires. Obviously, these are electrical hazards. While
some electrical tape might take care of a small problem temporarily, it's best to have the
tool repaired before using it.
Storing of Tools
Rust is public enemy number one when it comes to tools. To avoid rust when storing your
tools. Rules for storing tools:
1. Keep your tools in a dry place
2. Hang your carpentry hand tools.
3. Store power tools in their original cases.
4. Use silica gel packs or rust collector.

Preventive Maintenance Tasks

The following tasks should be performed at least every three months:
1. Clean the exterior and the interior of the equipment cabinet, using a vacuum
cleaner and/ or a clean cloth.
2. On larger systems clean air filter using a vacuum cleaner to remove accumulated
dust or dirt.
3. Visually inspect all wiring and cables for cuts, fraying, deterioration, kinks, strains
and mechanical holders. Tape, solder or replace any defective wiring or hooded
connectors.
4. Inspect all mechanical security: key switches, indicating lamps, control knobs, fans

68
 and data entry keyboards. Tighten or replace them as required.
5. Inspect all modules mounted in panels on I/O slots to insure that each module is
securely seated in its connector. Remove and clean any module which may have
collected excess dust or dirt.
6. Inspect the power supply for proper voltages and check components such as
capacitors or resistors for leakage or overheating. Replace any defective
components.
7. Check disk drive for proper speed. Adjust speed according to
the manufacturer’s specifications.
8. Clean disk drive heads, magnetic tape heads, or optical paper tape reader.

Self-Check:
1. What are the three types of maintenance?
2. What is the segregation procedure of tools?
3. Write down the types of lubricants.
4. What are the purposes of lubricating?

Answer Key :
1. What are the three types of maintenance?
Ans:
● Preventive maintenance,
● Corrective maintenance,
● Emergency maintenance
1. What are the segregation procedure of tools?
Ans: Procedure in segregating and Labeling Non-functional Tools and Equipment
Conduct an inventory of tools and equipment. Record the number of non-functional tools and
equipment. Segregate tools that are serviceable or unserviceable.
Report the number of tools and equipment that are non-functional but subject for repair. Label tools
and equipment which are condemnable. Return tools and equipment in the tool cabinet as per
operating procedures.
2. Write down the types of lubricants.
Ans: Liquid, Solid, Grease, Paste
3. What are the purposes of lubricating?
● Keeps movable part apart
● Reduces friction
● Transfers heat
● Carries away contaminant and debris
● Transmits power
● Protects against wear
● Prevents corrosion

69
 Job Sheet
Job Sheet - 1
Job How to Clean/Maintain hand tools and power tools after use:
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Cleaning of hand tools
4. Cleaning power tools
5. Keep the toolbox clean
6. Oiling electronic tools
7. Storing tools safely
8. Make it a habit to clean tools after each use before you
return them to storage.
9. Wipe them down with a rag or old towel and be sure they
are free of dust, grease and debris before you put them into
their proper places.
10. This is also an opportunity to look for any damage or
defects.
11.Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Tools and equipment: 1. Combination pliers 01 pc
2. Cutting pliers 01 pc
3. Nose pliers 01 pc
4. Screwdriver 01 pc
5. Wire stripper 01 pc
6. Pulley 01 pc
7. Crimping tools 01 pc
8. Fertilizer clip pliers 01 pc
9. Combination pliers 01 pc
10. Cutting pliers 01 pc

70
 Review of Competency

Performance Criteria Yes No

1. Appropriate tools are selected.  
2. Application of tools to job requirement is determined and  
demonstrated.
3. Usability of tools are checked and verified.  
4. Hand tools and power tools are prepared.  
5. Sources of power supply for power tools are identified.  
6. Appropriate hand tool for the job is used.  
7. Proper and safe use/operation of different hand tools is  
demonstrated.
8. A safety precaution is maintained when using hand tools.  
9. Unsafe or faulty tools are identified and marked for  
repair.
10. Power supply outlet and electrical cord are inspected for  
use in accordance with workplace safety requirements.
11. Proper sequence of operation is applied in using power  
tools to produce results.
12. Power tools are used safely in accordance with  
manufacturer’s operating specification
13. Dust and foreign materials are removed from power tools in  
accordance with workplace standard.
14. Condition of tools is checked after use.  
15. Appropriate lubricant is applied after use and prior to  
storage.
16. Measuring devices are checked and calibrated.  
17. Defective tools, instruments, power tools and accessories  
are inspected and corrected or replaced.

Now, I feel ready to undertake my formal competency assessment.

Signed:

Date:

71
 Carryout Precision Checks and Measurements

After completion this module trainee will able to:

1. Select the job to be checked and measured
2. Select measuring and checking tool/instrument.
3. Obtain measurements and checks
4. Record/communicate measurement and check results
5.Clean, maintain and store measuring instruments .

72
Module 03-S: Carryout Precision Checks and Measurements

Module Content

Module Descriptor
This unit covers the knowledge, skills and attitudes required to use measuring instrument in
the workplace. It specifically includes the tasks of selecting the job to be measured, using
measuring instrument appropriately, obtaining measurements, recording and communicating
measurements obtained, cleaning, maintaining and storing measuring instruments.
Nominal Duration: 10 hours

Learning Outcomes:

Upon completion of the module, the trainee should be able to:

1. Select the job to be checked and measured
2. Select measuring and checking tool/instrument.
3. Obtain measurements and checks
4. Record/communicate measurement and check results
5. Clean, maintain and store measuring instruments.

Performance Criteria:

1.1 Job is selected for measuring and checking.

1.2 Required dimensional measurement is determined in accordance with drawing/plan.
1.3 Required physical condition of job is identified in accordance with drawing/plan.
1.4 Job drawing is used to select the measuring instruments.
2.1. Appropriate measuring instruments is selected in accordance with job requirement.
2.2. Measuring instruments and checking instrument are identified.
2.3. Applications of measuring device is determined.
2.4. Usability and accuracy of measuring device is checked and verified.
2.5. Measuring device is prepared for measurement.
2.6. Fits, Tolerance, clearance and limits are identified according to job requirements.
3.1. Measurements are obtained using appropriate measuring instrument.
3.2. Systems of measurements are identified and converted where necessary.
3.3. Measurement is kept accurately in accordance to specification.
3.4. Measurement is checked against job requirement.
3.5. Physical conditions are checked in accordance with job requirement
4.1. Measurements are recorded in accordance with workplace procedure.
4.2. Measurement is interpreted, recorded and communicated to authority.
5.1. Dust and dirt are removed from the measuring instruments.
5.2. Condition of measuring instruments are checked.
5.3. Appropriate lubricant is applied after use and prior to storage.
5.4. Measuring instruments are checked and calibrated.
5.5. Measuring instruments are stored in accordance with workplace procedure.

73
 Learning Outcome 1:
Select the job to be checked and measured

Contents:

Instructions
11. Measuring Instruments
12. Drawing
13. Diagram
14. Sample product/work piece
15. Drawings and/or sketches/Diagram
16. Manual/CBLM

Assessment Criteria

1.1 Job is selected for measuring and checking.

1.2 Required dimensional measurement is determined in accordance with drawing/plan.
1.3 Required physical condition of job is identified in accordance with drawing/plan.
1.4 Job drawing is used to select the measuring instruments.

Resources required

The following resources must be provided to students/trainees): Different Type

Measuring Instruments, CBLM, White Board

Learning Activity 1.1

Resources/Special
Learning Activity
Instructions/References

Select the job to be ▪ Information Sheet:.1.1

checked and ▪ Self-Check:.1.1
measured ▪ Answer Sheet: 1.1

74
 Information Sheet 1.1
Select the job to be checked and measured:
Length
Distance is measured in length. Length
has the dimension of distance in the
International System of Quantities. The
majority of measurement systems
choose a base unit for length from which
all other units are derived. The meter
serves as the foundational unit of length
in the International System of Units (SI)
system.
Most people understand length to refer
to an object's longest dimension.
However, depending on the object's
position, this is not always the case.
Width
Measured across an object at a right
angle to its length, width is a dimension
used to describe distance from side to
side.

Width Calculations:
Identify the pair of shorter sides there are in the rectangle. You will need to measure
both if it is too near to tell. One of the shorter sides should be measured. It makes no
difference which side you measure because a rectangle has two sets of congruent
sides. The width is as shown. You may also get the width by dividing the area by the
width if you just know the length and area but not the width. For instance, if you know
a room will be 15 feet long and 105 square feet wide, you may divide 105 by 15 to
obtain 7 and the width of the room will be 7 feet. Identify a person's height and place
the start of
Depth
The difference between two vertical places is referred to as the vertical distance, and
depth is a particular sort of vertical distance. The use of depth in relation to water is
one of the most prevalent everyday examples. The vertical distance measured
perpendicularly from the water's surface to a specific point below it is known as the
depth of the water. The distance between the center of the boat and the lake's bottom
is depicted in the image below.

75
 Diameter
A circle's diameter is determined by
multiplying the radius by two. The diameter
is measured from one end of the circle to a
point on the other end, passing through the
center, whereas the radius is measured
from the center of a circle to one endpoint
on the circle's perimeter. The letter D is
used to identify it. A circle has an infinite
number of points on its circumference,
which translates to an endless number of
diameters with equal lengths for each
diameter.
Diameter of a Circle Using Diameter of a Circle Using Radius
Circumference The radius of a circle is the distance along
The diameter formula can be simply a line drawn from its center to one of its
derived from the circumference. The ends, whereas its diameter is equal to
circumference of a circle is calculated double that distance. Using this concept,
using the formula C = d, where C is the the diameter is calculated using the formula
circumference, d is the circle's diameter, D = Radius 2.
and = 22/7 or around 3.142. Diameter =
Circumference is the formula for diameter
using circumference.
Radius Formulas
The formulas you will learn in this part can
be used to determine the radius of a circle
and a sphere. We will discuss circle radius
formulas in this section. The section below
goes over the formula for the radius of a
sphere.
Rad Radius Formula from
Circumference:
The circumference of a circle is its furthest
boundary. It is a circle's edge, and its
definition is given by the formula C = 2r
units. Here, C is the circle's circumference,
r is its radius, and is a constant equal to
3.14159. The circumference divided by two
equals the radius. The radius formula
utilizing a circle's circumference is written
as follows:
Diameter/2 or D/2 units = Radius =
Circumference/2 or C/2 units
Height
A person or anything can be measured
from head to toe or from the bottom up by
their height. In other words, a person's
height indicates how tall they are. We may
assess how much taller we get as we age.
We frequently contrast the average heights
of men and women in various nations.

76
Self-Check 1.1
1. What is Length?
2. What is Radius?
3. What is Diameter?
4. What is Width?

Answer Key 1.1

1.What is Length?

Length is a measure of distance. In the International System of Quantities, length is a quantity

with dimension distance. In most systems of measurement a base unit for length is chosen, from
which all other units are derived. In the International System of Units (SI) system the base unit for
length is the meter
2. What is Radius?

In geometry, the radius is defined as a line segment joining the center of the circle or a sphere to
its circumference or boundary. It is an important part of circles and spheres which is generally
abbreviated as 'r'.
3. What is Diameter?

The diameter is defined as twice the length of the radius of a circle. The radius is measured from
the center of a circle to one endpoint on the boundary of the circle,
4. What is Width?

Width is a measure of distance from side to side, measuring across an object at right angles to
the length

Job Sheet
Job Sheet - 1
Job Identify Different Types of Measuring Instruments/Tools
Procedure: 1. Collect and wear the necessary clothing.
2. Collect different types Measuring Instruments/Tools.
3. Placed different types Measuring Instruments/Tools on
the working table.
4. List them different types Measuring Instruments/Tools.
5. Clean and restore Different Types of Measuring
Instruments/Tools
Personal Protective 1. Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1. Paper 01 sheet
2. Pencil 01 pc
3. Eraser 03 pc
Tools and equipment: 1. Selected Measuring Tools as per
requirements

77
 Learning Outcome 2:
Select measuring and checking tool/instrument.

Contents:
Instructions
5. Appropriate measuring instruments
6. Application of measuring instruments
7. Sample product/work piece
8. Drawings and/or sketches/Diagram
9. Manual/CBLM

Assessment Criteria
2.1. Appropriate measuring instruments is selected in accordance with job
requirement.
2.2. Measuring instruments and checking instrument are identified.
2.3. Applications of measuring device is determined.
2.4. Usability and accuracy of measuring device is checked and verified.
2.5. Measuring device is prepared for measurement.
2.6. Fits, Tolerance, clearance and limits are identified according to job requirements.

Resources required

The following resources must be provided to students/trainees): Appropriate measuring

instruments, CBLM, Manual, White Board, Marker.

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Select measuring and ▪ Information Sheet:.2.1

checking tool/instrument. ▪ Self-Check:.2.1
▪ Answer Sheet: 2.1

78
 (Information Sheet 2.1)
Select measuring and checking tool/instrument.:
Steel tape

A tape measure or measuring tape is a flexible

ruler used to measure length or distance.
. Surveyors use tape measures in lengths of over
100 m.
Accuracy and standardization
 Class I: accurate to ±1.10mm over 10m
length
 Class II: accurate to ±2.30mm over 10m
length
 Class III: accurate to ±4.60mm over 10m
length
Steel rule
There are rigorous and flexible steel norms.
While accurate measurement is their main
function, they can also be used as cutting guides
if they are sufficiently hard and as guides for
laying out lines. Measurements of rounded or
cambered work can also be made using the
thinner, more flexible guidelines.

Meter rule

A meter rule is a device which is used to

measure length of different objects. A meter rule
of length 1m is equal to 100 centimeters (cm).
On meter rule each cm is divided further in to 10
divisions which are called millimeters (mm). So,
a meter rule can measure up to 1mm as smallest
reading

Calculator

A calculator is a tool used to compute

mathematical operations on numbers. Simple
calculators can only perform the mathematical
operations of addition, subtraction, multiplication,
and division.

Digital Vernier slide caliper

A caliper is a tool used to gauge an object's
dimensions.
It is employed in a wide range of industries,
including mechanical engineering, metalworking,
forestry, woodworking, science, and medicine.

79
Micro meter

Along with other metrological instruments like

dial, vernier, and digital calipers, a micrometer—
also referred to as a micrometer screw gauge—
is a tool with a calibrated screw that is frequently
used for precise measurement of components in
mechanical engineering, machining, and most
mechanical trades.
To determine the apparent diameter of celestial
planets or tiny things, micrometers are also used
in telescopes and microscopes.

Digital micrometer

To measure the dimensions of length, diameter,

or thickness, utilize digital micrometers. The
frame, anvil, spindle, lock nut, sleeve, sleeve
numbers, sleeve long line, thimble marks,
thimble, and ratchet stop, LCD display, data
output port, mm/in conversion key, and ON/OFF
ZERO key are all components of a digital
micrometer.

AVO meter(analogue/digital)
Multi-meter, also known as AVO meter, is a
tester used to measure electrical voltage,
current, resistance and so on. Multi-meters are
mainly of two types, analog and digital. Both are
used for measuring and fault detection in
electrical circuits.
AVO meter stands for A – ampere, V – volt, O –
ohm meter. Functions of AVO meter:
●It is a very important instrument for measuring
volts, ohms, and amperes quickly and easily,
●As well as locating faults in electric or electronic
circuits.

Voltage Measuring Part:

This voltmeter has multiple ranges. This
component consists of a number of resistances,
each of which is linked in series to the
galvanometer's rotating coil. The ring switch is
used to connect it.

Current Measuring Part

It is a multifunctional ammeter. This component
consists of the quantity of low resistances
connected in parallel by a galvanometer. The
ammeter's range affects these resistances. A
range selection switch (SR) is also included in
this circuit for choosing a specific range.

80
 Resistance Measuring Part
Ohmmeter with multiple ranges. This component
comprises of an emf battery Vo, a variable
resistance Rs, and a resistance-based
galvanometer Rg coupled in series. The circuit is
linked to the X and Y terminals of the AVO-meter
while the function switch is in position X3.

AVO meter analog

AVO digital meter

Thermometers
An instrument that measures temperature is
a thermometer. It is able to gauge the
temperature of solids like food, liquids like
water, and gases like air. Celsius,
Fahrenheit, and kelvin are the three most
popular temperature measuring units.

Water meter
The volume of water that flows through a
pipe or other outlet is measured by a water
meter. In most cases, meters measure
volume in standard units like cubic feet or
gallons. Your meter records the total volume
of water that has traveled through it, just like
an odometer on a car.

Gas meter
The amount of fuel gases like natural gas
and liquefied petroleum gas is measured
using a gas meter, a type of flow meter. For
residential, commercial, and industrial
facilities that use fuel gas provided by a gas
utility, gas meters are used.

81
Clip on Ammeter
A clamp-on ammeter is a portable test
device that determines the strength of the
magnetic field surrounding a single
conductor to determine the current flowing
through a circuit.

Fits
The various fit categories have names. They start with an interference fit, in which the
components are designed to be forced together. Another terminology for this fit would be
heavy through to mild interference. A clearance fit, however, refers to parts that are
designed to have a gap between them. Other adjectives for this fit include tight through to
loose. The transition fit, where interference may or may not happen, lies between these two
fits. By stating the tolerance range for the parts' potential sizes, the quantity of interference
or clearance is obtained.
Tolerance
Machined goods cannot all be completely created to the same dimension due to slow
cutting tool wear, minute variations in the machine tool's internals caused by temperature
fluctuations, and wear/movement of internal elements. The part may be created to fall
within a range of sizes. The tolerance on the dimension refers to that range.
Clearance
Parts of an apparatus are either tightly pressed together and do not move in relation to one
another, or they are separated by a gap and can move independently of one another. The
clearance is the space or lack there of between the shaft and the hole. The size disparity
between the pieces determines clearance. The size range of pieces is specified using fits
and tolerances.

Self-Check 2.1
1. What are the functions of Clip on Ammeter?
2. What are the functions of AVO meter?
3. What is the functions Micro meter?

82
 Answer Key 2.1
1. What is the functions of Clip on Ammeter
A clamp-on ammeter is a portable test instrument that measures current in a circuit by measuring
the magnetic field's strength around a single conductor.
Clamp-on ammeters are used to measure current in a circuit with over 1 A of current and in
applications where the ammeter's jaws can easily be
2.What is the functions of AVO meter
Multi-meter, also known as AVO meter, is a tester used to measure electrical voltage, current,
resistance and so on. Multi-meters are mainly of two types, analog and digital. Both are used for
measuring and fault detection in electrical circuits.
3.What is the functions Micro meter
A micrometer, sometimes known as a micrometer screw gauge, is a device incorporating a
calibrated screw widely used for accurate measurement of components in mechanical
engineering and machining as well as most mechanical trades

Job Sheet
Job Sheet - 1
Job Select Appropriate Measuring Tools as per job requirement
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting appropriate Measuring Tools as per job.
3. Connect Measuring Tools as per diagram
4. Measure the Value as per job.
5. Calculate the Value
6. Analysis the Measuring Value
7. Clean and restore the Materials
Personal Protective 1.Apron, Hamlet, 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1. Appropriate Materials as per job as per
requirement requirement
2. Calculator 01 Pc
3. Diagram 1 Set
4. Cleaning Materials as per
requirement
Tools and equipment: 1. Measuring Tools as per Job 01 Set
requirements
2. Measuring related equipment as per 01 pc
job requirements

83
 Learning Outcome 3:
Obtain measurements and checks

Contents:

1. Measuring Instruments
2. Drawing
3. Diagram
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

3.1. Measurements are obtained using appropriate measuring instrument.

3.2. Systems of measurements are identified and converted where necessary.
3.3. Measurement is kept accurately in accordance to specification.
3.4. Measurement is checked against job requirement.
3.5. Physical conditions are checked in accordance with job requirement

Resources required

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC & HMI Software, HMI

Learning Activity 3.1

Learning Activity Resources/Special Instructions/References

Obtain measurements ▪ Information Sheet:.3.1

and checks ▪ Self-Check:.3.1
▪ Answer Sheet: 3.1

(Information Sheet 3.1)

Obtain measurements and checks:
You must make a comparison between the object being measured and a reference object in
order to determine its size. According to their measurement objective, technique, and

84
precision, measuring equipment used as reference objects span a wide range of products. It
is easy to determine whether the manufacturer complies with the necessary requirements by
accurately measuring the measurements (within tolerance). Thus, precise measurement is a
prerequisite to determining whether a product was made correctly.
The Importance of Measurement:
The foundation of production is accurate dimension measurement. To generate items that
meet the design and ensure their quality, all processes—from material acquisition to
processing, assembly, and quality inspection—are evaluated using the same benchmarks.
Quality cannot be ensured if measurement methods are not carried out at any point during
production. Customer complaints will result if damaged products are supplied alongside
other goods. At every step of the production process, measurements must be done
correctly..

Measurement Methods
Direct measurement and indirect measurement are the two categories of size measurement
techniques.
Direct measurement: A technique for measuring the target directly using measuring tools like
vernier calipers or three-dimensional measuring devices is also referred to as an absolute
measurement. Within the scale range of the measuring device, this method is capable of a
wide variety of measurements, but it runs the risk of producing inaccurate results if the scale
is interpreted incorrectly.
Indirect measurement is the process of comparing two objects to a reference object of the
same size and figuring out the distance between the two. As a result, comparative
measurement is another name for it.
Measurement Principle: Abbe's Principle
Abbe's principle is a crucial idea to follow when describing measurement precision and
creating measuring equipment. According to Abbe's principle, "the measurement direction of
the target being measured must be on the same line as the measuring equipment to
increase measurement accuracy."
For instance, the vernier caliper deviates from Abbe's principle since the scale of the caliper
is not attached to the measurement position. Because the measuring portion of the
micrometer is aligned with the target being measured, the outside diameter can be
measured with a high degree of accuracy according to Abbe's principle.

What are Tolerances?

The difference between the measured value and the actual value will always be some
amount. However it's crucial to specify the acceptable error range precisely. The term
"tolerance" in the measurement industry refers to the variation between an object's
maximum and minimum permitted sizes. Tolerances are another name for legally
recognized error ranges, as those found in industrial specifications.
The reference size is 60, the upper limit is 60.045, and the lower limit is 60.000 when a
dimension is specified in the actual drawing as "60 (+0.045 -0.000)".

Systems of measurements ISO standard:

The ISO standard known as ISO 10012:2003, Measurement management systems -
Requirements for measurement processes and measuring equipment, lays out general
requirements and offers instructions for the management of measurement processes and
metrological confirmation of measuring equipment used to support and demonstrate
compliance with metrological requirements. In order to ensure that metrological standards
are met, it describes the quality management requirements of a measurement management
system that can be utilized by an organization that performs measurements as part of its
overall management system.

85
Systems of measurements English system:
Although the metric system was officially sanctioned for use in the US in 1866, the country
has not yet made it the "official" system of measurement. The practice of taking
measurements with body parts and everyday objects gave rise to the US English System of
measurement. One mile is equal to 1,000 paces, while lesser ground distances were
measured with the human foot and greater distances were measured in paces. Household
goods like cups, pails (formerly called gallons), and baskets were used to measure
capacities.
This system undoubtedly allowed for differences in measurements taken by various
individuals. Eventually, a standard was established to guarantee that every measurement
corresponded to the same amount for everyone.
Length: Weight: Capacity:
1 foot (ft) = 12 inches (in) 1 pound (lb) = 16 ounces (oz) 1 tablespoon (tbsp) = 3 tea
1 yard (yd) = 3 feet 1 ton = 2000 pounds sponns (tsp)
1 mile (mi) = 5280 feet 1 cup (c) = 16 tablespoons
1 mile = 1760 yards 1 cup = 8 fluid ounces (oz)
1 pint (pt) = 2 cups
1 quart (qt) = 2 pints
1 gallon (gal) = 4 quarts

Systems of measurements Metric system:

An accepted decimal system of measuring, the metric system was developed in France in
1799. The metric system is the foundation of the International System of Units (SI), which is
the preferred standard of measurement in practically all nations worldwide.
In the metric system, there is only one fundamental unit of measure for each basic form of
measurement (length, weight, and capacity) (meter, gram, liter). Using factors of 10 to
multiply or divide allows for rapid conversions. Moving the decimal point to the right (for
smaller prefixes) or left (for larger prefixes) is all that is required (for larger prefixes).
Arrange the prefixes from largest to smallest to help you recall the correct decimal
movement:

Abbreviated
Purpose Metric Units
as

Millimeters mm

Centimeters cm
Measurement of Length
Meters m

Kilometers km

Milligrams mg

Centigrams cg
Mass/Weight Measurement
Grams g

Kilograms kg

86
 Abbreviated
Purpose Metric Units
as

Tonne t

Square centimeters sq. cm

Square meters sq. m

Measurement of Area
Square kilometers sq. km

Hectare (10,000 square

ha
meters)

Millimeters ml

Centiliters cl
Capacity Measurement
Liters l

Kiloliters kl

Length Mass/Weight Capacity

1 cm = 10 mm 1 cg = 10 mg 1 cl = 10 ml

1 mm = 0.1 cm 1 mg = 0.1 cg 1 ml = 0.1 cl

1 m = 100 cm 1 g = 100 cg 1 l = 100 cl

1 cm = 0.01 m 1 cg = 0.01 g 1 cl = 0.01 l

1 km = 1000 m 1 g = 1000 mg 1 l = 1000 ml

1 m = 0.001 km 1 mg = 0.001 g 1 ml = 0.001 l

1 kg = 1000 g 1 kl = 1000 l

1 g = 0.001 kg 1 l = 0.001 kl

1 tonne = 1000 kg

1 kg = 0.001 tonne

87
Accuracy
parameter inaccuracies is typically included in accuracy criteria. Offset errors are
independent of the strength of the input signal being measured and can be expressed as a
measurement in volts or ohms. No matter the range or gain settings, an example might be
stated as a 1.0 millivolt (mV) offset inaccuracy. Contrarily, gain mistakes are represented as
a percentage of the reading, such as 0.1%, and do depend on the strength of the input
signal. Hence, the two add up to a total accuracy of (0.1% of input +1.0 mV).
Total accuracy is therefore equal to the sum of the two: ±(0.1% of input +1.0 mV). An
example of this is illustrated in Table 1.

Table 1. Readings as a function of accuracy

Conditions: input 0-10 V, Accuracy = ±(0.1% of input + 1 mV))
Input Voltage Range of Readings within the Accuracy Specification
0V -1 mV to +1 mV
5V 4.994 V to 5.006 V (±6 mV)
10 V 9.989 V to 10.011 V (±11 mV)

Self-Check 3.1
1. What is Accuracy
2. Systems of measurements Metric system
3. What is Tolerances?

Answer Key 3.1

1. What is Accuracy
Accuracy can be defined as the amount of uncertainty in a measurement with respect to an
absolute standard. Accuracy specifications usually contain the effect of errors due to gain and
offset parameters
2. Systems of measurements Metric system
The metric system is an internationally agreed decimal system of measurement created in France
in 1799. The International System of Units (SI), the official system of measurement in almost
every country in the world, is based upon the metric system.
3. What is Tolerances?
In any case, there will always be some error between the measured value and the actual value.
But it is important to clearly define the allowable error range. In the field of measurement, the
difference between the maximum allowable size and the minimum allowable size of on object is
called the "tolerance". Legally recognized error ranges, such as those listed in industrial
specifications, are also known as tolerances

88
 Job Sheet

Job Sheet - 1
Job Perform Check Measurement
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the User manual
4. Check Accuracy
5. Check Torrance as per guideline
6. Check Measuring Tools before Measuring
7. Check proper environment and workplace
8. Check Calculations
9. Check others issue as per Job
Personal protective 1. Apron 01 Pc
equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1. User manual 1 Set
Tools and equipment: 1. Measuring Tools as per checking 1 Set
2. Calculator 1 Pcs

Learning Outcome 4:
Record/communicate measurement and check results

Contents:

1. Measuring Instruments
2. Drawing
3. Diagram
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

4.1. Measurements are recorded in accordance with workplace procedure.

4.2. Measurement is interpreted, recorded and communicated to authority.

89
 Resources required

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC & HMI Software, HMI

Learning Activity 4.1

Resources/Special
Learning Activity
Instructions/References

Record/communicate ▪ Information Sheet:.4.1

measurement and ▪ Self-Check:.4.1
check results ▪ Answer Sheet: 4.1

(Information Sheet 4.1)

Record/communicate measurement and check results:
There is frequently a need to store continuous measurements for later analysis in addition to
providing the most recent values of the measured parameters. Such recordings are
especially helpful when system failures arise because, in many cases, the cause of the fault
can be rapidly determined by analyzing changes in measured parameters during the period
before the fault is identified. Chart recorders, digital oscilloscopes, digital data recorders, and
hard-copy equipment like inkjet and laser printers are all options for data recording. Here,
the many kinds of recorders that are utilized are discussed.
Chart Recorders
In particular, chart recorders offer the benefit of a non-corruptible record with immediate
"view ability." This means that all types of chart recorders—aside from paperless ones—
meet industry standards that call for variables to be continuously tracked and recorded with
hard-copy output. Similar criteria are laid forth by ISO 9000 quality assurance procedures
and ISO 14000 environmental protection systems. Special restrictions in the defense
industry go even farther by mandating the 10-year retention of hard-copy output. As a result,
even though many people have been predicting the death of chart recorders, the truth is that
they will probably continue to be required in many industries for a very long time.
Pen strip chart recorder
The electromechanical potentiometric chart recorder previously mentioned has a
rudimentary variant known as a pen strip chart recorder. A hybrid chart recorder is another
name for it that some manufacturers use.
Multipoint strip chart recorder
A dot matrix print head striking against an ink ribbon rather than pens is used in a multipoint
strip chart recorder, which is a variation of the pen strip chart recorder. A typical model might
enable the simultaneous recording of up to 24 distinct signal inputs utilizing a six-color ink
ribbon.

90
Heated-stylus chart recorder
Another variation is a heated-stylus chart recorder, which captures the input signal by
pressing a heated stylus against heat-sensitive chart paper. The major goal of this alternate
printing process is to prevent the issue with pen cartridges or printer ribbons running out of
ink at inconvenient times that is present in other types of paper-based chart recorders.

Circular chart recorder

A spinning circular paper chart is used by a circular chart recorder to record the measured
signal using a servo-driven pen assembly. The chart's rotational speed can normally be
changed from one revolution every hour to one every 31 days.
Paperless chart recorder
A paperless chart recorder, also known as a virtual chart recorder or a digital chart recorder,
uses a color-matrix liquid crystal display to electronically display the time history of observed
signals. This eliminates the hassle of having to routinely replace the chart paper and ink
cartridges needed for other types of chart recorders. Comparing this technology to
electromechanical recorders, reliability is also improved.
Video graphic recorder
In addition to offering the same features as a paperless chart recorder, a video graphic
recorder also has extra display options such bar graphs (histograms) and digital numerals.
However, it should be emphasized that as manufacturers improve the features of their
instruments, the line between the various types of paperless recorders discussed earlier and
video graphic recorders is getting more and more hazy. Several manufacturers still refer to
their recording instruments by the names they have historically used for historical reasons,
however as the functions offered have expanded, there is now a significant amount of
overlap between their respective capabilities.
Other Recording Instruments
A large number of the devices indicated in Sections 5 and 7 have the ability to digitally store
measurement data. They include oscilloscopes for digital storage and data logging
acquisition devices.
Digital Data Recorders
Data loggers, commonly referred to as digital data recorders, were previously discussed in
Section 5 in relation to data acquisition. They offer yet another other method for digitally
storing measurement data. After being properly captured, the data can later be sent to a
computer for additional analysis, one of the hard-copy output devices, or any of the
measurement display devices covered in Sub-Section 2.
Presentation of Data
Tabular and graphical formats are the two options for presenting data on paper; their relative
advantages are contrasted subsequently. It's obviously advisable to use just one or the other
of these two options in some situations. To make the most of the advantages of each
technique, measurements and calculations are frequently expressed in part in tabular form
and in part visually in data collecting tasks. If a computer screen is utilized as the
presentation medium instead of paper, very comparable justifications may be made for the
relative benefits of graphical and tabular presentations.

Self-Check 4.1
1. What is Digital Data Recorder System
2. What is Chart Recorders
3. What is Paperless chart recorder

91
 Answer Key 4.1
1. What is Digital Data Recorder System?

Digital data recorders, also known as data loggers, have already been introduced in Section 5 in
the context of data acquisition. They provide a further alternative way of recording measurement
data in a digital format. Data so recorded can then be transferred at a future time to a computer
for further analysis, to any of the forms of measurement display devices discussed in Sub-Section
2, or to one of the hard-copy output devices
2. What is Chart Recorders?

Chart recorders have particular advantages in providing a non-corruptible record that has the
merit of instant "view ability."
3. What is Paperless chart recorder?

A paperless chart recorder, sometimes alternatively called a virtual chart recorder or a digital chart
recorder, displays the time history of measured signals electronically using a color-matrix liquid
crystal display

Job Sheet
Job Sheet - 1
Job Perform Measuring Data Recorder
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary measuring data recorder sheet.
3. Collect the Measuring data as per requirements
4. Check the accuracy and tolerance
5. Check the data as per guideline
6. Analysis the data for the next step
7. Restore the Data sheet
8. Clean the workplace.
Personal Protective 1.(Apron) 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1. Data Sheet 01 pc
2. Pen 01 pc
3. Pencil 01 pc
4. Eraser 01 Pc
5. User manual 01 Pc
6. Measuring Tools Adjustable set 1 Set
7. Calculator 1 Pcs
Tools and equipment: 1. Measuring Tools as per checking 1 Set
2. Calculator 1 Pcs

92
 Learning Outcome 5:
Clean, maintain and store measuring instruments.

Contents:

Instructions

1. Measuring Instruments
2. Drawing
3. Diagram
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

5.1. Dust and dirt are removed from the measuring instruments.
5.2. Condition of measuring instruments are checked.
5.3. Appropriate lubricant is applied after use and prior to storage.
5.4. Measuring instruments are checked and calibrated.
5.5. Measuring instruments are stored in accordance with workplace procedure.

Resources required

The following resources must be provided to students/trainees): Cleaning materials,

Store Manual, Workplace Cleaning Procedure.

Learning Activity 5.1

Resources/Special
Learning Activity
Instructions/References

93
Clean, maintain and ▪ Information Sheet:.5.1
store measuring ▪ Self-Check:.5.1
instruments. ▪ Answer Sheet: 5.1

(Information Sheet 5.1)

Clean, maintain and store measuring instruments:
If results cannot be trusted to be precise and dependable, even the best measuring devices
in the world are practically useless. By taking good care of them, measuring devices like
micrometers, calipers, and dial gauges can maintain a high level of accuracy and
dependability. What you should be aware of regarding the upkeep and maintenance of these
unique precision tools is provided below.

Lubricate Instruments Appropriately to Prevent Corrosion

The proper lubrication of measuring equipment will stop corrosion and oxidation-related
damage. After each use, precision measuring instruments should be lightly lubricated, and
any extra oil should be wiped off of metal surfaces using a dry, clean cloth. The internal wear
of precisely produced parts, especially those that move against one another, can be
accelerated by a visibly "wet" instrument's ability to draw and trap tiny particles.

Store Instruments in an Appropriate Environment

Be sure the site is well-protected from damaging elements before storing an instrument
there. Precision instruments should not be kept in a drawer where they may bump into one
another; instead, place the instruments in padded cases or use dividers to keep them apart
from one another. Unless the instruments are well-protected in cases, avoid stacking
instruments on top of each other.

Know How to Properly Handle Instruments during Use

When you have a precise measuring tool in your hands, it is even more crucial to keep it
safe from damage or giving inaccurate readings. Avoiding unexpected shocks or rough
treatment is one of several things you should do to assist preventing damage or
miscalibration during use. Measurement devices should not be dropped, thrown, or struck
against hard surfaces.

If you frequently use precise tools at a workbench, you might want to consider purchasing a
rubber mat that can be placed on the floor just below the edge of the bench. This will lessen
the chance that dropping your instruments will result in damage. It should also go without
saying that you should never pry or pound another object with a measurement tool.

Obtain Professional Recalibration Assistance

It's crucial to maintain a professional relationship with a supplier or maker of precision
instruments since some measuring devices need to be periodically recalibrated to guarantee
they continue to perform as intended. They can maintain your instruments to the highest
standards, ensuring years of dependable service.
.

94
1. To ensure that they continue to
perform as intended, some
measuring instruments need to be
periodically recalibrated, which is why
it's crucial to establish a solid working
relationship with a supplier or
manufacturer of precision equipment.
They can maintain your instruments
in excellent shape so that they will
give years of dependable service.G

2. To avoid dirt or dust from impairing

measuring accuracy, wipe the
measuring faces of a precision
measuring tool and the surface of the
work piece that will be measured.

3. For fear of bumping the precision

measuring equipment, never use
cutting tools, files, hammers, or drills
combined with precision measuring
tools.

4. Make use of your tools as intended. It

is not advisable to employ precision
measuring instruments in place of
other tools. Therefore, it is not
recommended to use vernier calipers
as scrap wipers or line markers,
micrometers as small hammers, or
steel linear as screwdrivers.
5. Preserve the temperature. The
findings of the measurement are
significantly influenced by
temperature. Only when the
temperature is close to 20 °C (68 °F)
should measurements of work
components be done precisely. In
most cases, measurements can be
performed at room temperature.
6. Be mindful of your surroundings. To
avoid being magnetized, precision
measuring tools should never be
placed close to magnetic areas, such
as magnetic worktables.

95
7. Users shouldn't be allowed to fix
precision measuring tools on their
own, let alone fix them with hammers,
files, or emery cloth for fear of
introducing further errors. Examples
of such aberrant phenomena include
rough surfaces, burrs, rusts,
distortions of the body, or inefficient
movements. Customers should send
damaged equipment to the repair
facility and use it once it has been
properly fixed!
8. After using the tools, users should
clean them. In order to prevent
rusting, tools other than those made
of stainless steel or encased in
protective materials should be
daubed with anti-rust oil, placed in a
particular case, and maintained in dry
areas.
9. Precision measurement equipment needs routine maintenance. Long-used precision
instruments should be routinely sent to authorize calibration facilities for testing and
calibration to prevent issues with product quality brought on by the tools' excessive
reading inaccuracies.

Self-Check 5.1
1. How you will Lubricate Instruments Appropriately to Prevent Corrosion
2. How You Will Store Instruments in an Appropriate Environment
3. How to Properly Handle Instruments During Use

Answer Key 5.1

1. How you will Lubricate Instruments Appropriately to Prevent Corrosion

Proper lubrication of measuring instruments will prevent damage due to corrosion and oxidation.
Precision measuring instruments should be lightly oiled after each use, and any excess oil should
be removed from metal surfaces with a clean, dry cloth. A visibly "wet" instrument can attract and
hold minute particles that can cause internal wear of precisely fabricated parts, especially those
that move against one another.

2. How You Will Store Instruments in an Appropriate Environment

Whenever you place an instrument in its storage location, be sure the location is well-protected
from destructive elements. Do not store precision instruments where they can jostle against one
another in a drawer; instead, separate instruments from one another using dividers or place them
in padded cases. Avoid stacking instruments on top of each other, unless they are well-protected

96
in cases.
3. How to Properly Handle Instruments During Use

Once you have a precise measuring instrument in your hand, it becomes that much more
important to protect that tool from harm or providing false readings. There are a few things you
should do that will help prevent damage or mis calibration during use, including avoiding sudden
shocks or rough treatment. Do not drop, throw, or bang measuring instruments against hard
surfaces

97
 Job Sheet

Job Sheet - 1
Job Perform Clean, maintain and store measuring instruments
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary Measuring Instruments from
workplace.
3. Clean the measuring instruments by using cleaning
materials
4. Restore the measuring instruments as per store
guideline.
5. Maintain the store register as per guideline

Personal Protective 1. Apron 01 Pc

Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1. 1. Cleaning Materials as per
requirements
2. 2. Waste cotton jute as per
requirements
3. 3. Brush 1 Pcs
4. 4. Check List Sheet
Tools and equipment: 1. 1. Air Compressor set 1 Set
2. 2. Air Blower Machine 1 Set
3. 3. Wire Brush 1 Pcs

98
 Review of Competency

Performance Criteria Yes No

1. Job is selected for measuring and checking.  
2. Required dimensional measurement is determined  
in accordance with drawing/plan.
3. Required physical condition of job is identified in  
accordance with drawing/plan.
4. Job drawing is used to select the measuring  
instruments.
5. Appropriate measuring instruments is selected in  
accordance with job requirement.
6. Measuring instruments and checking instrument are  
identified.
7. Measuring instruments and checking instrument are  
identified.
8. Applications of measuring device is determined.  
9. Applications of measuring device is determined.  
10. Usability and accuracy of measuring device is  
checked and verified.
11. Measuring device is prepared for measurement.  
12. Fits, Tolerance, clearance and limits are identified  
according to job requirements.
13. Measurements are obtained using appropriate  
measuring instrument.
14. Systems of measurements are identified and  
converted where necessary.
15. Measurement is kept accurately in accordance to  
specification.
16. Measurement is checked against job requirement.  
17. Physical conditions are checked in accordance with  
job requirement
18. Measurements are recorded in accordance with  
workplace procedure
19. Measurement is interpreted, recorded and  
communicated to authority
20. Dust and dirt are removed from the measuring  
instruments.
21. Conditions of measuring instruments are checked.  
22. Appropriate lubricant is applied after use and prior to  
storage
23. Measuring instruments are checked and calibrated.  
24. Measuring instruments are stored in accordance  
with workplace procedure.
Now, I feel ready to undertake my formal competency assessment.
Signed:

Date:

99
 Occupational Specific (Core) Competencies

100
 Perform Computer Operation Relevant to PLC

After completion this module trainee will able to:

1. Operate Computer and associated devices
2. Install and configure PLC relevant software
3. Install and configure Human Machine Interface (HMI) relevant software
4. Connect PC, PLC & HMI

101
Module 1: Perform Computer Operation Relevant to PLC

Module Content

Module Descriptor: This unit covers knowledge, skills and attitudes required to perform
computer operation relevant to PLC. It specifically includes operating Computer and
associated devices, installing and configuring PLC relevant software, installing and
configuring PLC relevant software, installing and configuring Human Machine Interface (HMI)
relevant software and connecting PC, PLC & HMI

Nominal Duration: 40 hours

Learning Outcomes

Upon completion of the module, the trainee should be able to:

1. Operate Computer and associated devices
2. Install and configure PLC relevant software
3. Install and configure Human Machine Interface (HMI) relevant software
4. Connect PC, PLC & HMI

Performance Criteria:

1.1. Computer hardware and peripherals are identified according to PLC operation.
1.2. Associated devices for PLC operation are identified and collected
1.3. Computer and associated devices are connected with power source as per standard.
1.4. Functionalities of computer and associated devices are checked.
2.1. Required software for PLC are identified and collected.
2.2. Software is installed as per manufacturer manual.
2.3. Software is run and functionality is tested.
3.1. Human Machine Interface (HMI) is interpreted.
3.2. Required software for HMI are identified and collected.
3.3. Software is installed as per manufacturer manual.
3.4. Software is run and functionality is tested.
4.1. Devices and cables are collected and connected as per manufacturer instruction.
4.2. IP address is configured with PLC, Computer and HMI.
4.3. Communication among PC, PLC & HMI is tested.

102
 Learning Outcome 1:
Operate Computer and associated devices

Contents:

Instructions
1. Hardware: Power Supply, PLC
2. PC
3. Software (PLC Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria:

1.1. Computer hardware and peripherals are identified according to PLC operation.
1.2. Associated devices for PLC operation are identified and collected
1.3. Computer and associated devices are connected with power source as per standard.
1.4. Functionalities of computer and associated devices are checked.

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, HMI, Power Supply and Interface Cable

Learning Activity 1.1

Resources/Special
Learning Activity
Instructions/References

▪ Information Sheet:.1.1
Operate Computer and ▪ Self-Check:.1.1
associated devices ▪ Answer Sheet: 1.1

103
 (Information Sheet 1.1)

1.1 Operate Computer and associated devices

The monitor, Processor, keyboard, mouse,
printer, sound system, Memory, hard drive,
and many other components make up the
computer system's hardware. Hardware is
used to collect user input data, store the
data, display the result, and carry out user-
given commands. 1.2 The PC and PLC
interface is examined.

Introduction to Types of Computer Hardware

Both hardware and software components are necessary for the Types of Computer
Hardware to function. Depending on the needs, a computer system may have numerous
hardware components attached to it. Both mechanical and electronic components of the
computer are found in the hardware. The monitor, Processor, keyboard, mouse, printer,
sound system, Memory, hard drive, and many other components make up the computer
system's hardware. Hardware is used to collect user input data, store the data, display the
result, and carry out user-given commands.
Many Computer Hardware Types
The various types of computer hardware are listed below:
1. RAM
A sort of computer hardware known as RAM (Random Access
Memory) is used to store information and subsequently
process it. RAM processes information far more quickly than a
hard drive, but it is a volatile device, meaning that when a
computer system shuts down, all of the information is erased
from RAM, whereas a hard drive is non-volatile and stores
data there permanently.

2. Hard disk
Another piece of computer hardware that is utilized to store
data is the hard disk. The hard drive can either be used as an
external device or as a preinstalled device in the CPU.
Because the hard drive is a non-volatile part, data is
permanently saved there and is not lost when the machine is
shut down. Huge amounts of data can be stored on the hard
disk's magnetic surface, which can also be quickly retrieved.

3. Monitor
As it is directly related to the CPU, computer hardware is
another component that is utilized to show output, movies, and
other images. The video card is used to display video on the
monitor. The resolution and visuals presented on the monitor
are far higher quality than those on the television set, which is
where the monitor and television differ from one another.
easily.

104
4. CPU
The central hardware component of a computer system,
known as the CPU (central processing unit), is used to
understand and carry out the majority of commands using
other computer components, such as software and hardware.
A crucial component of every PC, laptop, tablet, and notebook
is the CPU.
5. Mouse
To point to something on the screen, one uses a hand
operator input device. Both wired and wireless mice are
available.

6. Keyboard
Another piece of computer gear used to input text and issue
commands to the computer is the keyboard. There are wired
and wireless keyboard options.

7. Motherboard
The motherboard is at the heart of how a computer operates.
It serves as a hub via which all other gear connects and
houses the CPU. One of the most crucial pieces of hardware
in a computer is the motherboard, which serves as the brain,
allocating power where it is required and coordinating with all
other parts.

7. Power Supply Unit:

An internal piece of IT hardware is known as a power
supply unit (PSU). Power supply units (PSUs), despite
their name, don't actually give power to systems;
instead, they convert it. A power supply specifically
transforms alternating high voltage current (AC) to direct
current (DC) and regulates the DC output voltage to the
precise tolerances needed for contemporary computing
components. The majority of power supplies are
switched-mode (SMPS), which offers benefits for
efficiency and makes it simpler to design for various
voltage inputs.

Self-Check 1.1
Write the correct answer for the following questions.
1. What is computer hardware explain with example?
2. What are the 4 main functions of computer hardware?
3. What are the advantages of computer hardware?
4. What is computer hardware Brainly?
5. What is the most important function of hardware?

105
 Answer Key 1.1

1. What is computer hardware explain with example?

Ans: Image result for Perform of Computer hardware description Computer hardware includes the
physical parts of a computer, such as the case, central processing unit (CPU), random access
memory (RAM), monitor, mouse, keyboard, computer data storage, graphics card, sound card,
speakers and motherboard.
2. What are the 4 main functions of computer hardware?
Ans: Image result for Perform of Computer hardware description There are four main equipment
functions of a computer system: Input, Processing, Storage and Output. Input: the transferring of
information into a computer system; data entry
3. What are the advantages of computer hardware?
Ans: Reduce costs by automating routine tasks. Improve customer service or supplier relationships
through more effective communication. Improve your business efficiency. Extend your business
offered through an online shop, support facility or download center.
4. What is computer hardware Brainy?
Ans: Computer hardware is the collection of physical parts of a computer system. This includes
the computer case, monitor, keyboard, and mouse. It also includes all the parts inside the
computer case, such as the hard disk drive, motherboard, video card, and many others. Computer
hardware is what you can physically touch.
5. What is the most important function of hardware?
Ans: Hardware refers to the physical, tangible computer equipment and devices, which provide
support for major functions such as input, processing (internal storage, computation and control),
output, secondary storage (for data and programs), and communication.

Job Sheet

Job Sheet – 1.1

Job Identify Computer Hardware
Procedure: 1. First collect a computer.
2. Open all the parts of the computer.
3. Examine all the parts.
4. keep the work place clean after work
Personal Protective Apron, Hand Gloves, Googles, Safety 01 Pc
Equipment (PPE): Shoe
Materials 1. Computer 1 Pc
2. Mouse 1 Pc
3.Keyboard 1 Pc
4.Ram 1 Pc
5. Hard Disk 1 Pc
6.Power Supply 1 Pc
Tools and equipment: 1. Neon Tester 01 pc
2.Philis Screw driver 1 Pc

106
 (Information Sheet 1.2)

1.2 Operate Computer and associated devices

Computer hardware and peripherals are identified according to PLC operation.
1.2.1 Interface Cable
We offer PLC Interface Cable with the goal of
exceeding the expectations of our respected clients.
High efficiency, smooth operation, and simplicity of
repair are features.

1.2.2 The Ethernet: One kind of computer network

cable used for a wired network is the Ethernet cable.
Switches, monitors, and computers are connected to
the LAN using an Ethernet connection (Local Area
Network). The Ethernet cable's length and strength
provide information about the connection's quality. The
quality of the signal will be poor if the cable is too
lengthy and not sturdy.
1.2.3 Serial Cable
A serial cable is a type of cable used for serial
communication between two machines to transfer
data. The type of connectors utilized is determined by
the specific serial port being used. A null modem
cable is one that is designed to link two DTEs directly.

(Self-Check 1.2)
Write the correct answer for the following questions.
1. What cable is used for serial communication?
2. How many wires are in a serial cable?
3. What is a PLC interface?
4. What are the 3 types of PLC?
5. Does PLC have USB?
6. What is PLC Ethernet?

107
 (Answer Key 1.2)
1. What cable is used for serial communication?
Ans: What kind of cable do I need for a serial port connection between two computers? For the
type of connection we are talking about here, you need a so called 'null modem cable'. A null
modem cable is an RS-232 serial cable where the transmit and receive lines are cross-linked.
2. How many wires are in a serial cable?
A serial bus consists of just two wires - one for sending data and another for receiving. As such,
serial devices should have two serial pins: the receiver, RX, and the transmitter, TX.
3. What is a PLC interface?
PLC's act as the physical interfaces between devices on the plant or manufacturing floor and a
SCADA or HMI system. PLCs communicate, monitor and control automated processes like
assembly lines, machine functions, or robotic devices. A PLC's functions are divided into three
main categories: inputs, outputs and the CPU.
4. What are the 3 types of PLC?
PLC are divided into three types based on output namely Relay output, Transistor output, and
Triac Output PLC. The relay output type is best suited for both AC and DC output devices.
5. Does PLC have USB?
The DF1 protocol is usually used when you connect a RS-232 cable from your computer to a
PLC. The typical RS-232 cable uses a 9-pin connector as shown below: Now, to be honest, A-B
doesn't even make PLCs with serial ports anymore. Most new PLCs have a USB port and an
Ether Net/IP port.
6. What is PLC Ethernet?
Programmable logic controllers (PLCs) communicate using one of several possible open or
proprietary protocols, such as Ether Net/IP, Ether CAT, Modbus, Since H1, Profi bus, CAN open,
Device Net or FOUNDATION Fieldbus. The idea to use standard Ethernet makes these systems
more interoperable.

Job Sheet

Job Sheet – 1.2

Job Identify Computer Peripherals
Procedure: 1. First collect a computer.
2. collect a computer cable
3. collect a PLC with Interface cable, Ethernet cable, Serial
cable, USB cable
4. Connect with Pc and PLC
5. Examine all the Cable
6. keep the work place clean after work
Personal Protective 1.Apron 01 Pc
Equipment (PPE):
Materials 1. Computer 1 Pc
2. Mouse 1 Pc
3.Keyboard 1 Pc
4.Ram 1 Pc
5. Hard Disk 1 Pc
6.Power Supply 1 Pc
Tools and equipment: 1. Neon Tester 01 pc
2.Philis Screwdriver 1 Pc

108
 (Information Sheet 1.3)

1.3 Operate Computer and associated devices

1.3 Associated devices for PLC operation are identified and collected.
Perform of AC Drive Interface with 3 Phase Induction Motor:
What is a VFD?
VFD (Variable Frequency Drive) is a device that
helps drive various electronic devices by changing
the frequency.
The use of VFDs is especially high in industries,
because many motors are required to run at
different frequencies in industries.

Why is VFD used? Where are VFDs used?

As we know, the full meaning of VFD is variable 1. VFD is used for speed control of AC
frequency drive, so we can say that this device is induction motor.
used to change the frequency. 2. VFD is used in any small and large
VFD is used only in case of AC induction motor. industries.
3. We know that VFD is a complete package;
by using it we can control the speed of the
motor, get full protection of the motor, drive
the motor in forward reverse mode, and can
be used as a starter for the motor.

What are the advantages of using VFD? What are the disadvantages of using
⮚ Electricity is saving VFD?
⮚ Speed control and FWD/Rev operation are ⮚ The only disadvantage of using VFD is
available that since it is a complete package, its
⮚ The motor can be switched on and off cost is very high.
smoothly ⮚ As a complete package, you don't need
⮚ Full motor protection can be obtained by using separate starter for motor start, motor
VFD can be forward and reverse controlled,
⮚ Using a VFD does not require a separate using VFD provides full motor
starter to run the motor protection.
⮚ Apart from this, there are some special
features due to which the price of this
device is relatively high.

109
Perform of Siemens VFD Installation and troubleshooting:
Motor Parameters:
Motor Voltage : P0304- Motor Voltage Parameter. That is, here we will see the voltage
rating on the nameplate of the induction motor that we will use and set the voltage in the
motor voltage parameter of the AC driver. A variable frequency drive (VFD) is a type of
motor controller that drives an electric motor by varying the frequency and voltage of its
power supply.
Motor Current: P0305- Motor Current Parameter. That is, here we will see the Current
rating on the nameplate of the induction motor that we will use and set the Current in the
motor current parameter of the AC driver.
Motor Current: P0310- Motor Frequency Parameter. That is, here we will see the
Frequency rating on the nameplate of the induction motor that we will use and set the
Frequency in the motor Frequency parameter of the AC driver.
Motor Current: P0307- Motor power (Kilo Watt) Parameter. That is, here we will see the
power (Kilo Watt) rating on the nameplate of the induction motor that we will use and set the
power (Kilo Watt) in the motor Power parameter of the AC driver.
Motor Current : P0311- RPM/Pole Parameter. That is, here we will see the RPM/Pole
rating on the nameplate of the induction motor that we will use and set the RPM/Pole in the
motor RPM parameter of the AC driver.

Functional Parameters:
Master Frequency Command: Master Run/Drive Command: P700
P1000 Frequency Command. A variable Run Command. A VFD requires two
frequency drive controls the speed of an things at every moment of its operation: a r
AC motor by varying the frequency un command and speed reference. The
supplied to the motor. run command tells the drive it should
⮚ Here set 1 Frequency control by operate the motor, while speed reference
keypad/Local Mode. tells the VFD what frequency to run. Both
⮚ Set 2 Frequency control by Analog inputs are required to provide motor
Signal (0 to 10v) control. Otherwise, the motor sits idle.
⮚ Here set 3 Frequency control by ⮚ Here set 1 VFD Run by
Fixed Frequency / Multi state keypad/Local Mode.
switch. ⮚ Here set 2 VFD Run by
⮚ Here set 4 Frequency control by RS Terminal/Remote/Selector Mode
485 Mode /Modbus Mode ⮚ Here set 5 VFD Run by RS485
⮚ Set 7 Frequency control by Analog Mode
Signal (4 to 20 mA)
⮚ Set 10 Frequency control by Push
Button Switch
1180- Minimum Frequency P1082-Maximum Frequency
Acceleration/ De-acceleration time: Acceleration Time: VFD acceleration time
P1120 Acceleration time and P1121 is the time required by output frequency
Declaration time . from 0 Hz to the maximum frequency,

110
 De- acceleration Time: Deceleration time
is from maximum frequency dropped to 0
Hz. Usually uses the frequency setting
signal rise and fall to determine the
acc/dec time.

Troubleshooting: Fault and Solution

Fault Description Fault Description
F1 Overcurrent F3 Under voltage
F2 Overvoltage F4 Inverter over temperature
F5 2 F11 Motor over temperature
Inverter I t
F6 Chip temperature rise exceeds F12 Inverter temperature signal lost
critical levels
F20 DC ripple too high F41 Motor data identification failure
F35 Auto restart after n F51 Parameter EEPROM fault
F52 Inverter software fault F61 MMC / SD card parameter
cloning failed
F60 Asic timeout F62 Parameter cloning contents
invalid
F63 Parameter cloning contents F71 USS set point fault
incompatible
F64 Inverter attempted to do an F72 USS / MODBUS set point fault
automatic clone during startup
F80 AI lost input signal F100 Watchdog reset
F85 External fault F101 Stack overflow
F221 PID feedback below minimum F350 Configuration vector for the
value inverter failed
F222 PID feedback above maximum F395 Acceptance test / confirmation
value pending
F410 Cavitation protection failure F452 Belt failure

Hardware Connection:

111
 (Self-Check 1.3)
1. What is VFD short answer??
2. Why DC is used in VFD??
3. How does VFD control voltage??
4. What are the benefits of VFD?
5. What is the maximum frequency of VFD?
6. What faults can a VFD detect?

Answer Key (1.3)

1. What is VFD short answer?
Answer: A variable frequency drive (VFD) refers to AC drives only and a variable speed drive
(VSD) refers to either AC Drives or DC Drives. VFD's vary the speed of an AC motor by varying the
frequency to the motor. VSD's referring to DC motors varies the speed by varying the voltage to the
motor.

2. Why DC is used in VFD?

Benefits of DC Line Chokes: Less expensive than an AC line reactor for harmonic mitigation.
Reduces over voltage tripping of the drive due to voltage spikes. DC Link Chokes increase the
reliability & add years to the life of a VFD.
3. How does VFD control voltage?
VFDs manipulate the frequency of their output by rectifying an incoming AC current into DC, and
then using voltage pulse-width modulation to recreate an AC current and voltage output waveform.
However, this frequency conversion process causes 2% to 3% loss as heat in the VFD

4. What are the benefits of VFD?

ADVANTAGES
⮚ Potential for Energy Reduction. VFDs can be used to save energy at a pump
station. ...
⮚ Potential for Extended Pump Life. VFDs can be used to extend pump life. ...
⮚ Adaptable Pump Curve.
⮚ Simplify Pump Selection.
⮚ Closed Loop Control.
⮚ Mitigate Pressure Transients.
⮚ Controlling Inrush Currents.
⮚ Controlling Full Load Amps.
5. What is the maximum frequency of VFD?
With the use of Variable Frequency Drives (VFD), motors can be run at higher than 60 Hz, known
as an over speed condition, typically as direct drive fan wall/plenum fans (per NIH DRM 6.2. 4.2,
the maximum operating speed is 90 Hz).

6. What faults can a VFD detect?

Possible Causes Corrective Actions

Input voltage level too high Install isolation transformer, line filtering
Instantaneous voltage spike Ensure ac power supply is consistent
Loose power connections or control wiring Check all power and control connections and
tighten loose connections or wiring

112
 Job Sheet
Job Sheet – 1.3
Job Perform of Ac drive Interfacing 3 Phase Induction Motor
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the AC Drive
4. Construct the control circuit of VFD (as per diagram).
5. Construct the power circuit of VFD (as per diagram)
6. A power supply will Speed Control the motor.
7. Proper use and maintenance of equipment.
Personal Protective 1.Apron,Helmat,Safety Shoe 01 Pc
Equipment (PPE):
2. Safety Shoe 01 Pc
Materials 1.VFD 01 pc
2.Magnetic Contactor 01 pc
3.Selector Button Switch 03 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. 10 K variable Resister 01 Pc
7.MCB TP 01 pc
Tools and equipment: 1. 3 Phase induction Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

113
 (Information Sheet 1.3.1)

Operate Computer and associated devices

1.3.1Associated devices for PLC operation are identified and collected.
Perform of Servo Drive and Servo Motor Interface with PLC:
Servo Motor:
Servo motor is very torque compliant. Its motion
cannot be stopped by holding it with fingers. this
Usually used to move very heavy objects. But
this motor has limitations but 360
Moves between degrees.
Servo motors are used in robotics, CNC
machines.

Servo Drive
Motion control systems consist of four main
components: a motor, a drive, a controller, and a
feedback device.

How does a servo motor drive work?

Image result for servo drive and motor
A servo drive receives a command signal from a control system, amplifies the signal, and
transmits electric current to a servo motor in order to produce motion proportional to the
command signal.
Additional features:
1. Configurable feedback.
2. Firmware customization.
3. 2 configurable digital inputs.
4. 2 configurable digital outputs.
5. 2 configurable analog inputs.
6. 3 internal temperature sensors.
7. 1 inclinometer for safe monitoring in case of dangerous vehicle behavior.
8. Configured and controlled via TKSED, with options of:
9. Parameter configuration.
10. Current, speed and position adjustment.
11. Basic configuration.
12. I / O Debugger.
13. CAN Debugger.
14. Unit programmer.
15. Purpose.

114
Perform of Delta PLC and Delta Servo Motor Interfacing: Servo ASD-B2-Position
Control

Servo ASD-B2-Position Control; Switching Mode

⮚ Here 9 is Digital Input ⮚ Active Mode (9+14 Negative Switching)
⮚ 14 is Negative Source (-Com) ⮚ Active Mode (9+11 Positive Switching)
⮚ 17 is +24v Supply Drive ⮚ Pulse Mode (9+14+41 Negative Switching)
⮚ 11 is Positive Source (+Com) ⮚ Pulse Mode (9+11+43 Positive Switching)
⮚ 37 is Negative Direction ⮚ Direction Mode (9+14+41+37 Negative
⮚ 39 is Positive Direction Switching
⮚ 41 is Negative Pulse ⮚ Direction Mode (9+11+43+39 Positive
⮚ 43 is Positive Pulse Switching(11+17+35) Short for Switch
⮚ ing Mode Active(Negative 14+17+35) Short
for Switching Mode Active(Positive)
Gear Ration Setting:
 RPM- Rotation Per Minute
1 Rotation=360 Degree Here Encoder
Feedback/Resolution=17 bit= 160,000.
 Gear ration p1.44-800/ P1.45-001
Electronic gear ration =800 pulse
Servo Drive Position =160000/800
=200 pulse (D1 Position of Servo
drive) 360 Degree = 200 pulse, Mean
1 turn for servo Drive,180
degree=100 Pulse,
 Mean servo drive move ½ angel 1
degree= .5 pulse Speed of Servo
drive.

115
 1 minute = 60 sec 1 rotation=200 pulse Program:
RPM=200/60=3 pulse per second (d0) 1 Here,
RPM= 3 Pulse.  M0 Memory Coil Control Servo Pulse Y0
 D0-K3 (by which the drive moves at 3  M1 Memory coil Control servo Active Y1
pulses per second) and M2 Control Servo Direction Y2
 D1-k200-(by playing the drive will
move 360 degrees (ie
(The drive will move completely at
200 pulses).

Parameter Setting
Servo Factory Reset Program Setting
⮚ AL.013- P2-17-121 set ⮚ P0-01= 02
⮚ AL.014-P2-15-122 set ⮚ P0-01=0
⮚ AL.015-P2-16-123 set ⮚ P1.44- 800 set
⮚ P1.45-001 set
⮚ P2-10=101 SON Servo (DI 1
ON)
⮚ P2-30= 1 set for Jog
Operation
⮚ P2-08 –Set-Shift-00010-set-ok

Hardware Connection:

116
Self-Check 1.3.1
1. Can PLC control a servo motor?
2. Which sensor is used in servo motor?
3. What is a servo in PLC?
4. Is servo motor DC or AC?
5. What are the two types of servo motor?

Answer Key (1.3.1)

1. Can PLC control a servo motor?
Ans: PLCs are very capable of providing the signals required to command these servo and stepper
systems in a cost-effective and digital (noise-free) manner. In a typical motion control system there
are three basic components: the controller, the drive (sometimes referred to as an amplifier), and
the motor.

2. Which sensor is used in servo motor?

Ans: Control the servo motor by using the ultrasonic sensor.
3. What is a servo in PLC?
Ans: Summary Servomotors are basically a high-performance type of electrical motor. They must
be paired with a drive, which is also known as a motion controller. As a system, servos convert
electricity into precisely controlled motion.

4. Is servo motor DC or AC?

Ans: There are two types of servo motors, AC servos and DC servos. The main difference
between the two motors is their source of power. AC servo motors rely on an electric outlet, rather
than batteries like DC servo motors.
5. What are the two types of servo motor?
Ans: Generally, there are two main types of this motor based on the supply used For its function.
They are AC servo motors & DC servo motors.

117
 Job Sheet

Job Sheet – 1.3.1

Job Perform of Position Control Of Servo drive
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the Servo Drive and PLC.
4. Drawing of Position Control Ladder program
5. Construct the control circuit of Servo drive and PLC
(as per diagram).
6. Construct the power Servo drive and PLC (as per
diagram).
7. (as per diagram)
8. A power supply will Speed Control the motor.
9. Proper use and maintenance of equipment.
Personal 1.Apron 01 Pc
Protective Equipment (PPE) 2. Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2. Servo Drive 01 pc
3.Servo Motor 01 pc
4. Magnetic Contactor 01 pc
5.Selector Button Switch 03 pc
6.Cable 1.5 RM Some
7.Plight Lamp 02 pc
8. 10 K variable Resister 01 Pc
9.MCB TP 01 pc
Tools and equipment: 1. Combination Players 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc
5.Multi Meter 01 pc

(Information Sheet 1.3.2)

Operate Computer and associated devices

1.3.2 Associated devices for PLC operation are identified and collected.
Perform of Data logger printer Interface with PLC:
What is a data logger used for?
Data loggers are electronic devices that automatically track and log environmental factors
over time, enabling measurements, documentation, analysis, and validation of
circumstances. A sensor collects the data, and a computer chip stores it in the data logger.

Data Logger Printer: For delivery

vans, this tiny printed thermometer is
available. This can be used to print
out recorded temperature data while
transporting drugs or in other
situations.

118
Printer communications
Connecting printers to controllers is one of the most common uses for our products. There
are a variety of printers and applications, as you undoubtedly are aware. However, many of
them don't even print in the conventional sense. Several of them are actually embossers and
engraving machines. Others employ a variety of methods to physically encode information
on a product.
Let's discuss the various modes of operation for these printers and how to connect them to
your controllers.
Let's begin by discussing physical links. The two most common methods for connecting a
printer to a controller are serially and over Ethernet [I'm going to omit parallel printers
because, if you've chosen to use one, your options are completely out of the question. The
typical method is serial. and 90%.
Sometimes it's just plain ASCII with an LF (Line Feed) and CR (Carriage Return) at the end.
The easiest ones to handle are those. Many users just connect those to the controller's
serial port and send the printer data over RS232. Our 435NBX, however, extracts the string
data from the controller, appends the termination characters at the end, and delivers it
serially to the printer if your printer isn't close to the controller or you don't have a spare
serial port. If you need to find your printer remotely, that is a fantastic tool.
Moreover, the 490NBX is an analogous utility if the printer is on TCP. The 490NBX takes the
printer information out of your Controllogix data table and sends it over regular TCP/IP to the
printer. It functions identically like the 435NBX from a PLC standpoint.
What happens, though, if the printer data is more intricate? There are occasionally printer
control characters present. There may be multiple messages. The 435NBX and the 490NBX
can typically handle those circumstances. The printer control characters can frequently be
included directly in the ASCII string. For instructions, go to your PLC handbook.
Configure
Run the setup software that comes with a Data Logger after connecting it to your PC's USB
or Ethernet port. Adapt the data logger to your own needs by configuring it as follows:
In any order, you can enable or disable particular analog channels.
Define the input configuration (single-ended or differential) and channel gain for enabled
channels. Decide on the sample rate you choose. To avoid making assumptions when
interpreting findings, it is optional to establish the relationship between volts and engineering
units for each channel. Let the DI-71x Data Logger record data in those units for you if you're
recording, for instance, PSI, ft-lbs, and amps.
Record
Attach the signals you want to record, then enter an SD memory card and a 9-36 VDC
power supply (or use the included power converter). To enable local or distant data
uploading, it is optional to connect the data logger's USB or Ethernet interface to a PC or
LAN, respectively. Release the control button after pressing and holding it until the green
Mode LED stops flashing. When the data logger begins capturing data, the Mode LED turns
to flashing red. Data Upload and Analysis You can transfer collected data to your Laptop for
in-depth study moments, hours, or even days later. Upload data from an SD memory card
locally using a USB port, remotely using an Ethernet connector, or just slide the SD memory
card out of the data logger.

119
 (Self-Check 1.3.2)
1. WHAT IS PLC in data logger?
2. What does a data logger measure?
3. What is meant by data logging?
4. What are data loggers name their five applications?

Answer Key (1.3.2)

1. What is PLC in data logger?
Ans: Image result for what is data logger printer with PLC question PLC Data logging is the
process of gathering data from machines and connected devices (sensors) for analysis. An
example is the process of measuring the humidity in a factory oven as a digital value using a smart
sensor. To correctly evaluate the data it's labelled with a time and date stamp

2. What does a data logger measure?

Ans: Data loggers are electronic devices which automatically monitor and record environmental
parameters over time, allowing conditions to be measured, documented, analyzed and validated.
The data logger contains a sensor to receive the information and a computer chip to store it.
3. What is meant by data logging?
Ans: September 20, 2022. Data logging is the process of capturing; storing and displaying one or
more datasets to analyze activity identify trends and help predict future events.
4. What are data loggers name their five applications?
Ans: Data loggers are electronic sensors that record data over time. They are often small and
portable and, these days, are often part of the Internet of Things (IoT).Here are five common
applications for data loggers. Environmental monitoring. ...
⮚ Industrial health and safety. ...
⮚ Energy efficiency management. ...
⮚ Farming
⮚ Urban planning

120
 Job Sheet

Job Sheet
Job Perform of How to Set up Data Logger Printer
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the data Logger printer and PLC.
4. Drawing of Position Control Ladder program
5. Provide Power Data Logger and PLC
6. Communication Cable setup PLC and Data Logger printer.
7. Proper use and maintenance of equipment.
Personal Protective 1.Apron,Helmate 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2. Data Logger printer 01 pc
3.Comminacation cable 01 pc
Tools and Equipment: 1.Combanation Players 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

121
 (Information Sheet 1.3.3)

Operate Computer and associated devices

1.3.3 Perform of Computer and associated devices are connected with power source.
A computer's internal components receive
low-voltage, regulated DC power from a
power supply unit (PSU), which converts
mains AC. Switched-mode power supply are
utilized by all contemporary personal
computers. While some power supplies
automatically adjust to the mains voltage,
others offer a manual switch for choosing the
input voltage.
The ATX specification, which specifies form
factor and voltage tolerances, is followed by
the majority of contemporary desktop
personal computer power supplies. The 5-
volt standby (5VSB) power that an ATX
power supply always supplies when it is
connected to the mains supply powers the
computer's standby features and some
peripherals. A signal from the motherboard
turns on and off ATX power supplies.
IBM PC, XT and AT standard
The initial IBM PC's power supply unit (PSU)
provided +5 V and +12 V as its two main
voltages. It provided two additional voltages
of 5 V and 12 V, but only in small doses. The
majority of microchips at the time used 5 V
electricity. The majority of the 63.5 W that
these PSUs could produce was on this +5 V
rail.
+3.3 V and +5 V rails
Rail voltage supplies of +3.3 V and +5 V are
rarely a limiting factor; in general, any supply
with an appropriate +12 V rating will have
sufficient capacity at lower voltages. The
majority of hard drives or PCI cards,
however, will put more strain on the +5 V
rail.

(Self-Check 1.3.3)
1) What is connected to the power supply in a computer?
2) What is the power source of a computer called?
3) When devices are connected to the computer what are they called?
4) Where is the power supply in a computer?
5. What is power supply function?

122
Answer Key (1.3.3)

1. What is connected to the power supply in a computer?

Ans: These cables connect to the computer motherboard and other internal
components. A power supply connects to the motherboard using an ATX
style connector and may have one or more of the following cables to
connect power to other devices.
2. What is the power source of a computer called?
Ans: Power supply unit a power supply unit (PSU) converts mains AC to low-
voltage regulated DC power for the internal components of a computer.
Modern personal computers universally use switched-mode power supplies
3. When devices are connected to the computer what are they called?
Ans: Peripheral devices are those devices that connect to the core
computing unit. Four examples of peripheral devices are monitors, mice,
keyboards, and printers.
4. Where is the power supply in a computer?
Ans: In a personal computer (PC), the power supply is the metal box usually found in a corner of
the case. The power supply is visible from the back of many systems because it contains the
power-cord receptacle and the cooling fan
5. What is power supply function?
Ans: The main function of a power supply is to convert electric current from a source to the correct
voltage, current, and frequency to power the load. It could be AC to DC or DC to DC.
Consequently, power supplies are sometimes regarded as electric power converters.

Job Sheet
Job Sheet – 1.3.3
Job Perform of Computer and associated devices are connected
with power source.
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the Power Supply.
4. Check the Power Supply
5. Proper use and maintenance of equipment.
Personal Protective 1.Apron,Helmate 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Computer 01 pc
2. 12v Dc Power Supply 01 pc
3.Male to Female Rail 01 pc
Tools and equipment: 1.Combanation Players 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

123
 (Information Sheet 1.4)

Operate Computer and associated devices

1.4 Functionalities of computer and associated devices are checked.
Compatibility
The ability of two systems to function together without requiring modification is known as
compatibility. The same data formats are utilized by compatible software programs. For
instance, the user should be able to open their document files in either product if word
processing apps are compatible.
Processor design
(Redirected from CPU architecture)
Navigation jump Toggle search a processor is a crucial part of computer hardware, and
processor design is a branch of computer engineering and electronics engineering
(fabrication). Microarchitecture is created as a result of the design process, which also
entails selecting an instruction set and an execution paradigm (such as RISC or VLIW). This
microarchitecture may be specified using VHDL or Verilog, for example. This description is
then used to create a microprocessor using a variety of semiconductor devices.

Motherboard
The primary printed circuit board (PCB) of
general-purpose computers and other
extensible systems is known as a
motherboard. It is also referred to as a
mainboard, main circuit board, mb, mboard,
backplane board, base board, system board,
and logic board (only in Apple computers). It
provides connectors for various peripherals
and retains and enables communication
between many of the critical electronic parts
of a system, including the memory and
central processor unit (CPU). In contrast to a
backplane, a motherboard frequently houses
important sub-systems such the central CPU,
input/output and memory controllers for the
chipset, interface connectors, and other parts
that are integrated for general usage.
Operating system
An operating system (OS) is a type of system
software that controls how computer
hardware and software resources are used
and offers basic services to other software
applications. Operating systems that use
time-sharing plan activities to make the most
of the system's resources. They may also
contain accounting software to allocate costs
for processing time, mass storage, printing,
and other resources.
While some operating systems can operate
immediately from media or flash memory,
others may need to be installed or may come
pre-loaded with purchased computers (OEM-
installation).

124
RAM
A type of computer memory called random-
access memory, which can be read and
updated in any sequence, is often used to
store operational data and program code.
In contrast to other direct-access data
storage media, a random-access memory
device enables data items to be read or
written in approximately the same amount
of time regardless of the actual location of
data inside the memory (such as hard
disks, CD-RWs, DVD-RWs and the older
magnetic tapes and drum memory),
Static random-access memory (SRAM) and
dynamic random-access memory are the
two primary varieties of volatile random-
access semiconductor memory (DRAM).
Commercial uses of semiconductor RAM

Legacy system
A legacy system in computing is an antiquated technique, technology, computer system, or
application software that is still in use but "of, relating to, or being a previous or out-dated
computer system"[1]. When a system is referred to as "legacy," it usually signifies that it
helped establish the norms that came after it. This might also suggest that the system needs
to be updated or replaced.
Proprietary hardware
Computer hardware that is proprietary has an interface that is managed by the owner and is
frequently covered by trade secret or patent protection.
Mac-OS
Since 2001, Apple Inc. has developed and sold Mac-OS, a Unix operating system that was
formerly known as OS X and initially Mac OS X. It serves as the main operating system for
Mac computers made by Apple. It is the second-most popular desktop operating system in
the market for desktop and laptop computers, after Chrome OS and ahead of Microsoft
Windows.

(Self-Check 1.4)
1. What is hardware compatibility testing?
2. What are the three important things you must consider when performing
compatibility testing?
3. Why is OS and hardware compatibility important?
4. What are three types of software compatibility?

125
Answer Key (1.4)

1. What is hardware compatibility testing?

Ans: A compatibility test is an assessment used to ensure a software application is
properly working across different browsers, databases, operating systems (OS), mobile
devices, networks and hardware
2. What are the three important things you must consider when performing compatibility
testing?
Ans: Hardware Compatibility – Check if the hardware is capable of handling the
processing requirements. Network Compatibility – Check if the network is capable of
handling the bandwidth needs. Peripheral Systems Compatibility – Check if web pages
interact with the back-end systems seamlessly.
3. Why is OS and hardware compatibility important?
Ans: If the Operating system is not compatible with the computer hardware, the device
can lose functionality or perform at a much slower speed than expected. The impact of the
nonconformance is usually detrimental to the functionality of the computer
4. What are three types of software compatibility?
Ans:
Types of Compatibility Tests
Hardware: It checks software to be compatible with different hardware configurations.
Operating Systems: It checks your software to be compatible with different Operating
Systems like Windows, Unix, Mac OS etc.
Software: It checks your developed software to be compatible with other software.

Job Sheet
Job Sheet – 1.4
Job Perform of Computer and associated devices are Hardware
compatibility
Procedure: 1. Collect and wear the necessary clothing.
2. Collect necessary tools and equipment.
3. Collect the Power Supply.
4. Check the Power Supply
5. Check hardware compatibility
6. Proper use and maintenance of equipment.
Personal Protective 1.Apron,Helamte 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Computer 01 pc
2. 12v Dc Power Supply 01 pc
3.Male to Female Rail 01 pc
Tools and equipment: 1.Combanation Players 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

126
 Contents:

Instructions
1. Hardware: PLC,
2. PC
3. Software (PLC Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria:

2.1. Required software for PLC are identified and collected.

2.2. Software is installed as per manufacturer manual.
2.3. Software is run and functionality is tested.

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, HMI, and Interface Cable

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

▪ Information Sheet:.2.1
Install and configure ▪ Self-Check:.2.1
PLC relevant software ▪ Answer Sheet: 2.1

127
 (Information Sheet 2.1 )

Install and configure PLC relevant software operation

Required software for PLC are identified and collected.

PROGRAMMABLE LOGIC CONTROLLER

The state of input devices is continuously monitored by a PROGRAMMABLE LOGIC
CONTROLLER (PLC), an industrial computer control system, and decisions are made in
accordance with that information. A PLC's user projects and programs are created using
software, which enables the PLC to function.

Based on the given data and the logic that has been developed, the programmable logic
controller will process the inputs, carry out the commands from the program, and produce
the outputs. Once the user chooses the inputs and outputs, PLCs run in a repeating loop.
Professors are seeking for ways to provide students practical experience using
programmable logic controllers (PLCs) without a lab in light of pandemic precautions and
schools switching to virtual instruction. I also wanted to find a technique to teach PLC
programming ideas that others could learn at home without having to invest in costly
hardware and software, so I thought I'd share what I've discovered.

Install and configure PLC relevant software operation

Software is installed as per manufacturer manual.
Perform of Delta PLC Installation

1 2

3 4

128
 5

7
8

9 10

129
 11 Open software

Install and configure PLC relevant software operation

Software is run and functionality is tested.

1 2

130
3 4
Ladder Of Delta PLC

1 2

3
4
Timer

131
 2
1

Counter

132
 Program Reset System

Delta Digital Program

How to Cable Identify

133
Perform of Program Download & Upload

1 2

4
3

5
6

134
7
8

9
10

135
 Self-Check 2.1
1. How do I test a PLC program?
2. How do I run a program in PLC?
3. How do you start a PLC?
4. How do you start a PLC?

Answer Key 2.1

1. How do I test a PLC program?

1. Steps in PLC Commissioning
2. Cable connections must meet standards. ...
3. Check the power supply. ...
4. Check indicator lights of the PLC. ...
5. Put PLC in a test mode. ...
6. Check protective devices. ...
7. Check emergency stop buttons. ...
8. Check connection points of input and output devices. ...
9. Test the software

2. How do I run a program in PLC?

Ans:
Step-By-Step Procedure for Programming PLC Using Ladder Logic
Step 1: Analyze and Get the Idea of Control Application
Step 2: List All the Conditions and Get the Design using Flowchart
Step3: Open and Configure the PLC Programming Software.
Step 4: Add the Required Rungs and Address Them

3. How are PLCs run?

Ans:
There are four basic steps in the operation of all PLCs; Input Scan, Program Scan, Output
Scan, and Housekeeping. These steps continually take place in a repeating loop.
Energizes or de-energize all output devices that are connected to the PLC

4. How do you start a PLC?

136
Ans:

PLCs must:
Have at least two shareholders.
Have issued shares to the public to a value of at least £50,000 or the prescribed
equivalent in euros before it can trade.
Be registered with Companies House.
Have at least two directors - at least one must be an individual. ...
Have a qualified company secretary..

Job Sheet

Job Sheet – 2.1

Job Perform Software and functionality is tested.
Procedure: 1. Steps in PLC Commissioning
2. Cable connections must meet standards. ...
3. Check the power supply. ...
4. Check indicator lights of the PLC. ...
5. Put PLC in a test mode. ...
6. Check protective devices. ...
7. Check emergency stop buttons. ...
8. Check connection points of input and output devices. ...
9. Test the software
Personal Protective 1.Apron,Helmate 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Computer 01 pc
2. PLC 01 pc
3.Cable 01 pc
Tools and 1.Combanation Players 01 pc
equipment: 2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

137
 Learning Outcome 3:
Install and configure Human Machine Interface (HMI) relevant software

Contents:

Instructions
1. Hardware: PLC, HMI
2. PC
3. Software (PLC & HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria:

3.1. Human Machine Interface (HMI) is interpreted.

3.2. Required software for HMI are identified and collected.
3.3. Software is installed as per manufacturer manual.
3.4. Software is run and functionality is tested.

Resources required:

The following resources must be provided to students/trainees):

Computer, Mouse, Keyboard, PLC & HMI Software, HMI, Interface Cable

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Install and configure ▪ Information Sheet:.3.1

Human Machine ▪ Self-Check:.3.1
Interface (HMI) relevant ▪ Answer Sheet:3.1
software

138
 (Information Sheet 3.1)

Install and configure Human Machine Interface (HMI) relevant software

Human Machine Interface (HMI) is interpreted.
Human–machine interface
PLCs, RTUs, and IEDs can all be accessed by an operator through the use of human-
machine interfaces. HMIs represent the digital controls that are used to sense and affect that
process graphically in place of the manually operated switches, knobs, and other electrical
controls. Operators can start and stop cycles, change set points, and carry out other tasks
necessary to interface with and adapt a control process using HMIs. Physical cables and
controls are replaced with software parameters since the HMI is software-based.
Using industrial protocols like OLE for Process Control (OPC) or fieldbus protocols like Ether
Net/IP, the HMI communicates with one or more controllers directly or indirectly via an ICS
server.
Subsystem models
HMI
Just the Part Tracker is communicated with
by the HMI unit, which manages the user
interface.
The Overture (VDM) implementation and the
4DIAC+MQTT implementation are the two
complimentary HMI unit implementations
produced by the project. Even though they
cannot be utilized simultaneously, each is
beneficial for a particular kind of experiment.

The 4DIAC+MQTT solution enables manual

order placement, modification, and
cancellation at any time via apps for smart
devices and is designed to collect user
heuristics and analyze problems with real-
time order placement.
HMI Working Principal History of the HMI
In an automated system, HMIs are frequently HMI devices were initially created to satisfy
used in conjunction with a PLC the demand for equipment that was simple
(Programmable Logic Controller) to monitor to operate and produced the best results.
and control processes. In general, the HMI The Batch Interface (1945–1968),
gives the user a graphical interface through Command-Line User Interface (1969–
which to interact with the PLC (typically a present), and Graphical User Interface are
touchscreen). predecessors of the HMI (1981-Present).
Advantages of an HMI
The graphical interface of an HMI's is very user-friendly, which is its main benefit. The
graphical interface includes color coding for quick identification (red for danger, for instance),
as well as images and icons that enable quick recognition, lessening the difficulties caused
by language barriers.
Advantages of an HMI over a PLC alone
Without additional programming, a PLC cannot provide real-time feedback, trigger alarms, or
make changes to the system. The major advantage to an HMI is its functionality;
Convenience Interface Flexibility
The functionality attained by digitizing a The ability to customize the interface of an
system with an HMI is unmatched, and the HMI is one of its most advantageous
simplicity that an HMI offers is priceless. One characteristics. The most sophisticated
no longer needs to go to a red pushbutton to applications, with several screens and

139
halt the machine since an HMI integrates all active routines, can be completely
the control functions generally found across supported by an HMI.
the automation line and places them in one
central, remote location.

How to Select an HMI

Knowing precisely what is expected of an HMI is vital because it is a significant purchase.
HMIs often play one of three key roles: overseer, data handler, or pushbutton replacement.
The pushbutton replacer HMI replaces any mechanical device that performs a control
function, including LEDs, On/Off switches, and buttons. Applications that require continuous
feedback and monitoring are used with the data handler. These data controllers frequently
have huge capacity memories built in. The supervisor uses centralized SCADA and MES
systems to monitor and manage entire sites or complexes of sizable systems dispersed over
vast areas. To offer trends, diagnostic data, and management information, an overseer HMI
is typically connected to the SCADA system's databases and software applications.

1.1 Lamp: lamp is Output Component in HMI.

1.2 Motor: Motor is Output Component in HMI.
1.3 Valve: Valve is Output Component in HMI
Different valve types with pressure ranges from 3 bar to 12 bar, used for industrial coffee
machines/automatic coffee makers.
Features
• Freely mountable system
• Easy operation
• Small dimensions
• PLC control
• Safety circuit
• Precise pressure measurement
• High repeatability
1.4 Level: In an HMI, level is an input component. Level sensors are used to determine
where the surface is located inside a container that contains both liquids and solids in the
form of powders.
1.5 Flow: The HMI's input component is the flow sensor. Operators are crucial to the
conversation between humans and machines. They must make use of the knowledge they
have to take actions that ensure the installations and machines function effectively without
jeopardizing safety.

Self-Check 3.1
1. How does HMI operate?
2. What is HMI monitoring?
3. What is HMI explain with example?
4. What is HMI explain different types of HMI?
5. What is HMI design?

Answer Key 3.1

140
1. How does HMI operate?
Ans: HMIs allow operators to start and stop cycles, adjust set points, and perform other functions
required to adjust and interact with a control process. Because the HMI is software based, they
replace physical wires and controls with software parameters, allowing them to be adapted and
adjusted very easily.
2. What is HMI monitoring?
Ans: HMI stands for Human Machine Interface (HMI). A Human Machine Interface (HMI) is a
software application that presents information to an operator or user about the state of a process,
and to accept and implement the operators control instructions.
3.What is HMI explain with example?
Ans: A Human Machine Interface or HMI is defined as a feature or component of a certain device
or software application that enables humans to engage and interact with machines. Some
examples of common Human Machine Interface devices that we encounter in our daily lives include
touchscreens and keyboards.
4. What is HMI explain different types of HMI?
Ans: There are three basic types of HMIs: the pushbutton replacer, the data handler, and the
overseer. There are three basic types of HMIs: the pushbutton replacer, the data handler, and the
overseer.
5.What is HMI design?
Ans: HMI Design is the practice of building HMI screens that are intuitive to the end user, pleasing
to the eye and are efficient to operate.

Job Sheet

Job Sheet – 3.1

Job Perform of Introduction of HMI
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the HMI and PLC.
4. Proper use and maintenance of equipment.
Personal Protective 1.Apron,Helmate 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2. HMI 01 pc
Tools and equipment: 1. Computer 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

(Information Sheet 3.1.2)

Install and configure Human Machine Interface (HMI) relevant software
Required software for HMI are identified and collected

141
The Fundamentals of Software for
Human-Machine Interfaces In order to
monitor and control complex industrial
equipment, human-machine interface
(HMI) software offers a simple graphic
user interface with input/output controls.
HMI software can be loaded on
Computers, mobile phones, wearable
technology, or HMI hardware. HMI
Software Architecture
Features of HMI Software
The HMI features typically requested by Science Soft's customers can be united in the
following groups:

Security Input control

 Data input
 Role-based access control  Data recipes
 Data viewing restrictions Other
Output monitoring  Dashboard personalization
 Process visualization
 Automated status change
actions

HMI Feature: GUI Samples by Science-Soft

Output monitoring: Process visualization

Need HMI Software Implementation

Trust Science Soft's 33 years of experience serving the manufacturing sector to deliver HMI
solutions that are expertly crafted to your industrial workflows and hardware requirements.

142
 Important HMI Integrations
HMI software can only perform the majority of its duties when connected with other industrial
solutions because it is primarily an input-output solution. The following integration targets are
the most frequent ones in Science Soft's HMI projects:

● PLC - via Web API for mid/large-scale solutions or via Ethernet for small-scale solutions; to
enable communication with PLC and thus allow control of the machinery.
● SCADA - to bind multiple HMIs in a network that can be overseen via supervisory software.
● ERP - to allow ERP to regularly receive equipment operators’ activity logs that help measure
labor efficiency.

(Information Sheet 3.1.2)

Install and configure Human Machine Interface (HMI) relevant software

Software is installed as per manufacturer manual.
Software Installation:

+ Step 1: Extract the downloaded file + Step 2: Click on the DOPSoft

V2.00.7.04.exe and select Run

+ Step 3: Select a “language” the OK + Step 4: Choose Install

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 + Step 5: Waiting + Step 6: Choose Install to install the driver.

+ Step 7: Click Next to install SQL Server + Step 8: Choose I accept the terms in
Compact license agreement then Next.

+ Step 10: After the installation process SQL

+ Step 9: Choose Install Server completed, select Finish

144
 + Step 11: Click Close to Finish Setup

Self-Check 3.1.2
1. What language is an HMI programmed in?
2. How is HMI connected to PLC?
3. Where is HMI used?
4. What are the components of HMI?
5. What is HMI display?

Answer Sheet 3.1.2

1. What language is an HMI programmed in?

Net, Visual C#, C++ and other programming languages as well for their HMI automation, control
and monitoring systems.

2. How is HMI connected to PLC?

The HMI unit, depending upon which model you select, will communicate with the PLC using serial
communications or by way of an Ethernet connection. HMIs are programmed using free software
and via a serial port (USB, or standard DB9 port) available from the vendor.
3. Where is HMI used?
Uses of HMI
Industries such as energy, water, wastewater, buildings and transportation may also use HMIs.
Roles such as system integrators, operators and engineers, especially process control system
engineers, frequently use HMIs. These professionals may use HMIs to control machines, vehicles,
plants or buildings.
4. What are the components of HMI?
HMI functions
HMI Components offered by EAO include pushbuttons, illuminated pushbuttons, emergency stop
switches, key lock switches, buzzers, joysticks and lever switches. Numerous additional HMI
Components complete our comprehensive range.
5. What is HMI display?
HMI stands for Human Machine Interface. Generally, it refers to a screen or dashboard that
communicates information, data and metrics using graphics or visual representations of numbers.
The screen is controlled by an operator who monitors and controls equipment and processes in
factories and plants.

145
 Job Sheet
Job Sheet – 3.1.2
Job Perform of Delta HMI Software Installation.
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the HMI Software and Installation
4. Proper use and maintenance of equipment.
Personal Protective 1.Apron,Helmate 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.HMI 01 pc
Tools and 1. Computer 01 pc
equipment: 2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

(Inforation Sheet 3.1.3)

Install and configure Human Machine Interface (HMI) relevant software

Software is run and functionality is tested.
HMIs. HMIs are utilized as an operator control panel for PLCs, RTUs, and occasionally even
directly for IEDs. HMIs substitute graphical representations of the control process and digital
controls to affect that process for manually operated switches, dials, and other controls.
How to Create Program: First Open Dop-soft Software Then Go to File –New-HMI
Model Select-Ne

xt. Port Select:

146
Page Layout View: Input: Element-Momentary Push
Button-Tag set-Ok

Output: Element-Indicator-Tag set-Ok.

Timer /Counter: Timer Number Timer number Display-Numeric Display

means here how many timers we are using.

147
Timer value: Input-Numeric Input HMI program:
Program is compiled. Compiled is a very serious task after completing the program,
because the program is compiled to check that the tags of the program are correct before
downloading the program. Completion can identify whether the program is correct or
incorrect

Program Simulation: A simulation

employs a computer software that acts as
a mathematical model or description of a
real system. Equations that replicate the
functional relationships seen in the actual
system make up this model.
Without any hardware, Delta PLC
Simulator Connect HMI Successfully. To
link the Delta HMI offline simulation on
DOP-Soft 2.45, we used the PLC simulator
on wpl-soft. Online testing of the program
without any hardware is beneficial.

If you are a newbie and want to start learning Delta HMI & PLC programming without
hardware we recommend you to read it.
Simulation 2 type.
1. off Line Simulation without HMI and PLC only Software Base
2. On-Line Simulation Connect with HMI and PLC.

Program Upload Download: In the PLC world, Upload means transfer from the controller
(PLC) to the PC. Download means transfer the program from the PC to the controller (PLC).
Delta PLC Download: Generally, the connection between the HMI and computer is
established through a USB type B connection wire for uploading and downloading. The user
has to configure the HMI in accordance with different computer operating systems. Go to
Options > Configuration > Others > USB Download 1.

148
Program Download Media:
Several devices on the same bus can
communicate in both ways using the RS485
duplex communication protocol. As seen in
the aforementioned diagrams, RS-485 is
most frequently utilized as half-duplex with
just one communication line (a pair of lines
labeled "A" and "B").
RS232 – A common serial protocol called
RS232 is used to link computers to their
peripheral devices so that serial data can be
exchanged between them. As it gets the
voltage needed for the path the devices
utilize to exchange data.
The most popular cable type is Cat 5e-UTP
(unshielded twisted pair), which has low EMI
noise levels and can operate over shorter
distances in less demanding applications.

Ethernet Cable: A network communication standard called Ethernet/IP (Ethernet Industrial

Protocol) can handle massive amounts of data at rates of 10 Mbps or 100 Mbps and up to
1500 bytes per packet.
Troubleshooting: solving input and output problems. Now let's move on to the more typical
issue of debugging inputs and outputs. Finding out why the internal state of the PLC and
HMI (what the PLC believes is happening) does not coincide with the external condition is
the main objective of I/O troubleshooting (what is actually happening).

Self-Check 3.1.3
1. How does HMI interface with PLC?
2. Is HMI a component of PLC??
3. How do I program HMI display??
4. How do I start the HMI simulation in TIA Portal?
5. How do I download from HMI?
6. Why is HMI not working?

Answer Key 3.1

1. How does HMI interface with PLC?
Ans: In general terms, the HMI allows the user to communicate with the PLC via a graphical
interface (typically a touchscreen). This interface allows commands to be given, and also receives
and translates feedback data from the PLC, which is then presented in an easily accessible
visualization on the screen.

2. Is HMI a component of PLC?

Ans: A PLC, or Programmable Logic Controller, is a small digital computer that controls the input

149
and output positions to make sure the parts of the robot work together. An HMI, or human machine
interface, is connected to the PLC.
3. How do I program HMI display?
● Creating HMI Displays and Logic Programs
● Install GP-Pro EX. See the installation DVD-ROM's Readme. ...
● Start the software and create a new project. Set up the display unit model and
device/PLC. ...
● Confirm the device/PLC communication settings. ...
● Create the screen interface. ...
● Create a logic program.

4. How do I start the HMI simulation in TIA Portal?

Ans: With Siemens TIA Portal, PLCs can be simulated using the built-in simulation software
PLCSIM and WinCC Runtime Advanced can be used to simulate HMIs. To launch PLCSIM in TIA
Portal, simply select the PLC you wish to simulate, then click the “Start simulation” button on the
toolbar.

5. How do I download from HMI?

Ans: In the project tree right-click on the HMI device name then select “Download to device”. This
will bring up a window that displays a list of devices accessible, compatible, or with the same IP
address based on the selection. Click on “Start Search” and connect to your device.

6. Why is HMI not working?

Ans: The most frequently used keys on an HMI are those most likely to fail first. Keys like Start,
Enter or passcode keys are likely to experience the heaviest use, and the identifying lettering may
get worn away. Operators may find themselves pressing the key a bit harder each time, and
eventually these keys will fail.

150
 Job Sheet

Job Sheet – 3.1.3

Job Perform of Make simple program on Delta HMI.
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Frist open dop-soft software
4. Then take Start input switch from momentary push
switch
5. Then take stop input switch from momentary push
switch
6. Output from indicator
7. Timer number takes display.
8. Timer value takes input.
9. Connector To PC and HMI and PLC
10. Check Power PLC Power supply
11. Proper use and maintenance of equipment.
Personal Protective 1.(Apron) 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.HMI 01 pc
2.PLC 01 pc
3.SMPS 01 pc
4.Relay 01 pc
3.Magnetic Contactor 01 pc
3.Push switch NO/NC 01 pc
4. Communication Cable rs 232 01 pc
Tools and equipment: 1. Computer 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

Learning Outcome 4:
Connect PC, PLC & HMI

Contents:

Instructions
1. Hardware: PLC, HMI
2. PC
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

151
 Assessment Criteria:

4.4. Devices and cables are collected and connected as per manufacturer instruction.
4.5. IP address is configured with PLC, Computer and HMI.
4.6. Communication among PC, PLC & HMI is tested.

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, HMI, Interface Cable

Learning Activity 4.1

Resources/Special
Learning Activity
Instructions/References
Connect PC, PL& HMI ▪ Information Sheet:.4.1
▪ Self-Check:.4.1
▪ Answer Sheet:4.1

(Information Sheet 4.1)

Connect PC, PLC & HMI

Devices and cables are gathered and connected in accordance with manufacturer
recommendations. Keyboards and touchscreens are two prominent Human Machine
Interface devices that we come across on a regular basis. The majority of HMIs used in an
industrial setting are screens or touchscreens that link humans to equipment, systems, or
other objects.
Yet, it is becoming more and more
challenging to locate RS232 serial ports in
computers, and USB to RS232 converters
are not as reliable as they should be. For this
reason, I'd like to provide some options to
this issue:

152
Direct communication PC to PLC:
1. PC RS232 port to PLC RS232 port using
the wiring DVPACAB2A30
2. PC USB port to PLC RS485 port using the
device IFD6500 (Delta USB-RS485
Converter).
3. PC Ethernet port to PLC DVPEN01-SL
module (need compatibility with high speed
bus)
Communication PC to PLC trough Delta HMI
(Direct Link):
The direct link capability in Delta HMI is used
to communicate with the PLC and HMI with
one only wire. Furthermore this capability
have been improved lately and now is
possible monitor both of them at the same
time using only one wire. (Direct Link
function updated)
1. Direct Link function trough Standard USB
wire (WPLSoft and ISPSoft)
2. Direct Link function trough Ethernet
(WPLSoft and ISPSoft)
Exactly the same feature is available with the
new DOP-B HMI’s with Ethernet embedded,
really helpful for remote support.
3. Direct Link function trough USB host
(WPLSoft only).

153
Self-Check 4.1
1. How a computer processing and networks affect to HMI??
2. What are the 3 main types of HMI screens?
3. Is HMI a software or hardware?
4. What is the purpose of Human Machine Interface?

Answer Key 4.1

1. How a computer processing and networks affect to HMI?
Ans: HMIs allow operators to start and stop cycles, adjust set points, and perform other functions
required to adjust and interact with a control process. Because the HMI is software based, they
replace physical wires and controls with software parameters, allowing them to be adapted and
adjusted very easily.

2. What are the 3 main types of HMI screens?

Ans: There are three basic types of HMIs: the pushbutton replacer, the data handler, and the
overseer. There are three basic types of HMIs: the pushbutton replacer, the data handler, and the
overseer.
3. Is HMI a software or hardware?
Ans: Image result for Interfacing between PC and HMI question The human–machine interface
(HMI) software enables operators to manage industrial and process control machinery via a
computer-based graphical user interface (GUI). There are two basic types of HMI software:
supervisory level and machine level.

4. What is the purpose of Human Machine Interface?

Ans: Operators and engineers use HMIs to monitor and configure set points, control algorithms,
send commands, and adjust and establish parameters in the controller. The HMI also displays
process status information and historical information

154
 Job Sheet
Job Sheet – 4.1
Job Perform of PC and HMI Interface.
Procedure: 1. Collect and wear the necessary PPE.
2. Collecting necessary tools and equipment.
3. Collect the HMI & PC
4. Connector To PC & HMI
5. Check Power PC
6. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
3.Helmate 01 Pc
Materials 1.HMI 01 pc
2.PLC 01 Pc
3.Pen Drive 01 Pc
4. Communication Cable 01 pc
Tools and equipment: 1. Computer 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

Information Sheet 4.1.2)

Connect PC, PLC & HMI

1.
PLC, computer, and HMI are all
configured with IP addresses. The
PLC, computer, and HMI are
configured with IP addresses. If
caution is not used when configuring
IP addresses when connected to an
established network, communication
may be interrupted. Before moving
forward, speak with an expert in
networking.

2. Set the PC's IP address. 3. Set the Internet Protocol Version 4 dialog box to
Depending on the PC's operating "Use the following IP address," then enter an IP
system, this process may change. address for the PC with a matching subnet mask
Use a search engine to look up "Set and the first three sets of numbers that correspond
IP address in Windows xx" for details to those of the HMI (for example, set the IP
on where to find the IP settings on the address to 192.168.1.10; set the subnet mask to
computer. 7, 10, 11, etc. can be used 255.255.255.0)
in place of the xx.
4. Attach a straight through Ethernet cable from the Ethernet port of the PC to the Ethernet

155
 port of the HMI, or use a crossover Ethernet cable to do so.
5. To confirm the connection, ping the
HMI from the computer; If the HMI is
located, open Command Prompt and
type "ping 192.168.1.15" (the HMI's IP
address); if not, press "Enter."
Check the Ethernet cable for
appropriate connection and wiring if
the Ping feature doesn't work, and
then check the IP addressing of the
devices. The command prompt will
show the following information if the
device cannot be located:
6. Connect the PLC to the HMI
directly with a crossover Ethernet
cable or through the switch with a
straight through Ethernet cable.
Configure your PLC with an IP
address in the same range and the
same subnet mask (for example,
192.168.1.15 for the HMI and
192.168.1.20 for the PLC; the first
three sets of numbers need to match
for the devices to communicate
properly).

Information Sheet 4.1)

Connect PC, PLC & HMI

156
 Communication Among PC, PLC & HMI IS TESTED.

Communication Between DELTA HMI

And PC

Understanding the Delta HMI TP04 series

hardware interface and how to configure the
communication settings in the TP Editor
software program is preferable before
carrying out any communication. Please

 TP Settings: This controls the TP series'

communication address.
 RS232: It is used to configure the RS-232
communication's transmission speed
(baud rate), data length, parity check, and
stop bit.
 RS485: It is used to configure the RS-485
communication's transmission speed
(baud rate), data length, parity check, and
stop bit.

USING CONNECTION CABLE

DVPACAB530

Communication Method And Steps Are Described As Follows:

STEP 1. WHEN DOWNLOADING TO

TP SERIES, THE SOFTWARE
SHOULD FIRST BE COMPILED
AFTER COMPLETE EDITING IN THE
EDITOR. TO BUILD THE EDITING
PROGRAM, CLICK OR SELECT
COMPILE (C) > BUILD ALL (A).

157
 Step 2. Choose "1. D/L AP TP04G çPC"
from the TP series system main menu
next. Then, the phrase "WAIT COMM.."
will appear on the TP series' screen.

Step 3. Then, activate TP Editor

software program, click
Communication(M) > Write to TP(W)
The Confirm dialog box will display , and
then press Yes button for confirmation.
The system will start to download the
program to TP series. At the same time,
the downloading status (percentage of
downloading) will also show during
download process. After the download
succeeded, press OK button to
complete transmission.

Download Delta HMI Program

Then, the words of “RECEIVING……”

will display on the screen of TP series .

Step 4. The users may also use Read from TP(R), Write Boot Page to TP(B), and Write
Menu to TP(M) these commands in Communication(M) option. The communication
method is the same as the operation of Write to TP(W) command.

158
 Step 5. Usually, the functions of Write Boot Page to TP(B), and Write Menu to TP(M) are
disabled and cannot be used. They are available only when editing the Boot Page and user-
defined Menu.
Step 6. If the users want to edit Boot Page, just select View (V) > Boot Page(B). After
complete the editing, click Communication (M) > Write Boot Page to TP(B) to perform the
downloading.
Step 7. If the users want to edit user-define Menu, just select File (F) > User Menu
Setting(U). After complete the settings, click Communication (M) > Write Menu to
TP(M) to perform the downloading.

Self-Check 4.1
1. How do PLC and HMI communicate?
2. What is used for communication between PC and PLC?
3. What is HMI communication?
4. What is the use of HMI in PLC?
5. Why the PLC to PLC communication is needed?

Answer Key 4.1

1. How do PLC and HMI communicate?
Ans: The HMI unit, depending upon which model you select, will communicate with the PLC using
serial communications or by way of an Ethernet connection. HMIs are programmed using free
software and via a serial port (USB, or standard DB9 port) available from the vendor.
2. What is used for communication between PC and PLC?

Ans: You can establish PC-PLC communications via Ethernet or USB cable. Connect your PC to the
controller using an Ethernet cable. Access the controller's Ethernet settings by opening UniApps.
UniApps is a collection of applications and tools that are embedded in the operating system of the
controller.
3. What is HMI communication?

Ans: A Human-Machine Interface (HMI) is a user interface or dashboard that connects a person to a
machine, system, or device. While the term can technically be applied to any screen that allows a
user to interact with a device, HMI is most commonly used in the context of an industrial process.
4. What is the use of HMI in PLC?
Ans: Human machine interfaces (HMIs) are used as an operator control panel to PLCs, RTUs, and
in some cases directly to IEDs. HMIs replace manually activated switches, dials, and other controls
with graphical representations of the control process and digital controls to influence that process.

5. Why the PLC to PLC communication is needed?

Ans: The PLC communication is needed when the application needs to share the data outside the
process. During a PLC communication, the data will be shared with an external electronic device.
The PLC communication can be done by using a twisted pair of wire or by remotely through a
telephone or radio modem.

159
 Job Sheet

Job Sheet – 4.1

Job Perform of PC, PLC and HMI Interface.
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the HMI AND PC
4. Connector To PC and HMI
5. Check Power PC
6. Proper use and maintenance of equipment.
Personal Protective 1.Apron,Helmate 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.HMI 01 pc
2.PLC 01 pc
3.Pen Drive 01 pc
4. Communication Cable 01 pc
Tools and equipment: 1. Computer 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

160
 Review Of Competency

Performance Criteria Yes No

1. Computer hardware and peripherals are identified  
according to PLC operation.

2. Associated devices for PLC operation are identified  

and collected
3. Computer and associated devices are connected  
with power source as per standard.
4. Functionalities of computer and associated devices  
are checked.
5. Required software for PLC are identified and  
collected.
6. Software is installed as per manufacturer manual.  
7. Software is run and functionality is tested.  

8. Human Machine Interface (HMI) is interpreted.  

9. Required software for HMI are identified and  

collected.

10. Software is installed as per manufacturer manual.  

11. Software is run and functionality is tested.  

12. Devices and cables are collected and connected as  

per manufacturer instruction.

13. IP address is configured with PLC, Computer and  

HMI.

14. Communication among PC, PLC & HMI is tested.  

Now, I feel ready to undertake my formal competency assessment.

Signed:

Date:

161
 Perform Connection and Testing of Electrical Circuits

After completion this module trainee will able to:

Interpret electrical circuits and peripherals devices
2. Perform wiring of electrical circuits
3. Perform Testing of electrical circuit
4. Check the performance of electrical circuit

162
Module 2: Perform Connection and Testing of Electrical Circuits

Module Content:

Module Descriptor
This unit covers the knowledge, skills, and attitudes required to perform Connection and
Testing of Electrical Circuits. It specifically includes interpreting electric circuits and
peripherals devices, performing wiring of electrical circuits, performing Testing of electrical
circuit and checking the performance of electrical circuit

Nominal Duration: 100 hours

Learning Outcomes:

Upon completion of the module, the trainee should be able to:

▪ Interpret electrical circuits and peripherals devices
▪ Perform wiring of electrical circuits
▪ Perform Testing of electrical circuit
▪ Check the performance of electrical circuit

Performance Criteria:

1.1 PPE is worn and OSH is followed as required

1.2 Electrical circuits and peripherals devices are defined according to PLC operation
1.3 Peripherals are interpreted
1.4 Control and power circuits are interpreted
2.1. Diagram of electrical circuit is interpreted
2.2. Tools, equipment and materials for electrical circuit are identified and collected
2.3. Electrical circuit are prepared as per diagram
3.1. Required testing tools and equipment are identified and collected
3.2. Electrical circuit is tested as per standard procedure
3.3. Problems are fixed if required
4.1. Electrical circuit are connected with power source as per diagram
4.2. Functionality and performance of Electrical circuit is checked
4.3. Tools equipment and materials are restored
4.4. Workplace is cleaned

163
 Learning Outcome 1:
Interpret electrical circuits and peripherals devices

Contents:

Instructions
1. Hardware: PLC, Control circuit & Power Circuit devices
2. PC
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

1. PPE is worn and OSH is followed as required

2. Electrical circuits and peripherals devices are defined according to PLC operation
3. Peripherals are interpreted
4. Control and power circuits are interpreted

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, Control circuit & Power Circuit devices

Learning Activity 1.1

Resources/Special
Learning Activity
Instructions/References
Interpret electrical ▪ Information Sheet:.1.1
circuits and peripherals ▪ Self-Check:.1.1
devices ▪ Answer Sheet: 1.1

164
 (Information Sheet 1.1 )
Interpret electrical circuits and peripherals devices
According to PLC operation, electrical circuits and peripheral devices are defined.
Electric circuit: a conduit for the transmission of electricity. A battery or generator, a device
that provides energy to the charged particles that make up the current, a device that uses
current, such as a lamp, an electric motor, or a computer, and the connecting wires or
transmission lines make up an electric circuit.
Series Circuit Every component in a circuit that has
a series connection is said to be in a series circuit. A
series circuit therefore has the same current flowing
through it at all places. The source voltage is the sum
of the voltage drops across each element in the
circuit.

Parallel circuit electricity circuit. In a parallel circuit,

the branches divide the current so that only a portion
of it passes through each branch. The voltage, or
potential difference, across each branch of a parallel
circuit is the same, but the currents may vary.

Peripheral devices
Anything from a host computer and control console to a motor drive unit or field limit switch
might be considered a peripheral device to the PLC and its I/O base(s). Peripheral devices
also include printers and industrial terminals used for programming.
the optimized tracing result is produced by the result optimization processing unit, and the
tracing
The optimal tracing result and the time chart are collated by the result collation processing
unit, which also has the ability to detect timing shifts brought on by the passage of time.
Interpret electrical circuits and peripherals devices
Peripherals are interpreted

The Power Supply and Rack

So let’s start off by removing all our modules which leaves us with a naked PLC with only the
power supply and the rack.

The CPU
The brain of the whole PLC is the CPU module. This module typically lives in the slot beside
the power supply. Manufacturers offer different types of CPUs based on the complexity
needed for the system.

I/O System
The I/O system provides the physical connection between the equipment and the PLC.
Opening the doors on an I/O card reveals a terminal strip where the devices connect.
PLC face with doors open
Inputs

165
Input devices can consist of digital or analog devices. A digital input card handles discrete
devices which give a signal that is either on or off such as a pushbutton, limit switch, sensors
or selector switches

Outputs
Output devices can also consist of digital or analog types. A digital output card either turns a
device on or off such as lights, LEDs, small motors, and relays
Interpret electrical circuits and peripherals devices
Control and power circuits are interpreted
A power circuit offers enormous electrical
capacity to run heavy-duty equipment, such as
multi-horsepower motors or high-power
heaters. A load or loads use X watts of power
to carry out their function. This typically
denotes 240VAC 600VAC 3 phase in the
context of the inquiry. Kilowatts of power can
be drawn by these kinds of circuits.
Most 3-phase motor starters have identical power circuits; hence they are frequently not
mentioned in schematic drawings. The power circuit, as opposed to the control circuit,
supplies the high voltage and current values required by the motor itself.
They are different in terms of voltage, to start. At 0.6/1kV and above, power cables often
have a higher voltage than control wires. At 300/450/600/750V, control cables are in
operation.

(Self-Check 1.1)
Write the correct answer for the following questions.
1. What is Series Circuit?
2. What is Parallel Circuit?
3. What is function of control circuit?
4. What is function of power circuit?

(Answer Key 1.1)

1. What is Series Circuit?
A series circuit is one in which every component is arranged in a series connection. Therefore, a
series circuit has the same current at all points in the circuit. The voltage drops across each
component in the circuit sum to the source voltage.
2. What is Parallel Circuit?
In electric circuit. A parallel circuit comprises branches so that the current divides and only part of it
flows through any branch. The voltage, or potential difference, across each branch of a parallel
circuit is the same, but the currents may vary.

3. What is function of control circuit?

control circuit is control the internal circuit operations
4. What is function of power circuit?
power circuit is transferred to power to the Load

166
 Job Sheet

Job Sheet – 1.1

Job Perform Series Circuit
Procedure: 1. Collect PPE and wear PPF
2. Collect Tools and materials as per job requirements
3. Make a series circuit as per diagram
4. Test Series circuit
5. keep the work place clean after work
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Hand Gloves 01 Pc
3. Goggles 01 Pc
4. Safety Shoe 01 Pc
Materials 1. Computer 01 Pc
2. Mouse 01 Pc
3.Keyboard 01 Pc
4.Ram 01 Pc
5. Hard Disk 01 Pc
6.Power Supply 01 Pc
Tools and 1. Neon Tester 01 pc
equipment: 2.Philis Screwdriver 01 Pc

Learning Outcome 2:
Perform wiring of electrical circuits

Contents:

Instructions
1. Hardware: PLC, Control circuit & Power Circuit, Electrical diagram
2. PC
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

1. Diagram of electrical circuit is interpreted

2. Tools, equipment and materials for electrical circuit are identified and collected
3. Electrical circuit are prepared as per diagram

167
 Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, PLC, Control circuit & Power Circuit, Electrical diagram

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Perform wiring of ▪ Information Sheet:.2.1

electrical circuits ▪ Self-Check:.2.1
▪ Answer Sheet: 2.1

(Information Sheet 2.1 )

Perform wiring of electrical circuits
Tools, equipment and materials for electrical circuit are identified and collected
TOOLS
A tool is any physical item that can be used to achieve a goal, especially if the item is not
consumed in the process.
There are two primary classifications for tools used in carpentry.
3. Hand tools
4. Power tools
a. Portable Power Tools
b. Stationery Power Tools

HAND TOOLS
A hand tool is any tool that is not a power tool – that is, one powered by hand (manual labor)
rather than by an engine. Hand tools are generally less dangerous than power tools.

Tools
Name: Measuring Tape Name: One Foot Rule

Measuring irregular and

Used for: Used for: Taking simple measurement
regular shapes and distance

168
Name: Zig-Zag Rule Name: Try Square

Used for: Secure wood Used for: Used for squaring

Name: Digital Spirit Level Name: Flat-blade Screw Driver

Determine true horizontal or
Used for: Used for: Inserting flat head screws
vertical directions

POWER TOOLS
A power tool is a tool that is actuated by an additional power source and mechanism other
than the solely manual labor used with hand tools. The most common types of power tools
use electric motors.
Power tools are used in furniture industry for drilling, cutting, shaping, sanding, grinding,
routing, polishing, painting and more.
Power tools are classified as either stationary or portable, where portable means hand-held.
Portable Power Tools

Name: Circular Saw Name: Jig Saw

169
 Cut irregular curves on
Used for: Cut wood/board Used for:
wood/board

Name: Hand Grinder Name: Drill Machine

Used for: Cutting, grinding and polishing Used for: Drilling holes

Part I. List each item and its purpose. Fill in the open spaces below with your response.
After finishing the assignment, compare your responses to the answer key.
Any device that controls, generates, supplies, transforms, or transmits electricity at a voltage
greater than extra-low voltage, or that is powered by electricity at a voltage greater than
extra-low voltage, is considered electrical equipment. This includes any apparatus,
appliance, cable, conductor, fitting, insulator, material, meter, or wire.
Electrical Equipment
Generators Motors Transformers
Conductors and transmission Switching devices of all types Refining through electrolysis
lines and voltage levels / allied inventions
Bulbs and their equivalents Communication systems Batteries
Household appliances measuring devices

Materials
The movement of electrons across a substance in response to an electric or magnetic field
is known as electric current. All of the electrons in materials like ceramic, plastic, and wood
are constrained to the confines of their atoms. These substances don't conduct electricity
because there aren't any "free" electrons present.
Circuit Breakers
A circuit breaker is an electrical switch that operates automatically and is intended to guard
against overload or short circuit damage to an electrical circuit.

170
Magnetic Starters
An electromagnetically-operated switch known as a magnetic starter offers a secure way to
turn on an electric motor with a heavy load.
Lighting (Explosion Proof)
Due to its widespread use in industrial areas that must take a gaseous environment into
account, Graford Industrial offers a wide variety of explosion-proof lighting. We frequently
supply popular product lines from manufacturers including GE, Appleton, and Acuity Brands.
Cabling (& Glands)
A cable is often made up of two or more wires that are connected, twisted, or braided to form
a single assembly. Gray-ford Industrial offers a wide variety of cables for use across various
business sectors.
Panel Boards
Providing safety fuses or circuit breakers for each circuit in a single enclosure, panel boards
are a part of an electricity supply system that divides an electrical power flow into subsidiary
circuits.
Transformers
A static electrical device called a transformer uses inductive coupling to transmit energy
between its winding circuits.
Genrating Sets
Mechanical energy is transformed into electrical energy by electric generators. An external
circuit is made to flow electrical current by a generator. energy grids. Members of our staff
have extensive knowledge in providing electric generators, and they can help with numerous
specification details.
Contactors
Similar to a relay but with higher current ratings, a contractor is a power circuit switch that is
electrically operated.
Enclosures
For the mounting of overload protection equipment such as circuit breakers, switches, and
other equipment, Gray-ford Industrial offers a variety of enclosure brands. Hoffman
enclosures are a popular product that Gray ford Industrial has provided to a variety of clients
throughout the years.

Relays
An electrically controlled switch is a relay. Other operating principles are also utilized,
however electromagnets are frequently used in relays to mechanically activate a switching
mechanism. When a low-power signal is required to control a circuit (with perfect electrical
isolation between the control and controlled circuits), or when multiple circuits must be
controlled by a single signal, relays are utilized.

Switches
A switch is a device used in electrical engineering that has the ability to interrupt an electrical
circuit or change the direction of current flowing through a conductor.

Conduit Fittings
Conduit fittings are a minor but crucial component of the supply for electrical projects. They
may be inexpensive but are crucial.

171
 (Information Sheet 2.1)
Perform wiring of electrical circuits
Electrical circuits are prepared as per diagram
Perform of Direct On-Line Starter Circuit (DOL):
Direct On Line Starter
The fly starter provides power to the motor. The beginning current is not reduced by any
device in this manner. Only by turning on can a direct supply be provided to the engine. A
DOL starter is used to start the motor and deliver a maximum output of 7 horsepower. More
beginning current may be required if you operate a motor with more horsepower than this.
Little rotors' initial torque is about twice as much as their torque during full load. As a result,
only a little period of time is spent starting.

DOL Starter Application

In fields where machines need relatively little rotating power. Also, all the devices or
equipment that the motor may run are typically employed up to 1 to 5 horsepower, even
though the initial torque is not very high. The little induction motor is controlled by a DOL
starter.

How to create the circuit:

While operating a single phase motor, the magnetic contactor's coil voltage should be 250
volts AC, and when operating a three phase motor, it should be 440 volts AC. The line from
one phase should be linked to one end of the off switch and the other end will be connected
to the on switch, regardless of whether the motor is single-phase or three-phase and which
one wants to rotate. Connect the A1 coil from the bell's opposite end to the ON switch, then
connect the magnetic contactor's two ends to it. The other phase or neutral will be linked to
the A2 coil. Currently, the magnetic contractor and the motor both turn on when the ON
switch is turned on.

Circuit Diagram:

172
 (Self-Check 2.1)
Write the correct answer for the following questions.

1. What is direct online starter diagram??

2. What is the purpose of DOL starter?
3. How many contactors are in DOL starter?
4. Why DOL starter is used up to 5 HP?
5. Why is DOL starter not used in large AC motors?

Answer Key (2.1)

1. What is direct online starter diagram?
Ans: DOL Starter Wiring Diagram A direct online starter consists of two buttons, a GREEN button
for starting and a RED for stopping purpose of the motor. The DOL starter comprises an MCCB or
circuit breaker, contactor and an overload relay for protection
2. What is the purpose of DOL starter?
Ans: The DOL starters are used for motor having low power ratings. Where the starting current
does not damage the windings of the motor. For applications where the starting current does not
cause huge dips in the line voltage. Direct online starters are used for small water pumps, conveyor
belts, fans and compressors.
3. How many contactors are in DOL starter?
Ans: Construction of DOL Starter The two switches of the motor control the contacts. The motor
can be started when we shut the contact by pressing the green switch, and the full-line voltage
comes out to the induction motor. Generally, the contactors are 3-poles contactors or 4-pole
contactors.
4. Why DOL starter is used up to 5 HP?
Ans: The direct on line (DOL) starter method of an induction motor is simple and economical. In this
method, the starter is connected directly to supply voltage. By this method, small motors up to 5 kW
rating are started to avoid the supply voltage fluctuation.
5. Why is DOL starter not used in large AC motors?
Ans: While starting a motor using a DOL starter, the motor draws very high current compared to the
full load current of the motor which may cause large voltage drop in the supply main. Hence DOL
starter is used for very low power rating machines. Hence it is not suitable for large power rating
machines.

173
 Job Sheet
Job Sheet – 2.1
Job Perform of direct On Line Starter Circuit
Procedure: 1. Collect and wear the necessary clothing.
2. Collect the necessary tools and equipment.
3. Check contactor contact, check contactor coil, test
overload relay.
4. Drawing the DOL Circuit.
5. Construct the control circuit according to the diagram.
6. Draw the power circuit according to the diagram.
7. Check circuit with test lamp and ammeter as per
diagram.
8. The motor will connect and rotate the motor with the
power supply.
9. Use and maintain equipment properly.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 01 pc
2.Magnetic Contactor 01 pc
3.Push Button Switch 02 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Over Load Relay 01 Pc
Tools and Equipment: 1. 3 Phase Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

(Information Sheet 2.1)

Perform of Auto Star Delta Starter Circuit:
Automatic star delta starter:
Definition: The term "automatic star-delta starter" refers to a starter that actively converts a
motor's terminal voltage from lower voltage to full voltage within a short period of time and
keeps the motor running constantly. Motors with 10 to 300 horsepower can be used with it.

Star Delta Starter Principle:

We are aware that the line voltage in a three-phase LT system is 400 volts. Hence, starting a
three-phase induction motor with 400 volts applied across its terminals will result in
maximum starting torque. Beginning torque is inversely proportional to motor terminal torque.
Once more, the starting current of the motor is 5–6 times more, and if the motor is linked in
groups and the motor terminals are loaded at maximum voltage, the complete starting
current of the induction motor can be 8–10 times greater. The motor can be damaged if too
much beginning current is drawn from this line. As a result, the forward star rectifier is used
to start the three-phase induction motor. Once the motor has passed, the terminal rectifier is

174
completely changed to delta and maintained. To do this, a timed relay is used. The following
calculation can be used to calculate the time required by the timer to switch a three-phase
induction motor from master to delta. To complete (HP/2) + 5 Seconds, choose (15/2)+5 =
12.5 seconds on the timer.
How to make the circuit:
Use a test lamp or maintain the three magnetic contactors in the voltmeter's ohm range to
check them for overload relays, push switches, timers, and other components. Create a
control circuit first. Shut off the overload relay starting from any phase. From contact 96, the
off switch's one end will be linked by way of contact 95. The bell of the on switch will be
attached to one end from the opposite end. The primary magnetic contactor bell will be
connected to both ends of the ON switch. By connecting to delta coil O1 when the timer is
closed, the motor will always run in the delta position. From open contact 4 of the timer, A1
will be linked to the starter coil. The primary (common) magnetic contactor A2, the star, the
delta, the timer coil 7, and the connection to the opposing phase will all be shorted. Check
the circuit after the connection, connect the 220 volt, watch the timer operate and the
magnetic contactor turn on and off, then connect the motor in accordance with the power
circuit connection diagram and turn it on.
Control Circuit Diagram: Power Circuit Diagram:

(Self-Check 2.1)
Write the correct answer for the following questions.

1. Why delta connection is used in motor?

2. Why delta connection has no neutral?
3. Which is faster Star or Delta??
4. Is Delta high or low voltage?
5. Where is star delta starter used?
6. What is the advantage of delta connection?

175
Answer Key (2.1)
1.Why delta connection is used in motor?
The delta connection to the motor is used because it provides additional power and initial torque.
But the current start is high. A star connection is used where you may want to slow down the car
start to speed up and connect to the delta in normal operating mode.
2.Why delta connection has no neutral?
There is no common (neutral) point in between the phases. No there isn’t. Delta connection is a 3
phase connection, which simply means that 3 wires (single phase) are connected such that their
dissimilar ends are connected together. Being connected end to end, there isn’t one common point
as opposed to star connection.
3.Which is faster Star or Delta??
The speeds of Star connected motors are slower as they receive 1/√3 voltage. The speeds of Delta
connected motors are high because each phase gets the total of line voltage
4.Is Delta high or low voltage?
On machines rated for two voltages, the wye connection is for the high voltage; the delta
connection is for the low voltage. For a single voltage rating, most 6-lead machines are capable of
wye-delta starting (and will run in delta).
7. Where is star delta starter used?
Star delta starters are another device that may be used to reduce current demand during motor
startup. It is often used for starting three-phase induction motors, but can only be used when
starting the motor without load and when the required starting current is relatively low.
8. What is the advantage of delta connection?
An advantage of the Delta connection is higher reliability. If one of the three primary windings fails,
the secondary will still produce full voltage on all three phases. The only requirement is that the
remaining two phases must be able to carry the load

176
 Job Sheet
JOB SHEET – 2.1
Job Perform of Star Delta Starter Circuit
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Check the contacts of the contactor check the coil of the
contactor, test the overload relay.
4. Drawing the Star Delta Starter Circuit
5. Construct the control circuit (as per diagram).
6. Construct the power circuit (as per diagram)
7. Connect timer (as per diagram)
8. Check as per diagram.
9. A power supply will rotate the motor.
10. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 03 pc
2.Magnetic Contactor 03 pc
3.Push Button Switch 02 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Over Load Relay 03 Pc
7.Timer with base 01 pc
8.MCB TP 01 pc
Tools and Equipment: 1. 3 Phase induction Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

177
 (Information Sheet 2.2 )
Perform of Reverse Forward Starter Circuit:
Forward Reverse Starter:
Definition: Forward reverse starters can rotate a motor both clockwise and counterclockwise,
as well as right and left.
Procedure:
The major function of this starter is to alter the direction of rotation of the motor by changing
the phase sequence at the terminals of a 3 Phase induction motor(R, Y,B) (R, Y,B)
Connecting the terminals in order will make the motor rotate anti-clockwise. These starters
are still made using cam switches, although magnetic contactors are now the preferred
choice. Two magnetic contactors are used for this starter, as seen in the image. The three
push button switches employed in this starter, however, are an off switch, a forward on
switch, and a reverse on switch. Here, MC1 (Forward) and MC2 are employed (Reverse).
The push button switch does not turn on (R) when (F) is turned on. When I use the forward
switch to turn off the front magnetic contactor (MC, F), it happens once more. Thus, MC2 (R)
will be produced if the reverse (R) switch is activated. That is, two magnetic contactors are
connected in an interlocking manner.
How to make the circuit:
Connect the normally closed contact end of the OFF switch to any one phase line, and the
two normally open ends of the ON switch to the opposite end. Give one switch the label
"forward" and the other "reverse." After that, a wire will be attached to one side of the normal
coz end of the reverse magnetic contactor and the output end of the forward on switch.
Similar to this, attach the two ends of the normally open contact of the reverse magnetic
contactor to the output end of the ON switch of the reverse, then attach a wire to one side of
the normally closed end of the forward magnetic contactor from the other end of the
reverser's magnetic contactor. A1 needs to be linked to the coil, and A2 needs to be
attached to Contact point (95) of the over load relay. The opposite phase should be
connected to Contact point (96) of the over load relay. After connecting everything, double-
check each connection to see if there are any loose connections before connecting the
power and turning the motor while using the motor connection.
Circuit Diagram Control Power Circuit Diagram:

178
(Self-Check 2.2)
Write the correct answer for the following questions.

1. What is forward and reverse circuit??

2. How do you reverse a DC motor??
3. How many contactors are necessary for reversing starters??
4. What is the purpose of interlocking in reversing starter?
5. Where we use forward/reverse starter?

Answer Key (2.2)

1. What is forward and reverse circuit?
Ans: Normally-closed contacts used in forward/reverse control circuits that prevent both directions
coils from being energized at the same time. A physical barrier that is pushed into the path of one
coil's armature by the movement of the adjacent coil in a forward/reversing motor starter.
2. How do you reverse a DC motor?
Ans: How to Reverse Your DC Motor. Your DC motor can be configured to turn in either direction
by simply inverting the polarity of the applied voltage. The change in the flow of current switches
the direction of the spinning force, causing the motor's shaft to begin turning in the opposite
direction.
3. How many contactors are necessary for reversing starters?
Ans: Reversing starters wired to NEMA standards interchange lines L1 and L3, ill. 2. To do this,
two contactors for the starter assembly are required-one for the forward direction and one for the
reverse direction, ill. 3.
4. What is the purpose of interlocking in reversing starter?
Ans: Why are mechanical interlocks used in a reversing motor starter? To prevent line to line
shorts
5. Where we use forward/reverse starter?
Ans: It is designed to safely start and stop a motor, and provide overload protection. A physical
barrier that is pushed into the path of one coil's armature by the movement of the adjacent coil in a
forward/reversing motor starter. A contact that under normal conditions has continuity through it.

179
 Job Sheet
Job Sheet – 2.2
Job Perform of Reverse Forward Circuit
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Check the contacts of the contactor check the coil of the
contactor, test the overload relay.
4. Create Ladder diagram of Reverse Forward Circuit .
5. Construct the control circuit (as per diagram).
6. Construct the power circuit (as per diagram)
7. Connect timer (as per diagram)
8. Check as per diagram.
9. A power supply will rotate the motor.
10. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 02 pc
2.Magnetic Contactor 02 pc
3.Push Button Switch 03 pc
4.cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Over Load Relay 02 Pc
7.MCB TP 01 pc
Tools and Equipment: 1. 3 Phase induction Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

180
 (Information Sheet 2.3 )
Electrical circuit are prepared as per diagram
Panel Wiring:
Electrical Panel Design - Electrical Device Symbols
Not all of the significant elements were discussed in the section above. But since we delved
into Input and Output points connected to external devices, it is crucial to address those first
before moving on. In this section, we'll show you a device symbol that you could see in a
wiring diagram for an electrical panel, describe the device in a few words, and provide some
examples for your reference.
Wiring Symbols in Electrical Drawings
Wires are what ties the devices together. Lines are used to represent the wiring of the panel.
The basic lines you’ll encounter are as follows:
Basic Wire - A connection between two
components.

Wire Junction - A connection between multiple

conductors.

Wire Bypass - No current bypass of two

conductors. No connection is made between the
horizontal and vertical conductors.

Switch - [Left] - Normally Open

| [Center] - Normally Closed |
[Right] - Single Pole Dual
Throw (SPDT)

Push-Button - [Left] - Normally

Open | [Right] - Normally
Closed

A push button is a temporary

electrical switch that, when
closed, conducts current and,
when open, prevents current
from flowing. Push buttons and
switches function differently; a

181
push button will automatically
return to its initial state,
whereas a switch will remain in
that state until it is toggled.
Motor Coil Contact
An input of a contactor or variable frequency drive is a motor coil
contact. The drive will close the necessary contacts and turn on
the motor by igniting the coil. Keep in mind that the coil also
identifies the terminals where the connections must be connected.
The electrical sketch will show the direction (+24VDC vs 0VDC),
which is crucial.
Motor or Relay Contact - [Left] - Normally
Open | [Right] - Normally Closed

Motor Control Panel Schematic

● In the drawing above, we have 4 key elements:
● The entry point of the electrical bus comes from the previous page. If we navigate to
the first page of our electrical drawings, we can find the specification of the voltage
on the bus: 460 VAC 3 Phase 60 Hz.
● The 195-MC01 is a Motor Contactor that includes a circuit breaker, a thermal fuse
and a contact. The drawing calls out the setting of the circuit breaker: 5A.
● The 195-HSS01 is a motor disconnect switch. Note that the disconnect provides a
means to disconnect the high voltage from the motor, as well as feedback to the
PLC. The drawing specifies “LOCAL:I:4/08” as the disconnect input into the PLC.
● The 195-M01 is a 3-Phase Motor of 0.75 HP.
Electrical Panel - Basic Components
In this section, we'd want to start by taking a
look at a typical electrical panel, going through
its components, and comprehending the
considerations that went into its design and
placement. The electrical panel shown above
has a Micro Logix PLC, fuses for protection,
an unmanaged switch for connections, an
Ethernet to RS232 converter, terminal blocks,
and a power source.
Electrical Panel Design - Control Devices
The elements that will propel the process are
called control devices. They comprise devices
such as load cells, variable frequency motors,
and programmable logic controllers. We can
see a Micro Logix series PLC and a variety of
external I/O modules in the panel we
discussed earlier. Let's examine an illustration
of how they are represented in an electrical
panel drafting diagram.

182
 Self-Check 2.3
Write the correct answer for the following questions.

1. Why do motors have 3 wire controls??

2. What are motor control panels?
3. What are 3 types of motor controls?
4. Why starter is used in motor?
5. What is the difference between two wire and three wire?

Answer Key (2.3)

1. Why do motors have 3 wire controls?
Ans: The 3-wire control circuit provides what is known as “low-voltage protection.” In the event of a
power failure, the magnetic motor starter will drop out. In this case, however, once power is
restored the magnetic motor starter will not automatically re-energize
2. What are motor control panels?
Ans: An electric motor control panel uses a combination of drives, relays, switches, and
transformers to facilitate the power distribution to electric motors within the industrial facility. These
control panels can be used in both low and medium-voltage scenarios.
3. What are 3 types of motor controls?
Ans: Motor control devices are designed to be controlled in a manual, automatic, or remote
manner. They can be used for starting or stopping a motor attached to a machine as well as serve
several other purposes. These controls are categorized according to the type of motor they are
designed to operate.
4. Why starter is used in motor?
Ans: A motor starter provides defense by first controlling the electrical output of your device or
equipment at its initial point of operation (when you turn it on or it engages). From that point, the
starter continues to protect your system, operating as a fail-safe.

183
5. What is the difference between two wire and three wire?
Ans: The simple explanation is that a 2-wire system does not include a Neutral wire at the light
switch; the 3-wire system does include the Neutral at the switch.

Job Sheet

Job Sheet -2.3

Job Perform of Panel Wiring
Procedure: 1. Collect and wear the necessary clothing.
2. Collect the necessary tools and equipment.
3. Load calculation. It is better to postulate your electrical
needs before you even buy wires for your home
4. you even buy wires for your home
5. Place your concealed conduit PVC pipes in position. ...
6. Color coding of wires. ...
7. Passing wires through the pipes. ...
8. Earthling.
9. Fixing the switchboard
10. Use and maintain equipment properly.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 01 pc
2.Magnetic Contactor 01 pc
3.Push Button Switch 02 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Over Load Relay 01 Pc
7. Emergency Stop Switch 01 Pc
Tools and Equipment: 1. 3 Phase Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

Outcome 3:
Perform Testing of electrical circuit

Contents:
Instructions
1. Hardware: PLC, Control circuit & Power Circuit, Electrical diagram, AVO Meter,
Multi meter, Megger
2. PC
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

184
 Assessment Criteria

3.1Required testing tools and equipment are identified and collected

3.2Electrical circuit is tested as per standard procedure
3.3Problems are fixed if required

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, PLC, Control circuit & Power Circuit, Electrical diagram, AVO
Meter, Multi meter, Megger

Learning Activity 3.1

Resources/Special
Learning Activity
Instructions/References

Perform Testing of ▪ Information Sheet:.3.1

electrical circuit ▪ Self-Check:.3.1
▪ Answer Sheet: 3.1

(Information Sheet 3.1)

Perform Testing of electrical circuit
Required testing tools and equipment are identified and collected

185
CLAMP METERS
An electrical meter with an integrated AC
current clamp is known as a clamp meter (or
current clamp/clamp-on ammeter). In the
instance of a conventional 12/2 cable wired for
120V power, the same current goes down one
conductor and up the other. You now have a
net current of zero. An AC line separator,
which separates the positive and neutral lines
for convenient measurement, makes this
problem simple to fix. Voltage and resistance
can both be measured with clamp meters,
among other things. This practical tool is still
crucial for professionals.
Non-Contact Voltage Detector
A buying guide for electrical testing
instruments would be incomplete without
mentioning the most basic item you can own.
We're referring to a non-contact voltage
detector as a device that could actually protect
you from a shock.

Fork Meter
Like a clamp meter, a fork meter measures AC
current in addition to voltage (and often
resistance if it has test leads). When working
on a circuit and need to measure current,
clamp meters are ideal because all you need
to do is slide the tool's fork over the cable.
Digital Multi-meter
After you learn how to use it, the digital multi
meter, also referred to as a DMM, is arguably
one of your most useful pieces of electrical
testing equipment. Digital multi meters, also
known as voltmeters, ohmmeters, or volt-ohm
meters, come in a variety of forms.

Current Tester/Receptacle Meter

The circuit tester, also known as a receptacle
tester, instantaneously informs you if any point
along the circuit has an open ground, neutral, or
hot line. The majority of circuit testers also tell you
whether the hot

186
Circuit Analyzer
The equivalent of a circuit tester on steroids is a
circuit analyzer. It gives certain extra
functionalities that are absent from a fundamental
circuit tester. For instance, it will measure the
impedances of the hot and neutral conductors,
reveal phony (bootleg) grounds, and check the
functionality of GFCIs, EPDs (equipment
protective devices), and other devices that are
similar to GFCIs but trip at greater current levels.

(Information Sheet 3.2)

Perform Testing of electrical circuit
Electrical circuit is tested as per standard procedure

Perform of Continuity test:

A continuity test is crucial in identifying the broken wires or damaged components in a circuit.
Also, it can assist in figuring out whether the soldering is effective, whether the resistance is
too high to allow for current passage, or whether the electrical wire is damaged between two
locations. The existence of an entire path for current flow is continuity. When a switch is
closed, a circuit is finished.

How to Test Continuity with a Multi meter

Simply place two of the multi meter's terminals against the two endpoints of an electrical
current to check for continuity. If you're installing or repairing any electrical components in an
outlet, fuse box, car, or appliance, it's a good idea to test the continuity of a wire, current, or
fuse. The amount of resistance present in a closed electrical current is referred to as
continuity. A multi meter should be used to verify this component since a lack of continuity
might result in fires, electric shocks, or damage to your electrical devices. To avoid shocks
or fires, always unplug, turn off, or flip the breaker on the signal you're testing.

Perform of Polarity test:

A test that connects the questioned single pole device to the phase conductor and breaks
the circuit when the device is turned on verifies that the device must be connected to the
phase conductor by causing a change in the instrument's reading.
By using a multi meter
A multimeter is used to determine the
voltage at various terminals. The two
probes on the multimeter are red and
black. If the pointer exhibits any deflection,
we can deduce that the object is a line after
inserting the red probe into the Line and
the other into the neutral (L). If not, check
by sequentially attaching the probes to the
other terminals and evaluating the
deflection. Figure Right Side illustrates how
to determine the polarity using a multi-
meter.
By knowing the resistance value

187
Finding the windings' resistance allows one to determine the polarity. Compared to the Line,
the Earth wire has a lower resistance. To redirect surge currents in the event of a short
circuit, the earth wire must retain low resistance in comparison to the Line (L).

Procedure

Setting up Your Multi meter

Put "COM" and the red cord in the "mA V"
or "AV" slot. mA V stands for "measure
amperage, voltage, ohms," and is used to
measure current. COM is for "common,"
which is the ground. The port marked
"10A," which is designed to measure
extremely high currents, should not be
used. Switch on the multi meter.
 The red probe measures the active
current, while the black terminal
serves as the ground. There isn't a
significant difference in the cords
themselves, but if you're checking
voltage, it matters more.
 The exposed metal components at
the ends of the black and red wires
are known as terminals. Currents in
electricity are measured.
Join the corresponding slots on the
black and red terminals. The front of the
multi meter has several terminal hole
locations. Insert the black cord into the
designated slot.
Set the multi meter's dial to the continuity
position. Depending on your brand and
model, the representation of continuity
could be different. The diode sign, which
is a triangle with a line on the right side, is
typically used to represent the continuous
mode. Moreover, it might have a symbol
that resembles sound waves.
 In the absence of a designated
continuity setting on your multi meter,
you can still conduct a continuity test
by setting the dial in resistance mode
to the lowest value. Ohms are the unit
of measurement for resistance.
 If you're unsure how to set your multi
meter to continuity mode, go to the
instructions.

188
Touch the metal parts of your terminals
together to make sure it works. To test the
continuity setting’s calibration, touch the 2
terminals together and hold them in place.
If the number on the multi meter is less
than 1, then your multi meter is
functioning correctly. If the reading is a flat
0, that’s fine too.

 Most multi meters will also beep if the

signal is good to indicate that the
continuity setting is working properly.
 If there is no beep or you get a high
reading, check the dial to make sure
you’re on the right setting. Then,
check the ports that your terminals are
plugged in to. Finally, try replacing
your terminals before consulting your
manual to find out how you can reset
the multi meter.
 If the screen displays a 1 all the way
on the left-side of the screen and not
where it normally displays readings, it
usually means that the signal is
broken. This is a sign that your
terminals are bad.
 It’s okay if the number fluctuates a
little.

Self-Check 3.1
Write the correct answer for the following questions.

1. What is continuity test in electrical?

2. Why is continuity important electrical?
3. What is the maximum resistance allowed for continuity?
4. Is continuity and ohms the same?
5. What is earthling continuity?

Answer Key (3.1)

1. What is continuity test in electrical?
Ans: A continuity test is a quick check to see if a circuit is open or closed. Only a closed, complete
circuit (one that is switched ON) has continuity. During a continuity test, a digital multi meter sends
a small current through the circuit to measure resistance in the circuit.
2. Why is continuity important electrical? Why Is Continuity Important?
Ans: Continuity can help you determine several things during the testing and troubleshooting
phase: Determines if a circuit is open, closed, or shorted. Determines if a fuse is good or blown.

189
3. What is the maximum resistance allowed for continuity?
Ans: The limit for the Earth Continuity Test is (0.1 + R)Ω.
4. Is continuity and ohms the same?
Ans: An ohmmeter is used to measure the resistance to electrical flow between two points. The
ohmmeter is most commonly used to check continuity. Continuity is not a “measurement” as much
as it is a yes/no statement. To say there is continuity is to say that there is a good electrical path
between two points.
5. What is earthing continuity?
Ans: An earth continuity test ensures that in the case of a fault, those safety measures will work as
intended. The test checks the resistance between the earth point on an appliance or power point
and the switchboard.

Job Sheet

Job Sheet – 3.1

Job Perform of Continuity test by Multi meter
Procedure: 1. Collect and wear the necessary clothing.
2. Will procure the necessary goods.
3. First select the selector Multi meter.
4. Measure the continuity of other terminals with terminal
No.
5. The between the two terminals is less. Those two
terminals are the two ends of the current coil of the
watt meter.
6. Observe the meter reading.
7. Keeping equipment and materials in proper place and
cleaning work area.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 01 pc
2.Magnetic Contactor 01 pc
3.Push Button Switch 02 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Multi meter 01 Pc
Tools and Equipment: 1. 3 Phase Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

190
 (Information Sheet 3.2)
Perform Testing of electrical circuit
Electrical circuit is tested as per standard procedure
Insulation Testing Test the insulation resistance of the circuit with a megger:
Meggar:
The insulation resistance of electrical
circuits, machinery, transformers, etc. is
measured using a megger. Another name for
it is a hand-operated generator. Megger is
the name of a meter that is used to measure
high resistance.
The classification of Megar is as follows:
A Megger of the X Hand Operated Generator
Type (500 to 1000 Volts)
Type Megger for X Electronics (500 to 1000
Volts)

Name of different parts of Meggar:-

1. X is a manually operated DC generator
2. x current coil
3. X pressure coil
4. X pointer or fork
5. X is the positive and negative ends
6. X Guard Terminal
A megger is used to gauge a circuit's high-
level resistance. Mega-ohms are the
measure of value obtained from a megger.
An example of a DC generator is a megger.
After wire work in a home or workplace is
complete, a megger is used to test insulation
resistance, continuity, and other factors.
Megas are available in analog and digital
forms.
The following list of testing techniques using
a megger is provided:

Method for measuring insulation resistance between phase and neutral wire with
megger:
The megger must first be checked as previously before measuring the insulating resistance
between the phase and neutral wires. Then, with the switches in the ON position, turn off the
main switches, remove the cutouts, and also disconnect the loads from the supply. The
meter's positive wiring line (L) is then connected to the phase, and the meter's neutral (E) is
connected to the positive wiring line's neutral. Then, rotate the megger's handle at a specific
rate (120 times per minute). If the megger's cut does not reach zero, it will display some
readings; if this happens, it is safe to assume that the wiring's insulation resistance is
appropriate and it should be known that there is a leak or short circuit someplace in the
wiring if the insulation resistance value is less than 1 mega ohm or zero.

191
 Self-Check 3.2
Write the correct answer for the following questions
1. What is measured with the help of megger meter?
2. Where does Mega get its supplies from?
3. What type of supply does Megger work on?
4. What is mega?
5. What can be done with megger / where is megger usually used?
6. What is the speed of Megar?

Answer Key 3.2

1) What is measured with the help of megger meter?
Answer: High quality resistance is measured, insulation resistance is measured, and continuity test
is done.
2) Where does Mega get its supplies from?
Answer: Usually from the hand operated generator that is inside the megaphone.
3) What type of supply does Megger work on?
Answer: Megger works on DC supply.
4) What is mega?
Answer: The meter used to measure high resistance is called Megger.
5) What is the speed of Megar?
Answer: 120 times per minute.

192
 Job Sheet

Job Sheet – 3.2

Job Perform Insulation Testing Test the insulation resistance of
the circuit with a Megger.
Procedure: 1. Collect and wear the necessary clothing.
2. Will procure the necessary goods.
3. Switch off the L main switch and remove the cut out.
4. All loads should be removed and switches should be kept
on.
5. The L and E terminals of the megger should be connected
to the neutral and phase of the circuit
6. The handle of the x-meter should be turned (120 times
per minute) and the reading of the meter should be noted
7. Keeping equipment and materials in proper place and
cleaning the work area.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Batten Holder (5 Amp 250 Volt) 01 pc
2. Way Switch (Piano Type) 01 pc
3.Incandescent lamps 03 pc
4.Cable (14/.029) Some
5.Insulation tape 02 pc
6.circuit breaker 01 Pc
7.Megger 01 Pc
Tools and Equipment: 1. Nose Players 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

Learning Outcome 4:
Check the performance of electrical circuit

Contents:

Instructions
1. Hardware: PLC, Control circuit & Power Circuit, Electrical diagram, AVO Meter,
Multi meter, Megger
2. PC
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

193
 Assessment Criteria

1. Electrical circuit are connected with power source as per diagram

2. Functionality and performance of Electrical circuit is checked
3. Tools equipment and materials are restored
4. Workplace is cleaned

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, CAD Software, PLC, Control circuit & Power Circuit, Electrical diagram, AVO
Meter, Multi meter, Megger

Learning Activity 4.1

Resources/Special
Learning Activity
Instructions/References

Check the ▪ Information Sheet:.4.1

performance of ▪ Self-Check:.4.1
electrical circuit ▪ Answer Sheet: 4.1

(Information Sheet 4.1)

Check the performance of electrical circuit
Electrical circuit are connected with power source as per diagram
All connected equipment's power should be
immediately released during an emergency
halt. A major contractor will often quit, cutting
off all electricity to all motor equipment to
ensure that there are no live parts. A
circumstance where a system reset is
necessary before power is restored must
also be created by initiating an Emergency
Stop command.
For example, if you take the eStop button out
once again, power is not restored until the
system resets it.
Eg: The associated motor is operating at full
speed thanks to my motor controller. E stop
would turn off all power in the panel as well
as the power to the control unit. If the motor

194
has brakes, they would immediately apply
and halt the system. ABSENT brakes? The
motor would then come to a stop by coasting
or by applying a dynamic brake (depending
on the motor).
halt, a ramp's end:

Self-Check 4.1
Write the correct answer for the following questions.

1. What is the purpose of emergency stop?

2. How does emergency stop button work?
3. What are the five requirements of an E-stop device?
4. Why are e-stop normally closed?

Answer Key (4.1)

1. What is the purpose of emergency stop?
Ans: Simply put, an emergency stop function is a function that is initiated by a human action and is
intended to shut down equipment in the case of an emergency. The emergency stop device is a
manual control device. It is the method of initiating the emergency stop function.
2. How does emergency stop button work?
Ans: How does an emergency stop button work? Emergency stop buttons are wired in series with
the control circuit of machinery equipment. When pushing the mushroom head of emergency stop
button will break the circuit of machinery equipment and removes power supply from that keeps the
circuit energized.
3. What are the five requirements of an E-stop device?
● Five Essential Requirements for the Behavior of Emergency Stop...
● The e-stop must have positive operation. ...
● The e-stop function must be available and in operation at all times. ...
● There can't be a padlock on the e-stop. ...
● The e-stop shouldn't stand in for other necessary safety measures
4.Why are e-stop normally closed?
Ans: By using a normally closed contact as stop actuator. This is because the normally closed
contact as an input actuator won't create dangerous situations under failure. Meaning that when a
fail occurs (the wire-break), the input will act as the normally closed contact has been activated

195
 Job Sheet
Job Sheet – 4.1
Job Perform of direct On Line Starter Circuit with Emergency Stop
Procedure: 1. Collect and wear the necessary clothing.
2. Collect the necessary tools and equipment.
3. Check contactor contact, check contactor coil, test
overload relay.
4. Drawing the DOL Circuit.
5. Construct the control circuit according to the diagram.
6. Draw the power circuit according to the diagram.
7. Check circuit with test lamp and ammeter as per
diagram.
8. The motor will connect and rotate the motor with the
power supply.
9. Use and maintain equipment properly.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 01 pc
2.Magnetic Contactor 01 pc
3.Push Button Switch 02 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Over Load Relay 01 Pc
7. Emergency Stop Switch 01 Pc
Tools and Equipment: 1. 3 Phase Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

(Information Sheet 4.2).

Check the performance of electrical circuit
Functionality and performance of Electrical circuit is checked
Circuitry's compliance with specifications is ensured by functional tests. Testing is typically
carried out "at speed" using BON fixtures and/or DUT connectors. In comparison to an ICT
fixture, a functional test fixture often requires fewer pogo pins.
The test environment and tools should be identified. Determine your testing resources,
testing environments, and production resources.
1. Define Acceptable Performance Criteria.
2. Plan and Design Tests.
3. Prepare Test Environment and Tools
4. Run the Performance Tests
5. Resolve and Retest

196
Cleanliness and safety go hand in hand
Additionally, when it comes to safety, workplace cleaning is more than just a necessary evil:
Clean floors, such as those devoid of puddles of oil, reduce the chance of slipping, which is
necessary to minimize work accidents, including falls. Using a sweeper or vacuum to
remove loose dirt reduces the possibility of getting hurt by things like sharp objects.
Creating a cleaning schedule
Creating a complex plan for routine workshop cleaning may initially seem like extra labor
that will burden personnel. On the other hand, regular workshop cleaning will pay off in the
long run and may even result in cost savings.
Extensive deep cleaning
In any event, periodic deeper cleaning should still be carried out. For instance, the floor has
to be thoroughly washed with water, the windows need to be cleaned, outdated tools need to
be thrown away, rarely used places need to be cleaned, filters need to be cleaned or
replaced, stains need to be taken out, and specific trash needs to be disposed of correctly,
etc.

(Self-Check 4.2)
Write the correct answer for the following questions.
1.How do you check electrical circuits?
2.What is short circuit performance?
3.What are 3 types of electrical circuits?
4.What are the 2 main types of circuits?

Answer Key (4.2)

1.How do you check electrical circuits?
Ans: To test for power with a non-contact voltage tester, touch the sensor tip of the tester to each
of the circuit wires. If the tester lights up when touching any of the wires, the circuit still has power
2.What is short circuit performance?
Ans: A short circuit is when there is a low resistance connection between two conductors supplying
electrical power to a circuit. This would generate an excess of voltage streaming and cause an
excessive current flow in the power source.
3.What are 3 types of electrical circuits?
Ans: There are 5 Main Types of Electric Circuit – Close Circuit, Open Circuit, Short Circuit, Series
Circuit and Parallel Circuit. Learn in Detail. There are 5 Main Types of Electric Circuit – Close
Circuit, Open Circuit, Short Circuit, Series Circuit and Parallel Circuit
4.What are the 2 main types of circuits?
There are two types of circuit we can make, called series and parallel. The components in a circuit
are joined by wires. If there are no branches then it's a series circuit. If there are branches it's a
parallel circuit.

197
 Job Shee
Job Sheet – 4.1
Job Perform of check short circuit with multi-meter
Procedure: 1. Collect and wear the necessary clothing.
2. Collect the necessary tools and equipment.
3. Preparation and Safety.
4. Turn on the Multi-meter and Set it to Continuity or
Resistance. ...
5. Test the Function of the Multi-meter.
6. Identify and Locate the Circuit Component. ...
7. Apply the Probe Tips to the Circuit. ...
8. Check the Display of the Multi-meter Use and maintain
equipment properly.
Personal Protective 1.Apron 01 Pc
Equipment (PPE) 2. Safety Shoe 01 Pc
Materials 1. Multi-meter 01 pc
2.Magnetic Contactor 01 pc
3.Push Button Switch 02 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Over Load Relay 01 Pc
7. Emergency Stop Switch 01 Pc
Tools and 1. 3 Phase Motor 01 pc
Equipment: 2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

198
 Review Of Competency

Performance Criteria Yes No

1. PPE is worn and OSH is followed as required  
2. Electrical circuits and peripherals devices are defined  
according to PLC operation
3. Peripherals are interpreted  
4. Control and power circuits are interpreted  
5. Diagram of electrical circuit is interpreted  
6. Tools, equipment and materials for electrical circuit are  
identified and collected
7. Electrical circuit are prepared as per diagram  
8. Required testing tools and equipment are identified and  
collected
9. Electrical circuit is tested as per standard procedure  
10. Problems are fixed if required  
11. Electrical circuit are connected with power source as per  
diagram
12. Functionality and performance of Electrical circuit is  
checked
13. Tools equipment and materials are restored  
14. Workplace is cleaned  

Now, I feel ready to undertake my formal competency assessment.

Signed:

Date:

199
 Install Automation Instruments and Devices

After completion this module trainee will able to:

1. Interpret automation instruments and devices
2. Interpret the concepts of Industrial Robot
3. Install and configure automation instruments and devices

200
Module 3: Install Automation Instruments and Devices

Module Content

Module Descriptor
This unit covers the knowledge, skills and attitudes required to Install Automation
Instruments and devices. It includes interpreting automation instruments and devices,
interpreting the concepts of Industrial Robot and installing and configuring automation
instruments and devices

Nominal Duration: 40 hours

(Learning Outcomes):
Upon completion of the module, the trainee should be able to:
▪ Interpret automation instruments and devices
▪ Interpret the concepts of Industrial Robot
▪ Install and configure automation instruments and devices

Performance Criteria:

1.1 Automation instrument and devices are identified and defined

1.2 Uses of instrument and device are interpreted according to manuals
2.1. Robotics concepts are identified and defined
2.2. Application of robotics are interpreted
3.1 Diagram for automation is collected and interpreted as per manual
3.2 Instrument’s and devices are selected and collected
3.3 Tools, devices and materials for the job are identified and collected as per job
requirement
3.4 Automation instrument and devices are assembled as per manual and diagram
3.5 Instrument and devices are set and configured

Learning Outcome: 1
Interpret automation instruments and devices

201
 Contents:

Instructions
1. Hardware: PLC, Control circuit & Power Circuit, Electrical diagram, AVO Meter,
Multi meter, Megger, HMI and others PLC related all devices
2. PC
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

1. Automation instrument and devices are identified and defined

2. Uses of instrument and device are interpreted according to manuals

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, Hardware: PLC, Control circuit & Power Circuit, Electrical
diagram, AVO Meter, Multi meter, Megger, HMI and others PLC related all devices

Learning Activity 1.1

Resources/Special
Learning Activity
Instructions/References

Interpret automation ▪ Information Sheet:.1.1

instruments and ▪ Self-Check:.1.1
devices ▪ Answer Sheet: 1.1

202
 (Information Sheet 1.1 )

Perform of Automation Instruments and Devices

Automation instrument and devices are identified and defined (Input)
Limit Switch: A limit switch is an
electromechanical device that responds to
the physical pressure that an object exerts on
it. Limit switches are used to determine if an
object is present or not. These switches were
given the moniker Limit Switch since their
original purpose was to specify an object's
limit of travel.
Types of limit switches
There are 4 general types of limit switches:
1. Whisker
2. Roller
3. Lever
4. Plunger
A limit switch could be a hybrid of two of the
common types, such as roller-lever,
depending on the need.
Limit switches are used to determine if an
object is present or not.
These switches were given the moniker Limit
Switch since their original purpose was to
specify an object's limit of travel.
Limit switches applications
A light within the refrigerator illuminates
when the door is opened. What causes that
to occur? You guessed it, so, yes! To
determine whether the refrigerator door is
open or closed, a limit switch is employed.
Let's examine another use for a limit switch
that you might see at home. The movement
of many overhead garage doors is stopped
when they reach their fully opened position by
a limit switch.
settings for limit switches Limit switches
come in a variety of switch designs,
including one of each of normally open and
normally closed.

203
Symbols of limit switches
Depending on where the electrical
schematic came from, limit switches may
be depicted in several ways.

The symbols used by the National Electrical

Manufacturers Association (NEMA) and the
International Electro technical Commission
(IEC) differ somewhat.
Micro switch
Let's take a peek inside a limit switch called
a micro switch. Two limit switches working
together and sharing a shared terminal
make up a micro switch. The first limit
switch is often open, whereas the second
one is typically closed.

Micro switches simple circuit:

Let's attach the micro switch to a lamp
circuit now. The Red lamp is on while the
device is in the dormant condition since
nothing is pushing on the trigger to operate
it.
The device will turn on and the Green lamp
will turn on when the Trigger is pushed.

(Self-Check 1.1)
Write the correct answer for the following questions.
1. What is an example of a limit switch?
2. What are the 3 primary parts components of a limit switch?
3. Why are limit switches needed?
4. Are limit switches normally open?
5. .Is a limit switch analog or digital?

(Answer Key 1.1)

1. What is an example of a limit switch?

Ans: Limit switches can also be used as safety interlocks to prevent machine parts from moving
any further when a specific point is reached. A good example of this is an automatic garage door.
2. What are the 3 primary parts components of a limit switch?
Ans: The main components that make up a Limit Switch are the actuator, cover, built-in switch
and switch case.
3. Why are limit switches needed?
Ans: The purpose of the limit switch is to send a signal that will stop the axis from trying to move
past the end of its travel range. A CNC can have one or two limit switches per axis. Limit switches
have an advantage in open loop system. Open loop means that there is no feedback to the

204
controller
3. Are limit switches normally open?
Ans: A limit switch may be normally open (NO) or normally closed (NC) in its normal resting
position. A NO device, when actuated, switches to close (or "make") the circuit, whereas an NC
switch would open and break the circuit when actuated.
5. Is a limit switch analog or digital?
Ans: A limit switch is a digital device, as it contains two possible positions, depressed or not.
When an object pushes against a limit switch, an electrical signal is either created or broken,
which is turn indicates to a control device that the limit switch as be depressed

Job Sheet

Job Sheet – 1.1

Job Perform of Limit Switch Hardware Connection.

Procedure: 1. Selected Limit Switch .

2. Hardware Connection PLC and Limit Switch Sensor.
3. Check Diagram as per as Drawing.
4. Draw ladder Diagram.
5. Program Simulated.
6. Program Download PC to PLC.
Personal Protective 1.Apron, 01 Pc
Equipment (PPE): 2. Helmate 01 Pc
3. Safety Shoe 01 Pc
Materials 1. Limit Switch 01 Pc
2. Relay 01 Pc
3.Cable 01 Pc
4.SMPS 01 Pc
5.Magnetic Contactor 01 Pc
6.Control Valve 01 Pc
Tools and Equipment: 1.Computer 01 pc
2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

205
 (Information Sheet 1.2 )

Perform of Automation Instruments and Devices

Automation instrument and devices are identified and defined (Input)
Perform of Encoder: Encoders are angular motion sensors that can detect angular motion,
Mechanical Encoder
To measure the rotation in this method, a
variable resistor is used. Potentiometers are
the name for these encoders. A change in
current allows for the detection of the
resistance change.

Magnetic Encoder
A magnetic sensor is put next to the
permanent magnet, which is coupled to the
shaft. The sensor monitors the variations in
the magnetic field caused by the shaft's
movement.

Electromagnetic Induction Encoder

The electromagnetic encoder detects rotation
from inside the motor by employing induction
principles. A detecting coil and an excitation
coil make up the motor. Transformer action
induces voltage inside the sensing coil, which
aids in motion detection.

Optical Encoders
An optical encoder employs a photodiode as
a light detector, a disc with slits as a light
source, and an LED as the light source. While
the shaft rotates, light filters and passes
through the slits of the disc. The rotation is
converted into electrical pulses by the light
detector. By counting the electrical pulses,
the rotation may be quantified. Several newer
encoders are available.
direction, speed, and agles of the rotatio
Desired Output of Encoders
An ideal encoder can provide the following information about the rotating shaft.
1. An encoder can tell us about the angular position of the shaft
2. The speed of the shaft
3. Rotational direction, i.e., the rotation is clockwise or counterclockwise
4. Number of rotations

206
Robots
Industry productivity and product precision
have both grown because to robotic arms. A
robotic arm is similar to a human arm in that it
has several joints, including the wrist, elbow,
and shoulder. Encoders are used to track the
robotic arm's movement.

Actuators
Actuators with gear assemblies and motors are
frequently utilized to increase or reduce output
torque. In addition, a straightforward 3D printer
uses an electric motor to drive a linear slide as
an actuator. Encoders are used to monitor the
slide's motion.

Servomotor
A closed loop motor is a servomotor. Where a
goal angle and speed are specified for the
motor. the means of an encoder

Creating a Signal:
Encoders create signals using a variety of
technologies, with optical being the most
popular. These technologies include
mechanical, magnetic, resistive, and optical.
As shown, the encoder in optical sensing
delivers feedback based on the interruption of
light.

Resolution
The Cycles Per Revolution (CPR) for
incremental encoders is referred to as
resolution. Each incremental encoder
generates a specific number of cycles for
each 360-degree shaft rotation. A counter or
motion sensor keeps track of these cycles.

Uses of Encoders
Industrial processes
The majority of procedures in today's modern industry are automated, continuous, and
redundant. A computer may be able to manage such a procedure. These procedures, which

207
include PCB board fabrication, hole drilling, component insertion, and PCB board testing,
can be straightforward or intricate. Encoders are used in these sectors to measure every
machine motion.

Application Example
a typical motion control application using an
encoder as an illustration. Applications for
encoders include cut-to-length, plotters,
packaging and conveying, automation and
sorting, filling, imaging, and robotics. The
procedure is the same: the controller sends a
signal to the machine to perform a function
after receiving a count from the encoder,
which is sent to the controller.

(Self-Check Questionnaire 1.2)

Write the correct answer for the following questions.

1. How many types of encoder are there?

2. What causes encoder failure?
3. How many wires are in an encoder?
4. What is the output of encoder?
5. What is the Z wire on an encoder?

(Answer Sheet 1.2)

1. How many types of encoder are there?
Ans: An encoder is classified into four types: mechanical, optical, magnetic, and electromagnetic
induction types. There are four types of information necessary to rotate the motor with high
accuracy: rotation amount, rotational speed, rotational direction, and rotational position.
2. What causes encoder failure?
Ans: The most common cause of encoder failure is a warped/ bent shaft that is no longer sitting
on the bearings properly, an issue also referred to as shaft run-out. A warped shaft adds stress to
the internal bearings and may lead to bearing failure and eventual overheating of the encoder.
3. How many wires are in an encoder?
Ans: Encoder Cabling Schemes
Incremental encoders will require one wire for power, one wire for ground, and one wire for each
additional channel
4. What is the output of encoder?
Ans: An encoder that contains a differential line driver generates two output signals; one matches
the original signal, while the other is an exact opposite or complementary signal.
5. What is the Z wire on an encoder?
Ans: Index pulse, also known as Z, marker, or I
Electrical cycle, but can be gated to reduce the pulse width. The Index (Z) pulse can be used to
verify correct pulse count. The Incremental Encoder Index pulse is commonly used for precision
homing. As an example, a lead screw may bring a carriage back to a limit switch

208
 Job sheet

Job Sheet – 1.2

Job Perform of Encoder with PLC.

Procedure: 1. Selected Encoder.

2. Hardware Connection PLC and Limit Encoder.
3. Check Diagram as per as Drawing.
4. Draw ladder Diagram.
5. Program Simulated.
6. Program Download PC to PLC.
Personal Protective 1.Apron,Helmate,Safety Shoe 01 Pc
Equipment (PPE):
Materials 1. Encoder 01 Pc
2. Relay 01 Pc
3.PLC 01 Pc
4.SMPS 01 Pc
5.Magnetic Contactor 01 Pc
6.Control Valve 01 Pc
Tools and Equipment: 1.Computer 01 pc
2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

209
 (Information Sheet 1.3 )

Perform of Automation Instruments and Devices

Automation instrument and devices are identified and defined (Input)
Temperature Sensor: Temperature sensor working
In order to record, monitor, or communicate principles
temperature changes, a temperature sensor is an A temperature sensor is a device
electronic device that monitors the temperature of its that measures temperature
surroundings and turns the input data into electronic through an electrical connection
data. and typically consists of a
thermocouple or resistance
temperature detector.
Contact Type Temperature Sensors: A few Non-Contact Type Temperature
temperature meters can determine how hot or cool Sensors: These kinds of
something is simply by making direct contact with it. thermometers assess the degree
These temperature sensors are under the contact-type of hotness or coolness through
category. They can be used to find objects that are the radiation that the heat source
solid, liquid, or gaseous throughout a wide temperature emits rather than being in direct
range. touch with the thing.
Thermostats
A thermostat is a form of contact temperature sensor
that consists of a bi-metallic strip made of two metals
that are not similar to one another, such as tungsten
and aluminum.
When exposed to heat, the two metals' different
coefficients of linear expansion cause them to produce
a mechanical bending action.

Thermistors
Thermistors, also known as thermally sensitive
resistors, are the ones that alter physically in response
to temperature changes. The thermistors can readily
deform since they are made of ceramic materials such
oxides of nickel, manganese, or cobalt that are coated
with glass.
The majority of thermistors have a negative
temperature coefficient (NTC), which implies that as
the temperature rises, so does their resistance.
However, certain thermistors have a positive
temperature coefficient (PTC), meaning that their
resistance rises as the temperature rises.

210
Resistive Temperature Detectors (RTD)
RTDs are highly pure conducting metals twisted into
coils, such as platinum, copper, or nickel, to create
precise temperature sensors. An RTD's electrical
resistance varies similarly to a thermistor's.

Thermocouples
Thermocouples are among the most popular
temperature sensors due to their broad temperature
operating range, dependability, accuracy, simplicity,
and sensitivity.

Thermistor with Negative Temperature Coefficient

(NTC)In essence, a thermistor is a sensitive
temperature sensor that responds precisely to even the
smallest temperature changes. At extremely low
temperatures, it offers a considerable resilience. This
indicates that as soon as the temperature rises, the
resistance begins to rapidly decrease.

Temperature Sensor Connect with PLC:

211
Where is the temperature sensor used?
The temperature sensor’s applications include:
⮚ The temperature sensors are used for verifying design assumptions that will promote
safer and economical design and construction.
⮚ They are used to measure the temperature rise during the process of curing
concrete.
⮚ They can measure rock temperatures near liquid gas storage tanks and ground
freezing operations.
⮚ be used to study the temperature effect on other installed instruments.

PLC and Thermocouple Hardware

Connection

(Self-Check 1.3)
Write the correct answer for the following questions.
1. What are the 2 types of temperature sensor?
2. Where is temperature sensor used?
3. What is the main function of temperature sensor?
4. Which temperature sensor is best?
5. What is the use of temperature?

(Answer Key 1.3)

1. What are the 2 types of temperature sensor?
Ans: Types of Temperature Sensors Thermocouples, Thermocouples are the most commonly
used type of temperature sensor. ... RTD (Resistance Temperature Detector) as temperature
changes, the resistance of any metal changes as well. ...
Thermistors. ...
Semiconductor based ICs. ...

2. Where is temperature sensor used?

Ans: Temperature sensors are devices used to measure temperature in solids, liquids or gases.
They are used within industrial applications and have many more commercial uses. Most of the
temperature sensors we supply monitor temperature by measuring the change in resistance of an
electrical current.

212
3. What is the main function of temperature sensor?
Ans: A temperature sensor is an electronic device that measures the temperature of its
environment and converts the input data into electronic data to record, monitor, or signal
temperature changes. There are many different types of temperature sensors.
4. Which temperature sensor is best?
Ans: The most well-known are Pt100 (with a resistance of 100 ohms at 0°C) and Pt1000 (with a
resistance of 1,000 ohms at 0°C). The Pt1000 offers better accuracy and a larger tolerance to long
wire lengths than the Pt100. Compared to thermocouples; resistance sensors offer better accuracy
and a more linear response.
5. What is the use of temperature?
Ans: Temperature is the measure of hotness or coldness expressed in terms of any of several
scales, including Fahrenheit and Celsius. Temperature indicates the direction in which heat energy
will spontaneously flow—i.e., from a hotter body (one at a higher temperature) to a colder body
(one at a lower temperature).

Job Sheet

Job Sheet – 1.3

Job Perform of Interface temperature Sensor and PLC
Procedure: 1.Selected Thermocouple Temperature Sensor
2.Hardware Connection PLC and Thermocouple Temperature
Sensor.
3.Check Diagram as per as Drawing
4.Draw ladder Diagram
5.Program Simulated
6.Program Download PC to PLC
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Helmate 01 Pc
3. Safety Shoe 01 Pc
Materials 1. PLC 01 Pc
2. Analog Input /Output Module 01 Pc
3.Termocople 01 Pc
4.SMPS 01 Pc
5.lamp 01 Pc
6.Magnetic contactor 01 Pc
Tools and Equipment: 1.Computer 01 pc
2.Philis Screw driver 01 Pc
3.Neon Tester 01 Pc

213
 (Information Sheet 1.4 )

Perform of Automation Instruments and Devices

Automation instrument and devices are identified and defined

Pressure Sensor: A pressure sensor is a
device made up of a pressure sensitive
element that uses various working
principles to identify the actual pressure
applied to the sensor and other
components that turn this information into
an output signal.

An electronic device known as a pressure

sensor detects, controls, or monitors
pressure and transforms sensed physical
information into an electronic signal.

Types of pressure sensors

These are:
⮚ Potentiometric pressure sensors.
⮚ Inductive pressure sensors.
⮚ Capacitive pressure sensors.
⮚ Piezoelectric pressure sensors.
⮚ Strain gauge pressure sensors.
⮚ Variable reluctance pressure sensors.

(Self-Check 1.4)
Write the correct answer for the following questions.
1. What is Analog Signal?
2. Which sensor is used for pressure?
3. What are the 4 types of pressure??
4. What is the output of a pressure sensor?
5. Is a pressure sensor analog or digital?

214
 (Answer Sheet 1.4)

1. What is Analog Signal?

An analog signal is one whose value continually varies over time. They are best represented as a
continuous signal like a sine wave. Each point on the wave has a precisely defined value. For
example, analog inputs for PLCs can include signals from pressure transducers and temperature
from thermocouples
2. Which sensor is used for pressure?
A manometer is a fluid pressure sensor that provides a relatively simple design structure and an
accuracy level greater than that afforded by most aneroid barometers. It takes measurements by
recording the effect of pressure on a column of liquid.
3. What are the 4 types of pressure?
Types of Pressure - Absolute Pressure, Gauge Pressure, Differential Pressure and Sealed
Pressure.
4. What is the output of a pressure sensor?
A typical pressure sensor works producing a strain gauge output as the deflection of a diaphragm
is caused. Depending on the strain gauge technology the output can vary from 1 to 3 millivolts per
volt (mV/V) to as much as 10 to 30 mV/V.
5. Is a pressure sensor analog or digital?
Some common examples of analog sensors are light sensors (LDRs), sound sensors, pressure
sensors, and analog temperature sensors. Similarly, there are some commonly used digital
sensors such as digital temperature sensors and digital pressure sensors.

Job Sheet
Job Sheet – 1.4
Job How to Interface Pressure Sensor and PLC

Procedure: 1.Selected 2 wire pressure Sensor

2. Hardware Connection PLC and Pressure sensor.
3.Check Diagram as per as Drawing
4.Draw ladder Diagram
5.Program Simulated
6.Program Download PC to PLC
Personal Protective 1.Apron, , 01 Pc
Equipment (PPE):
2. Helmate 01 Pc
3. Safety Shoe 01 Pc
Materials 1. PLC 01 Pc
2. Analog Input /Output Module 01 Pc
3.Pressure Sensor 01 Pc
4.SMPS 01 Pc
5.lamp 01 Pc
6.Control Valve 01 Pc
Tools and Equipment: 1.Computer 01 pc
2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

215
 (Iformation Sheet 1.5)

Perform of Automation Instruments and Devices

Automation instrument and devices are identified and defined.

Flow Sensor
The mass or volume of a fluid flowing
through a pipe is measured by flow
sensors, which are equipment (or a tube).
There are numerous types of flow sensors;
the ones most frequently employed in the
sector include

1. Obstruction type
2. Turbine type
3. Electromagnetic
4. Positive displacement
5. Vortex
6. Anemometer
7. Ultrasonic
8. Mass flow meter

A turbine flow sensor with a pulse output,

the YF-S201. A turbine rotor installed on a
shaft within the cylindrical container housing
the liquid stream makes up a turbine flow
sensor. The turbine blades experience a
torque that drives when liquid passes over
the sensor.

The Hall Effect sensor outputs electrical

pulses at its terminal upon each rotation of
the turbine rotor. The amount of fluid flow is
related to the number of pulses the Hall
Effect sensor provides.
YF-S201 Specifications
While there is no information regarding the
manufacturer of the sensor, the YF-S201
sensor's specs are not well known. As a
result, it is unwise to rely on the online
datasheet. It is a good idea to use the
sensor under circumstances that are very
different from the official specs,
nevertheless. The following are the online
specifications:
Wiring
Being an NPN sensor, the YF-S201 should
be connected to a sourcing digital input
module, as was already indicated.

216
(Self-Check 1.5)
Write the correct answer for the following questions.
1. What do flow sensors measure?
2. Which sensor is used in flow meter?
3. What is flow range?
4. Why is flow rate important.

(Answer Key 1.5)

1.What do flow sensors measure
A flow meter (or a flow sensor) is an instrument that is used to indicate the amount of liquid, gas, or
vapor moving through a pipe or conduit by measuring linear, non-linear, mass, or volumetric flow
rates
2.Which sensor is used in flow meter?
Thermal Mass Flow Meter uses two sensors to take temperature measurements with an active heat
sensor to measure heat loss in the liquid and a flow meter to determine the flow rate. Mass Gas
Flow Meter, or Carioles flow meters, work on the basis of the Carioles Effect, motion mechanics.
3.What is flow range?
It indicates the range in which a flow meter or controller can accurately measure the fluid. In other
words, it's simply the high end of a measurement range compared to the low end, expressed in a
ratio and is calculated using a simple formula. Turndown Ratio = maximum flow / minimum flow
4.Why is flow rate important?
Flow rate is the volume of fluid that passes through a given cross-sectional area per unit time.
Accurate flow rate measurement using an appropriate flow meter is paramount to ensuring fluid
control processes run smoothly, safely and cost-effectively.

217
 JOB SHEET – 1.5
Job Preform of Interface Flow sensor and PLC

Procedure: 1. Selected Flow Sensor.

2. Hardware Connection PLC and Flow Sensor.
3. Check Diagram as per as Drawing.
4.Draw ladder Diagram
5. Program Simulated.
6. Program Download PC to PLC.
Personal Protective 1.Apron 01 Pc
Equipment (PPE):
2. Helmate 01 Pc
3. Safety Shoe 01 Pc
Materials 1. PLC 01 Pc
2. Analog Input /Output Module 01 Pc
3.Flow Sensor 01 Pc
4.SMPS 01 Pc
5.Lamp 01 Pc
6.Control Valve 01 Pc
Tools and Equipment: 1.Computer 01 pc
2.Philis Screwdriver 01 Pc
3.Nyon Tester 01 Pc

218
 (Information Sheet 1.6)

Perform of Automation Instruments and Devices

Automation instrument and devices are identified and defined
Level Sensor:
A level sensor is a tool used to maintain, measure, and monitor liquid (and occasionally solid)
levels. Following the detection of the liquid level, the sensor transforms the observed
information into an electric signal.

Mechanical Sensors
Mechanical sensors don't employ any
electronic signals or signal processing;
they only use mechanical means of
sensing and signaling. There are a few
fundamental mechanical sensors covered
in this section. The drawback of these
sensors is that no data is relayed to the
control room; just a local indication is
provided.

Electronic Sensors
For the purpose of transforming
mechanical motion or sound waves into
electrical signals, electronic level sensors
require electronic components. The
control room uses these signals to display
data, operate pumps, and control other
machinery. Cost and complexity of sensor
maintenance are drawbacks of these
sorts of sensors. Nonetheless, their
benefits in terms of accuracy, speed, and
accessibility to data at a distant place are
strong arguments for choosing them in
most applications.

Float Switch Sensor

As the level rises over or falls below a
predetermined value, the float in this sort
of sensor activates a switch. The switch's
ability to deliver a voltage signal to a PLC
upon activation. This can be used as an
alert or to operate a pump. Due to their
ease of use and comprehension, these
sensors are quite popular. The precision
is great and there aren't many moving
components. They are a popular option in
both industrial and residential applications
because to their high cost-effectiveness.

219
Ultrasonic Sensors
Ultrasonic sensors have the advantage of
not having any moving parts and of being
non-contact type.

An ultrasonic sensor is used to measure

the liquid level in a tank. Orange box that
serves as a highlight for the sensor. The
conical sound beam is represented by the
yellow concentric circles. Sensors for Non-
Contact Capacitance

1215c AC/DC/Rly Siemens PLC module

with two analog inputs. The highlighted
area shows how an analog level sensor
can be wired to this PLC module. The circle
with ”+” and ”-” represents an analog level
sensor.

A Siemens code snippet for measuring an

input signal of 1-5 VDC or 4-20 mA. The
analog input is scaled to represent a level
0.0–10.0 engineering value in the specified
units. A pump is activated when the scaled
level drops to 1.5 or lower. The PLC
detects the voltage signal that the digital
level sensors send when they reach a
predetermined level and uses it to regulate
actions like turning on or off a pump.
PLC 1215c AC/DC/Rly by Siemens
In the image above, a Siemens PLC 1215c
AC/DC/Rly CPU may be seen. A digital
switch that is connected to the PLC's input
may be seen in the orange-highlighted
area.
The bit of Siemens code above
demonstrates how a pump can be turned
off when a tank reaches a high level using
a digital level sensor.

Level sensor Application

⮚ reactors,
⮚ distillation columns,
⮚ evaporators,
⮚ mixing tanks,.

220
(Self-Check 1.6)
Write the correct answer for the following questions.
1. Which sensor is used for level?
2. What is an example of a level sensor?
3. What is the output of level sensor?
4. How many types of level sensors are there?

(Answer Key 1.6)

1.Which sensor is used for level?

There are two main classifications for level sensors: point level sensors and continuous level
sensors. Point level sensors are designed to indicate whether a liquid has reached a specific point
in a container. Continuous level sensors, on the other hand, are used to render precise liquid level
measurements.

2.What is an example of a level sensor?

Level sensors allow for the level control of fluid in a vessel. Examples of where these sensors are
installed include reactors, distillation columns, evaporators, mixing tanks,

3.What is the output of level sensor?

The sensors can be obtained with voltage output (0-5VDC, 1-5VDC, 0-10VDC), current (4-20mA),
with digital interface (RS232 or RS485), or with contact type output (NPN open collector or relay ),
depending on the mod

4.How many types of level sensors are there?

Liquid level sensors have been around for decades, in markets such agriculture, automotive and
white goods for leak detection or level food and beverage, industrial, medical and domestic,
printing as

221
 Job Sheet
Job Sheet – 1.6
Job Perform of Interface Level Sensor and PLC
Procedure: 1. Selected Level Sensor.
2. Hardware Connection PLC and Level Sensor.
3. Check Diagram as per as Drawing.
4.Draw ladder Diagram
5. Program Simulated.
6. Program Download PC to PLC.
Personal Protective 1.Apron, , 01 Pc
Equipment (PPE): 2. Helmate 01 Pc
3. Safety Shoe 01 Pc
Materials 1. PLC 01 Pc
2. Analog Input /Output Module 01 Pc
3.Level Sensor 01 Pc
4.SMPS 01 Pc
5.lamp 01 Pc
6.Control Valve 01 Pc
Tools and Equipment: 1.Computer 01 pc
2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

(Information Sheet 1.7 )

Perform of Automation Instruments and Devices

Uses of instrument and device are interpreted according to manuals

Relay: A relay is essentially a kind of

electromechanical switch that turns power on
and off for a circuit, acting as a switch. Coils
have switching contacts, just like magnetic
contactors do. Less current can pass via the
contact pairs of the coil, which is how a coil
differs from a coil. The control circuit uses
around 10 amperes of current. Any forms of
loads, whether they draw more or less current,
can be handled by magnetic contactors. It
frequently appears in power circuits. The
reel's coil pitch is (6-24r) for DC and
(220/400r) for AC.

222
Timing Relay/Timer: The timer contains two
common coil type relays. Moreover, a timing
circuit is present that, after a predetermined
amount of time, activates or turns on the relay
coil. Timing is done in either seconds or
minutes. The year's Scorpion falls between
220th and 400th AC/ 12th to 24th DC. The
timer is used with a timer base. Also, the Line,
NO, and NC Contact pair of the timer, which is
inscribed on the timer's base, are marked with
specific numerals. Fundamentally, the timer's
connection schematic is provided if it is
utilized as a motor starter.

Magnetic Contactor: It is an electromagnetic

switching technology that enables
simultaneous operation of many switches. Coil
and switching contact make up the two
components of a magnetic contactor. Both
control circuits and power circuits can use
magnetic contactors.

Magnetic contactor coil:

Low voltage release coil is the name given to
the magnetic contactor's coil. This coil's
supply voltage ranges from 220 to 400 volts.
A1, A2 stand for the coil's terminal pair.
Magnetic contactor contact switch: Several
open and close contacts are present in a
magnetic contactor; collectively, they are
referred to as NO, NC (Normally Open,
Normally Closed) Contacts. The buzzer
changes to buzzer and the buzzer position
changes to buzzer when the coil of the
magnetite contactor is activated..

Push Button Switch:

Unlike a typical switch, the push button switch
used in motor circuit breakers has two
settings. Both are normally closed (NC) and
one is normally open (NO) (NC).

223
(Self-Check 1.7)
1. What are the devices used in motor controller?
2. What are the parts of magnetic contactor?
3. What is A1 and A2 in magnetic contactor?
4. What are industrial relays used for?
5. What are the 4 parts of a relay?
6. How the relay works on timer?

Answer Key (1.7)

1. What are the devices used in motor controller?

o Motor Control
o Manual Motor Starters. Manual motor starters are motor control components that are
used for motor protection. ...
o Motor Circuit Breakers. ...
o Contactors. ...
o Mini Contactors. ...
o Thermal Overload Relays.
o Motor Control Accessories.

2. What are the parts of magnetic contactor?

A magnetic contactor has two incoming circuits which include the main circuit to power the load and
an auxiliary circuit to operate the contactor itself. The auxiliary circuit connects to an induction coil,
and when current flows through the circuit, the coil generates a magnetic field.
3. What is A1 and A2 in magnetic contactor?
What Do A1 and A2 Mean on a Contactor? A1 and A2 on a contactor typically refer to either end of
the electromagnetic coil assembly. Most contactor manufacturers use A1 and A2 to designate the
two terminals connecting electrical power to the contactor's magnetic coil.
4. What are industrial relays used for?
In industrial applications, they are commonly used in control panels for various tasks such as
monitoring power or controlling a motor or valve or other electrical devices in automation.
5. What are the 4 parts of a relay?
An electromechanical relay is basically designed using few mechanical parts like Electromagnet, a
movable armature, contacts, yoke, and a spring/frame/stand, these parts are showing in the
internal pictures of Relay below.

6. How the relay works on timer?

Electromagnetism is the timer relay working principle. One relay coil is always on, while the other
can be turned off and on with an electric signal sent through it from a control device such as a
phone or computer system. The “on” coil receives power all the time, making it ready to activate at
a moment's notice.

224
 Job Sheet
JOB SHEET – 1.7
Job Introduction/identification of various parts of industrial motor
control circuit
Procedure: 1. Collect and wear PPE.
2. Turn on the coils A1 and A2 of the magnetic contactor.
3. Test the coils A1 and A2 of the magnetic contactor, by
AVO Meter and Series lamp.
4. Test the magnetic contactor normally open and close
(NO/NC) AVO Meter and Series lamp
5. Check normally open and normally close (NO/NC) of
over relay by probe and test lamp.
6. Check normally open and normally close (NO/NC) by
probe and test lamp.
7. Check the timer normally open and normally close by
AVO Meter and Series lamp.
8. Intrinsically proper use and maintenance.).
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Helmate 01Pc
3. Safety Shoe 01 Pc
2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 01 pc
2.Magnetic Contactor 01 pc
3.Push Button Switch 02 pc
4.Timer with base 01 pc
5.Relay With base 01 pc
6. Over Load Relay 01 Pc
Tools and Equipment: 1. 3 Phase Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

225
 (Information Sheet 1.8 )
Perform of Automation Instruments and Devices
Uses of instrument and device are interpreted according to manuals
Perform of Power Transistor:
Among semiconductor devices is the transistor. It serves as the foundation for all digital
components. A point contact transistor was the first type of transistor ever created. A
transistor's primary job is to amplify weak signals and regulate them appropriately. Silicon,
germanium, gallium-arsenide, and other semiconductor materials make up a transistor.
Based on their structure, they can be divided into two groups: field-effect transistors (FETs),
which include junction function transistors and metal oxide transistors (MOSFETs), and
bipolar junction transistors (BJTs), which are used in junction transistors, NPN transistors,
and PNP transistors, respectively (like Small-signal transistor, Small switching transistor,
Power transistor, High-frequency transistor, Phototransistor, Uni junction transistors). Emitter
(E), Base (B), and Collector (C) or Source (S), Drain (D), and Gate (G) are its three primary
components (G).

Power Transistor
The three-terminal device which is designed specifically to control high current – voltage
rating and handle a large number of power levels in a device or a circuit is a power transistor.
The classifications of power transistor include the following.
 Bipolar junction transistor (BJTs)
 Metal oxide semiconductor field-effect transistor (MOSFETs)
 Static induction transistor (SITs)
 Insulated-gate bipolar transistor (IGBTs).

Bipolar Junction Transistor

A BJT, also known as a current control
device, is a bipolar junction transistor that
can manage two polarities (holes and
electrons). It can be used as a switch, an
amplifier, or both. The following are the
qualities of a Power BJT:
It is larger so that the greatest amount of
current may pass through it.

MOS-metal-oxide-semiconductor-field-
effect-transistor-(MOSFETs)-FETs
A MOSFET is a type of FET transistor that
has three terminals: a source terminal, a
base terminal, and a drain terminal. The
channel's width determines how well a
MOSFET functions. That is, it operates
effectively if the channel width is large. The
properties of a MOSFET are as follows:
Structure of Power Transistor
The Power Transistor BJT is a vertically
oriented component with a sizable cross-
sectional area and alternately connected P
and N-type layers. Either a P-N-P or an N-
P-N transistor can be used to design it.

226
PNP-and-NPN-transistor
The P-N-P type, which has emitter, base,
and collector terminals, is illustrated in the
construction below. Where the collector drift
region, also known as the "collector drift
region," determines the device's break-over
voltage, the emitter terminal is connected to
a highly doped n-type layer, which is below
which is a moderately doped p-layer with a
concentration of 1016 cm-3. Finally, it has
an n+ layer, which is a highly doped n-type
layer with a concentration of 1019 cm-3,
where the collector is etched away for user
convenience.

SCR
The globe of electronic 2Hp Variable Speed
SCR Drive Controller can be divided. There
are two types of motor drives: AC and DC.
SCR Drives are nearly always DC (Silicon
Controlled Rectifier Drive). A motor drive
regulates a motor's output horsepower as
well as its speed, torque, and direction. A
shunt wound DC motor with separate
armature and field circuits is normally
controlled by a DC drive. Like their DC
counterparts, AC drives are used to control
the speed, torque, and horsepower of AC
induction motors.
Solenoid valve:
A solenoid valve is an electro-mechanical
valve that is frequently used to control the
flow of liquid or gas, according to the
definition. There are many different kinds of
solenoid valves, but the two most common
varieties are direct acting and pilot driven.
The primary orifice in the valve body is
opened and closed by pilot controlled
valves, which are the most popular type.
While Direct driven solenoid valves are the
only flow path in the valve, they directly
open or close the primary valve orifice.
They are utilized in applications or systems
that call for modest flow rates or low
pressure differentials across the valve
orifice.

Function of solenoid valves

A solenoid valve regulates the flow of gases or liquids in either a positive, fully-closed, or
fully-open mode. They are frequently used for remote control or to replace manual valves.
When a solenoid valve operates, an orifice in the valve body is either opened or closed,
allowing or preventing flow through the valve. By activating the coil, a plunger raises or
lowers the aperture by raising or lowering it within a sleeve tube.

227
 Solenoid valve Application
The majority of flow control applications need starting or stopping the circuit's flow in order to
regulate the system's fluids. Typically, an electronically controlled solenoid valve is
employed for this. Solenoid valves can be placed in remote areas and conveniently operated
by basic electrical switches because they are solenoid actuated.
Solenoid valves can be found in many different sectors, including:
 Water supply
 Treatment of drinking water
 Waste water treatment
NAMUR solenoid valve
NAMUR is an acronym for the User Association of Automation Technology in Process
Industries, which serves as a standard for automated valve technology.

(Self-Check 1.8)
1. What is power transistor explain??
2. What are the applications of power transistor
3. How do you identify a power transistor?
4. Why are transistors important?

Answer Key (1.8)

1.What is power transistor explain?
What Are Power Transistors? Power transistors are three terminal devices which are composed of
semiconductor materials. They feature emitter, base and collector terminals. These devices are
particularly designed to control high current – voltage rating
2.What are the applications of power transistor?
⮚ Applications of a Power Transistor
⮚ It is used in converters.
⮚ It is also used in relays.
⮚ It is used in an inverter.
⮚ It is used for the amplification of the power as a power amplifier in electronic devices.
⮚ It is also used in DC to AC converters.
⮚ It is used in the supply of power.
⮚ It is used in power control circuits too.

3.How do you identify a power transistor?

Hook the positive lead from the multi meter to the to the BASE (B) of the transistor. Hook the
negative meter lead to the EMITTER (E) of the transistor. For an good NPN transistor, the meter
should show a voltage drop between 0.45V and 0.9V. If you are testing PNP transistor, you should
see “OL” (Over Limit)
4.Why are transistors important?
Transistors transformed the world of electronics and had a huge impact on computer design.
Transistors made of semiconductors replaced tubes in the construction of computers. By replacing
bulky and unreliable vacuum tubes with transistors, computers could now perform the same
functions, using less power and space.

228
 Job Sheet
Job Sheet – 1.8
Job Perform of Power Transistor
Procedure: 1. Collect and wear PPE.
2. Turn on the Power Transistor Components.
3. Test the Power Transistor Components. by AVO Meter
and Series lamp.
4. Intrinsically proper use and maintenance.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Doide 01 pc
2.Register 01 pc
3.Mosfet 02 pc
4.Veroboard 01 pc
5.DC Power Supply 01 pc
6. Cable 01 Pc
Tools and equipment: 2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

Learning Outcome: 2
Interpret the concepts of Industrial Robot

Contents:

Instructions
1. Hardware: Robotics
2. PC
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

2.1 Robotics concepts are identified and defined

2.2 Application of robotics are interpreted

229
Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, and Robotics

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Interpret the concepts ▪ Information Sheet:.2.1

of Industrial Robot ▪ Self-Check:.2.1
▪ Answer Sheet: 2.1

(Information Sheet 2.1 )

Interpret the concepts of Industrial Robot

Robotics concepts are identified and defined

Robotics is the synthesis of science, engineering, and technology that results in devices,
referred to as robots, that mimic or take the place of human beings in performing tasks.
Robots have long been a source of fascination in popular culture; examples include R2-D2,
the Terminator, and WALL-E. These exaggerated, anthropomorphic representations of
robots frequently seem to be parodies of the genuine thing. But are they more futuristic than
we think? Robots are developing cognitive and mechanical abilities that don't rule out the
potential of a machine that looks like R2-D2 in the future.

Robotics Defined
Even though the field of robotics as a whole is growing, a robot always contains the following
traits: Robots are made of some kind of mechanical design. A robot's mechanical
component aids in its ability to carry out activities in the setting for which it was created. For
instance, the Mars 2020 Rover's individual motorized titanium tubing wheels help it maintain
a strong hold on the challenging surface of the red planet.

Main Components of a Robot

Robotic arms:
Industry productivity and product precision have
both grown because to robotic arms. A robotic
arm is similar to a human arm in that it has
several joints, including the wrist, elbow, and
shoulder. Encoders are used to track the robotic
arm's movement.

230
Actuators
To increase or reduce the output torque,
actuators with gear assemblies and motors are
frequently employed. By controlling the motion
of the electric motor, a straightforward 3D printer
also employs a motor as an actuator in a linear
slide. Encoders are used to keep track of the
slide's movement.

Servomotor
A closed loop motor is a servomotor. where a goal angle and speed are specified for the
motor. It determines whether the motor has reached the target or not with the aid of an
encoder. The motor will keep trying until it reaches the desired speed and angle. An AC or
DC brushless motor, a servo amplifier or driver, and an encoder are all combined to form a
servo motor.

Encoders translate movement into an electrical signal that a counter or PLC, or any form of
control device in a motion control system, can read. A feedback signal from the encoder
can be used to calculate position, count, speed, or direction. This data can be used by a
control device to transmit a command for a specific task.
Control System
All of the parts that make up a robot's central processing unit, also known as its control
system, are considered to be part of computation. In a fashion similar to how the human
brain transmits signals throughout the body, control systems are programmed to instruct a
robot how to use particular components in order to carry out a given task. Anything from
minimally invasive surgery to assembly line packing could be included in these robotic jobs.
Sensors
Robots can interact with the outside world thanks to sensors, which offer stimuli in the form
of electrical signals that are analyzed by the controller. Robots frequently contain sensors
such as video cameras, which serve as their eyes, photo resistors, which respond to light,
and microphones, which serve as their ears. These sensors enable the robot to observe its
surroundings, analyze the most logical conclusion given the circumstances at hand, and
transmit commands to the extra components through the controller.
Power Supply
Robots require power to function, much like the human body does. Robots typically use an
internal battery, though stationary robots like those used in factories may also function on
AC power through a wall socket. Most robots use lead-acid batteries because of their
durability and safety, while some may use the more portable but more expensive silver-
cadmium variant. While constructing a robot's power supply, it's crucial to keep safety,
weight, replace ability, and lifecycle in mind..

End Effectors
End effectors are the tangible, frequently exterior parts that enable robots to complete their
duties. Robots used in manufacturing facilities frequently feature interchangeable tools like
paint sprayers and drills, while those used in surgery may have scalpels. Other robot types
might be designed with grasping claws or even hands for activities like deliveries, packing,
bomb dispersion, and many other things.

Uses for Industrial Robots

The automobile industry has been using robotics for decades, but other industries have also
realized the advantages of robotic automation. The "Three D's" rule is a general guideline for
which industrial jobs robots are best suited for: any dirty, boring, or hazardous work. Most

231
robotic applications are straightforward, repetitive operations that demand specialized
resources to complete.

Different Robot Applications in Industries

Industrial robots may be used in any sector that produces or transports goods on a large
scale. Robotics are typically utilized in the creation, finishing, transfer, and assembly of
products in the industrial sector. Moreover, businesses are beginning to use collaborative
Uses of Robots
Robots are the ideal technology for the future since they can be used in a wide range of
situations. Robots will soon be virtually ubiquitous. They'll be present at hotels, hospitals,
and even on the streets.
Applications of Robotics
 Conservation: fighting forest fires.
 Manufacturing: working in factories, finding and carrying items in warehouses.
 Companionship: providing company to elderly individuals.
 Healthcare: assisting in surgical procedures.
 Delivery: completing food delivery and last-mile fulfillment.
 Household: vacuuming and mowing the grass.
 Rescue: undertaking search-and-rescue missions after natural disasters.
 Military Operations: detecting landmines in war zones.

Robotics in Manufacturing
The employment of robots in production is likely the oldest and most well-known. These co-
bots, or robots that assist humans in their work, efficiently test and assemble goods like
automobiles and industrial machinery. More than three million industrial robots are thought
to be in use at this time.

Logistics Robots
Handling, shipping, and quality assurance For the majority of merchants and logistics firms,
robots are becoming a necessity. Logistics businesses utilize robots in warehouses and
even on the road since we now demand that our packages arrive as quickly as possible.
This helps to maximize time efficiency.

Robots for Home

It’s not science fiction anymore. Robots can be seen all over our homes, helping with chores,
reminding us of our schedules and even entertaining our kids.

Travel Robots
Is there anything more science fiction-like than autonomous vehicles? These self-driving
cars are no longer just imagination.

Healthcare Robotics
Robots have made enormous strides in the healthcare industry. These mechanical marvels
have use in just about every aspect of healthcare, from robot-assisted surgeries to bots that

232
help humans recover from injury in physical therapy.
(Self-Check 2.1)
1. What is concept of robotics?
2. What are 3 things that define a robot?
3. What are the four 4 types of robotics?
4. What are the 5 primary areas of robotics?

Answer Key: 2.1

1. What is concept of robotics?
Ans: Robotics is a branch of engineering that involves the conception, design, manufacture and
operation of robots. The objective of the robotics field is to create intelligent machines that can
assist humans in a variety of ways. Robotics can take on a number of forms.
2. What are 3 things that define a robot?
Ans: The thing to keep in mind about this or any other definition is that robots can typically do
three things: sense, compute, and act. These three components vary widely from robot to robot.
3. What are the four 4 types of robotics?
Ans: 4 Types of Robots Every Manufacturer Should Know
Articulated Robots. An articulated robot is the type of robot that comes to mind when most people
think about robots.
SCARA Robots.
Delta Robots.
Cartesian Robots.
4. What are the 5 primary areas of robotics?
Ans: Understanding the 5 Primary Areas of Robotics
Operator interface.
Mobility or locomotion.
Manipulators & Effectors.
Programming.
Sensing & Perception

233
 Job Sheet
JOB SHEET – 2.1
Job Perform of make Robot?
Procedure: 1. Collect and wear PPE.
2. Create a rigid body object.
3. Create a joint and assign it to the rigid body. ...
4. Create a rigid body tree.
5. Add the first body to the tree.
6. Create a second body.
7. Add other bodies.
8. Intrinsically proper use and maintenance.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe a 01 Pc
3. Safety Shoe 01 Pc
Materials 1.Doide 01 pc
2.Register 01 pc
3. Sensor. 02 pc
4.Veroboard 01 pc
5.DC Power Supply 01 pc
6. Motors 01 Pc
7. Servos 01 Pc
Tools and Equipment: 2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

234
Learning Outcome: 3
Install and configure automation instruments and devices

Contents:

Instructions
1. Hardware: Robotics
2. PC
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria
3.1Diagram for automation is collected and interpreted as per manual
3.2 Instrument’s and devices are selected and collected
3.3Tools, devices and materials for the job are identified and collected as per job
requirement
3.4 Automation instrument and devices are assembled as per manual and diagram
3.5 Instrument and devices are set and configured

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, and Robotics

Learning Activity 3.1

Resources/Special
Learning Activity
Instructions/References

Install and configure ▪ Information Sheet:.3.1

automation instruments ▪ Self-Check:.3.1
and devices ▪ Answer Sheet: 3.1

235
 (Information Sheet 3.1 )
Install and configure automation instruments and devices
Diagram for automation is collected and interpreted as per manual
Perform of AC Drive Interface with 3 Phase Induction Motor:
VFD VFD Application:
A VFD (Variable Frequency Drive) is a tool We may claim that this device is utilized to
that adjusts frequency to drive various modify the frequency because we are aware
electronic devices. that the complete definition of VFD is
In sectors where numerous motors are variable frequency drive.
required to operate at various frequencies, Only in the case of an AC induction motor is
VFD usage is particularly prevalent. a VFD used.
AFD (AFD) stands for an adjustable 1. An AC induction motor's speed is
frequency drive, and VVVFD is an acronym controlled by a VFD.
for variable voltage variable frequency drive. 2. Both small and large companies employ
VFDs.
3. We are aware that the VFD is a complete
solution; it allows us to manage the motor's
speed, ensure total motor protection, operate
the motor in forward and reverse modes, and
act as the motor's starter.

Advantages of VFD Disadvantages of VFD?

⮚ The only disadvantage of using VFD is
⮚ Electricity is saving that since it is a complete package, its
⮚ Speed control and FWD/Rev operation cost is very high.
are available
⮚ The motor can be switched on and off
smoothly
⮚ Full motor protection can be obtained by
using VFD
⮚ Using a VFD does not require a
separate starter to run the motor

Perform of Siemens VFD Installation and troubleshooting:

Motor Parameters:
Motor Voltage 2.1.1-P0304- Motor Voltage Motor Current 2.1.2-P0305- Motor Current
Parameter. In other words, we will specify Parameter. In other words, we will set the
the voltage in the motor voltage parameter of Current in the motor current parameter of the
the AC driver and see the voltage rating on AC driver and see the Current rating on the
the nameplate of the induction motor that we nameplate of the induction motor that we will
will utilize. A motor controller known as a utilize.
variable frequency drive (VFD) uses
changes in the power supply's frequency and
voltage to drive an electric motor.
MotorCurrent2.1.3-P0310-Motor Motor Current 2.1.4- P0307- Motor power
Frequency Parameter. In other words, we (Kilo Watt) Parameter. This means that we
will specify the Frequency in the motor will specify the power (Kilo-Watt) in the motor
Frequency parameter of the AC driver and Power parameter of the AC driver after
see the Frequency rating on the nameplate viewing the power (Kilo Watt) rating on the

236
of the induction motor that we will utilize. nameplate of the induction motor that we
plan to utilize.
Motor Current 2.1.5- P0311- RPM/Pole Master Frequency Command 2.2.1:
Parameter. That is, we will set the RPM/Pole P1000 Frequency Command. A variable
in the motor RPM parameter of the AC driver frequency drive controls the speed of an AC
after seeing the RPM/Pole rating on the motor by varying the frequency supplied to
nameplate of the induction motor that we will the motor.
use. ⮚ Here set 1 Frequency control by
keypad/Local Mode.
⮚ Set 2 Frequency control by Analog
Signal (0 to 10v)
⮚ Here set 3 Frequency control by
Fixed Frequency / Multi state switch.
⮚ Here set 4 Frequency control by RS
485 Mode /Modbus Mode
⮚ Set 7 Frequency control by Analog
Signal (4 to 20 mA)
⮚ Set 10 Frequency control by Push
Button Switch
Master Run/Drive Command 2.2.2: P700 Acceleration/ De-acceleration time 2.2.3 :
Run Command. A speed reference and a r P1120 Acceleration time and P1121
un command are essential for a VFD to Declaration time .
function at all times. Run instructs the drive Acceleration Time : VFD acceleration time
to run the motor, and Speed Reference is the time required by output frequency from
instructs the VFD what frequency to operate 0 Hz to the maximum frequency
at. Motor control must be provided by both
inputs. If not, the motor is inactive.
⮚ Here set 1 VFD Run by keypad/Local De- acceleration Time : Deceleration time is
Mode. from maximum frequency dropped to 0 Hz.
⮚ Here set 2 VFD Run by Usually use the frequency setting signal rise
Terminal/Remote/Selector Mode and fall to determine the acc/dec time
⮚ Here set 5 VFD Run by RS485 Mode

Troubleshooting: Fault and Solution

Fault Description Fault Description
F1 Overcurrent F62 Parameter cloning contents invalid
F2 Overvoltage F63 Parameter cloning contents
incompatible
F3 Under voltage F64 Inverter attempted to do an automatic
clone during startup
F4 Inverter over F71 USS set point fault
temperature
F5 2 F72 USS / MODBUS set point fault
Inverter I t
F6 Chip temperature rise F80 AI lost input signal
exceeds critical levels
F11 Motor over temperature F85 External fault
F12 Inverter temperature F100 Watchdog reset
signal lost
F20 DC ripple too high F101 Stack overflow

237
F35 Auto restart after n F221 PID feedback below minimum value
F41 Motor data identification F222 PID feedback above maximum value
failure
F51 Parameter EEPROM F350 Configuration vector for the inverter
fault failed
F52 Inverter software fault F395 Acceptance test / confirmation pending
F60 Asic timeout F410 Cavitation protection failure
F61 MMC / SD card F452 Belt failure
parameter cloning failed
Hardware Connection:

(Self-Check 3.1)
1) What is VFD short answer??
2) Why DC is used in VFD??
3. How does VFD control voltage??
4. What are the benefits of VFD?
5. What is the maximum frequency of VFD?
6) What faults can a VFD detect?

238
 Answer Sheet (3.1)
1.What is VFD short answer?

Answer : A variable frequency drive (VFD) refers to AC drives only and a variable speed drive
(VSD) refers to either AC Drives or DC Drives. VFD's vary the speed of an AC motor by varying the
frequency to the motor. VSD's referring to DC motors vary the speed by varying the voltage to the
motor.
2. Why DC is used in VFD?
Less expensive than an AC line reactor for harmonic mitigation. Reduces over voltage tripping of
the drive due to voltage spikes. DC Link Chokes increase the reliability & add years to the life of a
VFD.
3.How does VFD control voltage?
VFDs manipulate the frequency of their output by rectifying an incoming AC current into DC, and
then using voltage pulse-width modulation to recreate an AC current and voltage output waveform.
However, this frequency conversion process causes 2% to 3% loss as heat in the VFD
4.What are the benefits of VFD?
ADVANTAGES
⮚ Potential for Energy Reduction. VFDs can be used to save energy at a pump
station. ...
⮚ Potential for Extended Pump Life. VFDs can be used to extend pump life. ...
⮚ Adaptable Pump Curve.
⮚ Simplify Pump Selection.
⮚ Closed Loop Control.
⮚ Mitigate Pressure Transients.
⮚ Controlling Inrush Currents.

5.What is the maximum frequency of VFD?

Controlling Full Load Amps.
With the use of Variable Frequency Drives (VFD), motors can be run at higher than 60 Hz, known
as an over speed condition, typically as direct drive fan wall/plenum fans (per NIH DRM 6.2. 4.2,
the maximum operating speed is 90 Hz).

6. What faults can a VFD detect?

Possible Causes Corrective Actions
Input voltage level too high Install isolation transformer, line filtering
Instantaneous voltage spike Ensure ac power supply is consistent
Loose power connections or control wiring Check all power and control connections and
tighten loose connections or wiring

239
 Job Sheet
Job Sheet – 3.1
Job Perform of Ac drive Interfacing 3 Phase Induction Motor
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the AC Drive
4. Construct the control circuit of VFD (as per diagram).
5. Construct the power circuit of VFD (as per diagram)
6. Power supplies will Speed Control the motor.
7. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.VFD 01 pc
2.Magnetic Contactor 01 pc
3.Selector Button Switch 03 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. 10 K variable Resister 01 Pc
7.MCB TP 01 pc
Tools and Equipment: 1. 3 Phase induction Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

(Information Sheet 3.2 )

Install and configure automation instruments and devices

Instrument’s and devices are selected and collected
Perform of Servo drive & Motor Interface with PLC Motor:
Servo Drive & Motor:
Servo motor is very torque compliant. Its motion cannot be stopped by holding it with fingers.

Servo Drive:
Motion control systems consist of four main components: a motor, a drive, a controller, and a
feedback device..

Servo motor drive working Principal

In order to generate motion proportional to the command signal, a servo drive receives a
command signal from a control system, amplifies the signal, and sends electric current to a
servo motor. The command signal typically denotes the intended velocity, but it may also
denote the desired torque or location.

1. Additional features:
2. Configurable feedback.

240
3. Firmware customization.
4. 2 configurable digital inputs.
5. 2 configurable digital outputs.
6. 2 configurable analog inputs.
7. 3 internal temperature sensors.
8. 1 inclinometer for safe monitoring in case of dangerous vehicle behaviour.
9. Configured and controlled via TKSED, with options of:
10. Parameter configuration.
11. Current, speed and position adjustment.
12. Basic configuration.
13. I / O Debugger.
14. CAN Debugger.
15. Unit programmer.
16. Purpose.

Servo ASD-B2-Position Control

Servo ASD-B2-Position Control;

⮚ Here 9 is Digital Input Switching Mode
⮚ 14 is Negative Source (-Com) ⮚ Active Mode (9+14 Negative Switching)
⮚ 17 is +24v Supply Drive ⮚ Active Mode (9+11 Positive Switching)
⮚ 11 is Positive Source (+Com) ⮚ Pulse Mode (9+14+41 Negative
⮚ 37 is Negative Direction Switching)
⮚ 39 is Positive Direction ⮚ Pulse Mode (9+11+43 Positive

241
 ⮚ 41 is Negative Pulse Switching)
⮚ 43 is Positive Pulse ⮚ Direction Mode (9+14+41+37 Negative
Switching
⮚ Direction Mode (9+11+43+39 Positive
Switching
⮚ (11+17+35) Short for Switching Mode
Active(Negative 14+17+35) Short for
Switching Mode Active(Positive)

Gear Ration Setting:

RPM- Rotation Per Minute
1 Rotation=360 Degree Here Encoder
Feedback/Resolution=17 bit= 160,000.
Gear ration p1.44-800/ P1.45-001 Electronic
gear ration =800 pulse Servo Drive Position
=160000/800 =200 pulse (D1 Position of
Servo drive) 360 Degree = 200 pulse, Mean
1 turn for servo Drive,

180 degree=100 Pulse, Mean servo drive

move ½ angel 1 degree= .5 pulse Speed of
Program:
Servo drive. Here,
1 minute = 60 sec 1 rotation=200 pulse M0 Memory Coil Control Servo Pulse Y0
RPM=200/60=3 pulse per second (d0) 1 M1 Memory coil Control servo Active Y1
RPM= 3 Pulse. And M2 Control Servo Direction Y2.
D0-K3 (by which the drive moves at 3 pulses
per second)
D1-k200-(by playing the drive will move 360
degrees
Parameter Setting Program Setting
Servo Factory Reset ⮚ P0-01= 02
⮚ AL.013- P2-17-121 set ⮚ P0-01=0
⮚ AL.014-P2-15-122 set ⮚ P1.44- 800 set
⮚ AL.015-P2-16-123 set ⮚ P1.45-001 set
⮚ P2-10=101 SON Servo (DI 1
ON)
⮚ P2-30= 1 set for Jog
Operation
⮚ P2-08 –Set-Shift-00010-set-
ok

Hardware Connection

242
(Self-Check 3.2)
1. Can PLC controls a servo motor?
2. Which sensor is used in servo motor?
3. What is a servo in PLC?
4. Is servo motor DC or AC?
5. What are the two types of servo motor?

Answer Key (3.2)

1.Can PLC control a servo motor?
PLCs are very capable of providing the signals required to command these servo and stepper
systems in a cost-effective and digital (noise-free) manner. In a typical motion control system there
are three basic components: the controller, the drive (sometimes referred to as an amplifier), and
the motor
2.Which sensor is used in servo motor?
Control the servo motor by using the ultrasonic sensor.
3.What is a servo in PLC?
Summary. Servomotors are basically a high-performance type of electrical motor. They must be
paired with a drive, which is also known as a motion controller. As a system, servos convert
electricity into precisely controlled motion.

243
4.Is servo motor DC or AC?
There are two types of servo motors, AC servos and DC servos. The main difference between the
two motors is their source of power. AC servo motors rely on an electric outlet, rather than batteries
like DC servo motors
5.What are the two types of servo motor?
Generally, there are two main types of this motor based on the supply used for its function. They
are AC servo motors & DC servo motors.

Job Sheet
Job Sheet – 3.2
Job Perform of Position Control Of Servo drive
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the Servo Drive and PLC.
4. Drawing of Position Control Ladder program
5. Construct the control circuit of Servo drive and PLC (as
per diagram).
6. Construct the power Servo drive and PLC (as per
diagram).
(as per diagram)
7. A power supply wills Speed Control the motor.
8. Proper use and maintenance of equipment.

Personal Protective 1.Apron 01 Pc

Equipment (PPE): 2.Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2.Servo Drive 01 pc
3.Servo Motor 01 pc
4.Magnetic Contactor 01 pc
5.Selector Button Switch 03 pc
6.Cable 1.5 RM Some
7.Plight Lamp 02 pc
8.10 K variable Resister 01 Pc
9.MCB TP 01 pc
Tools and Equipment: 1.Combination Players 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4.Neon Tester 01 pc

244
 (Information Sheet 3.3 )
Install and configure automation instruments and devices
Instrument’s and devices are selected and collected
Perform of Stepper drive & Motor Interface with PLC Motor:
Stepper motor control with PLC
A stepper motor's operation in this application is managed by a PLC. The PLC software,
Ladder Logic Diagram, implements the control method using step ladder instructions. The
stepper motor speed and rotational direction are controlled by the motion control algorithm.
Stepper Motor Control
Continuous rotation motors include stepper motors. These motors rotate in a specific
number of steps each time. By instructing the motor when to step and in which direction, you
may control position and speed.
Different wire counts are used, but step and direction signals are sent to regulate the system.
Stepper motors can be extremely accurate if you use them within their capabilities.
Nevertheless, they are unable to provide any response to let you know they have arrived at
the address you provided. You can use an encoder to add this feedback if your application
requires it.
Using Velocio’s Motion Output functions, you can control up to 3 Stepper Motors per PLC.
Wiring PLC to Stepper Motor
Your PLC will provide the step and direction
pulses, and takes care of any needed
ramping up/down of speed. You will need a
Stepper Driver to interface between the
PLC’s step and direction signals and the
Stepper Motor. Often the inputs to Stepper
Drivers include differential pairs for Step
and Direction, consisting of Step+, Step-,
Dir+ and Dir-. All Velocio digital outputs are
sinking transistor type, so they can make
the – connections (Step- and Dir-) in this
arrangement and you’ll connect the positive
connections (Step+ and Dir+) to the +
voltage you’re using to power your PLC.
Below is an example showing this wiring.

Motor Connection
4 type wire use to Stepper drive Motor &
Connect to Stepper Drive.
1. Black=A+ Connect to Stepper
Drive
2.Green=A- Connect to Stepper
Drive
Red=B+ Connect to Stepper Drive
Blue=B- Connect to Stepper Drive

245
Dip Switch
SW1 SW2 SW3 RPM SETTING
ON ON OFF 200 RPM SET
ON OFF ON 400 RPM SET
ON OFF OFF 800 RPM SET
OFF ON OFF 1600 RPM SET
OFF OFF ON 3200 RMP SET
OFF OFF OFF 6400 RPM SET

Calculation: Program:
Here Here A+ and A- Internal Short.
D0- Speed/ Frequency B+ & B- Internal Short
D1-Number of Pulse/ Position When I hold A + and A- with the meter, the
Now. D0=k50 meter's buzzer mode will sound
D1 = k1000 = 1000/200 = 5 years (No. 1
and No. 2 are on and No. 3 is off, then
1000 must be divided by 200, then the
motor will rotate 5 times)
D1 = k1000 = 1000/400 = 2.5 revolutions
(number 1 and number 3 are on and
number 2 is off then 1000 must be divided
by 400, then the motor will rotate 2.5
revolutions).

Stepper Drive Hardware Connection:

246
 (Self-Check 3.3)
1. Can a PLC drive a stepper motor?
2. How does PLC control motor speed?
3. How does a stepper motor connect to a PLC?
4. What is the main application of SCR?
5. What is SCR electronic application?

Answer Sheet (3.3)

1. Can a PLC drive a stepper motor?
Ans: In this application PLC is used to control the operation of a stepper motor. Ladder Logic
Diagram, the PLC program, uses step ladder instructions for implementation of the control
algorithm. The motion control algorithm includes the control of stepper motor speed and direction of
rotation.
2. How does PLC control motor speed?
Ans: The PLC has to give set point for VFD drive to control the motor speed, this can achieved
either automatically from the PLC or by the operator action from the HMI. According to set point
value, PLC will control the drive speed and VFD drive finally controls the motor speed.
3. How does a stepper motor connect to a PLC?
Ans: There are two main connection ways between stepper motor and PLC: one is the stepper
motor at both ends of the wire winding to the output points of PLC, as shown in figure 1, by writing
program control electricity, each coil in a certain order to achieve positive &negative; another way is
to use PLC high-speed pulse.
4. What is the main application of SCR?
Ans: Applications. SCRs are mainly used in devices where the control of high power, possibly
coupled with high voltage, is demanded. Their operation makes them suitable for use in medium- to
high-voltage AC power control applications, such as lamp dimming, power regulators and motor
control
5. What is SCR electronic application?
Ans: A silicon controlled rectifier (SCR) is a four-layer solid state current controlling device with 3
terminals. They have anode and cathode terminals like a conventional diode and a third control
terminal, referred to as the Gate.

247
 Job Sheet
Job Sheet – 3.3
Job Perform of Position Control of Stepper drive
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the Stepper Drive and PLC.
4. Drawing of Position Control Ladder program
5. Construct the control circuit of Servo drive and PLC (as per
diagram).
6. Construct the power Servo drive and PLC (as per diagram).
(as per diagram)
7. A power supply wills Speed Control the motor.
8. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipmet (PPE): 2. Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2. Stepper Drive 01 pc
3.Stepper Motor 01 pc
4.Magnetic Contactor 01 pc
5.Selector Button Switch 03 pc
6.Cable 1.5 RM Some
7.Plight Lamp 02 pc
8. 10 K variable Resister 01 Pc
9.MCB TP 01 pc
Tools and 1. Combination Players 01 pc
Equipment: 2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

(Information Sheet 3.4 )

Install and configure automation instruments and devices
Automation instrument and devices are assembled as per manual and diagram
A single item or product is made with the
use of automated and mechanized
machines that all conduct different
operations within an automated assembly
system. Typically, mechanical systems are
made to carry out predetermined,
repeatable actions, such as the fixed
sequences required for assembling parts
and goods.

248
 Manual Assembly
Manual assembly is the process of
combining previously manufactured
components and/or sub-assemblies into a
finished good or unit of a good. This work
is generally done by people using their
natural dexterity, ability, and judgment.

Automatic assembly
A clear distinction was drawn between manual assembly and automatic assembly in the
preceding section. Due to the inherently varying natures of the two assembly methods, the
design guidelines for automatic assembly are significantly different from those for manual
assembly. These guidelines are as follows:

Proximity Sensor: Proximity In PLC

automation, sensors are typically used to
check whether certain items made of
different materials are present or not.
Without making eye contact, they do so. The
output is binary, HIGH or LOW, just like a
switch, which is why they are sometimes
referred to as "proximity switches.".

Range: Thus the proximity of the object is detected by a change in capacitance. The sensor
can also be used to detect a wide variety of non-metallic and metallic objects and typically
operate over a range of 3 to 30 mm.

Selection a proximity sensor

Selecting a Capacitive Proximity Sensor
● Body style (barrel or block)
● Switching output type (NPN or PNP)
● Output function (NO or NC)
● Detection and sensing range.
● Target type (i.e. what it senses)
● IP rating.
● Installation type (flush or non-flush)
● Whether it is shielded, partially shielded, or unshielded.

Proximity sensors detect the presence or absence of objects using electromagnetic fields,
light, and sound. There are many types, each suited to specific applications and
environments.

249
Inductive sensors
These non-contact proximity sensors are
designed to find mild steel targets that are
at least one millimeter thick. A ferrite core
with coils, an oscillator, a Schmitt trigger,
and an output amplifier make up their four
main parts. The ferrite core and coil array
at the sensor face emit a symmetrical,
oscillating magnetic field that is produced
by the oscillator. Eddy currents, which are
tiny, independent electrical currents, are
induced on the surface of a ferrous object
when it enters this magnetic field.

Proximity Sensor 2 type: We must determine

the device's PNP or NPN type in order to
connect a "three-wire" discrete DC device to the
PLC.
Bi-polar transistors, which are merely solid-state
switches, come in two varieties: NPN and PNP.
To ensure you are familiar with the configuration
of the device you plan to connect to the PLC,
you should always consult the manufacturer's
datasheet.
1. PNP
2. NPN
PNP and NPN sensors, as they are commonly
known, are both supplied with positive and
negative power lines, after which they both
output a signal to denote a "on" state. When
connected to industrial controls, PNP sensors
output a positive signal, whereas NPN sensors
output a negative signal when in the "on" state.
1. PNP Proximity Sensor: An active HIGH
output is provided by PNP proximity sensors.
The output of the sensor is linked to +24V when
an object enters its detection range. This is
recognized by the device as a logic HIGH signal
when connected to a PLC input. The term
"Source" is another name for PNP proximity
sensors.
Proximity PNP Sensor Interfacing with PLC:
A "source" switch is the term used to describe a
PNP sensor. According to the diagram below,
the "load," which is the PLC input, is wired in this
manner. Keep in mind that the PLC module's
common terminal is linked to the blue "common"
wire. In other words, the switch "sources" or
provides +24 Volts DC to the PLC input when it
changes state.

250
2. NPN Proximity Sensor: An active LOW
output is provided by NPN proximity sensors.
This indicates that the sensor's output
connected to the ground when an object enters
its detection range. This particular sensor is also
referred to as a "sinking" sensor.

Capacitive sensors
Both metallic and non-metallic targets in
powder granulate, liquid, and solid form
are detectable by capacitive proximity
sensors. This, together with their capacity
to sense through nonferrous materials,
makes them perfect for applications such
as hopper powder level recognition, tank
liquid level detection, and sight glass
monitoring.

Proximity Sensor wire Diagram:

Advantages of proximity sensor:

● It can detect both metallic and non-metallic targets.
● It has good stability.
● High speed provided.
● High switching rate.
● Work in harsh environmental conditions.
● Low cost and power consumption.
● A capacitive sensor is good in terms of power usage

(Self-Check 3.4)
1. Write the correct answer for the following questions.
2. Which protocol is used by proximity sensors?
3. What can proximity sensor be used for?
4. What is the range of proximity sensors?
5. Is proximity sensor necessary?

251
 (Answer Key 3.4)
1. Which protocol is used by proximity sensors?
Ans: Which protocol is used by proximity sensor? Explanation: Microcontroller communication is
via standard I2C, where the host can set measurement parameters and request results. If desired,
programmable threshold allow the VCNL4100 to interrupt the host once threshold values are
crossed, thereby minimizing device polling.
2. What can proximity sensor are used for?
Ans: A proximity sensor is a device that can detect or sense the approach or presence of nearby
objects and for this it does not need physical contact
3. What is the range of proximity sensors?
Ans: Thus the proximity of the object is detected by a change in capacitance. The sensor can also
be used to detect a wide variety of non-metallic an
4. Is proximity sensor necessary?
Ans: The proximity sensor is not something so important that you cannot use your phone without,
and you may find that it is quite easy to get used to your phone without its conveniences

Job Sheet
Job Sheet – 3.4
Job Perform of Interface Proximity sensor and PLC
Procedure: 1. Selected Proximity PNP OR NPN Sensor.
2. Hardware Connection PLC and proximity Sensor.
3. Check Diagram as per as Drawing.
4.Draw ladder Diagram
5. Program Simulated.
6. Program Download PC to PLC.
Personal Protective 1.Apron,Helmate,Sefty Shoe 01 Pc
Equipment (PPE):
Materials 1. PLC 01 Pc
2. Relay 01 Pc
3.Proximity Sensor 01 Pc
4.SMPS 01 Pc
5.Magnetic Contactor 01 Pc
6.Control Valve 01 Pc
Tools and 1.Computer 01 pc
Equipment: 2.Philis Screwdriver 01 Pc
3.Nyon Tester 01 Pc

252
 Review of Competency

Performance Criteria Yes No

1. Automation instrument and devices are identified and  
defined
2. Uses of instrument and device are interpreted according  
to manuals
3. Robotics concepts are identified and defined  
4. Application of robotics are interpreted  
5. Diagram for automation is collected and interpreted as
per manual
6. Instrument’s and devices are selected and collected  
7. Tools, devices and materials for the job are identified  
and collected as per job requirement
8. Automation instrument and devices are assembled as  
per manual and diagram
9. Instrument and devices are set and configured  

Now, I feel ready to undertake my formal competency assessment.

Signed:

Date:

253
 After completion this module trainee will able to:
1. Interpret specifications of PLC
2. Write the program
3. Simulate and troubleshoot the program

254
Module 4: Perform Computer Operation Relevant to PLC

Module Content

Module Descriptor: This unit covers the knowledge, skills, and attitudes required to
Perform PLC Programming. It specifically includes interpreting specifications of PLC, writing
the program and simulating and troubleshooting the program

Nominal Duration: 60 hours

Learning Outcomes

Upon completion of the module, the trainee should be able to:

1. Interpret specifications of PLC .
2. Write the program.
3. Simulate and troubleshoot the program.

Performance Criteria:

1.1. diagram of PLC is interpreted

1.2. Virtual Components of PLC are listed and interpreted
1.3. Logic gates are interpreted
1.4. Technical specifications of PLC are identified and interpreted as per job requirement
2.1 Interfacing between PC and PLC is checked
2.2 PLC functions are identified as per job
2.3 PLC programming is created through programming language.
2.4 Program is compiled
2.5 Program is downloaded
2.6 Program is used
3.1 Program is simulated
3.2 Troubleshooting is performed if required
3.3 Ladder logic is modified if require

Learning Outcome 1:
Interpret specifications of PLC

255
 Contents:
Instructions
7. Hardware: PLC, Logic Gate
8. PC
9. Software (PLC &HMI Software)
10. Sample product/work piece
11. Drawings and/or sketches/Diagram
12. Manual/CBLM

Assessment Criteria:

1.1. Diagram of PLC is interpreted

1.2. Virtual Components of PLC are listed and interpreted
1.3. Logic gates are interpreted
1.4. Technical specifications of PLC are identified and interpreted as per job requirement

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, HMI, Interface Cable, Logic Gate

Learning Activity 1.1

Resources/Special
Learning Activity
Instructions/References

▪ Information Sheet:.1.1
Interpret specifications ▪ Self-Check:.1.1
of PLC ▪ Answer Sheet: 1.1

(Information Sheet 1.1 )

Interpret specifications of PLC
Diagram of PLC is interpreted
PLC:
The full name of PLC is Programmable Logic Controller (Programmable Logic Controller). It
is a tool that makes controlling other tools simple. It is a particular class of industrial
computer control system that, as soon as it detects any signal at the input, decides based on

256
a personalized program and controls the output. PLC often includes a microprocessor, also
known as a computer. I need assistance programming. The program is primarily created in
computer software and fed into the PLC using cable.

PLC Application
As is common knowledge, a PLC is a digital computer that manages the necessary
equipment in various factories. The use of any automated machine, nuclear power plant,
chemical industry, automated industry, home automation, cement factory, food factory,
biomedical, production and control of robots, etc.

Brand Name of PLC:

1. Delta
PLC

2. Allen
Bradley
PLC

257
 3. Mitsubish
i PLC

4. fuji PLC

5. Panasoni
c PLC

6. Omron
PL PLC
C

258
 7. LS PLC

8. Toshiba
PLC

9. Siemens
PLC

10. Schneide
r PLC

PLC working Principal

An example of a control system based on a microcontroller is a PLC. It has a memory that
may be programmed to store different instructions. This carries out arithmetic (mathematical),
logical, sequencing, timing, etc. functions. PLC operation is dependent on the input signal
provided in the first step, and the second step's processing of the ladder diagram will result
in the appropriate output signal. It is simple to control many devices.

259
PLC has three main sections:
1. Power supply
2. Input\output
3. Central Processing Unit

1. Power Supply:
The PLC must be powered in order to operate. The power supply's job is to give the input,
Processor, and output the necessary power. Moreover, it must be earthed. The software
might not function correctly or might get erased if earthing is not performed.
Depending on the PLC, less or more power may be needed. For instance, many PLCs need
between 115 and 240 volts AC/DC to function. Moreover, many PLCs can only run on DC 24
volts.
Input:
Various types of information are provided
here. According to the ladder diagram,
information received at the input device is
transferred to various locations on the
output device. Typical inputs include a
variety of switches, sensors, temperature
data, variable voltage, etc. Sent to the
central processing unit is information.

Output:
The machine relays information from the
central processor, and while doing so,
delivers information to the input through
various devices, including sensors. This
cycle is automatic.

CPU:

Power supply:
A facility's electrical distribution voltage, such as 230 VAC, 120 VAC, or 125 VDC, is
converted by the power supply into signal level voltage that the PLC processor and other
modules use.
Processor:
The processor module contains the microprocessor that performs control
functions and computations, as well as the memory required to store the
program.

Communication:
Many industry-standard communication network connections are supported by
communications modules. They enable the transport of digital data between PLCs and other
systems inside the facility.

260
Communication Media and Protocols:
The most common communication media used are copper-wire, coaxial, fibre-optics, and
wireless. The most common “open” communication protocols are Ethernet, Ethernet/IP, and
Device Net.

Redundancy:
Many PLCs are capable of being configured for redundant operation in which one processor
backs up another.

Advantage of PLC:
▪ Industrial automation using PLC very efficient.
▪ They are very fast in operation.
▪ Additional advanced tasks can be performing using PLC.
▪ Easy to use and very good experience.
▪ Automated control is also a great advantage of PLC

(Self-Check 1.1)
Write the correct answer for the following questions.

1. What is PLC and where PLC is used?

2. How does PLC work?
3. Various Brands write the PLC Name?
4. What is used as input in PLC

(Answer Key 1.1)

1. What is PLC and where PLC is used

PLC stands for Programmable Logic Controller. They are industrial computers used to
control different electro-mechanical processes for use in manufacturing, plants, or
other automation environments. PLCs vary in size and form factors
2. How does PLC work?
PLC is a type of microcontroller based control system. It contains a programmable memory that
stores various instructions. Arithmetic (mathematical) logical, sequencing, timing etc. functions are
performed through this. PLC work depends on the input signal given in the first step, the desired
output signal will be obtained by processing through the ladder diagram in the second step. It can
easily control other devices.
3. Various Brands write the PLC Name?
(1.Delta) (2.Allen Bradley) 3 Mitsubishi) 3.fuji) 4.Panasonic) 5. (Omron) 6.(LS) 7.(Toshiba)
8.(Siemens) 9.(Fatek ) 10.(Schneider)
4. What is used as input in PLC?
▪ Selector Switch
▪ Push Button Switch
▪ Proximity Sensor
▪ Photo Sensor
▪ Level Sensor

261
 Job heet

Job Sheet – 1.1

Job Perform of PLC Diagram
Procedure: 1.Select the PLC
2. Explain PLC Input side
3. Explain PLC Centre Processing Unit
4. Explain PLC Internal Diagram
5. Explain PLC External Diagram
6. Explain PLC Output side
Personal Protective 1.Apron 01 Pc
Equipment (PPE):
Materials 1.PLC 01 pc
2.Power Supply 01 pc
3.Push Button Switch 01 pc
4.SMPS 01 pc
5.Communacation cable 01 pc
Tools and Equipment: 1.Computer 01 pc
2. Philips screw driver 01 pc

(Information Sheet 1.2 )

Interpret specifications of PLC
Virtual Components of PLC are listed and interpreted

Interpreted of Virtual Components of PLC:

Components of PLC: Contact

The programmable logic controller is the You may know the difference between
suggested controller for SCADA systems normally open and normally closed contacts,
(PLC). PLCs are multipurpose but do you know where to use them
microprocessor-based controllers that
support network communications and offer
logic, timing, counting, and analog control.

Hardware Logic Software Logic

Input actuators and wiring (what is actually The logic of your PLC program (the logic you
connected to the input). program into the PLC).

262
Hardware Logic
Start with some digital inputs and link some actuators to them.
All digital inputs have two states, and all digital input actuators follow suit:
Yet, digital actuators are not limited to just two states. In addition, they may serve one of two
purposes:
● Normally open
● Normally closed

Normally open (NO): A contact that is

normally open does not allow current to flow
through it. The contact will shut when it is
powered up and turned on, allowing current
to flow. The input bit of a usually open
actuator is zero when it is in the default Some of the most common uses for NO
condition (inactivated). The input bit will contact symbols are for:
change to 1 when a normally open actuator  Power buttons
is activated.  Light switches

Normally Close (NC). In the default state

(inactivated) of a normally closed actuator
the input bit is 1.

When you activate a normally closed

actuator, the input bit is 0. The most common uses for NC contacts are:
 Stop buttons
 Heat monitoring

In contrast to typically open actuators,

normally closed actuators have the opposite
effect on the state of the inputs they are
attached to.
Remember that the actuator's state
influences the input's state, which then
impacts the input bit. These are the values
that the input bits will be updated to each
time the PLC scan cycle gets to the part
where it updates the input bit.

263
Software Logic
Logic will also be used when writing a PLC
program. But, you will now have ladder
logic contacts or Boolean instructions
instead of hardware logic with actuators.

Coil
Auxiliary/Memory Coil: The internal
memory bits come in very handy for
creating intricate ladder logic routines. In
addition to using these statuses on the input
side, we can use these internal relays and
memory bits in the output instructions.

By avoiding dual coils (output), as illustrated

when writing same input conditions as
shown below, auxiliary’s relays are
practical.
Wrong Right
Moreover, the presence of an electrical
current might cause a contact to open. As a
result, a control system can use electrical
current to turn on or off a large load by
activating a switch that can handle a lot of
current. A relay is the most basic type of
contact for this situation.

Several internal "relays" in a PLC are

intended to function similarly to a standard
electromagnetic relay. An internal relay is
said to be "powered" when it is turned ON,
unlike an output (such the "Lamp" output),
which has a physical connection outside of
the PLC, but you won't notice any changes
in the PLC's physical I/Os. The PLC
internally maintains the logic state. The
ladder diagram can then use the relay's
contact to turn on or off additional relays or
outputs. There is no restriction on the
amount of contacts a relay can have, and a
relay contact in the ladder diagram can be
either normally-open or normally-closed.

264
Output Coil:
Out Coils. A PLC output is really just an
internal relay with a physical connection
that can supply electrical power to control
an external load. Thus, like a relay, an
output can also have unlimited number of
contacts that can be used in the ladder
program.
Coil- A direct coil writes a value to a
database item. If there is power from the left
rail, it writes a 1 value. If there is no power
from the left rail, it writes a 0 value..

Inverted Coil- flipped coil This output

inserts a value into an item in the database.
It works the opposite way from a straight
coil. It writes a 0 value if the left rail is
powered. It writes a value of 1 if there is no
power coming from the left rail.

Set coil- When there is electricity coming

from the left rail, this output is set to 1.
When Set Coil is powered by the left rail
and set to On, it functions similarly to a "On"
switch; once On, it stays that way until it is
specifically set to Off (by a reset).

Reset Coil- coil, reset. When there is

electricity coming from the left rail, its output
is set to 0. When Set Coil is powered from
the left rail and set to Off, it behaves
similarly to a "Off" switch; however, unless it
is specifically switched to On (by a Set).
Positive sensing coil. As a pulse, its
output serves. The coil produces a value of
1 when the input from the left rail changes
from 0 to 1. The positive sensing coil
switches back to having a 0 output when
the next rung of the ladder diagram is
completed.

Negative sensing coil. As a pulse, its

output serves. The coil outputs a value of 1
when the input from the left rail goes from 1
to 0. The positive sensing coil switches
back to having a 0 output when the next
rung of the ladder diagram is completed.

Pulse Width Modulation (PWM):

Multiple controls Pulse Width Modulation (PWM) can be utilized by a Nano programmable
logic controller (PLC) to regulate the electrical power provided to an electrical heater in a
furnace (PWM). To provide the system with full power, a variable pulse is used..

265
Timer :
A PLC timer is a command to control and run
the device for a predetermined amount of time.
We can carry out any certain operations for a
specific amount of time using the timer.
One of the most important and practical
objects is a timer.
By using the timer command in PLC
programming, you can set time-based
activities. There are several timer functions for
each PLC.
To offer programming logic and choose when
to switch on or off the circuit, the timer
instruction is employed. It has contacts that
are either ordinarily open (NO) or normally
closed (NC).

Here, we'll examine how the input and output

timer NO and NC contacts are represented in
LD programming.

Basic Internal Circuit of PLC Timer

We are now examining the PLC's internal
timing circuit. The four major components of
the timer circuit form its foundation.
The timer circuit's core components all have
different features and functions. According to
the diagram, they are constructed and
connected in this manner.

On Delay Timer (TON)

Programming instructions called on-delay
timers (TON) are used to initiate brief pulses
for a predetermined amount of time.
Let's look at a straightforward programming
instruction for the AB PLC On-Delay Timer.

Off Delay Timer (TOFF)

A PLC programming command known as an
off-delay (TOF) timer is used to turn off an
output or system after a certain period of time..

266
Retentive On/Off Timer (RTO)
The RTO's primary purpose is to hold or store
the preset (accumulated) time. When the rung
state changes, there is a power outage, or
there is any other system interruption, RTO is
applied.

Timer Instructions Address for Multiple PLC Brands

We have seen three timers provide the time delay functions to control the PLC operations.
There are four main values that timer deals with.

⮚ Timer Address Each timer instruction has three very useful

⮚ Pre set Value status bits. These bits are…
⮚ Timer Base Value ⮚ Enable bit (EN)
⮚ Accumulated value ⮚ Timer Timing bit (TT)
⮚ Done Bit (DN).

In the AB and Siemens PLC, the output bit is often called the timer’s ‘Done bit’. And it
indicates the timer has reached its preset time.

Addressing for ABB PLC Addressing for AB (Rockwell) PLC

We only need to enter the ladder diagram's For the AB PLC, the timer has the address
I/O timer address in the ABB PLC ranging from ‘T4:0′ up to ‘T4:255‘.
programming. The timer value can be set in Where, T4 is the file type.
the "T0" to "T255" range. The Addressing format for timer instruction
representation of the I/O contact is shown in with the three status bits.
the diagram above. File tpye: Element Number/ Bit status
Enable bit (EN) address is ranging from
‘T4:0/EN’ upto ‘T4:255/EN’.
The addressing for Timer timing bit (TT) is
ranging from ‘T4:0/TT’ up to ‘T4:255/TT’.
Done bit (DN) address is ranging from
‘T4:0/DN’ up to ‘T4:255/DN’.
Addressing for Siemens PLC
In the Siemens, LD program can be written
with the five types of timers

Addressing for Delta PLC

You can utilize timer addressing for the
WPLSoft software (Delta PLC) that ranges
from "T0" to "T127." The Delta PLC displays
the input timer address as a general
representation (T0, T1, etc.). Moreover, the
output coil is represented as T(Address
rang) K(10*timer value). where "K" is the
constant term and "T0" is the timer address
in the Delta PLC timer block diagram:

267
For Delta PLC, the timer starts for a 10-
second. It should be written in the form of
‘T0 K100’.

Addressing for Mitsubishi PLC

Both Delta PLC and Mitsubishi PLC employ the same timer addressing format. Using an
example from the PLC Timer Instruction Traffic signal control with PLC is a very simple and
practical example. Each side signal must switch on and off after a predetermined amount of
time. Only one side traffic signal should be active at once. Simple PLC timers can be utilized
to create this logic.
What are the Applications of Timer Instruction?
These are a few simple applications for timers in a PLC automation environment. use in the
delay-related activity It executes user orders to begin or stop operations. An intermediate
time value can be stored or tracked with the help of the RTO timer. The primary subject at
hand is PLC timer. This topic is quite broad. I tried to make things simple. If you have any
questions, feel free to ask them in the comment section.
Counter:
In the PLC program, input or output signals can be counted using PLC counters, which are
internal PLC instructions. Although you cannot hold a PLC counter in your hand and they do
not require wire connections to function, these counters function similarly to relay counters.
A two-bit counter exists. Counter 1.16 bit Counter in 2.32 bits
What data type is a counter in PLC?
Internal PLC instructions called PLC counters can be used to count input or output signals in
a PLC program. While PLC counters cannot be held in the hand and do not require wire
connections in order to function, these counters function similarly to relay counters. has a
two-bit counter. 1.16% Counter 2.32 Bit Count

How PLC Counter Works Block Diagram

Auxiliary power supply (APS), an input-
output terminal, a counter circuit, and a
digital display are necessary for the basic
internal counter circuit. You may view the
internal construction of a PLC counter using
the block diagram that is provided.
Difference Between timer and counter in PLC
Both perform the identical task of providing programming instructions to run and control the
gadget. The counter counts the consecutive digital pulse in binary form, which is the main
distinction between the two. Time intervals are used by the timer to count and control the
process. Instructions for LD programming can be utilized with PLC timers and counters.

Counter in LD Programming
The numerous functions of the programming instructions make up the ladder diagram
programming language. Let's look at a ladder diagram example where we are using an ABB
PLC counter.

Input counter contact is shown using two vertical parallel lines. Output counter contact is
shown in the coil form or box form or rectangular form. In AB and Siemens PLC, it is
represented in the box shape.

268
What are the types of the PLC Counter?
Basically, PLC counter operates into four
modes such as up mode, down mode,
bidirectional mode, and the quadrature
mode.
Counters in PLC are classified into three
main different parts.
⮚ Up Counter (operates up mode)
⮚ Down Counter (operated in down
mode)
⮚ Up/Down Counter (operates in
bidirectional and quadrature mode)
Let’s see the counter and their mode one-
by-one.

What is a Up Counter?
Up counter counts up from 0 to the
predetermined amount. In essence, it raises
the pulse or quantity.
The up counter is sometimes referred to as
the "CTU," "CNT," "CC," or "CTR."
Function block diagram for the up counter

As an additional input to the counter, we

may set the initial and target values.
Here, the PLC's up-counter can tally the
difference between the starting value and
the desired value. This starting point must
be lower than the goal. It is frequently set to
zero..

What is Down Counter?

The down counter starts at the pre-set value
and counts down to zero. The pulse or
number is reduced.
The down counter is abbreviated as "CTD"
or "CD."
Block diagram for the down counter function:
By lowering it, the down counter counts
backwards from the target value to the
starting value. This starting point must be
lower than the goal.

What is Up-Down Counter?

The up-down counter records values from
zero to a predetermined value or from a
predetermined value to zero.
In other words, this counter has two possible
states: down and up.
CTUD stands for up-down counter.
The up-down counter is chosen depending
on the status (high or low) of the designated

269
 count input terminal for the bidirectional and
quadrature operation modes.
Diagram of the up-down counter function:

What is Reset Counter Function?

The reset counter function returns the counter to its initial or default setting. Use this function
if you wish to begin counting at the starting point. With digital pulse counting, the up and
down counter reset functions operate differently.
Data Register
What is data register in PLC?
Data Register is Specific memory area of CPU where we can store our data pr move our
data from one point to other point. Data Register have Write D
What are PLC data types?
Data Types in PLC - Bit, Byte, Integer, Real, String.
There are 4 types data Registers in PLC
▪ General: These data Registers store data as our instruction but lost their if PLC lost its
power.
▪ Latched: These data Registers store data as our instruction but does not lost their if
PLC lost its power.
▪ Special: These data Register has Specification functions as PLC Designer load in it.
We cannot use it as our instruction.
▪ Special Module: These data Register are used for special module like analog Module.

Math function (ADD, SUB, DIV, MUL): Functional math is a very important part in PLC. In
the case of programs, many times addition, subtraction, multiplication and division are
required, so these math functions are used.

ADD (Addition) SUB (Subtract)

Parameter Name Parameter Name
A Addend A A Minuend, original value

B Addend B B Subtrahend, subtracted from Minuend

C Sum, output value of A+B C Difference: output value of A-B

MUL (Multiply) DIV (Divide)

Parameter Name Parameter Name
A Multiplicand, original value A Dividend, original value

B Multiplier, multiplies the Multiplicand B Divisor, divides the Dividend

C Product: output value of A x B C Quotient: output value of A/B

270
 (Self-Check 1.2)
Write the correct answer for the following questions.
1. What is PLC and where PLC is used?
2. What is NO and NC?
3. What is Timer?
4. What is means by 16 bit Counter?
5. (Which Components are used in PLC Program)?

(Answer Key 1.2)

1. What is PLC and where PLC is used
PLC stands for Programmable Logic Controller. They are industrial computers used to
control different electro-mechanical processes for use in manufacturing, plants, or
other automation environments. PLCs vary in size and form factors

2. What is NO and NC?

Normally open (NO) and normally closed (NC) are terms used to define the states of
switches, sensors or relay contacts under when its coil is not excited.

3. What is Timer?
PLC timers are internal PLC instructions that can be used to delay input and output
signals in the PLC program. These timers operate like relay timers but you cannot hold a
PLC timer in your hand and they do not need to be connected to wires to operate.

4. What is means by 16 bit Counter?

When the program is running on the PLC the program typically displays the current or
"accumulated" value for us so we can see the current count value. Typically
counters can count from 0 to 9999, -32,768 to +32,767 or 0 to 65535. Why the
weird numbers? Because most PLC's have 16-bit counters. We'll get into what this
means in a later chapter but for now suffice it to say that 0-9999 is 16-bit BCD
(binary coded decimal) and that -32,768 to 32767 and 0 to 65535 is 16-bit binary.

5.(Which Components are used in PLC Program)?

The Hardware components of a PLC include the following: Processor, Power Supply,
Input/output Modules, and a Programming Device

271
 Job Sheet
JOB SHEET – 1.2
Job Perform of 3 phase motor control using timer.
Procedure: 1. Open the Delta PLC Program.
2. Click to New part then Selected PLC Model Ok for solid
works.
3.Select the toolbars that will use throughout drawing
4. First we will take a NO contact from make contact.
5. Then take a NC contact from the brake contact.
6. Then take the memory coil from the Output coil.
7. Then take On Delay timer from a timer coil.
8. Finally, take a coil from the output coil.)
Personal Protective 1.Apron, 01 Pc
Equipment (PPE): 2. Helmate 01 Pc
3. Safety Shoe 01 Pc
Materials Some Cable Same
Magnetic Contactor 01 pc
Push Button Switch) 01 pc
SMPS 01 pc
Communication cable 01 pc
Tools and 1.Computer 01 pc
Equipment: 2.PLC 01 pc
3.3 Phase Motor 01 pc

(Information Sheet 1.3 )

Interpret specifications of PLC
Logic gates are interpreted
Why we do use Logic gates In PLC:
As is common knowledge, logic gates serve as the foundation for digital circuits.
It accepts a binary input (0, 1) and outputs a binary value based on the input. If
you want to improve your electrical and electronic skills, you must learn how to
use logic gates with a programmable logic controller (PLC).
Types of Logic Gates using PLC Ladder
Different types of ladder logic diagram that perform different logic gate functions. Basically,
there are seven types of logic gates as below.

1. NOT Gate
2. AND Gate
3. OR Gate
4. NAND Gate
5. NOR Gate
6. EX-OR Gate
7. EX-NOR Gate

272
Note: The circuit diagrams are connected to make and break input (I) and output (Q) contact
in series and parallel circuits.
Let’s see the explanation for each logic gate with PLC implementation,
Input (I1) Output (Q1)
1. NOT GATE
0 1
In electronics, NOT GATE is also called an
‘Inverter’ or ‘Buffer’. 1 0
Working: NOT gate works as inversion. It
takes one input and gives one output. When the
input is high then the output is low and vice-
versa.
NOT Gate in PLC programming:
In the case of PLC ladder, there will be a push
button to provide input. When (I1) is pressed
then the coil (Q1) is on. And when Input (I1) is
released then coil( Q1 is off
Symbolic Representation.

Output
AND GATE Input (I1) Input (I2)
(Q1)
Working: In AND Gate, when both
0 0 0
inputs (I1 and I2) are high then the
0 1 0
output (Q1) will be high. For all other
inputs, output (Q1) will be the low. 1 0 o
1 1 1

AND Gate in PLC programming:

Two switches (I1 and I2) are connected
as input and a coil/lamp (Q1) is
connected as output using a ladder
diagram software.
The lamp (Q1) will shine in the event that
both switches (I1 and I2) are closed. In a
different scenario, lamp (Q1) will not
glow if either switch (I1 or I2) is open.
Representation in Symbols as,

Output
Input (I1) Input (I2)
(Q1)
3. OR GATE Working:
0 0 0
If both inputs are low in the OR gate, 0 1 1
then the output will be low. For all 1 0 1
other cases, the output will be high. 1 1 1

273
OR Gate in PLC programming:
In case both or anyone inputs (I1 and I2)
are closed then coil (Q1) will on.
Symbolic Representation as,

Input (I1) Input (I2) Output (Q1)

4. NAND GATE
0 0 1
The inverter comes after the NAND gate,
0 1 1
which is used as an AND gate.
Working: When both inputs are high in a 1 0 1
NAND gate, the output will be low. All other 1 1 0
scenarios will result in high production.
NAND Gate in PLC programming:
If both switches (I1 and I2) or anyone switch
(I1 or I2) are closed, the lamp will be glow.
In the case, both switches are open then
the lamp will not be glow.

Input (I1) Input (I2) Output (Q1)

5. NOR GATE
0 0 1
NOR Gate is operated OR Gate followed by
0 1 0
the NOT Gate.
1 0 0
1 1 0
When both inputs are low then the output
will be high. Otherwise, the low output will
occur if both inputs are high.

NOR Gate in PLC programming:

The Coil (Q1) will be activated if both inputs
are closed. Coil (Q1) will be deactivated if
anyone the inputs are open.

274
 Input (I1) Input (I2) Output (Q1)
EX-OR GATE
0 0 0
Working: If both inputs are high or low, the
0 1 1
output will become low. For any other input
condition, the output will be high. 1 0 1
1 1 0
EX-OR Gate in PLC programming:
In the function of EX-OR Gate, the lamp will
be on if one switch is closed and another
switch is opened.

Input (I1) Input (I2) Output (Q1)

EX-NOR GATE
0 0 1
Working: When both inputs (I1 and I2) are
0 1 0
high or low then the output will high. If
anyone input is high or low then the output 1 0 0
will become low. 1 1 1

EX_NOR gate in PLC programming:

If both switches (I1 and I2) are open or
closed, the lamp (Q1) will be not on
according to the EX-NOR Gate's function. If
any switch (I1) is turned on while another
switch (I2) is deactivated, the lamp (Q1)
won't turn on..

PLC's technical requirements are identified and interpreted in accordance with job
requirements. The design, development, manufacture, inspection, shop testing, assembly,
packing, supply, transportation, delivery to site, installation, testing, internal and external
wiring, testing at site, commissioning, start-up, test runs, and guarantee of PLC systems,
HMI systems, SCADA development for the up gradation of Dryers, MAPS are all covered by
this specification. Furthermore included in the scope are the provision of hard copies and
digital copies of as-built drawings, pertinent technical material, operation and maintenance
manuals, test & calibration procedures, test reports, and training of PURCHASER's staff..

275
 (Self-Check 1.3)
Write the correct answer for the following questions.
1. What is Logic Gates?
2. Why we Use Logic gates In PLC?
3. Why are relays used in logic gates?
4. What is truth table in PLC?
5. What logic is used for programming in PLC?

(Answer Key 1.3)

1. What is Logic Gates?
A logic gate is an idealized or physical device implementing a Boolean function, a logical
operation performed on one or more binary inputs that produces a single binary
output.

2. Why we Use Logic gates In PLC?

Logic gates are an important concept if you are studying electronics. These are important digital
devices that are mainly based on the Boolean function. Logic gates are used to carry out logical
operations on single or multiple binary inputs and give one binary output.
3. Why are relays used in logic gates?
The circuit incorporates relays along with other components such as switches, motors, timers,
actuators, contactors etc. The relay logic control works efficiently to perform basic
ON/OFF operations by opening or closing the relay contacts but it involves a
humongous wiring.

4. What is truth table in PLC?

Truth table is a mathematical table that lists the output of a particular digital logic circuit for all the
possible combinations of its inputs. These truth tables can be used to deduce the logical expression for
a given digital circuit, and are used extensively in Boolean algebra.
5. What logic is used for programming in PLC?
Ladder Logic. PLCs often use “ladder logic,” a simplistic programming language that is well
suited for industrial applications. Ladder logic is based on relay-based logic and can
be thought of as a set of connections between inputs (contacts) and outputs (coils).

276
 Job Sheet
Job Sheet – 1.3
Job Perform of Creating programs using logic gates (DOL Program)
Procedure: 1.Open the Delta PLC Program
2.Click to New part then Selected PLC Model Ok for solid works
3.Select the toolbars that will use throughout drawing
4.First we will take a NO contact from make contact
5. Then take a NC contact from the brake contact.
6. Then take the Main Output coil from the Output coil.
Personal Protective 1. Apron 01 Pc
Equipment (PPE): 2.Helmate 01 Pc
3.Safety shoe 01 Pc
Materials 1.PLC 01 pc
2.Power Supply 01 pc
3.Push Button Switch 01 pc
4.SMPS 01 pc
5. Magnetic Contactor 01 pc
5.Communacation cable 01 pc
Tools and 1.Computer 01 pc
Equipment: 2. Philips screw driver 01 pc
3. 3 Phase Motor 01 pc
4. Wire Stripper 01 pc
5. Neon Tester 01 pc

Learning Outcome 2:

Write the program

Contents:
Instructions
17. Hardware: PLC,
18. PC
19. Software (PLC &HMI Software)

Sample product/work piece

20. Drawings and/or sketches/Diagram
21. Manual/CBLM

277
 Assessment Criteria:

2.1 Interfacing between PC and PLC is checked

2.2 PLC functions are identified as per job
2.3 PLC programming is created through programming language
2.4 Program is compiled
2.5 Program is downloaded
2.6 Program is used

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, HMI, Interface Cable

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Write the program ▪ Information Sheet:.2.1

▪ Self-Check:.2.1
▪ Answer Sheet: 2.1

(Information Sheet 2.1)

Write the program
Interfacing between PC and PLC is checked
The interface modules facilitate
communication and interface channels
between the PLC and other control cabinet
elements such servo drive controllers and
relays.
4 way PC to PLC interface
1. Use a small B USB cable to directly
connect your PC to the controller.
2. On the program ribbon, select the PLC
tab, then choose Communication.
3. After choosing USB, the network
discovery tool will start looking for Uni
Stream devices.
4. Click the desired gadget to start a
conversation. Related Subjects.
Communications.

278
Interface of PLC to pc
Start by running the RSLinx Classic program found in All Programs - Rockwell Software. The
symbol ought to be visible in the system tray if the RSLinx program is active. In order to
communicate with the PLCs on the network, the RsLinx software must be operating.
Opening this software while the PLC is active should display the PLC's status in a window.

Unlike the Ethernet/IP driver, the Allen Bradley RsLinx Ethernet device driver is not plug-
and-play. The IP addresses that RsLinx should use to search for devices must be configured.

1. Choose Communications - Configure Drivers from the menu at the top of RsLinx.
2. Choose "Ethernet Devices" under "Available Drive Type" and then click "Add New." "AB
ETH-1" is the device's default name. You may alter it at this time by clicking "OK."
3. The "Station Mapping dialog" will now appear.
4. Type in your device's IP address and click "OK."
5. Choose Communications - RsWho from the main menu on RsLinx. Locate your "ABETH-
1" driver in the pane to the left and click on it. You should now be able to view your
device in the right pane in a short while.

For communication between the PC and the PLC, the communication settings have already
been set up. To accomplish this within RSLinx, choose a driver first (Communications-
Configure Driver). This was accomplished by choosing AB ETHIP-1 as the driver name and
Ether Net/IP Driver as the driver type (the default). Table 1 lists the IP addresses for the four
PLC trainers in the lab. Keep in mind that these IP addresses were issued dynamically and
could change.

In a network, a PLC's unique IP address can be verified on the PLC itself. Press the front
panel ESC button on the Micro Logix 1100 PLC, then click the down arrow key to select the
Advance Set function. Hit OK and the down arrow key together to choose the ENET CFG
function. To see the PLC's current IP address, press OK. Up until the I/O Status function is
chosen, press ESC. To return to the I/O Status panel, click OK.
PLC functions are identified as per job Ladder Logic and Programming PLCs
When 120 VAC power is applied between
each input terminal and the Common
terminal inside the PLC housing, an opto-
isolator device (Light-Emitting Diode) that
is connected between each input terminal
and the Common terminal sends an
electrically isolated "high" logic signal to
the computer's circuitry (a photo-transistor
interprets the LED's light). An "energized"
input is visually indicated by an indicating
LED on the PLC's front panel:

279
The "Source" terminal is connected to
either of the "Y-" labeled output terminals,
and output signals are produced by the
PLC's computer circuitry triggering a
switching device (transistor, TRIAC, or
even an electromechanical relay). Thus,
the "Source" connection is often wired to
the L1 side of the 120 VAC power source.
An indicating LED on the PLC's front
panel provides visible confirmation of a
"activated" output, just like it does for
each input:

The PLC can connect with switches and

solenoids in the actual world in this
fashion. Through the use of a computer
program, the PLC establishes the true
logic of the control system. Which output
is activated under which input conditions
is determined by this program.
Nothing powers the PLC's X1 input when
the pushbutton switch is not triggered (not
depressed). No "power" will be applied to
the Y1 coil after the program, which
displays a normally-open X1 contact in
series with a Y1 coil. As a result, the
PLC's Y1 output remains de-energized
and the attached indicator bulb is left
inactive.

The X1 input of the PLC, however, will

receive electricity if the pushbutton switch
is activated. All X1 contacts that are
mentioned in the program will be in the
actuated (non-normal) state, acting as if
they were relay contacts that were
activated by the energizing of a relay coil
with the designation "X1".
The typically open X1 contact will "close"
in this scenario when the X1 input is
activated, sending "power" to the Y1 coil.
The true Y1 output will activate when the
program's Y1 coil "energizes," illuminating
the lamp attached to it.:

It is important to realize that the X1

contact, Y1 coil, connecting wires, and
"power" that show in the display of the
personal computer are all fictitious. In
terms of actual electrical components,
they don't exist. They only exist as
commands in a piece of software that just
so happens to look like a schematic
diagram for a relay.

280
In this next illustration, the switch is
shown actuated (pressed):

The ability to reuse input signals as often

as required within the program is one
benefit of implementing logical control in
software rather than hardware. Consider
the circuit and software shown below,
which aim to turn on the lamp if two or
more of the three pushbuttons are
simultaneously pressed.

Three electromechanical relays with two

normally-open contacts each would be
required to create an analogous circuit in
order to supply two contacts for each
input switch. But, by using a PLC, which
only requires a single bit of digital memory
(either 0 or 1) and can be recalled as
many times as necessary for each input
or output, we may program as many
contacts as we like for each "X" input
without using any additional hardware.
We can also assign contacts in a PLC
program to be "actuated" by an output (Y)
status as each output in the PLC is
nothing more than a bit in its memory. As
an illustration, consider the following
system, a motor start-stop control circuit:
The "Start" switch is the pushbutton
switch attached to input X1, and the
"Stop" switch is the switch connected to
input X2. In order to keep the motor
contactor powered after the "Start"
pushbutton switch has been withdrawn,
another contact in the program named Y1
directly uses the output coil status as a
seal-in contact. The normally closed
contact X2 is represented by a colored
block, indicating that it is closed (or
"electrically conducting").
Activating input X1 would "close" the X1
contact in the program, energize the Y1
output, send "power" to the Y1 "coil," and
provide 120 volts of AC power to the
actual motor contactor coil. Furthermore

281
"closing," or latching the "circuit" in an
electrified state, is the parallel Y1 contact:
The normally-open X1 "contact" will now
return to its "open" state if we depress the
"Start" pushbutton, but the motor will still
operate since the Y1 seal-in "contact"
keeps providing "continuity" to "power"
coil Y1, keeping the Y1 output energized:

Pressing the "Stop" pushbutton for a brief

period of time will activate the X2 input,
"open" the normally-closed "contact," and
break continuity to the Y1 "coil" in order to
halt the motor:

Input X2 will de-energize upon withdrawal

of the "Stop" pushbutton, restoring
"contact" X2 to its default, "closed" state.
The "seal-in" of Y1 has been lost,
therefore the motor will not restart until the
"Start" pushbutton is pressed:

The fact that fail-safe design is equally

crucial for PLC-controlled systems and
electromechanical relay-controlled
systems should not be overlooked in this
context. Always take into account how
defective (open) wiring may affect the
equipment or devices being controlled.
We have a problem with this motor control
circuit example because there would be
no way to stop the motor if the input wiring
for X2 (the "Stop" switch) failed open.
Reversing the logic between the PLC
program's "contact" X2 and the actual
"Stop" pushbutton switch will solve this
issue.

282
The typically closed "Stop" pushbutton
switch will power the PLC's X2 input when
it is not triggered (not depressed),
"closing" the X2 "contact" inside the
program. This enables the motor to start
when input X1 is activated and to keep
running even after the "Start" pushbutton
has been released. Input X2 will de-
energize when the "Stop" pushbutton is
pressed, "opening" the X2 "contact" within
the PLC program and turning off the
motor.
So, it is clear that this new design and the
previous design are functionally
equivalent. However, input X2 would de-
energize in the same way as when the
"Stop" pushbutton is pressed if the input
wire on that input were to fail open. So, if
there is a wiring issue with the X2 input,
the motor will immediately stop.
The bulb will stay on in this circuit as long
as any pushbuttons are not depressed (un
pressed). We must activate (push) all
three switches in order to turn the lamp
off.

(Self-Check 2.1)
Write the correct answer for the following questions.
1. What are the 5 PLC programming languages?
2. What are the 3 types of PLC?
3. What is PLC ladder diagram?
4. What is PLC diagram?
5.Why is ladder logic preferred?

283
 (Answer Sheet 2.1)
1. What are the 5 PLC programming languages?

The 5 most popular types of PLC Programming Languages are:

⮚ Ladder Diagram (LD)
⮚ Sequential Function Charts (SFC)
⮚ Function Block Diagram (FBD)
⮚ Structured Text (ST)
⮚ Instruction List (IL)
2. What are the 3 types of PLC?
PLC are divided into three types based on output namely Relay output, Transistor output, and Triac
Output PLC.
3. What is PLC ladder diagram?
Ladder Diagram is a graphical programming language that you use to develop software for
programmable logic controllers (PLCs). It is one of the languages that the IEC 61131 standard
specifies for use with PLCs. A program in ladder diagram notation is a circuit diagram that emulates
circuits of relay logic Hardwar
4. What is PLC diagram?
In an effort to make PLCs easy to program, their programming language was designed to resemble
ladder logic diagrams. Thus, an industrial electrician or electrical engineer accustomed to reading
ladder logic schematics would feel comfortable programming a PLC to perform the same control
functions.
5. Why is ladder logic preferred?
The ladder logic language is preferred over other programming languages because of its easy
readability. It is much more visible and easier to learn this language due to the familiarity of symbols
typically used on electrical schematics.

284
 Job Sheet
Job Sheet – 2.1
Job Perform of Creating programs using Ladder Diagram (Star Delta Stat rer
Program)
Procedure: 1.Open the Delta PLC Program
2.Click to New part then Selected PLC Model Ok for solid works
3.Select the toolbars that will use throughout drawing
4.First we will take a NO contact from make contact
5. Then take a NC contact from the brake contact.
6. Then take the Main Output coil from the Output coil.
7. Then take the Timer from the timer output coil.
8. Take the Star Output coil from the Output coil.
9. Then take the Delta Output coil from the Output coil.
Personal Protective 1. Apron 01 Pc
Equipment (PPE):
2.Helmate 01 Pc
3.Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2.Power Supply 01 pc
3.Push Button Switch 02 pc
4.SMPS 01 pc
5. Magnetic Contactor 03 pc
5.Communacation cable 01 pc
Tools and 1.Computer 01 pc
Equipment: 2. Philips screw driver 01 pc
3. 3 Phase Motor 01 pc
4. wire Stepper 01 pc
5. Neon Tester 01 pc

285
 (Information Sheet 2.2)
Write the program
PLC programming is created throu01 Pc h programming language
Programm

ing Language:

PLC Programming
It's crucial to define and apply concepts when utilizing a PLC that are specific to your use
case. To begin, we must learn more about the particulars of PLC programming.
A PLC program is a collection of textual or visual instructions that reflect the rules that
govern the process that the PLC is controlling. PLC programming languages fall into two
basic categories, each of which has numerous sub classifications.
1. Textual Language 2. Graphical Form
● Instruction list ● Ladder Diagrams (LD) (i.e.
● Structured text Ladder Logic)
● Function Block Diagram (FBD)
● Sequential Function Chart (SFC)

1.1 Ladder Logic

Ladder logic is the simplest form of
PLC programming. It is also known as
“relay logic”. The relay contacts used
in relay controlled systems are
represented using ladder logic.

286
PLC Ladder Logic
Two pushbuttons are utilized to
operate the Star Delta circuit in the
aforementioned example. When a
switch is closed, the main contact and
star contact start, the timer begins to
run, and after the timer has finished,
the star contact closes and the delta
contact begins.

Although all of these PLC programming languages can be used to program a PLC,
graphical languages (like ladder logic) are typically preferred to textual languages (like
structured text programming).

Advantage of Ladder Diagram (LD):

⮚ LD is simple logic construction and more reliable than an electronic circuit controller.
⮚ Easy to learn and read the program.
⮚ Every programming symbol performs specific actions.
⮚ It having good representation for discrete logic.
⮚ Easy to troubleshoot.
⮚ Shut down the power without the switch (i.e. hardware devices).
1.2 Functional Block Diagrams
A straightforward and pictorial way for
programming several PLC operations is the
Functional Block Diagram (FBD). Using FBD is
covered by PLC Open in standard IEC 61131-3.
As a program's instructions are executed, a
function block produces one or more output
values..

Function Block Diagram.

Functional Block Programming Ladder diagram and its function block

equivalent in Siemens notation.

287
 Ladder to functional block

1.3 Sequential Function Charts (SFC)

If you have any experience with flowcharts, then this PLC Programming language will feel
familiar to you. In Sequential Function Charts, you use steps and transitions to achieve your
end results.
1.4 Instruction List (IL)
I will now show you the 5th and final PLC Programming Language which is Instruction List.
The Instruction List is also a textual based language.
Advantages of IL:
⮚ It has a high execution speed.
⮚ It takes less memory as compared to other programming languages.

1.5Structured Text Programming

Structured text is a textual programming
language that utilizes statements to determine
what to execute. It follows more conventional
programming protocols but it is not case
sensitive.

Advantages of ST:
⮚ ST is very easier to understand for both novice and experienced programmers.
⮚ Because of its standard coding format, it is easy to edit and modify program written
in ST language.

288
PLC Programming
Examples
If a pump is operating and the pressure is
satisfactory or if the lamp test switch is closed,
a signal lamp must be turned on. If a lamp
output is necessary for this application, inputs
from pressure and pump sensors are both
needed. Thus, AND logic gates are employed.

Think about a valve that needs to be opened to

lift a load when a pump is running and either
the lift switch is opened or a switch that
indicates the load hasn't been lifted yet and is
at the bottom of its lift channel is opened.

PLC Program to Operate Valve

Write the program

Program is compiled
A PLC compiler will compile the high-level language that was written by the user. Therefore,
BASIC language compiler is very important to convert the user high-level language into a
specific microchip PIC16F8XX assembly language

Program is compiled

Explanation: In the PLC world, Upload means transfer from the controller (PLC) to the PC.

289
Download means transfer the program from the PC to the controller (PLC).

Program Upload

In terms of a PLC upload refers to getting the logic running on the PLC to the programming
software running on your computer. An upload is always initiated from the computer.
Download refers to getting logic from your computer to the PLC.

(Self-Check 2.2)
Write the correct answer for the following questions.
1. What are the 5 PLC programming languages?
2. What are the 3 types of PLC?
3. What is PLC ladder diagram?
4. What is PLC diagram?
5. Why is ladder logic preferred?

(Answer Sheet 2.2)

1. What are the 5 PLC programming languages?
The 5 most popular types of PLC Programming Languages are:
⮚ Ladder Diagram (LD)
⮚ Sequential Function Charts (SFC)
⮚ Function Block Diagram (FBD)
⮚ Structured Text (ST)
⮚ Instruction List (IL)
2. What are the 3 types of PLC?
PLC are divided into three types based on output namely Relay output, Transistor output, and Triac
Output PLC.
3. What is PLC ladder diagram?
Ladder Diagram is a graphical programming language that you use to develop software for
programmable logic controllers (PLCs). It is one of the languages that the IEC 61131 standard
specifies for use with PLCs. A program in ladder diagram notation is a circuit diagram that emulates
circuits of relay logic Hardwar
4. What is PLC diagram?
In an effort to make PLCs easy to program, their programming language was designed to resemble

290
ladder logic diagrams. Thus, an industrial electrician or electrical engineer accustomed to reading
ladder logic schematics would feel comfortable programming a PLC to perform the same control
functions.
5. Why is ladder logic preferred?
The ladder logic language is preferred over other programming languages because of its easy
readability. It is much more visible and easier to learn this language due to the familiarity of symbols
typically used on electrical schematics.

Job Sheet

Job Sheet – 2.2

Job Perform of Creating programs using Ladder Diagram (Star Delta Stat rer
Program)
Procedure: 1.Open the Delta PLC Program
2.Click to New part then Selected PLC Model Ok for solid works
3.Select the toolbars that will use throughout drawing
4.First we will take a NO contact from make contact
5. Then take a NC contact from the brake contact.
6. Then take the Main Output coil from the Output coil.
7. Then take the Timer from the timer output coil.
8. Take the Star Output coil from the Output coil.
9. Then take the Delta Output coil from the Output coil.
Personal Protective 1. Apron 01 Pc
Equipment (PPE): 2.Helmate 01 pc
3.Safety Shoe 01 pc
Materials 1.PLC 01 pc
2.Power Supply 01 pc
3.Push Button Switch 02 pc
4.SMPS 01 pc
5. Magnetic Contactor 03 pc
5.Communacation cable 01 pc
Tools and 1.Computer 01 pc
Equipment: 2. Philips screw driver 01 pc
3. 3 Phase Motor 01 pc
4. Wire Stepper 01 pc
5. Neon Tester 01 pc

291
Learning Outcome 3:
Write the program

Contents:

Instructions
1. Hardware: PLC,
2. PC
3. Software (PLC &HMI Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria:

3.1. Program is simulated

3.2. Troubleshooting is performed if required
3.3. Ladder logic is modified if required

Resources required:

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, HMI, Interface Cable

Learning Activity 3.1

Resources/Special
Learning Activity
Instructions/References

Simulate and ▪ Information Sheet:.3.1

troubleshoot the ▪ Self-Check:.3.1
program ▪ Answer Sheet: 3.1

292
 (Information Sheet 3.1 ):
Simulate and troubleshoot the program
Program is simulated
Simulation:
The process of designing and evaluating algorithms using PLC simulation. PLC simulation
software is used by engineers to create control systems, control logic, and assess system
performance using a model of the plant.
There are two types of simulations in PLC
▪ Off Line Simulation
▪ ON Line Simulation

How do you simulate a PLC?

An industrial processor with high reliability, a PLC reads inputs, performs a set of internal
instructions, and adjusts outputs as necessary. The code is run directly from the file that will
be used on a real PLC, therefore it is possible to utilize tools that will run code created for a
PLC on a conventional laptop or desktop computer. The simulation results they offer are
quite close to those of a real PLC. These systems have the disadvantages of being
frequently expensive and OEM-locked.

Offline (Software)
Offline program means the program which resides in the PC
Getting Started in PLC Simulation
Step 1 - Launch Delta PLC WPLSOFT.
Step 2 - Create program written in Delta PLC.

Step 3 - Press “Compiler” Step 4 – Click IP

293
Step 5 – Online Mode Step 6 – Click Run

On Line Mode:

Online program means the program which resides in the PLC.

Diagnostic PLC Indicators
LED status indicators can reveal a lot of details about the wiring, I/O Module, and field
devices. Most input/output modules feature at least one indication, often a power indicator
for input modules and a logic indicator for output modules.
A bright power LED on an input module denotes that the input device is active and that the
module has received its signal. Because this indication cannot isolate module problems on
its own, some manufacturers offer a second diagnostic indicator called a logic indicator. The
input signal has been acknowledged by the input circuit's logic section, as indicated by an
ON logic LED.
Troubleshooting Input
A fault could exist between the L1 connection and the input module if the field device linked
to it doesn't appear to turn on. The status indicators of an input module can provide details
about the field device, the module, and the cabling of the field device to the module that will
help identify the issue.
Troubleshooting PLC Output
Status indicators on PLC output ports often offer helpful troubleshooting information. The
first step in troubleshooting outputs is to narrow down the source of the issue to the module,
the field device, or the wiring, just like when troubleshooting PLC inputs.
Troubleshooting PLC CPU
Moreover, PLCs offer diagnostic markers. that display the PLC and CPU status These
indicators include communications Conditions, memory Conditions, and power Conditions.
Then, confirm that the transformer is providing adequate power to the PLC to support all the
loads. Check for or for blown fuses if the PLC is still not functioning.

If there is a problem, the diagnostic indicators on the CPU's front will either signal a memory
issue or a communications issue. One of these indicators may need to be replaced if it is
illuminated.

Simulate and troubleshoot the program

Ladder logic is modified if required
To edit a variable on a Ladder Diagram: In the Variables list above the Ladder Diagram,
right-click on the variable you want to edit (on the Direct tab or Internal tab as appropriate).
A context sensitive menu is displayed. Select the Edit option.

294
(Self-Check 3.1)
Write the correct answer for the following questions.
1. What is Simulation?
2. Why we Use Simulation in PLC?
3. What is On Line Simulation?
4. What is Off Line Simulation?

(Answer Key 3.1)

1. What is Simulation?
PLC simulation is a method of designing and verifying algorithms. Engineers use PLC simulation
software to design control systems and control logic and evaluate system behavior through a model of
the plant.
2. Why we Use Simulation in PLC?
As it is obvious from its name “Simulator” it is a virtual PLC, you can say. Mostly PLC manufactures
provide a simulation feature with their Programming Software to test/verify the logic without a physical
PLC
3. What is On Line Simulation?
Online program means the program which resides in the PLC
4. What is Off Line Simulation?
Offline program means the program which resides in the PC.

295
 Job Sheet
Job Sheet – 3.1
Job How to Program simulated Off Line in PLC
Procedure: 1.Open the Delta PLC Program
2.Click to New part then Selected PLC Model Ok for solid works
3.Click Complied and check program Error
4. Click IP
5. Click Online Mode and Yes
5.Then Run Button Click
Personal Protective 1.Apron 01 Pc
Equipment (PPE):
Materials 1. PLC 01 Pc
Tools and Equipment: 1.Computer 01 c

Review Of Competency

Performance Criteria Yes No

1. diagram of PLC is interpreted  
2. Virtual Components of PLC are listed and interpreted  
3. Logic gates are interpreted  
4. Technical specifications of PLC are identified and  
interpreted as per job requirement
5. Interfacing between PC and PLC is checked  
6. PLC functions are identified as per job  
7. PLC programming is created through programming  
language.
8. Program is compiled  
9. Program is downloaded  
10. Program is used  
11. Program is simulated  
12. Troubleshooting is performed if required  
13. Ladder logic is modified if required  

Now, I feel ready to undertake my formal competency assessment.

Signed:

Date:

296
 Perform HMI Programming and Interfacing

297
 Module 05-O: Perform HMI Programming and interfacing

Module Content

Module Descriptor
This unit covers the knowledge, skills, and attitudes required to perform HMI programming
and interfacing. It specifically includes interpreting specifications of HMI, writing program and
running and testing HMI program,

Nominal Duration: 50 hours

Learning Outcomes:

Upon completion of the module, the trainee should be able to:

1. Interpret specifications of HMI
2. Write program
3. Run and test HMI program

Performance Criteria:

1.1 HMI operation is interpreted.

1.2 Configuration of HMI is interpreted
1.3 Symbols with HMI are interpreted
2.1. Required software are collected and installed
2.2. Control Circuit and Power circuit diagram are drawn on the drawing sheet as per given
HMI Manual Book circuit diagram
2.3. Interfacing between PC and HMI is checked
2.4. HMI functions are identified as per PLC program
2.5. HMI program is created
2.6. Program is compiled
2.7. Program is simulated and modified if required
2.8. Program is downloaded into HMI using selected media
2.9. Troubleshooting is performed
3.1. HMI program is run
3.2. Connection of HMI with PLC is tested

298
 Learning Outcome 1:
Interpret specifications of HMI

Contents:
Instructions
22. Hardware: PLC, HMI
23. PC
24. Software (PLC &HMI Software)
25. Sample product/work piece
26. Drawings and/or sketches/Diagram
27. Manual/CBLM

Assessment Criteria

1.1 HMI operation is interpreted.

1.2 Configuration of HMI is interpreted
1.3 Symbols with HMI are interpreted

Resources required

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC & HMI Software, HMI

Learning Activity 1.1

Resources/Special
Learning Activity
Instructions/References

Interpret specifications ▪ Information Sheet:.1.1

of HMI ▪ Self-Check:.1.1
▪ Answer Sheet: 1.1

299
 Information Sheet 1.1)
Interpret specifications of HMI
HMI operation is interpreted:
Human–machine interface
PLCs, RTUs, and IEDs can all be accessed by
an operator through the use of human-machine
interfaces. HMIs represent the digital controls
that are used to sense and affect that process
graphically in place of the manually operated
switches, knobs, and other electrical controls.
Operators can start and stop cycles, change set
points, and carry out other tasks necessary to
interface with and adapt a control process using
HMIs. As the HMI is software-based, they can
be quickly modified and updated because
software parameters take the role of physical
cables and controllers. Figure 4.6 illustrates how
the HMI works with the overall ICS design as
previously described.

Human–machine interfaces are modern software applications that come in two predominant
form-factors. The first runs on modern operating systems like Windows 7, and are capable of
Subsystem models
HMI
Just the Part Tracker is communicated with
by the HMI unit, which manages the user
interface.
The Overture (VDM) implementation and the
4DIAC+MQTT implementation are the two
complimentary HMI unit implementations
produced by the project. Even though they
cannot be utilized simultaneously, each is
beneficial for a particular kind of experiment.

The 4DIAC+MQTT solution enables manual

order placement, modification, or
cancellation at any time using smart device
apps, as shown in Fig. 7.6. It is designed to
collect user heuristics and analyze problems
with real-time order placement.

Interaction between other applications and the specific HMI.

300
The Overture (VDM) model, which enables an automatic feed of orders through a comma-
separated values file, is more beneficial for the study of the system (CVS). This strategy is
both adaptable and effective. The power comes from the repeatability of studies, while
flexibility comes from the capacity to build scenarios with different ordering to cover
statistical possibilities. The co-simulation can be conducted with different parameters and
the same input orders while using the same input (CVS) file, creating a thorough picture of
the behavior of the system in carefully monitored, repeatable tests..

How Does an HMI Work?

In an automated system, HMIs are frequently used in conjunction with a PLC
(Programmable Logic Controller) to monitor and control processes. In general, the HMI gives
the user a graphical interface through which to interact with the PLC (typically a
touchscreen). In addition to allowing orders to be issued, this interface also collects and
translates feedback data from the PLC, which is subsequently displayed on the screen in an
understandable manner. This gives the operator crucial flexibility and command over a
particular system. A tablet or smartphone with an integrated touchscreen that enables
people to interact with the machine's programming is a fantastic illustration of a typical HMI.

History of the HMI

HMI devices were initially created to satisfy the demand for equipment that was simple to
operate and produced the best results. The Batch Interface (1945–1968), Command-Line
User Interface (1969–present), and Graphical User Interface are predecessors of the HMI
(1981-Present).
Advantages of an HMI
The graphical interface of an HMI's is very user-friendly, which is its main benefit. The
graphical interface includes color coding for quick identification (red indicating danger, for
instance), as well as images and icons that enable for quick recognition, lessening the
difficulties caused by language barriers.

Advantages of an HMI over a PLC alone

A PLC on its own cannot provide any real-time feedback, and cannot set off alarms nor
modify the system without reprogramming the PLC

Interface Flexibility
One of the most valuable features of an HMI is the ability to personalize the interface. An
HMI can fully support the most complex applications, with multiple screens and several
routines running. 1.1 Lamp: lamp is Output Component in HMI.

1.2 Motor: Motor is Output Component in HMI.

1.3 Valve: Valve is Output Component in HMI

The system for testing valves serves as an automated testing facility for various valve types
and pressure ranges (3 bar to 12 bar). Via the integrated HMI, the proper valve type is
chosen before to the test. The sliding door can then be opened, and the valve can then be
inserted. The safety contact is turned and the system is ready for testing when the sliding
door is closed. The testing is launched by pressing the start button.
Application areas
Different valve types with pressure ranges from 3 bar to 12 bar, used for industrial coffee
machines/automatic coffee makers.
Features
• Freely mountable system
• Easy operation
• Small dimensions
• PLC control

301
• Safety circuit
• Precise pressure measurement
• High repeatability
1.4 Level: In an HMI, level is an input component. In some type of container containing both
liquids and solids in the form of powders, level sensors are employed to monitor the location
of the surface.
1.5 Flow: The HMI's input component is the flow sensor. Operators are crucial to the
conversation between humans and machines. They must make use of the knowledge they
have to take measures that ensure the machines and installations function effectively
without compromising availability and safety:

Configuration of HMI is interpreted

Configuring the HMI Human-computer interaction A Human Machine Interface (HMI) is a
piece of analytical software that connects the operator's view of the machine's details with
those that the machine sees. The user interface displays the system controls and notifies the
operator of any ineffective system behavior.
.
How to Select an HMI
Knowing precisely what is expected of an HMI is vital because it is a significant purchase.
HMIs often play one of three key roles: overseer, data handler, or pushbutton replacement.
The pushbutton replacer HMI replaces any mechanical device that performs a control
function, including LEDs, On/Off switches, and buttons. Applications that require continuous
feedback and monitoring are used with the data handler. These data controllers frequently
have huge capacity memories built in. The supervisor uses centralized SCADA and MES
systems to monitor and manage entire sites or complexes of massive systems dispersed
across a wide area. Typically, an overseer HMI is connected to the databases and software
of the SCADA system to give trends, diagnostic data, and management information.

302
 (Self-Check 1.1)
1. How does HMI operate?
2. What is HMI monitoring?
3. What is HMI explain with example?
4. What is HMI explain different types of HMI?
5. What is HMI design?

Answer Key (1.1)

1.How does HMI operate?
HMIs allow operators to start and stop cycles, adjust set points, and perform other functions required to
adjust and interact with a control process. Because the HMI is software based, they replace physical
wires and controls with software parameters, allowing them to be adapted and adjusted very easily.

2.What is HMI monitoring?

HMI stands for Human Machine Interface (HMI). A Human Machine Interface (HMI) is a software
application that presents information to an operator or user about the state of a process, and to accept
and implement the operators control instructions.
3.What is HMI explain with example?
A Human Machine Interface or HMI is defined as a feature or component of a certain device or
software application that enables humans to engage and interact with machines. Some examples of
common Human Machine Interface devices that we encounter in our daily lives include touchscreens
and keyboards.
4.What is HMI explain different types of HMI?
There are three basic types of HMIs: the pushbutton replacer, the data handler, and the overseer.
There are three basic types of HMIs: the pushbutton replacer, the data handler, and the overseer.
5.What is HMI design?
HMI Design is the practice of building HMI screens that are intuitive to the end user, pleasing to the eye
and are efficient to operate.

303
 Job Sheet

Job Sheet – 1.1

Job Perform of Introduction of HMI
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the HMI and PLC.
4. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2. HMI 01 pc
Tools and 1. Computer 01 pc
Equipment: 2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

LearninOutcome 2:
Write program

Contents:
Instructions
10. Hardware: PLC, HMI
11. PC
12. Software (PLC &HMI Software)
13. Sample product/work piece
14. Drawings and/or sketches/Diagram
15. Manual/CBLM

Assessment Criteria
2.7. Required software are collected and installed
2.8. Control Circuit and Power circuit diagram are drawn on the drawing sheet as
per given HMI Manual Book circuit diagram
2.9. Interfacing between PC and HMI is checked
2.10. HMI functions are identified as per PLC program
2.11. HMI program is created
2.12. Program is compiled
2.13. Program is simulated and modified if required
2.14. Program is downloaded into HMI using selected media
2.15. Troubleshooting is performed

304
 Resources required

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC & HMI Software, HMI

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Write program ▪ Information Sheet:.2.1

▪ Self-Check:.2.1
▪ Answer Sheet: 2.1

(Information Sheet 2.1)

Required software are collected and installed

In order to monitor and control complex industrial equipment, human-machine interface (HMI)
software offers a simple graphic user interface with input/output controls. HMI software can
be set up on wearables, normal PCs, mobile devices, or HMI hardware.
Installation Delta HMI Dopsoft Software
+ Step 1: Extract the downloaded file + Step 2: Click on the DOPSoft V2.00.7.04.exe and
select Run

+ Step 3: Select a “language” the OK + Step 4: Choose Install

305
+ Step 5: Waiting + Step 6: Choose Install to install the driver.

Step 7: Click Next to install SQL Server Compact + Step 8: Choose I accept the terms in license
agreement then Next.

+ Step 9: Choose Install + Step 10: After the installation process

SQL Server completed, select Finish

+ Step 11: Click Close to Finish Setup

306
 (Self-Check 2.1 )
1. What language is an HMI programmed in?
2. How is HMI connected to PLC?
3. Where is HMI used?
4. What are the components of HMI?
5. What is HMI display?

Answer Key (2.1)

1. What language is an HMI programmed in?
Net, Visual C#, C++ and other programming languages as well for their HMI automation, control and
monitoring systems.
2. How is HMI connected to PLC?
The HMI unit, depending upon which model you select, will communicate with the PLC using serial
communications or by way of an Ethernet connection. HMIs are programmed using free software and
via a serial port (USB, or standard DB9 port) available from the vendor.
3. Where is HMI used?
Uses of HMI Industries such as energy, water, wastewater, buildings and transportation may also use
HMIs. Roles such as system integrators, operators and engineers, especially process control system
engineers, frequently use HMIs. These professionals may use HMIs to control machines, vehicles,
plants or buildings.
4. What are the components of HMI?
HMI functions HMI Components offered by EAO include pushbuttons, illuminated pushbuttons,
emergency stop switches, key lock switches, buzzers, joysticks and lever switches. Numerous
additional HMI Components complete our comprehensive range.
5. What is HMI display?
HMI stands for Human Machine Interface. Generally, it refers to a screen or dashboard that
communicates information, data and metrics using graphics or visual representations of numbers. The
screen is controlled by an operator who monitors and controls equipment and processes in factories
and plants.

307
 Job Sheet
Job Sheet – 2.1
Job Perform of Delta HMI Software Installation.
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the HMI Software and Installation
4. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.HMI 01 pc
Tools and e 1. Computer 01 pc
quipment: 2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

(Informaion Sheet 2.2)

Write Program
Control Circuit and Power circuit diagram are drawn on the drawing sheet as per given HMI
Manual Book circuit diagram

Depending on the model you choose, the HMI unit will either use serial communications or
an Ethernet connection to connect to the PLC. With free software and a serial port (USB or
conventional DB9 port) provided by the vendor, HMIs can be configured.

308
 (Self-Check 2.2 )
1. Can HMI work without PLC?
2. WHAT IS PLC in HMI?
3. How HMI and PLC are connected

Answer Key (2.2)

1. Can HMI work without PLC?
A new I/O module easily interfaces with Beiger Electronics' HMI and allows the user to implement
simple monitoring and automation tasks without a PLC. The compact HMI I/O controller is developed
for the plus version of the H-T40, the H-T40m-P, which features extended memory
2.WHAT IS PLC in HMI?
Many modern control systems use a Programmable Logic Controller (PLC) to control valves, pumps,
motors and other machines used in a process. Process personnel can interact with the PLC system
with a computer-based Human Machine Interface (HMI) product.
3.How HMI and PLC are connected?
The HMI unit, depending upon which model you select, will communicate with the PLC using serial
communications or by way of an Ethernet connection. HMIs are programmed using free software and
via a serial port (USB, or standard DB9 port) available from the vendor.

Job Sheet

JOB SHEET – 2.2

Job Perform of control and Power Circuit of HMI.
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the HMI ,PLC
4. Check Control Circuit as per as Diagram
5. Check Power Circuit as per as Diagram
6. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE):
2. Safety Shoe 01 Pc
Materials 1.HMI 01 pc
2.PLC 01 Pc
3.VFD 01 Pc
4.SMPS 01 pc
5.Communication Cable 01 Pc
Tools and equipment: 1. Computer 01 Pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

309
(Information Sheet 2.3)

Write Program
Perform of Interfacing between PC and HMI.
Keyboards and touchscreens are two prominent Human Machine Interface devices that we
come across on a regular basis. HMIs are often screens or touchscreens that use USB to
connect users to machines, systems, or devices in an industrial setting. We first need to
install the drivers before we can complete the Ethernet connection.
PC to DVP communication interface (Delta PLC) many people are unfamiliar with some of
the ways we can connect our Computer to the Delta PLCs. But, it is getting more and harder
to find RS232 serial connections in computers, and USB to RS232 converters aren't as
reliable as they should be. For this reason, I'd like to provide several options to that issue.
Direct communication PC to PLC:
1. Using wire DVPACAB2A30, connect a
PC's RS232 port to a PLC's RS232
port.
2. With the IFD6500 (Delta USB-RS485
Converter), a PC USB port can be
converted to a PLC RS485 port.
3. PLC DVPEN01-SL module to PC
Ethernet port (need compatibility with
high speed bus)
Direct Connect Communication from PC to
PLC through Delta HMI:
With a single cable, Delta HMI's direct link
feature allows it to communicate with both
the PLC and the HMI. Additionally, this
feature has recently been enhanced,
making it possible to monitor both of them
simultaneously using just one wire.
(Updated direct Link feature)
1. Direct Link function trough Standard USB
wire (WPLSoft and ISPSoft)

2. Direct Link function trough Ethernet

(WPLSoft and ISPSoft)
Exactly the same feature is available with
the new DOP-B HMI’s with Ethernet
embedded, really helpful for remote
support.
3. Direct Link function trough USB host
(WPLSoft only).

310
 (Self-Check 2.3 )
1. How a computer processing and networks affect to HMI?
2. What are the 3 main types of HMI screens?
3. Is HMI a software or hardware?
4. What is the purpose of Human Machine Interface?

Answer Key (2.3)

1. How a computer processing and networks affect to HMI?
HMIs allow operators to start and stop cycles, adjust set points, and perform other functions required to
adjust and interact with a control process. Because the HMI is software based, they replace physical
wires and controls with software parameters, allowing them to be adapted and adjusted very easily.
2. What are the 3 main types of HMI screens?
There are three basic types of HMIs: the pushbutton replacer, the data handler, and the overseer.
There are three basic types of HMIs: the pushbutton replacer, the data handler, and the overseer.
3. Is HMI a software or hardware
Image result for Interfacing between PC and HMI question
The human–machine interface (HMI) software enables operators to manage industrial and process
control machinery via a computer-based graphical user interface (GUI). There are two basic types of
HMI software: supervisory level and machine level.
4. What is the purpose of Human Machine Interface?
Operators and engineers use HMIs to monitor and configure set points, control algorithms, send
commands, and adjust and establish parameters in the controller. The HMI also displays process
status information and historical information.

Job Sheet
Job Sheet – 2.3
Job Perform of PC and HMI Interface.
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the HMI AND PC
4. Connected To PC and HMI
5. Check Power PC
6. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.HMI 01 pc
2.PLC 01 Pc
3.Pen Drive 01 Pc
4. Communication Cable 01 pc
Tools and 1. Computer 01 pc
Equipment: 2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

311
(Information Sheet 2.4)
Write program
HMI features are listed in accordance with the PLC software. HMIs. HMIs are utilized as an
operator control panel for PLCs, RTUs, and occasionally even directly for IEDs. HMIs
substitute graphical representations of the control process and digital controls to affect that
process for manually operated switches, dials, and other controls.
.
Write program
HMI program is created.
How to Create Program: First Open Dopsoft Software Then Go to File –New-HMI
Model Select-Next Port Select:

Page Layout View: Input: Element-Momentary Push Button-

Tag set-Ok

Output: Element-Indicator-Tag set-Oke.

Timer /Counter: Timer Number Timer number means here how many timers we are

312
using.
Display-Numeric Display Timer value: Input-Numeric Input

HMI program:

Write program
Program is compiled.
Compiled is a very serious task after completing the program, because the program is
Compiled to check that the tags of the program are correct before downloading the program.
Completion can identify whether the program is correct or incorrect.
Tool Compiler
Program is simulated and modified if required.
Program Simulation: A simulation uses a mathematical description, or model, of a real
system in the form of a computer program. This model is composed of equations that
duplicate the functional relationships within the real system.
Simulation 2 type.
1. off Line Simulation without HMI and PLC only Software Base
2. On Line Simulation Connect with HMI and PLC .
Tool off Line

313
Program

Program Upload Download: In the PLC world, Upload means transfer from the controller
(PLC) to the PC. Download means transfer the program from the PC to the controller (PLC).
Delta PLC Download: Generally, the connection between the HMI and computer is
established through a USB type B connection wire for uploading and downloading.

(Self-Check 2.3 )
1. What is HMI interview?
2. What are the three 3 main types of HMI screens?
3. What are the two main categories in HMI?
4. What are HMI tools?

Answer Key (2.4)

What is HMI interview?
"Human machine interface, or HMI, refers to how people interact with technology and the benefits they
obtain from using it. Naturally, this involves input devices such as keyboards and mice and output
devices such as monitors, audio systems, and printers.

What are the three 3 main types of HMI screens?

There are three basic types of HMIs: the pushbutton replacer, the data handler, and the overseer.
There are three basic types of HMIs: the pushbutton replacer, the data handler, and the overseer.
What are the two main categories in HMI?
The human–machine interface (HMI) software enables operators to manage industrial and process
control machinery via a computer-based graphical user interface (GUI). There are two basic types of
HMI software: supervisory level and machine level.
What are HMI tools?
A Human-Machine Interface (HMI) is a user interface or dashboard that connects a person to a
machine, system, or device. While the term can technically be applied to any screen that allows a user
to interact with a device, HMI is most commonly used in the context of an industrial process.

314
 Job Sheet
Job Sheet – 2.4
Job Perform of Make simple program on Delta HMI.
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Frist open dopsoft software
4. Then take Start input switch from momentary push switch
5. Then take stop input switch from momentary push switch
6. Output from indicator
7. Timer number takes display.
8. Timer value takes input.
9. connected To PC and HMI and PLC
10. Check Power PLC Power supply
11. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.HMI 01 pc
2.PLC 01 pc
3.SMPS 01 pc
4.Relay 01 pc
3.Magnetic Contactor 01 pc
3.Push switch NO/NC 01 pc
4. Communication Cable rs 232 01 pc
Tools and Equipment: 1. Computer 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

(Information Sheet 2.5)

Write program
Program is downloaded into HMI using selected med

RS485- Several devices on the same bus can interact in both

directions using the duplex RS-485 communication protocol. As seen in the aforementioned
figures, RS-485 is most frequently utilized as half-duplex with just a single communication
line ('A' and 'B' as a pair).

315
RS232 – A common serial protocol called RS232 is used to link computers to their
peripheral devices so that serial data can be exchanged between them. As it determines the
voltage for the path utilized for the devices' data exchange.
RS232 is a protocol and interface that uses serial binary data transmission between data
terminal equipment (DTE) and data communication equipment (DCE). In this case, the most
recent version is C. A motherboard-mounted Universal Asynchronous Data Receiver and
Transmitter (UART) is used in conjunction with RS232 to transmit data from its DTE
interface to any serial device, such as a modem or printer.

Ethernet Cable: A network

communication standard called Ethernet/IP (Ethernet Industrial Protocol) can handle
massive amounts of data at rates of 10 Mbps or 100 Mbps and up to 1500 bytes per packet.
At the application layer, the specification makes use of an open protocol. Particularly for
control applications, it is well-liked.
Write program
Troubleshooting is performed.
Troubleshooting: solving input and output problems. Now let's move on to the more typical
issue of debugging inputs and outputs. Finding out why the internal condition of the PLC and
HMI does not coincide with the exterior situation is the main objective of I/O troubleshooting.

(Self-Check 2.5)
1. How does HMI interface with PLC?
2. Is HMI a component of PLC??
3. How do I program HMI display??
4. How do I start the HMI simulation in TIA Portal?
5. How do I download from HMI?
6. Why is HMI not working?

Answer Key (2.5)

1. How does HMI interface with PLC?
In general terms, the HMI allows the user to communicate with the PLC via a graphical interface
(typically a touchscreen). This interface allows commands to be given, and also receives and translates
feedback data from the PLC, which is then presented in an easily accessible visualization on the
screen.
2. Is HMI a component of PLC?
A PLC, or Programmable Logic Controller, is a small digital computer that controls the input and output
positions to make sure the parts of the robot work together. An HMI, or human machine interface, is
connected to the PLC.
3. How do I program HMI display?
● Creating HMI Displays and Logic Programs
● Install GP-Pro EX. See the installation DVD-ROM's Readme. ...

316
 ● Start the software and create a new project. Set up the display unit model and
device/PLC. ...
● Confirm the device/PLC communication settings. ...
● Create the screen interface. ...
● Create a logic program.
4. How do I start the HMI simulation in TIA Portal?
With Siemens TIA Portal, PLCs can be simulated using the built-in simulation software PLCSIM and
Win CC Runtime Advanced can be used to simulate HMIs. To launch PLCSIM in TIA Portal, simply
select the PLC you wish to simulate, then click the “Start simulation” button on the toolbar.
5. How do I download from HMI?
In the project tree right-click on the HMI device name then select “Download to device”. This will bring
up a window that displays a list of devices accessible, compatible, or with the same IP address based
on the selection. Click on “Start Search” and connect to your device.
6. Why is HMI not working?
The most frequently used keys on an HMI are those most likely to fail first. Keys like Start, Enter or
passcode keys are likely to experience the heaviest use, and the identifying lettering may get worn
away. Operators may find themselves pressing the key a bit harder each time, and eventually these
keys will fail.

Job Sheet

Job Sheet – 2.5

Job Perform of Make simple program on Delta HMI.
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Frist open dopsoft software
4. Then take Start input switch from momentary push switch
5. Then take stop input switch from momentary push switch
6. Output from indicator
7. Timer number take display.
8. Timer value takes input.
9. Connected To PC and HMI and PLC
10. Check Power PLC Power supply
11. Proper use and maintenance of equipment.
Personal Protective 1.(Apron) 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.HMI 01 pc
2.PLC 01 pc
3.SMPS 01 pc
4.Relay 01 pc
3.Magnetic Contactor 01 pc
3.Push switch NO/NC 01 pc
4. Communication Cable rs 232 01 pc
Tools and Equipment: 1. Computer 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

317
 Learning Outcome 3:
Run and test HMI program

Contents:

Instructions
15. Hardware: PLC, HMI
16. PC
17. Software (PLC &HMI Software)
18. Sample product/work piece
19. Drawings and/or sketches/Diagram
20. Manual/CBLM

Assessment Criteria

3.1. HMI program is run

3.2. Connection of HMI with PLC is tested

Resources required

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC & HMI Software, HMI

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Run and test HMI ▪ Information Sheet:.3.1

program ▪ Self-Check:.3.1
▪ Answer Sheet: 3.1

318
 (Information Sheet 3.1)
Run and test HMI program
HMI program is run
Software and custom application
development solutions that offer a
graphical user interface (GUI) to aid in
operating or monitoring industrial
automation devices and equipment are
referred to as human-machine interface
(HMI) software.

Run and test HMI program

HMI functions essentially as a human-
machine interface. It functions much like a
switch. However in order to do this, it
needs to be programmed using this clock
program. Installing the Dopsoft software is
a prerequisite for using any Delta Dopsoft
product. Open the software now, and then
choose the call option you want to
connect to. I'll now navigate to Elements,
grab the summary pushbutton, and
choose the Proper Edron Check program.
To get the output from the indicator,
remove the indicator lamp. To get timers
and counters, use a numerical display and
numerical input. Here, the terms "Numeric
Display" and "Numeric Input" both refer to
timer or counter addresses.

(Self-Check 3.1)
1. How do you program an HMI?
2. What is HMI protocol?
3. How does HMI communicate with PLC?
4. Can HMI work without PLC?

319
Answer Key (3.1)
How do you program an HMI?
Ten steps to creating the perfect HMI
Less is more. It's important to keep the HMI simple and with the operator in mind.
Right-size displays.
Design tips.
Plant review forum.
Location, location, location.
Back-up work periodically.
Visualize the process.
Only essential data
What is HMI protocol?
A Human-Machine Interface (HMI) is a user interface or dashboard that connects a person to a
machine, system, or device. While the term can technically be applied to any screen that allows a user
to interact with a device, HMI is most commonly used in the context of an industrial process.
How does HMI communicate with PLC?
When you develop the HMI program, in each screen you create graphic interfaces that reflect and send
commands to the PLC program through the configured protocol. You do that because every
input/output field, alarm display, status icon you generate is linked to a tag, linked to an address of a
register in the PLC
Can HMI work without PLC?
You say you have no PLC programming experience, which does not mean you cannot plan and
program the HMI; you must simply be aware that you must ensure the PLC is programmed and
configured correctly, that all the values you need to show on the HMI screens are available (and
correctly scaled) for your application in the

Job Sheet

Job Sheet – 3.1

Job Perform of connect a HMI to a PLC
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Frist open dopsoft software
4. Click on add new device in the project tree. ...
5. Click on HMI and search for the correct HMI screen. ...
6. Select the PLC to make a connection. ...
7. The HMI screen and PLC are now connected. ...
8. Change the Internal tag connection to HMI connection. ...
9. A communication DB is created containing Valve 1 Valve 1
has a UDT data type.
10. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.HMI 01 pc
2.PLC 01 pc
3.SMPS 01 pc
4.Relay 01 pc
3.Magnetic Contactor 01 pc
3.Push switch NO/NC 01 pc
4. Communication Cable rs 232 01 pc
Tools and 1. Computer 01 pc
Equipment: 2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

320
 Review of Competency

Performance Criteria Yes No

1. HMI operation is interpreted.  
2. Configuration of HMI is interpreted  
3. Symbols with HMI are interpreted  
4. Required software are collected and installed  
5. Control Circuit and Power circuit diagram are drawn on  
the drawing sheet as per given HMI Manual Book
circuit diagram
6. Interfacing between PC and HMI is checked  
7. HMI functions are identified as per PLC program  
8. HMI program is created  
9. Program is compiled  
10. Program is simulated and modified if required  
11. Program is downloaded into HMI using selected media  
12. Troubleshooting is performed  
13. HMI program is run  
14. Connection of HMI with PLC is tested  

Now, I feel ready to undertake my formal competency assessment.

Signed:

Date:

321
 Perform PLC Operation

After completion this module trainee will able to:

 Interface Sensors with PLC
 Control Induction Motor using PLC
 Control AC drive using PLC
 Control Pneumatic and hydraulic instruments using PLC

322
Module 6: Perform HMI Programming and Interfacing

Module Content

Module Descriptor
This unit covers the knowledge, skills, and attitudes required to perform PLC operations. It
specifically includes interfacing Sensors with PLC, controlling Induction Motor using PLC,
controlling AC drive using PLC and controlling pneumatic and hydraulic instruments using
PLC

Nominal Duration: 20 hours

Learning Outcomes:

Upon completion of the module, the trainee should be able to:

1. Interface Sensors with PLC
2. Control Induction Motor using PLC
3. Control AC drive using PLC
4. Control Pneumatic and hydraulic instruments using PLC

Performance Criteria:

1.1. PLC is connected with PC using appropriate cable

1.2. Interfacing between PC and PLC is checked
1.3. Sensors are wired with PLC as per diagram
1.4. Program is written and simulated
1.5. Functions of sensors are checked using PLC
2.1. PLC is connected with PC using appropriate cable
2.2. Interfacing between PC and PLC is checked
2.3. Wiring of Motor Controlling starters are performed
2.4. Starters are connected with PLC
2.5. Motor is connected with Magnetic Contactor
2.6. Motor is controlled and operated using PLC
3.1. PLC is connected with PC using appropriate cable
3.2. Interfacing between PC and PLC is checked
3.3. AC drive parameters are set as per requirement
3.4. VFD, Servo drive and stepper drive functions are controlled with PLC
4.1. PLC is connected with PC using appropriate cable
4.2. Interfacing between PC and PLC is checked
4.3. Pneumatic and hydraulic instruments with PLC are integrated as per requirement
4.4. Pneumatic and hydraulic instruments are operated using PLC

Learning Outcome 1:

323
 Interface Sensors with PLC

Contents:

Instructions
1. Hardware: PLC, Sensor
2. PC
3. Software (PLC Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

1.1 PLC is connected with PC using appropriate cable

1.2 Interfacing between PC and PLC is checked
1.3 Sensors are wired with PLC as per diagram
1.4 Program is written and simulated
1.5 Functions of sensors are checked using PLC

Resources required

The following resources must be provided to students/trainees):

Computer, Mouse, Keyboard, PLC Software, Sensors

Learning Activity 1.1

Resources/Special
Learning Activity
Instructions/References

Interface Sensors with ▪ Information Sheet:.1.1

PLC ▪ Self-Check:.1.1
▪ Answer Sheet: 1.1

324
 (Information Sheet 1.1)

Interfacing between PC and PLC is checked

Sensor Interface with PLC
PLC and PC are linked together using
the proper cable. Cables and interfaces
ranging from RS232 serial to Micro USB
to Cat5e Ethernet may be needed for
PLC communication. For PLC
programming and I/O expansion, a
variety of specialized PLC
communication cables are available.
Patch cables for Cat5e (2 to 50 ft.)
1. Use a small B USB cable to directly
connect your PC to the controller.
2. On the program ribbon, select the
PLC tab, then choose
Communication.
3. After choosing USB, the network
discovery tool starts looking for Uni-
Stream devices.
4. To start a conversation, click the
selected device. Related Subjects.
Communications.
Sensors wired with PLC
Connections as per diagram
A sensor is a tool that collects physical
input from its surroundings and
transforms it into information that can be
used by either a machine or a human to
understand. The majority of sensors are
electronic (converting the data into
electronic data), although some are
simpler, like a glass thermometer that
displays visual data.

Types of sensors:
1. Analog Sensor
2. Digital Sensor
Analog Sensor:
The quantity measured by analog sensors is converted into analog signals. In contrast,
when performing a measurement, digital sensors generate digital signals. As was
previously noted, the most popular varieties of analog sensors.
▪ Pressure Sensor
▪ Temperature Sensor
▪ Level Sensor
▪ Flow Sensor
▪ Ph Sensor

325
5.1 Pressure Sensor:
A pressure sensor is a device made up of
a pressure sensitive element that uses
various working principles to identify the
actual pressure applied to the sensor and
other components that turn this information
into an output signal.
pressure sensor Applications Pressure Sensor Connect with PLC:
An electronic device known as a pressure
sensor detects, controls, or monitors
pressure and transforms sensed physical
information into an electronic signal.

Additional Integration of a local indicator into the PLC

Types of pressure sensors

⮚ Inductive pressure sensors.
⮚ Capacitive pressure sensors.
⮚ Piezoelectric pressure sensors.
⮚ Strain gauge pressure sensors.
⮚ Variable reluctance pressure sensors.
⮚ Potentiometric pressure sensors.

(Self-Check 1.1)
Write the correct answer for the following questions.
1. What is Analog Signal?
2. Which sensor is used for pressure?
3. What are the 4 types of pressure??
4. What is the output of a pressure sensor?
5. Is a pressure sensor analog or digital?

326
 (Answer Key1.1)
1. What is Analog Signal?
An analog signal is one whose value continually varies over time. They are best represented as a
continuous signal like a sine wave. Each point on the wave has a precisely defined value. For
example, analog inputs for PLCs can include signals from pressure transducers and temperature from
thermocouples.
2. Which sensor is used for pressure?
A manometer is a fluid pressure sensor that provides a relatively simple design structure and an
accuracy level greater than that afforded by most aneroid barometers. It takes measurements by
recording the effect of pressure on a column of liquid.
3. What are the 4 types of pressure?
Types of Pressure - Absolute Pressure, Gauge Pressure, Differential Pressure and Sealed Pressure.
4. What is the output of a pressure sensor?
A typical pressure sensor works producing a strain gauge output as the deflection of a diaphragm is
caused. Depending on the strain gauge technology the output can vary from 1 to 3 millivolts per volt
(mV/V) to as much as 10 to 30 mV/V.
5. Is a pressure sensor analog or digital?
Some common examples of analog sensors are light sensors (LDRs), sound sensors, pressure
sensors, and analog temperature sensors. Similarly, there are some commonly used digital sensors
such as digital temperature sensors and digital pressure sensors.

Job Sheet
Job Sheet – 1.1
Job Perform of Interface Pressure Sensor and PLC
Procedure: 1.Selected 2 wire pressure Sensor
2. Hardware Connection PLC and Pressure sensor.
3.Check Diagram as per as Drawing
4.Draw ladder Diagram
5.Program Simulated
6.Program Download PC to PLC
Personal Protective 1.Apron 01 pc
Equipment (PPE): 2.Safety Shoe 01 Pc
3.Googles
Materials 1. PLC 01 Pc
2. Analog Input /Output Module 01 Pc
3.Pressure Sensor 01 Pc
4.SMPS 01 Pc
5.lamp 01 Pc
6.Control Valve 01 Pc
Tools and Equipment: 1.Computer 01 pc
2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

327
 (Information Sheet 1.2)

Interfacing between PC and PLC is checked

1.5.2 Temperature Sensor:
Temperature sensor
In order to record, monitor, or communicate temperature changes, a temperature sensor is
an electronic device that monitors the temperature of its environment and transforms the
input data into electronic data.
Temperature sensor working principles:
A temperature sensor is a device that, typically, measures temperature through an
electrical signal using a thermocouple or resistance temperature detector. The most basic
type of temperature meter, used to gauge how hot or chilly something is, is a thermometer.
The voltage across the diode terminals is the fundamental operating mechanism of the
temperature sensors. When the voltage rises, the temperature rises as well, which is
followed by a voltage drop between the base and emitter transistor terminals in a diode.

Contact Type Temperature Sensors: A few temperature meters can determine how hot or
cool something is simply by making direct contact with it. These temperature sensors are
under the contact-type category. They may be used to find objects at a variety of
temperatures, whether they be solids, liquids, or gases.
Non-Contact Type Temperature Sensors: These kinds of thermometers assess the
degree of hotness or coolness through the radiation that the heat source emits rather than
being in direct touch with the thing.
Other divisions of the contact and non-contact temperature sensors include:
Thermostats
A thermostat is a form of contact temperature sensor
that consists of a bi-metallic strip made of two metals
that are not similar to one another, such as tungsten
and aluminum.
When exposed to heat, the two metals' different
coefficients of linear expansion cause them to produce
a mechanical bending action.

Thermistors
Thermistors, also known as thermally sensitive
resistors, are the ones that alter physically in response
to temperature changes. The thermistors can readily
deform since they are made of ceramic materials such
oxides of nickel, manganese, or cobalt that are coated
with glass.
The majority of thermistors have a negative
temperature coefficient (NTC), which implies that as
the temperature rises, so does their resistance.
However, certain thermistors have a positive
temperature coefficient (PTC), meaning that as the
temperature rises, so does their resistance.

328
Resistive Temperature Detectors (RTD)
RTDs are highly pure conducting metals twisted into
coils, such as platinum, copper, or nickel, to create
precise temperature sensors. Similar to how a
thermistor's electrical resistance fluctuates, an RTD's
does as well.

Thermocouples
Thermocouples are one of the most used temperature
sensors due to its broad temperature operating range,
dependability, accuracy, simplicity, and sensitivity.

Negative Temperature Coefficient (NTC) Thermistor

In essence, a thermistor is a sensitive temperature
sensor that responds precisely to even the smallest
temperature changes. At extremely low temperatures,
it offers a considerable resilience. This indicates that
as soon as the temperature rises, the resistance
rapidly decreases.
.

Temperature Sensor Connect with PLC:

Temperature sensor use: PLC and Thermocouple Hardware

The temperature sensor’s applications Connection:
include:
⮚ The temperature sensors are
used for verifying design
assumptions that will promote
safer and economical design and
construction.
⮚ They are used to measure the
temperature rise during the

329
 process of curing concrete.

( Self-Check 1.2)
Write the correct answer for the following questions.
1. What are the 2 types of temperature sensor?
2. Where is temperature sensor used?
3. What is the main function of temperature sensor?
4. Which temperature sensor is best?
5. What is the use of temperature?

Answer Key 1.2

1. What are the 2 types of temperature sensor?
Types of Temperature Sensors Thermocouples, Thermocouples are the most commonly used type of
temperature sensor. ...RTD (Resistance Temperature Detector) as temperature changes, the
resistance of any metal changes as well. ...Thermistors. ...Semiconductor based ICs.
2. Where is temperature sensor used?
Temperature sensors are devices used to measure temperature in solids, liquids or gases. They are
used within industrial applications and have many more commercial uses. Most of the temperature
sensors we supply monitor temperature by measuring the change in resistance of an electrical current.
3. What is the main function of temperature sensor?
A temperature sensor is an electronic device that measures the temperature of its environment and
converts the input data into electronic data to record, monitor, or signal temperature changes. There
are many different types of temperature sensors.

4.Which temperature sensor is best?

The most well-known are Pt100 (with a resistance of 100 ohms at 0°C) and Pt1000 (with a resistance
of 1,000 ohms at 0°C). The Pt1000 offers better accuracy and a larger tolerance to long wire lengths
than the Pt100. Compared to thermocouples, resistance sensors offer better accuracy and a more
linear response.
5.What is the use of temperature?
Temperature is the measure of hotness or coldness expressed in terms of any of several scales,
including Fahrenheit and Celsius. Temperature indicates the direction in which heat energy will
spontaneously flow—i.e., from a hotter body (one at a higher temperature) to a colder body (one at a
lower temperature).

330
 Job Sheet

Job Sheet – 1.2

Job Perform of Interface temperature Sensor and PLC
Procedure: 1.Selected Thermocouple Temperature Sensor
2. Hardware Connection PLC and Thermocouple Temperature
Sensor.
3.Check Diagram as per as Drawing
4.Draw ladder Diagram
5.Program Simulated
6.Program Download PC to PLC
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2.Safety Shoe 01 pc
3.Googles 01 Pc
Materials 1. PLC 01 Pc
2. Analog Input /Output Module 01 Pc
3.Termocople 01 Pc
4.SMPS 01 Pc
5.lamp 01 Pc
6.Magnetic contactor 01 Pc
Tools and 1.Computer 01 pc
Equipment: 2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

(Information Sheet 1.3)

1.5.3 Level Sensor:

A level sensor is a tool used to maintain, measure, and monitor liquid (and occasionally solid)
levels. Following the detection of the liquid level, the sensor transforms the observed
information into an electric signal.

Types of Level Sensors

Although though sensors have progressed significantly over the past few decades,
industries still use primarily mechanical sensors. We will discuss both mechanical and
electronic level sensors in this section.

Mechanical Sensors
Mechanical sensors don't employ any
electronic signals or signal processing;
they only use mechanical means of
sensing and signaling. There are a few
fundamental mechanical sensors covered
in this section. The drawback of these
sensors is that no data is relayed to the
control room; just a local indication is
provided.

331
Electronic Sensors
For the purpose of transforming mechanical motion or sound waves into electrical signals,
electronic level sensors require electronic components. The control room uses these signals
to display data, operate pumps, and control other machinery. Cost and complexity of sensor
maintenance are drawbacks of these sorts of sensors. Nonetheless, their benefits in terms
of accuracy, speed, and accessibility to data at a distant place are strong arguments for
choosing them in most applications.

Float Switch Sensor

As the level rises over or falls below a
predetermined value, the float in this sort of
sensor activates a switch. The switch's ability to
deliver a voltage signal to a PLC upon
activation. This can be used as an alert or to
operate a pump. Due to their ease of use and
comprehension, these sensors are quite
popular. The precision is great and there aren't
many moving components. They are a popular
option in both industrial and residential
applications because to their high cost-
effectiveness.
Ultrasonic Sensors
The advantages of ultrasonic sensors include
their lack of moving parts and non-contact
nature. The apparatus produces an ultrasonic
sound at a very high frequency and then waits
for the sound waves to reverberate off the liquid
surface. The sensor picks up these reflected
sound waves. The liquid level is determined by
measuring the time it takes for the sound wave
to travel from the sensor to the liquid surface
and back.
There are fixed level measurement kinds and
continuous measurement types. The level of
ultrapure water is measured (= 0 ppm of total
dissolved solids). A great example of how to use
ultrasonic sensors.

A 1215c AC/DC/Rly Siemens PLC module with two analog inputs(level sensor)

332
Siemens PLC 1215c AC/DC/Rly CPU

Where is the Level sensor used?

⮚ reactors,
⮚ distillation columns,
⮚ evaporators,
⮚ Mixing tanks,.

(Self-Check 1.3)
Write the correct answer for the following questions.
1. Which sensor is used for level?
2. What is an example of a level sensor?
3. What is the output of level sensor?
4. How many types of level sensors are there?

333
(Answer Sheet 1.3)
1.Which sensor is used for level?
There are two main classifications for level sensors: point level sensors and continuous level sensors.
Point level sensors are designed to indicate whether a liquid has reached a specific point in a
container. Continuous level sensors, on the other hand, are used to render precise liquid level
measurements.
2.What is an example of a level sensor?
Level sensors allow for the level control of fluid in a vessel. Examples of where these sensors are
installed include reactors, distillation columns, evaporators, mixing tanks,
3.What is the output of level sensor?
The sensors can be obtained with voltage output (0-5VDC, 1-5VDC, 0-10VDC), current (4-20mA),
with digital interface (RS232 or RS485), or with contact type output (NPN open collector or relay ),
depending on the mod
4.How many types of level sensors are there?
Liquid level sensors have been around for decades, in markets such agriculture, automotive and
white goods for leak detection or level food and beverage, industrial, medical and domestic, printing
as.

Job Sheet

Job Sheet – 1.
Job Perform of Interface Level and PLC

Procedure: 1. Selected Level Sensor.

2. Hardware Connection PLC and Level Sensor.
3. Check Diagram as per as Drawing.
4.Draw ladder Diagram
5. Program Simulated.
6. Program Download PC to PLC.
Personal Protective 1.Apron 01 Pc
Equipment (PPE):
2.Safety Shoe 01 Pc
Materials 1. PLC 01 Pc
2. Analog Input /Output Module 01 Pc
3.Level Sensor 01 Pc
4.SMPS 01 Pc
5.lamp 01 Pc
6.Control Valve 01 pc
Tools and 1.Computer 01 Pc
Equipment: 2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

334
 (Information Sheet 1.4)

1.5.4 Flow Sensor

Flow sensors are devices that measure the flow in terms of the mass or the volume of a fluid
passing through a pipe (or a tube). There are different types of flow sensors, the ones widely
used in the industry are

1. Obstruction type
2. Turbine type
3. Electromagnetic
4. Positive displacement
5. Anemometer
6. Ultrasonic
7. Mass flow meter
Most types of flow sensors operate under the
premise of calculating flow using the forces
generated by the flowing stream. Each flow
sensor must have a primary flow element
that is put in the way of the fluid to act as an
obstruction. The main component generates
a physical characteristic associated with the
flow.
YF-S201 is a very cheap sensor available in the market for academic usage. Despite being
categorized as a low-quality and price sensor, it can efficiently do the job in a plant not
working in harsh conditions 24/7, which is the case.
YF-S201 Flow sensor
A turbine flow sensor with a pulse output, the
YF-S201. A turbine rotor installed on a shaft
within the cylindrical container housing the
liquid stream makes up a turbine flow
sensor. The turbine blades experience a
torque when liquid passes past the sensor,
which propels the rotor. The speed is related
to the fluid velocity once a stable rotation
speed has been attained. A hall effect
sensor, which is employed in the YF-S201
rotational speed measurement device, is
used to measure the turbine's rotational
speed. Figure 2 provides a picture of the YF-
S201 sensor's internal design.

YF-S201 Specifications
While there is no information regarding the manufacturer of the sensor, the YF-S201
sensor's specs are not well known. As a result, it is unwise to rely on the online datasheet. It
is a good idea to use the sensor under circumstances that are very different from the official
specs, nevertheless. The following are the online specifications:

335
Wiring
Being an NPN sensor, the YF-S201 should
be connected to a sourcing digital input
module, as was already indicated. A YF-
S201i wiring schematic showing how the
sensor is linked to the PLC's I/O. Diagram of
the YF-S201 flow sensor's wiring

(Self-Check 1.4)
Write the correct answer for the following questions.
1.What do flow sensors measure?
2.Which sensor is used in flow meter?
3.What is flow range?
4.Why is flow rate important?

(Answer Key 1.4)

1.What do flow sensors measure?
A flow meter (or a flow sensor) is an instrument that is used to indicate the amount of liquid, gas, or
vapor moving through a pipe or conduit by measuring linear, non-linear, mass, or volumetric flow rates
2.Which sensor is used in flow meter?
Thermal Mass Flow Meter uses two sensors to take temperature measurements with an active heat
sensor to measure heat loss in the liquid and a flow meter to determine the flow rate. Mass Gas Flow
Meter, or Coriolis flow meters, work on the basis of the Coriolis Effect, motion mechanics.
3.What is flow range?
It indicates the range in which a flow meter or controller can accurately measure the fluid. In other
words, it's simply the high end of a measurement range compared to the low end, expressed in a ratio
and is calculated using a simple formula. Turndown Ratio = maximum flow / minimum flo
4.Why is flow rate important?
Flow rate is the volume of fluid that passes through a given cross-sectional area per unit time. Accurate
flow rate measurement using an appropriate flow meter is paramount to ensuring fluid control
processes run smoothly, safely and cost-effectively.

336
 Job Sheet
Job Sheet – 1.4
Job Perform of Interface Flow sensor and PLC
Procedure: 1. Selected Flow Sensor.
2. Hardware Connection PLC and Flow Sensor.
3. Check Diagram as per as Drawing.
4.Draw ladder Diagram
5. Program Simulated.
6. Program Download PC to PLC.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2.Safety Shoe 01 Pc
Materials 1. PLC 01 Pc
2. Analog Input /Output Module 01 Pc
3.Flow Sensor 01 Pc
4.SMPS 01 Pc
5.Lamp 01 Pc
6.Control Valve 01 Pc
Tools and equipment: 1.Computer 01 pc
2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

(Information Sheet 1.5)

1.5.5 pH Sensor: In order to establish if a liquid is neutral, acidic, or alkaline, a watery

liquid's pH concentration is measured (base). A glass combination electrode is typically used
to measure pH. This electrode generates a millivolt potential proportional to pH, which is
then amplified inside the pH equipment to provide an instantaneous measurement.
pH Transmitter
The 4-wire pH transmitter's calibrated
range is 2 to 12 pH, with a signal output
range of 4 to 20 mA. By using a loop
calibrator to gauge the current signal being
delivered to the indicating controller, an
instrument technician can start to identify
the issue. Input from the loop calibrator is
15.43 milliamps.

337
Connecting Arc pH/ORP Sensors to the
PLC
Arc pH/ORP sensors are well suited for
direct connection to PLCs because they
have both 4 - 20 mA analog and Modbus
digital outputs. No additional transmitter is
required. This tactic is excellent for cutting
expenses and preserving priceless panel
area in new bioreactor designs. Options
for wiring connections are displayed
below.

2-wire connection
Arc pH sensors can also use this 2-wire
connecting method. The diagram
demonstrates a connection using non-
powered passive inputs. As Wi Bluetooth
wireless adapters cannot be added, this
straightforward connection method is less
popular. This wiring configuration does not
require galvanic isolation.

Modbus RS485 serial communication

Modbus RS485 digital communication is a
standard feature on all Arc pH sensors.
These installations keep power and signal
apart. The Hamilton programmer's manual
should be examined because Modbus
does require some additional PLC
programming.

(Self-Check 1.5)
Write the correct answer for the following questions.
1.What is the working principle of pH sensor?
2.Is a pH sensor analog or digital?
3.Is a pH sensor input or output?

4.Why is pH sensor used?

338
(Answer Key 1.5)
1.What is the working principle of pH sensor?
The overall working principle of pH sensor and pH meter depends upon the exchange of ions from
sample solution to the inner solution (pH 7 buffer) of glass electrode through the glass membrane. The
porosity of the glass membrane decreases with the continuous use that decreases the performance of
the probe.
2.Is a pH sensor analog or digital?
The pHD Product Family is available as either analog or digital pH sensors, the most common being
the digital sensor version. All digital pHD products have part numbers that begin with “DP” (eg.
DPD1P1), whereas the analog pHD product part numbers start with a “P” .
3.Is a pH sensor input or output?
The pH electrode is a passive sensor, which means no excitation source (voltage or current) is
required. Because the electrode's output can swing above and below the reference point, it is classified
as a bipolar sensor. It produces a voltage output that is linearly dependent upon the pH of the solution
being measured.
4.Why is pH sensor used?
A pH sensor helps to measure the acidity or alkalinity of the water with a value between 0-14. When
the pH value dips below seven, the water starts to become more acidic. Any number above seven
equates to more alkaline. Each type of pH sensor works differently to measure the quality of the wate

Job Sheet
Job Sheet – 1.5
Job Perform of Interface pH sensor and PLC

Procedure: 1. Selected pH Sensor.

2. Hardware Connection PLC and pH Sensor.
3. Check Diagram as per as Drawing.
4.Draw ladder Diagram
5. Program Simulated.
6. Program Download PC to PLC.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2.Safety Shoe 01 pc
Materials 1. PLC 01 Pc
2. Analog Input /Output Module 01 Pc
3.pH Sensor 01 Pc
4.SMPS 01 Pc
5.Lamp 01 Pc
6.Control Valve 01 Pc
Tools and 1.Computer 01 pc
Equipment: 2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

339
 (Information Sheet 1.6)

Digital Sensor: A door sensor is a common example of a digital sensor since it can
output in either usually closed (NC) or ordinarily open (NO) states depending on whether the
door is open or closed. Digital sensors include pushbutton switches, LED lights, magnetic
door sensors, alarms, and more.
1.5.6 Proximity Sensor: Proximity In
PLC automation, sensors are typically
used to check whether certain items
made of different materials are present
or not. Without making eye contact, they
do so. The output is binary, HIGH or
LOW, just like a switch, which is why
they are sometimes referred to as
"proximity switches.

Range: A change in capacitance can Proximity sensor selections:

therefore be used to determine how What to Consider when Selecting a Capacitive
close an object is. The sensor typically Proximity Sensor
operates across a range of 3 to 30 mm ● Body style (barrel or block)
and can be used to detect a wide range ● Switching output type (NPN or PNP)
of metallic and non-metallic items. ● Output function (NO or NC)
● Detection and sensing range.
● Target type (i.e. what it senses)
● IP rating.
● Installation type (flush or non-flush)
● Whether it is shielded, partially shielded,
or unshielded.

Proximity sensors detect the presence or absence of objects using electromagnetic fields,
light, and sound. There are many types, each suited to specific applications and
environments.
Inductive sensors
These non-contact proximity sensors
are designed to find mild steel targets
that are at least one millimeter thick. A
ferrite core with coils, an oscillator, a
Schmitt trigger, and an output amplifier
make up their four main parts. The
ferrite core and coil array at the sensor
face emit a symmetrical, oscillating
magnetic field that is produced by the
oscillator. Eddy currents, which are tiny
independent electrical currents, are
induced on the surface of a ferrous
object when it enters this magnetic field.

340
.Capacitive sensors
Both metallic and non-metallic targets in
powder, granulate, liquid, and solid form
are detectable by capacitive proximity
sensors. This, together with their
capacity to detect through nonferrous
materials, makes them perfect for
hopper powder level recognition, sight
glass monitoring, and tank liquid level
detection.

Capacitive sensing ranges from 10 to

50 Hz, with a detecting scope from 3 to
60 mm, however it is a little slower than
inductive sensing because it includes
charging plates. There are various
housing types available;
Proximity Sensor :
We must determine the device's PNP or
NPN type in order to connect a "three-
wire" discrete DC device to the PLC.
Bi-polar transistors, which are merely
solid-state switches, come in two
varieties: NPN and PNP. Always make
sure you are familiar with the
configuration of the device you plan to
connect to the PLC by consulting the
manufacturer's datasheet.

Both PNP and NPN sensors receive power

from positive and negative inputs, and both
then provide a signal to denote a "on" state.
Whereas NPN sensors produce a negative
signal when they are turned "on," PNP
sensors provide a positive signal to your
industrial controls input.
PNP Proximity Sensor:
An active HIGH output is provided by PNP
proximity sensors. The output of the sensor is
linked to +24V when an object enters its
detection range. This is recognized by the
device as a logic HIGH signal when
connected to a PLC input. The term "Source"
is another name for PNP proximity sensors.
A "source" switch is the term used to describe
a PNP sensor. According to the diagram
below, the "load," which is the PLC input, is
wired in this manner. Keep in mind that the
PLC module's common terminal is linked to
the blue "common" wire. In other words, the
switch "sources" or provides +24 Volts DC to
the PLC input when it changes state.

341
NPN Proximity Sensor :
An active LOW output is provided by NPN
proximity sensors. This indicates that the
sensor's output is connected to the ground
when an object enters its detection range.
This particular sensor is also referred to as a
"sinking" sensor.

Advantages of proximity sensor:

● It can detect both metallic and non-metallic targets.
● It has good stability.
● High speed provided.
● High switching rate.
● Work in harsh environmental conditions.
● Low cost and power consumption.
● A capacitive sensor is good in terms of power usage.

1.5.7 Photo Electric Sensor:

An infrared or visible light beam is
emitted by the light-emitting element
of a photoelectric sensor. The light
beam that is reflected from the target
is picked up by a reflective-type
photoelectric sensor. To gauge the
change in light quantity brought on by
the target crossing the optical axis, a
through beam type sensor is
employed.

Photo Electric Sensor Working

Principle
An Emitter for generating light and a
Receiver for receiving light make up
the majority of a photoelectric sensor.
The amount of light that reaches the
Receiver changes when emitted light
is stopped or reflected by the
detecting device. This change is
picked up by the receiver, which
transforms it into an electrical output.
Range: The sensing distance for this
optical system is the range of object
regular-reflective light that may be
reliably detected. As a result,
depending on the top and lower
restrictions, the detecting distance
might vary from 10 to 35 mm.

342
 Float Sensor:
A level sensor of the kind used to
measure the liquid level in a tank is
a float switch. The switch can
operate a pump, serve as an alert or
indicator, or regulate other
equipment. In one variety of float
switch, a hinged float contains a
mercury switch.

(Self-Check 1.6)
Write the correct answer for the following questions.
8. Which protocol is used by proximity sensors?
9. What can proximity sensor be used for?
10. What is the range of proximity sensors?
11. Is proximity sensor necessary?

(Answer Key 1.6)

1. Which protocol is used by proximity sensors?
Which protocol is used by proximity sensor? Explanation: Microcontroller communication is via
standard I2C, where the host can set measurement parameters and request results. If desired,
programmable threshold allow the VCNL4100 to interrupt the host once threshold values are crossed,
thereby minimizing device polling.
2. What can proximity sensor be used for?
A proximity sensor is a device that can detect or sense the approach or presence of nearby objects
and for this it does not need physical contact
3. What is the range of proximity sensors?
Thus the proximity of the object is detected by a change in capacitance. The sensor can also be used
to detect a wide variety of non-metallic an
4. Is proximity sensor necessary?
The proximity sensor is not something so important that you cannot use your phone without, and you
may find that it is quite easy to get used to your phone without its conveniences

343
 Job Sheet
Job Sheet – 1.6
Job Perform of Interface Proximity sensor and PLC

Procedure: 1. Selected Proximity PNP OR NPN Sensor.

2. Hardware Connection PLC and proximity Sensor.
3. Check Diagram as per as Drawing.
4.Draw ladder Diagram
5. Program Simulated.
6. Program Download PC to PLC.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2.Safety Shoe 01 Pc
Materials 1. PLC 01 Pc
2. Relay 01 Pc
3.Proximity Sensor 01 Pc
4.SMPS 01 Pc
5.Magnetic Contactor 01 Pc
6.Control Valve 01 Pc
Tools and Equipment: 1.Computer 01 pc
2.Philis Screwdriver 01 Pc
3.Neon Tester 01 Pc

(Information Sheet 1.7)

Sensor Interface with PLC

Program is written and simulated
Program: Conveyer Belt and Bottle Filling by Photo Sensor Using by PLC.
Procedure: I'll use the normally open contact I1 to turn on the circuit TK, the normally open
contact I2 to shut it off, the memory coil M1 to turn on the contact M1 for the conveyor belt,
and finally I'll latch I1 with the conveyor's make and model. This will be linked in series with
belt contact Q1 in the circuit. The first justification for removing Q1 coil is to automate the
circuit then.
By making contact between the picture sensor I3 and the break contact I2, closing the Q1
by the break contact and Q2, and also making the normally open contact between the
solenoid valve and the timer's coil voltage T1, one can shut the Q1 and begin timing the
timer. The valve will then be opened, allowing for further loading of the bottle. The solenoid
valve will be closed by the timer's brake contact when the timer's time counter reaches zero,
and the conveyor belt will begin operating automatically once more.

344
Program: Program Simulated

Hardware Connection List of Input Output

Digital Input
● Circuit start-I1
● Circuit Stop-I2
● Photo Sensor-I3

Digital Output
● Conveyor belt-Q1
● Solenoid Valve-Q2

Memory Coil
● Automatic Conveyor Belt Srtat-M1
Timer
● Timer 1

Functions of sensors are checked using PLC:

The transducer known as a sensor transforms a physical object into an equivalent electrical
quantity.
PLC is used to automate a variety of industrial processes. The system must be aware of
both the current value and the needed value (set point) for any task to be completed. These
settings determine the actions the PLC program will take.
For instance, in a liquid heating system, the present liquid temperature is 25°C, and the set
point fed by the operator is 60°C. But how will the PLC determine the liquid's current
temperature? Straightforward, via sensor. The temperature value will be converted by the
sensor into an equivalent electrical current and sent to the PLC. Now that the PLC is aware
of the temperature, it may take the necessary steps to keep the liquid at 60 °C.

345
(Self-Check 1.7)
Write the correct answer for the following questions.
1. What are the 4 types of photoelectric sensors?
2.What is a photoelectric sensor used for?
3. What are 3 examples of sensors?
4.What is the output of photoelectric sensor?
5.What activates a float switch?

(Answer Key 1.7)

1.What are the 4 types of photoelectric sensors?
There are many different styles of photoelectric sensors, but really only four basic technologies:
through-beam, reflective, diffuse, and background suppression
2.What is a photoelectric sensor used for?
A photoelectric sensor is a device used to determine the distance, absence, or presence of an object
by using a light transmitter, often infrared, and a photoelectric receiver.
3. What are 3 examples of sensors?
Different Types of Sensors
⮚ Temperature Sensor.
⮚ Proximity Sensor.
⮚ Accelerometer.
⮚ IR Sensor (Infrared Sensor)
⮚ Pressure Sensor.
⮚ Light Sensor.
⮚ Ultrasonic Sensor.
⮚ Smoke, Gas and Alcohol Sensor.
4.What is the output of photoelectric sensor?
Outputs from photoelectric sensors are typically either digital or analog. Digital outputs are on or off
and are usually three wire PNP (sourcing output) or NPN (sinking outputs). The exception to this is a
relay output that provides a dry or isolated contact requiring voltage being applied to one pole
5.What activates a float switch?
Basically, float switch systems work by opening and closing dry contacts. Once the dry contacts are
opened or closed, they will send an electrical signal to set off a water level alarm. The water level alarm
is used to tell the control panel whether the water level is too low or high.or its atmosphere. Space
borne active sensors have a variety of applications related to meteorology and observation of the
Earth's surface and atmosphere.

346
 Job Sheet
Job Sheet – 1.7
Job Perform of Automatic Conveyer Belt and Bottle Filling Program by
PLC
Procedure: 1.Open the Delta PLC Program
2.Click to New part then Selected PLC Model Ok for solid works
3.Select the toolbars that will use throughout drawing
4.First we will take a NO (I1) contact from make contact
5. Then take a NC(I2) contact from the brake contact.
6. Then take the Main Output coil from the Memory coil.
7. Then take the Main Output coil from the Output coil.(Conveyer
belt)
8. First we will take a NO(I3) contact from make contact
9.Take the Output coil from the Output coil.(Valve)
10. Then take the timer from timer coil (ON delay timer).
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2.Safety Shoe 01 pc
Materials 1.PLC 01 pc
2.Magnetic Contactor 01 pc
3.Push Button Switch 02 pc
4.SMPS 01 pc
5.Communacation cable 01 pc
6. Photo sensor 01 pc
7. Valve 01 pc
Tools and 1. Computer 01 pc
Equipment: 2.Motor 01 pc

Learning Outcome 2:
Control Induction Motor using PLC

Contents:

Instructions
1. Hardware: PLC, Sensor, Motor
2. PC
3. Software (PLC Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

347
 Assessment Criteria

2.1 PLC is connected with PC using appropriate cable

2.2 Interfacing between PC and PLC is checked
2.3 Wiring of Motor Controlling starters are performed
2.4 Starters are connected with PLC
2.5 Motor is connected with Magnetic Contactor
2.6 Motor is controlled and operated using PLC

Resources required

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC, PLC Software, Sensors, Motor

Learning Activity 2.1

Resources/Special
Learning Activity
Instructions/References

Control Induction Motor ▪ Information Sheet:.2.1

using PLC ▪ Self-Check:.2.1
▪ Answer Sheet: 2.1

(Information Sheet 2.1)

Control Induction Motor using PLC

PLC is connected with PC using appropriate cable

Cables and interfaces ranging from
RS232 serial to Micro USB to Cat5e
Ethernet may be needed for PLC
communication. For PLC programming
and I/O expansion, a variety of
specialized PLC communication cables
are available. Patch cables for Cat5e (2
to 50 ft.)
 PLC-Controlled Induction Motor
 The PLC and PC interface is
examined.

348
 1. Directly connect your PC to the
controller using a mini B USB cable.
2. Click the PLC tab on the program
ribbon, and then click
Communication.
3. Select USB; the network Discovery
utility will begin to search for Uni
Stream devices.
4. Click the desired device to establish
communications. Related Topics.
Communications.
Via an Ethernet or USB cable, PC-PLC
communication can be established. Use
an Ethernet wire to connect your PC to
the controller. Open Uni Apps to access
the controller's Ethernet settings. A
group of programs and tools known as
UniApps are built into the controller's
operating system.

1.6 Perform of Direct On-line Starter Circuit (DOL):

Direct On Line Starter
The fly starter provides power to the motor. This method does not employ a device to lower
the initial current. Only by turning on does the motor receive a direct supply. The DOL starter
allows the motor to be operated up to a maximum of 7 horsepower. There is a chance that a
motor with more horsepower than this will go full-throttle and require more starting current.
Small rotors have starting torque that is almost twice as great as the torque at full load.
Because of this, the starting time is brief.

Where is DOL Starter used?

in fields where machines need relatively little rotating power. And even though the starting
torque is not very high, all the machines or pieces of equipment that the motor may run
typically utilize 1 to 5 horsepower. The tiny Induction Motor is controlled by a DOL- starter..
How to create the circuit:
An ON switch will be removed from the MAKE contact first, followed by an OFF switch from
the BREAK contact. the relay coil's Q1 output, then. Then, latching the output's clock
contract with the clock switch.
Ladder Diagram: Hardware Connection :

Power Diagram: Communication:

349
 1st step→ cable check→ computer→
manage → Device → manager →port.
2nd step→ Tools→ Select Hardware→
Tools → Option→ Interface →port Selection
Download Tools→ Transfer→ PC to Logo→
Ok.
Upload→ Tools→ Transfer→ Logo to PC→
Ok.
Simulation→ Monitor→ Start Monitoring→
Ok.
List of Components:
Make contact (NO) =I1
Break Contact(NC)=I2
Output Coil= Q1

(Self-Check 2.1)
1. What is DOL circuit??
2. Why do we need DOL starter?
3. What is the range of DOL starter?
4. Why does a 3 phase motor need a DOL starter??

Answer Key (2.1)

1. What is DOL circuit?
Direct on line (DOL) motor starting is when a motor is started at full load, with full line voltage applied to
motor terminals. As this causes the motor to draw a large amount of current, it is only suitable for motor
powers up to 4Kw, with a maximum motor size of 10Kw connected this way
2.Why do we need DOL starter?
The DOL starters are used for motor having low power ratings. Where the starting current does not
damage the windings of the motor. For applications where the starting current does not cause huge
dips in the line voltage. Direct online starters are used for small water pumps, conveyor belts, fans and
compressors.
3.What is the range of DOL starter?
DOL Starters: Range: 0.5 to 7.5Hp:
Contactor protects the motor against under voltage whereas the relay protects the same against
overloads.
4.Why does a 3 phase motor need a DOL starter?
The benefit of a DOL starter is to avoid phase failure with the help of an overload relay, and it is also
used to remote control the motor automatically; the circuit breaker must be connected before – the
DOL Starter is connected to the power supply to avoid phase failure.

350
 Job Sheet

Job Sheet – 2.1

Job Perform of Ladder diagram direct On Line Starter Circuit
Procedure: 1. Collect and wear the necessary clothing.
2. Collect the necessary tools and equipment.
3. Check contactor contact, check contactor coil, test overload
relay.
4. Drawing of Ladder diagram of DOL Circuit
5. Construct the control circuit according to the diagram.
6. Draw the power circuit according to the diagram.
7. Check circuit with test lamp and ammeter as per diagram.
8. The motor will connect and rotate the motor with the power
supply.
9. Use and maintain equipment properly.
Personal Protective 1.Apron,Helmate 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 01 pc
2.Magnetic Contactor 01 pc
3.Push Button Switch 02 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Over Load Relay 01 Pc
7. PLC 01 Pc
Tools and 1. 3 Phase Motor 01 pc
Equipment: 2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

(Information Sheet 2.2)

Control Induction Motor using PLC
Wiring of Motor Controlling starters are performed
1.7 Perform of Auto Star Delta Starter Circuit:
Automatic star delta starter:
Definition: The term "automatic star-delta starter" refers to a starter that actively converts a
motor's terminal voltage from lower voltage to full voltage within a short period of time and
keeps the motor running constantly. Motors with 10 to 300 horsepower can be used with it.
How to create the circuit: An ON switch will be removed from the MAKE contact first,
followed by an OFF switch from the BREAK contact. the relay coil's Q1 output, then. The
output clock contract will then be latched using the NO switch. After that (Q1), I'll start a
timer in conjunction with the agreement. I will then multiply the output (Q2) by the timer's NO.
And using timer NC, take (Q3output. )'s The brake contact of (Q3) will then be put in front of
the coil after the brake contact of (Q2) is equal to that of (Q3) (Q2).
Ladder Diagram Star Connection and Delta Connection
Diagram

351
Hardware Connection

Star Delta Power Circuit:

List of Components: Digital Output
Digital Input ● Main Comtact-Q1
● Circuit Start-I1 ● Delta Contact-Q2
● Circuit Stop-I2 ● Star Contact-Q3
Timer
● Automatic Star to Delta Convert
timer-Timer 1

Difference between star connection and delta connection:

Star connection Delta connection
The neutral point is the point at which all three He three phases of the circuit are not connected
phases of the circuit are connected to one at any point, so there is no neutral point.
another.
In this system three phase three wire, three phase In this system three phase three wire supply is
four wire supply is possible possible, but three phase four wire supply is not
possible.

n this method the line voltage is √3 times the In this method line voltage and phase voltage are
phase voltage equal
In this method line current and phase current are In this method line current and phase current √3
equal. count
This method creates a closed circuit.
No closed circuit is created in this method.

352
(Self-Check 2.2)
1) What is automatic star delta starter?
2) How many magnetic contacts are required to make an automatic star delta starter
circuit?
3) How much horse power motor can be operated with automatic star delta starter
circuit?
4) What are the materials used in automatic star delta starter?
5) What is equal in delta connection?
6) What is equal in star connection?

Answer Key (2.2)

1) What is automatic star delta starter?
Ans: A starter in which a motor is started at reduced voltage, and after a few seconds is kept running
continuously by actively converting the terminal voltage of the motor from reduced voltage to full
voltage is called automatic star-delta starter.
2) How many magnetic contactors are required to make an automatic star delta starter circuit?

Ans:3Nos magnetic contactor

3) How much horse power motor can be operated with automatic star delta starter circuit?
Ans: A 10 horse power motor can be operated with a motor above that.
4) What are the materials used in automatic star delta starter?
Ans: Magnetic contactor. Push button switch.Timer.Timer base. Over load relay. Pilot lamp.
5) What is equal in delta connection?
Ans: Line voltage and phase voltage are equal, i.e. VL = Vp
6) What is equal in star connection?
Ans: Line current and phase current are equal, ie Ip = IL

353
 Job Sheet
Job Sheet – 2.2
Job Perform of Ladder Diagram Star Delta Starter Circuit
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Check the contacts of the contactor check the coil of the
contactor, test the overload relay.
4. Drawing ladder Diagram of Star Delta Starter Circuit
5. Construct the control circuit (as per diagram).
6. Construct the power circuit (as per diagram)
7. Connect timer (as per diagram)
8. Check as per diagram.
9. A power supply will rotate the motor.
10. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 03 pc
2.Magnetic Contactor 03 pc
3.Push Button Switch 02 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Over Load Relay 03 Pc
7.Timer with base 01 pc
8.MCB TP 01 pc
9. PLC 01 pc
Tools and 1. 3 Phase induction Motor 01 pc
Equipment: 2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

(Information Sheet 2.3)

Control Induction Motor using PLC
Wiring of Motor Controlling starters are performed
1.8 Perform of Reverse Forward Starter Circuit:
Forward Reverse Starter:
Forward reverse starters have the ability to turn a motor both clockwise and
counterclockwise, as well as right and left.
Procedure:
This starter's primary purpose is to change the direction of rotation of a three-phase
induction motor by altering the phase sequence at the motor's terminals (R,Y,B) The motor
will rotate counterclockwise if the connections are connected in the correct order. These
starters are still made using cam switches, although magnetic contactors are now the
preferred choice.
Two magnetic contactors are used for this starter, as seen in the image. The three push
button switches in this starter, however, are an off switch, a forward ON switch, and a
reverse ON switch. Here, MC1 (Forward) and MC2 are employed (Reverse). When the push

354
button switch is used to turn on (F), (R) does not turn ON. Once more when I use the
forward switch to turn off the front magnetic contactor (MC,F). Thus, MC2 (R) will be
produced if the reverse (R) switch is activated. That is, two magnetic contactors are
connected in an interlocking manner.
How to make the circuit: We'll remove an ON (I1) switch from the MAKE contact first,
followed by an OFF (I2) switch from the BREAK contact. the relay coil's Q1 (Forward) output,
and so on. Then using the NO switch to latch the output's NO contract.
A second switch will be taken from the MAKE contact (I3), followed by a switch from the
BREAK contact. The relay coil's Q2 (Reverse) output and so forth. then using the NO switch
to latch the output's NO contract.

Ladder Diagram:

Hardware Connection: Power Circuit Diagram:

List of Components: Digital Output

Digital Input  Forward Comtact-Q1
 Forward Start-I1  Reverse Contact-Q2
 Circuit Stop-I2
 Reverse Start-I3

355
(Self-Check 2.3)
1) How does reverse/forward work?
2) Why does motor rotate in reverse direction?
3. How many magnetic contactors are required to make a Reverse Forward starter
circuit?
4. How many switches are required to make a Reverse Forward starter circuit?
5. How many phase changes are required to make a reactive starter circuit?
6) What are the materials 5 needed to perform the forward reverse motor control?

Answer Key (2.3)

1.How does reverse/forward work?
A forward/reverse magnetic motor starter is constructed from two regular contactors installed with a
mechanical interlock that prevents both coils from pulling in simultaneously. They are connected so
that under normal conditions, one coil will connect L1 with T1, L2 with T2, and L3 with T3.
2.Why does motor rotate in reverse direction?
Since each wire consists of a positive and negative current within the magnetic fields, the flip-flopping
of main and starter wires causes the motor to run in reverse rotation. This easy switching of wires
works because the polarity of the magnetic field is reversed, thus reversing the motor.

3. How many magnetic contactors are required to make a Reverse Forward starter circuit?
Ans: 02
4. How many switches are required to make a Reverse Forward starter circuit?
Ans: 03 (Two Normally Open Switch and One Normally Closed switch)
5. How many phase changes are required to make a Reverse Forward starter circuit?
Ans: 02
6.What are the materials 5 needed to perform the forward reverse motor control?
The below shows the required components for the motor forward & reverse circuits.
⮚ Miniature Circuit Breaker (MCB)
⮚ Contactor.
⮚ Push Buttons.
⮚ Start Push Button.
⮚ Stop Push Button.
⮚ Multi meter.

356
 Job Sheet

Job Sheet – 2.3

Job Perform of Reverse Forward Circuit
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Check the contacts of the contactor check the coil of
the contactor, test the overload relay.
4. Create Ladder diagram of Reverse Forward
Circuit .
5. Construct the control circuit (as per diagram).
6. Construct the power circuit (as per diagram)
7. Connect timer (as per diagram)
8. Check as per diagram.
9. A power supply will rotate the motor.
10. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 02 pc
2. PLC 01 pc
3.Magnetic Contactor 02 pc
4.Push Button Switch 03 pc
5.Cable 1.5 RM Some
6.Plight Lamp 02 pc
7. Over Load Relay 02 Pc
8.MCB TP 01 pc
Tools and Equipment: 1. 3 Phase induction Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

357
(Information Sheet 2.4)
Control Induction Motor using PLC
Motor is connected with Magnetic Contactor

Magnetic Contactor Connection Diagram

Construction of Magnetic
Contractors
Three components make up a
magnetic contactor. power coil, an
additional coil, and a spring
mechanism The auxiliary contactor
gets a signal to open or close the
contactor or to transmit the status of
the contactor (on or off) to external
systems like PLC and SCDA while
the power coil is carrying a high
current. The contact can be turned
on or off using mechanical force from
the spring mechanism.

These contacts are auxiliary ones. These loads are produced when using the automated
mode or the protection circuit.
NC = Usually Close regularly, its Auxiliary contract is closed when its coil is not energized.
NO = Normal means that its Auxiliary contract is open while its coil is not powered.
The NC point will turn into NO and the NO point will turn into NC when the coil is energized
(by the power source).It features an accessory block to attach to the accessory..

Magnet contactor's coil Voltage:

 It comes in various ranges such as 24VDC, 24VAC, 110VAC, 240VAC, 415VAC
 It is commonly referred to as a Magnetic Contactor. Usually, the terminals of the coil
are marked by both A1 and A2.

Magnetic Contactor Types

The main categories in which the magnetic contactors are classified are the ac contactors
and the dc contactors.
Applications: Feature to Choose Magnetic Contractors
 Magnetic starter.  The utilization category.
 Reversing starter.  Motor’s inrush current. AC1, AC3,
 Star-Delta starter. kW/HP rating.
 Mercury contactor.  The site electrical supply voltage.
 Vacuum contactor.
 Mercury-wetted contactor.

Calculate the Sizing of Magnetic Contractor

Consider these factors when sizing the magnetic contactor:

358
 Load Type: AC-1 or Inductive ( AC-3 ) *Refer IEC rating table

Duty Cycle: One direction, reversing, plugging * Refer to the manual instruction

Horse Power (hp)

Full Load Ampere ( FLA ) * Refer to the motor data plate information.

Control Induction Motor using PLC

Starters are connected with PLC

PLC Program for Motor Starter

PLC tutorial explaining step by step procedure to program PLC for motor starter.

Motor starters are of many types however the scope of this PLC tutorial is confined to

simple motor starter.
 It should have the following provisions.
 Push button to start the motor : The motor should continue to rotate even when the
push button is released.
 Stop Push button to halt the motor after it started.
 Over current protection : In case of over load, the motor should stop automatically by
the signal coming from contactors of overload relay.
 Limit switch : It should prevent the motor from starting and can also stop the running
motor.
 The motor starter should also have indicator (Lights) to show ON or OFF status of
motor.
Motor Electrical Schematic & Ladder diagram for Motor starter:

Ladder diagram for Motor starter:

 Start Button I1 :
 Because the motor should only turn on when the button is pressed, normally open
contact (Make contact) is utilized.
 Stop Button I2 :
 A normally closed (break contact) contact is employed since the motor should typically
run with the button closed or raised. When the button is pressed, it ought to open.
Contrary to the start push button.
 Overload relay I3 :
 This relay should, under normal circumstances, permit the motor to rotate; therefore
generally close contact is used for it. When the motor is overloaded, it will shut it off by
opening the contact..
 Limit switch I4 :
 The motor should only rotate when the limit switch is closed therefore normally open
contact is used.
 Output Q1, Q2, Q3 :
 Relay coil Q1, Q2 and Q3 represent motor output, motor indication ON and indication
OFF respectively.

359
 The generally open input that depends on output Q1 provides input to the ON indicator.
The output-dependent OFF indicator is fed by ordinarily nearby input. Q2.
 Input Q1 ( for continuous rotation):
 Since it is required that once push button is pressed, motor should run continuously
even if the push button is released.
 To achieve this part, an input Q1 (normally open) is used and connected in parallel with
I1. This input depends upon output Q1.
 When output is high, input Q1 is also high. Since input Q1 provides parallel path with I1,
so if any of them is to be high, motor will run (if other conditions are also satisfied).
 Start button (Normally open), stop button (Normally close), overload relay (Normally
close) and limit switch (Normally open) are connected in series. So motor will run if start
button is pushed, stop button is not pressed, overload relay is not picked and limit switch
is closed.
 Note : This post for educational or reference purpose only. For a live circuit, there will be
some additions to the above circuit like safety related, as per application, some
interlocks etc.

(Self-Check 2.4)
1) 1.Why contactor is used in motor?
2.How do you choose a magnetic contactor for a motor?
3.What is a magnetic contactor used for?
4.What are the parts of a magnetic contactor?

Answer Key (2.4)

1.Why contactor is used in motor?
Why are Contactors Used? Contactors are used for high power applications. They allow a lower
voltage and current to switch a much higher power circuit, so they are generally larger and more
heavy-duty than control relays, enabling them to switch higher power loads on and off for many
thousands of cycles
2.How do you choose a magnetic contactor for a motor?
As per above chart:
Type of Contactor = AC7b.
Size of Main Contactor = 100%X Full Load Current (Line).
Size of Main Contactor = 100%x6 = 6 Amp.
Making/Breaking Capacity of Contactor = Value above Chart x Full Load Current (Line).
Making/Breaking Capacity of Contactor = 8×6 = 52 Amp
3.What is a magnetic contactor used for?
A magnetic contactor is an electromechanical switch used in applications that require a circuit “on and
off” process, such as starting motors, heaters, and lighting applications. Through the switch contacts,
the magnetic contactor takes care of transferring energy from one place to another.
4.What are the parts of a magnetic contactor?
The basic elements of magnetic contactors are as follows.
Iron Core. The iron core is divided into two parts:
Fixed Core. It becomes an electromagnet when the coil is energized.
Moving Core. When the coil gets energized, a magnetic contactor is closed and it makes the
moving core slide into the fixed core.
Coil
Contact.

360
 Job Sheet

1. Job Sheet – 2.4

Job Perform of Magnetic Contactor Connection Diagram
Procedure: 1. Collect and wear the necessary clothing.
2. Collect the necessary tools and equipment.
3. Check contactor contact, check contactor coil, test overload
relay.
4. Drawing the Magnetic Contactor Connection Diagram
Circuit.
5. Construct the control circuit according to the diagram.
6. Draw the power circuit according to the diagram.
7. Check circuit with test lamp and ammeter as per diagram.
8. The motor will connect and rotate the motor with the power
supply.
9. Use and maintain equipment properly.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 01 pc
2.Magnetic Contactor 01 pc
3.Push Button Switch 02 pc
4.MCCB 01 PC
5.Plight Lamp 02 pc
6. Over Load Relay 01 Pc
Tools and Equipment: 1. 3 Phase Motor 01 pc
2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

(Information Sheet 2.5)

Control Induction Motor using PLC

PLC MOTOR CONTROL LADDER LOGIC

PROGRAMMING
We are currently talking about how a PLC motor control
works. Before diving into the subject, let's make a few
assumptions. When the Start button is hit, a Motor must be
started by a PLC. There are three interlocks: high motor
vibration, overload, and high motor temperature. If any of the
interlocks are activated, the PLC is required to instantly halt
the motor. If the stop button is pressed, the PLC is required to
stop the motor. Only when the motor is in remote mode must
the PLC trip logic or interlock be enabled.
Motor is controlled and perated using PLC

361
PLC Motor Control
In above figure : Red LED indicator lights on the input and output cards of the PLC indicate if
those respective I/O channels are energized.
Note :
1. In above figure, Local Control Panel signals are not shown. Local control panel is
connected to motor feeder directly.
2. 24v DC power directly connected ( in general fuses or barriers will be used, power
will be distributed through bus bar)
PLC Inputs PLC Outputs
● Start push button ● Start Command (Remote Start)
● Stop push button ● Stop Command (Remote Stop)
● Vibration High ● Start Permissive ( Optional)
● Temperature High
● Overload Trip
● Run feedback
● Local/Remote status

The motor is powered by a device that runs

on three phases of 415V AC. Hence,
substations or motor control centers that are
electrically maintained will by default be used
to power high voltage equipment (MCC). So,
we presume that this motor is connected to
the fundamental motor feeder of the
substation. The local control panel in the
field and the PLC both frequently provide
inputs to the motor feeder.

Please take note that the motor feeder may contain signals for start, stop, and other
excursions (such as overload, etc.) in the motor feeder panel that are not depicted in the fig.
They are fixed to the panel for the motor feeder (in addition to LCP). The signals are referred
to as remote start and remote stop signals if the motor feeder receives start and stop
command inputs from the PLC.

(Self-Check 2.5)
1. How is a motor controlled by a PLC?
2. How does PLC control motor speed?
3. Can a PLC control a 3 phase motor?
4. How do you control the frequency of a motor?
5. What is a PLC ladder diagram?

Answer Key (2.5)

1.How is a motor controlled by a PLC?

A PLC has to start a Motor when the Start button is pressed. It has three interlocks which are Motor
Vibration High, Overload & Motor Temperature High. if any of the interlock activated then PLC has to
stop the motor immediately. PLC has to stop the motor if the stop button is pressed.

2.How does PLC control motor speed?

362
The PLC has to give set point for VFD drive to control the motor speed, this can achieved either
automatically from the PLC or by the operator action from the HMI. According to set point value, PLC
will control the drive speed and VFD drive finally controls the motor speed.
3.Can a PLC control a 3 phase motor?
So a PLC can also be used to control the operation of a VFD, hence to finally control the connected 3
Phase Induction Motor.
4.How do you control the frequency of a motor?
Variable frequency drive is a technique used to control the speed and frequency of AC induction
motors thus it is also known as adjustable speed drive or variable speed drive.in this phenomenon
voltage and frequency of the motor is controlled using a technique named as PWM (Pulse Width
Modulation).
5.What is a PLC ladder diagram?
Ladder Diagram is a graphical programming language that you use to develop software for
programmable logic controllers (PLCs). It is one of the languages that the IEC 61131 standard
specifies for use with PLCs. A program in ladder diagram notation is a circuit diagram that emulates
circuits of relay logic hardware.

Job Sheet

JOB SHEET – 2.5

Job Perform Plc Motor Control Ladder Logic Programming
Procedure: 1. Collect and wear the necessary clothing.
2. Collect the necessary tools and equipment.
3. Check contactor contact, check contactor coil, test overload
relay.
4. Drawing of Ladder diagram of Simple Circuit
5. Construct the control circuit according to the diagram.
6. Draw the power circuit according to the diagram.
7. Check circuit with test lamp and ammeter as per diagram.
8. The motor will connect and rotate the motor with the power
supply.
9. Use and maintain equipment properly.

Personal Protective 1.Apron 01 Pc

Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.Auxulari Contact 01 pc
2.Magnetic Contactor 03 pc
3.Push Button Switch 02 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. Over Load Relay 01 Pc
7. PLC 01 Pc
Tools and 1. 3 Phase Motor 01 pc
Equipment: 2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

363
Learning Outcome 3:
Control AC drive using PLC

Contents:

Instructions
1. Hardware: PLC, Sensor, AC Drive, Motor, VFD
2. PC
3. Software (PLC Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

3.1 PLC is connected with PC using appropriate cable

3.2 Interfacing between PC and PLC is checked
3.3 AC drive parameters are set as per requirement
3.4 VFD, Servo drive and stepper drive functions are controlled with PLC

Resources required

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, PLC, Sensor, AC Drive, Motor, VFD

Learning Activity 3.1

Resources/Special
Learning Activity
Instructions/References

Control AC drive using ▪ Information Sheet:.3.1

PLC ▪ Self-Check:.3.1
▪ Answer Sheet: 3.1

364
 (Information Sheet 3.1)
Control AC drive using PLC

PLC is connected with PC using appropriate cable

Cables and interfaces ranging from

RS232 serial to Micro USB to Cat5e
Ethernet may be needed for PLC
communication. For PLC programming
and I/O expansion, a variety of
specialized PLC communication cables
are available. Patch cables for Cat5e (2
to 50 ft.) PLC-controlled AC drive The
PC and PLC interface is examined.
1. Directly connect your PC to the
controller using a mini B USB cable.
2. Click the PLC tab on the program
ribbon, and then click
Communication.
3. Select USB; the network Discovery
utility will begin to search for
UniStream devices.
4. Click the desired device to establish
communications. Related Topics.
Communications.
You can establish PC-PLC
communications via Ethernet or USB
cable. Connect your PC to the
controller using an Ethernet cable.
Access the controller's Ethernet
settings by opening UniApps. UniApps
is a collection of applications and tools
that are embedded in the operating
system of the controller.

Control AC drive using PLC

AC drive parameters are set as per requirement
What is a VFD? Why is VFD used?
A VFD (Variable Frequency Drive) is a We may claim that this device is utilized to
device that adjusts the frequency to assist in modify the frequency because we are aware
driving various electronic devices. that the complete definition of VFD is
variable frequency drive.Only in the case of
an AC induction motor is a VFD used.
Where are VFDs used? What are the advantages of using VFD?
1. VFD is used for speed control of AC ⮚Electricity is saving
induction motor. ⮚Speed control and FWD/Rev operation are
2. VFD is used in any small and large available
industries. ⮚The motor can be switched on and off
3. We know that VFD is a complete package,
smoothly
by using it we can control the speed of the
motor, get full protection of the motor, drive ⮚Full motor protection can be obtained by

365
the motor in forward reverse mode, and can using VFD
be used as a starter for the motor. ⮚Using a VFD does not require a separate
starter to run the motor
What are the disadvantages of using VFD?
⮚The only disadvantage of using VFD is that since it is a complete package, its cost is very
high.
⮚As a complete package, you don't need separate starter for motor start, motor can be
forward and reverse controlled, using VFD provides full motor protection.
⮚Apart from this, there are some special features due to which the price of this device is
relatively high.
Perform of Siemens VFD Installation and troubleshooting:
2.1 Motor Parameters:

Motor Voltage 2.1.1- P0304- Motor Motor Current 2.1.2- P0305- Motor
Voltage Parameter Current Parameter
Motor Current 2.1.3- P0310- Motor Motor Current 2.1.4- P0307- Motor power
Frequency Parameter (Kilo Watt) Parameter
Motor Current 2.1.5- P0311- RPM/Pole
Parameter
2.2 Functional Parameters:
Master Frequency Command 2.2.1:
P1000 Frequency Command. A variable frequency drive controls the speed of an AC motor
by varying the frequency supplied to the motor.
⮚Here set 1 Frequency control by keypad/Local Mode.
⮚Set 2 Frequency control by Analog Signal (0 to 10v)
⮚Here set 3 Frequency control by Fixed Frequency / Multi state switch.
⮚Here set 4 Frequency control by RS 485 Mode /Modbus Mode
⮚Set 7 Frequency control by Analog Signal (4 to 20 mA)
Set 10 Frequency control by Push Button Switch
Master Run/Drive Command 2.2.2: P700 Run Command. A VFD requires two things at
every moment of its operation: a r un command and speed reference. The run command
tells the drive it should operate the motor, while speed reference tells the VFD what
frequency to run. Both inputs are required to provide motor control. Otherwise, the motor sits
idle.
⮚ Here set 1 VFD Run by keypad/Local Mode.
⮚ Here set 2 VFD Run by Terminal/Remote/Selector Mode
⮚ Here set 5 VFD Run by RS485 Mode

Acceleration/ De-acceleration time 2.2.3 : P1120 Acceleration time and P1121

Declaration time
Acceleration Time : VFD acceleration time is the time required by output frequency from 0
Hz to the maximum frequency,
De- acceleration Time: Deceleration time is
from maximum frequency dropped to 0 Hz.
Usually use the frequency setting signal rise
and fall to determine the acc/dec time.

366
 b7 B6 b5 b4

0 0 0 1 110
0 0 1 0 150
0 0 1 1 300
0 1 0 0 600
0 1 0 1 1200
0 1 1 0 2400
0 1 1 1 4800
1 0 0 0 9600
1 0 0 1 19200
1 0 1 0 38400
1 0 1 1 57600
1 1 0 0 115200

2.3 Communication parameters:

RTU/ASCII 2.3.1: Up to 247 slaves can be
supported using the master-slave
communication protocol MODBUS
ASCII/RTU in a bus or star network. On a
single line, the protocol makes use of a
simplex connection. The communication
messages travel in two opposing directions
along a single line in this manner.
Modbus: Modbus is a serial protocol for
communicating with different devices.

Modbus is 2 types

RTU Mode-All data will be communicated in 0 or 1.

ASCII Mode.-All data will be communicated in characters from.
⚫ RTU- H87 Hexadecimal to Convert Binary.
B7 B6 B5 B4 B3 B2 B1 B0
1 0 0 0 0 1 1 1

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Modbus Address 2.3.2: P2021 set
to 01 Address (Master/Slave)
Bound Rate 2.3.3: P2010 set 6
(9600)

Transmission Speed
Stop Bit 2.3.4:
+ VFD Control Address = 99 (dec)
Set Word 99 = 1151 >>> Forward Run
= 3199 >>> Reverse Run
Set Word 99 = 1150 >>> Stop
Set Word 99 = 1278 >>> VFD Reset
+ Frequency Setting
Address = 100 (dec)

Parity bit 2.3.5 :

(b0 =1,so vfd setting 8 ASCII,
otherwise b0=1 so, vfd setting
8 RTU)
B1,B2: Parity.
0 0= none
0 1= odd
1 1= even
So we Select 8E1

Troubleshooting:
Fault and Solution

Fault Description Fault Description

F1 Overcurrent F60 Asic timeout
F2 Overvoltage F61 MMC / SD card parameter
cloning failed
F3 Under voltage F62 Parameter cloning contents
invalid
F4 Inverter over temperature F63 Parameter cloning contents
incompatible
F5 2 F64 Inverter attempted to do an
Inverter I t
automatic clone during startup
F6 Chip temperature rise exceeds F71 USS set point fault
critical levels
F11 Motor over temperature F41 Motor data identification failure
F12 Inverter temperature signal lost F51 Parameter EEPROM fault
F20 DC ripple too high F52 Inverter software fault
F35 Auto restart after n F72 USS / MODBUS set point fault
F80 AI lost input signal F85 External fault
F100 Watchdog reset F101 Stack overflow
F221 PID feedback below minimum value F222 PID feedback above maximum
value
F350 Configuration vector for the inverter F395 Acceptance test / confirmation
failed pending
F410 Cavitation protection failure F452 Belt failure

368
Hardware Connection:

(Self-Check 3.1)
1) What is VFD short answer??
2) Why DC is used in VFD??
3. How does VFD control voltage??
4. What are the benefits of VFD?
5. What is the maximum frequency of VFD?
6) What faults can a VFD detect?

Answer Key (3.1)

1.What is VFD short answer?
Answer : A variable frequency drive (VFD) refers to AC drives only and a variable speed drive (VSD)
refers to either AC Drives or DC Drives. VFD's vary the speed of an AC motor by varying the frequency
to the motor. VSD's referring to DC motors vary the speed by varying the voltage to the motor.

2.Why DC is used in VFD?

Benefits of DC Line Chokes:
Less expensive than an AC line reactor for harmonic mitigation. Reduces over voltage tripping of the
drive due to voltage spikes. DC Link Chokes increase the reliability & add years to the life of a VFD.
3.How does VFD control voltage?

369
VFDs manipulate the frequency of their output by rectifying an incoming AC current into DC, and then
using voltage pulse-width modulation to recreate an AC current and voltage output waveform.
However, this frequency conversion process causes 2% to 3% loss as heat in the VFD
4.What are the benefits of VFD?
ADVANTAGES
⮚ Potential for Energy Reduction. VFDs can be used to save energy at a pump
station. ...
⮚ Potential for Extended Pump Life. VFDs can be used to extend pump life. ...
⮚ Adaptable Pump Curve.
⮚ Simplify Pump Selection.
⮚ Closed Loop Control.
⮚ Mitigate Pressure Transients.
⮚ Controlling Inrush Currents.
⮚ Controlling Full Load Amps.
5.What is the maximum frequency of VFD?
With the use of Variable Frequency Drives (VFD), motors can be run at higher than 60 Hz, known as
an overspeed condition, typically as direct drive fan wall/plenum fans (per NIH DRM 6.2. 4.2, the
maximum operating speed is 90 Hz).
6. What faults can a VFD detect?
Possible Causes Corrective Actions
Input voltage level too high Install isolation transformer, line filtering
Instantaneous voltage spike Ensure ac power supply is consistent
Loose power connections or control wiring Check all power and control connections and tighten
loose connections or wiring

Job Sheet
Job Sheet – 3.
Job Perform of Ac drive Interfacing 3 Phase Induction Motor
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the AC Drive
4. Construct the control circuit of VFD (as per diagram).
5. Construct the power circuit of VFD (as per diagram)
6. A power supply will Speed Control the motor.
7. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.VFD 01 pc
2.Magnetic Contactor 01 pc
3.Selector Button Switch 03 pc
4.Cable 1.5 RM Some
5.Plight Lamp 02 pc
6. 10 K variable Resister 01 Pc
7.MCB TP 01 pc
Tools and 1. 3 Phase induction Motor 01 pc
Equipment: 2. Combination Players 01 pc
3.Wire Stepper 01 pc
4.Philips Screwdriver 01 pc
5. Neon Tester 01 pc

370
 (Information Sheet 3.2)
Control AC drive using PLC
VFD, Servo drive and stepper drive functions are controlled with PLC
Perform of Servo drive & Motor Interface with PLC Motor:
Servo Drive & Motor:
The servo drive and motor are particularly torque compliant. Holding it with fingers won't be
able to stop it from moving. Technique is frequently employed to move extremely heavy
things. Nevertheless, this motor is limited to 360 degree rotations only. Robotics and CNC
machines both require servo motors. An example of an induction motor is a servo motor.
The fact that you can servo it sets it apart from other motors.
Perform of Delta PLC and Delta Servo Motor Interfacing:

Servo ASD-B2-Position Control

Servo ASD-B2-Position Control; Switching Mode

⮚ Here 9 is Digital Input ⮚ Active Mode (9+14 Negative Switching)
⮚ 14 is Negative Source (- ⮚ Active Mode (9+11 Positive Switching)
Com) ⮚ Pulse Mode (9+14+41 Negative Switching)
⮚ 17 is +24v Supply Drive ⮚ Pulse Mode (9+11+43 Positive Switching)
⮚ 11 is Positive Source ⮚ Direction Mode (9+14+41+37 Negative
(+Com) Switching
⮚ 37 is Negative Direction ⮚ Direction Mode (9+11+43+39 Positive Switching
⮚ 39 is Positive Direction ⮚ (11+17+35) Short for Switching Mode Active
⮚ 41 is Negative Pulse (Negative 14+17+35) Short for Switching Mode

371
 ⮚ 43 is Positive Pulse Active(Positive)

Gear Ration Setting:

RPM- Rotation Per Minute
1 Rotation=360 Degree Here
Encoder Feedback/Resolution=17
bit= 160,000.
Gear ration p1.44-800/ P1.45-001
Electronic gear ration =800 pulse
Servo Drive Position =160000/800
=200 pulse (D1 Position of Servo
drive) 360 Degree = 200 pulse,
Mean 1 turn for servo Drive,

180 degree=100 Pulse, Mean servo

drive move ½ angel 1 degree= .5
pulse Speed of Servo drive.
1 minute = 60 sec 1 rotation=200 Parameter Setting
pulse RPM=200/60=3 pulse per Servo Factory Reset
second (d0) 1 RPM= 3 Pulse. ⮚ AL.013- P2-17-121 set
D0-K3 (by which the drive moves at ⮚ AL.014-P2-15-122 set
3 pulses per second) ⮚ AL.015-P2-16-123 set
D1-k200-(by playing the drive will
move 360 degrees (ie
(The drive will move completely at
200 pulses).

Program: Program Setting

Here, ⮚ P0-01= 02
M0 Memory Coil Control Servo ⮚ P0-01=0
Pulse Y0 ⮚ P1.44- 800 set
M1 Memory coil Control servo Active
⮚ P1.45-001 set
Y1
And M2 Control Servo Direction Y2. ⮚ P2-10=101 SON Servo (DI 1 ON)
⮚ P2-30= 1 set for Jog Operation
⮚ P2-08 –Set-Shift-00010-set-ok
⮚
Hardware Connection:

372
373
(Self-Check 3.2)
1. Which sensor is used in servo motor?
2. What is a servo in PLC?
3. Is servo motor DC or AC?
4. What are the two types of servo motor?

Answer Key (3.2)

1. Which sensor is used in servo motor?
Control the servo motor by using the ultrasonic sensor.
2. What is a servo in PLC?
Summary. Servomotors are basically a high-performance type of electrical motor. They must be paired
with a drive, which is also known as a motion controller. As a system, servos convert electricity into
precisely controlled motion.
3. Is servo motor DC or AC?
There are two types of servo motors, AC servos and DC servos. The main difference between the two
motors is their source of power. AC servo motors rely on an electric outlet, rather than batteries like DC
servo motors.
4.What are the two types of servo motor?
Generally, there are two main types of this motor based on the supply used for its function. They are
AC servo motors & DC servo motors.

Job Sheet

Job Sheet – 3.2

Job Perform of Position Control Of Servo drive
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the Servo Drive and PLC.
4. Drawing of Position Control Ladder program
5. Construct the control circuit of Servo drive and PLC (as
per diagram).
6. Construct the power Servo drive and PLC (as per
diagram).
7. (as per diagram)
8. A power supply wills Speed Control the motor.
9. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2. Servo Drive 01 pc
3.Servo Motor 01 pc

374
 4.Magnetic Contactor 01 pc
5.Selector Button Switch 03 pc
6.Cable 1.5 RM Some
7.Plight Lamp 02 pc
8. 10 K variable Resister 01 Pc
9.MCB TP 01 pc
Tools and Equipment: 1. Combination Players 01 pc
2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

(Information Sheet 3.3)

Control AC drive using PLC
VFD, Servo drive and stepper drive functions are controlled with PLC
Perform of Stepper drive & Motor Interface with PLC Motor:
Stepper motor control with PLC
A stepper motor's operation in this application is managed by a PLC. The PLC software,
Ladder Logic Diagram, implements the control method using step ladder instructions. The
stepper motor's rotational speed and direction are controlled by the motion control algorithm.
Stepper Motor Control
Continuous rotation motors include stepper motors. These motors rotate in a specific
number of steps each time. By commanding the motor when to step and in which direction,
you may regulate position and speed.
Several wire counts are used, but delivering step and direction signals is how control is
carried out. Stepper motors can be extremely accurate if you use them within their
capabilities. Yet, they don't have any feedback letting you know they're at the address you
gave. You can use an encoder to add this feedback if your application requires it.

Using Velocio’s Motion Output functions, you can control up to 3 Stepper Motors per PLC.
Wiring PLC to Stepper Motor
The step and direction pulses will be
supplied by your PLC, and it will also handle
any necessary speed ramping up and down.
To connect the step and direction signals
from the PLC to the stepper motor, you will
need a stepper driver. Differential pairs for
Step and Direction, consisting of Step+, Step-
, Dir+, and Dir-, are frequently included in the
inputs to stepper drivers. Due to the fact that
all Velocio digital outputs are sinking
transistor types, the Negative connections
(Step- and Dir-) can be made in this
configuration, and the positive connections
(Step+ and Dir+) will be connected to the +
voltage that is being used to power your PLC.
This is an illustration of this wiring.
More choices like Enable might be available
in the Stepper Driver. They are frequently
optional and can be managed by a different

375
digital output.
Motor Connection
4 type wire use to Stepper drive Motor
& Connect to Stepper Drive.
1. Black=A+ Connect to Stepper Drive
2.Green=A- Connect to Stepper Drive
Red=B+ Connect to Stepper Drive
Blue=B- Connect to Stepper Drive

Micro step Driver

Dip Switch
SW1 SW2 SW3 RPM SETTING Calculation:
ON ON OFF 200 RPM SET Here
ON OFF ON 400 RPM SET D0- Speed/ Frequency
ON OFF OFF 800 RPM SET D1-Number of Pulse/ Position
Now. D0=k50
OFF ON OFF 1600 RPM SET D1 = k1000 = 1000/200 = 5 years (No. 1 and No. 2 are on
OFF OFF ON 3200 RMP SET and No. 3 is off, then 1000 must be divided by 200, then
OFF OFF OFF 6400 RPM SET the motor will rotate 5 times)
D1 = k1000 = 1000/400 = 2.5 revolutions (number 1 and
number 3 are on and number 2 is off then 1000 must be
divided by 400, then the motor will rotate 2.5 revolutions).

376
Program:

Here A+ and A- Internal Short.

B+ & B- Internal Short
When I hold A + and A- with the meter, the meter's buzzer mode will sound

Stepper Drive Hardware Connection

Sourcing (PNP) Connection

Sourcing (NPN) Connection:

377
SCR Drive
The globe of electronic 2Hp Variable
Speed SCR Drive Controller can be
divided. There are two types of motor
drives: AC and DC. SCR Drives are
nearly always DC (Silicon Controlled
Rectifier Drive). A motor drive
regulates a motor's output horsepower
as well as its speed, torque, and
direction. A shunt wound DC motor
with separate armature and field
circuits is normally controlled by a DC
drive. Like their DC counterparts, AC
drives are used to control the speed,
torque, and horsepower of AC
induction motors.

(Self-Check 3.3)
1. How does PLC control motor speed?
2. How does a stepper motor connect to a PLC?
3. What is the main application of SCR?
4. What is SCR electronic application?

Answer Key (3.3)

1.How does PLC control motor speed?
The PLC has to give set point for VFD drive to control the motor speed, this can achieved either
automatically from the PLC or by the operator action from the HMI. According to set point value, PLC
will control the drive speed and VFD drive finally controls the motor speed.
2. How does a stepper motor connect to a PLC?
There are two main connection ways between stepper motor and PLC: one is the stepper motor at both
ends of the wire winding to the output points of PLC, as shown in figure 1, by writing program control

378
electricity, each coil in a certain order to achieve positive &negative; Another way is to use PLC high-
speed pulse.
3. What is the main application of SCR?
Applications. SCRs are mainly used in devices where the control of high power, possibly coupled with
high voltage, is demanded. Their operation makes them suitable for use in medium- to high-voltage AC
power control applications, such as lamp dimming, power regulators and motor control
4. What is SCR electronic application?
A silicon controlled rectifier (SCR) is a four-layer solid state current controlling device with 3 terminals.
They have anode and cathode terminals like a conventional diode and a third control terminal, referred
to as the Gate.

Job Sheet
Job Sheet -3.3
Job Perform of Position Control of Stepper drive
Procedure: 1. Collect And Wear The Necessary Clothing.
2. Collecting Necessary Tools And Equipment.
3. Collect The Stepper Drive And PLC.
4. Drawing Of Position Control Ladder Program
5. Construct The Control Circuit Of Servo Drive And PLC (As Per
Diagram).
6. Construct The Power Servo Drive And PLC (As Per Diagram).
7. (As Per Diagram)
8. A Power Supply Wills Speed Control The Motor.
9. Proper Use And Maintenance Of Equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE) 2. Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2. Stepper Drive 01 pc
3.Stepper Motor 01 pc
4.Magnetic Contactor 01 pc
5.Selector Button Switch 03 pc
6.Cable 1.5 RM Some
7.Plight Lamp 02 pc
8. 10 K variable Resister 01 Pc
9.MCB TP 01 pc
Tools and 1. Combination Players 01 pc
Equipment: 2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

379
Learning Outcome 4:
Control Pneumatic and hydraulic instruments using PLC

Contents:

Instructions
1. Hardware: PLC, Sensor, Motor, AC Drive, VFD, Pneumatic and hydraulic
instruments
2. PC
3. Software (PLC Software)
4. Sample product/work piece
5. Drawings and/or sketches/Diagram
6. Manual/CBLM

Assessment Criteria

4.1 PLC is connected with PC using appropriate cable

4.2 Interfacing between PC and PLC is checked
4.3 Pneumatic and hydraulic instruments with PLC are integrated as per requirement
4.4 Pneumatic and hydraulic instruments are operated using PLC

Resources required

The following resources must be provided to students/trainees): Computer, Mouse,

Keyboard, PLC Software, PLC, Sensor, Motor, AC Drive, VFD, Pneumatic and hydraulic
instruments

Learning Activity 4.1

Resources/Special
Learning Activity
Instructions/References

Control Pneumatic and ▪ Information Sheet:.4.1

hydraulic instruments ▪ Self-Check:.4.1
using PLC ▪ Answer Sheet: 4.1

380
 Information Sheet 4.1)
Control Pneumatic and hydraulic instruments using PLC

PLC is linked to the computer via

the proper cable. Cables and
interfaces ranging from RS232
serial to Micro USB to Cat5e
Ethernet may be needed for PLC
communication. For PLC
programming and I/O expansion,
a variety of specialized PLC
communication cables are
available. Patch cables for Cat5e
(2 to 50 ft.)

Control Pneumatic and hydraulic instruments using PLC

Pneumatic and hydraulic instruments with PLC are integrated as per requirement.
Pneumatic control System
Simple pneumatic pressure controllers
send "signals" of pressurized or
compressed air through copper or plastic
tubes from a controller to a device.
Electronic controls, which transmit and
receive electric or electronic signals,
contrast pneumatic controls.
4 Fundamental Pneumatic Circuits
Here are four straightforward pneumatic
component circuits that can be utilized on
their own or as building blocks for more
complex systems.
Compressed air must be properly prepared
before being used in a pneumatic device to
prevent component damage. A pneumatic
apparatus that prepares compressed air
from a single source is shown
schematically below.
All the pneumatic parts required to build a
compressed air preparation system are
present in this circuit. It has a soft-
start/dump valve (VLV02), a filter (FIL01), a
regulator and gauge (REG01 and GAU01),
a pneumatic distribution block (not shown),
a manual shut-off relief valve (VLV01), and,
if necessary, a lubricator (LUB01). It is also
possible to combine a filter, regulator, and
lubricator (FRL).
Then, one line delivers lubricated air, while
the other delivers unlubricated air. The
second regulator that supplies the
electrically driven soft-start/dump valve is
fed by the non-lubricated line (VLV02).
When an emergency stop button is
depressed, this valve normally serves as a

381
 safety measure by releasing pressure from
pneumatic equipment that cause motion,
such as cylinders and actuators.
To avoid clogging these devices, the
recommended method of lubrication for
applications like pneumatic tools and
motors is mild oiling.
Using a device that includes all the air-
preparation components and controls can
simplify the installation of circuits like this
one (below). Additionally, it has a clogged
filter indicator, an adjustable pressure
switch with LED indicators, and adjustable
port diameters to accommodate varying
flow rates.
This total air prep (TAP) unit contains all
the major components and controls for air
preparation

Double-Acting Cylinder
A typical automation application is shown
in the design below, which uses a 4-way
solenoid valve (SOL01) to extend and
retract a double-acting cylinder (CYL01).
The symbol's side-by-side triangles denote
the presence of a single-solenoid, pilot-
activated spring-return valve.
.

The solenoid valve is fueled by filtered air

and is typically powered by a 24 V dc PLC
output. This opens the valve, allowing air to
freely pass through the flow control and
exit through port B, extending the cylinder
rod and plunger to the left. To lessen
exhaust noise, the flow control on the
valve's port A forces air from the cylinder's
left side to exit through port R and a
muffler.

382
 Two-Hand Control
Two pneumatic buttons (VLV01 and
VLV02) are set up as 3-way valves in the
circuit for a two-hand safety control system
for a press application (schematic below).
They supply a 4-way valve with pilot air
(VLV03). Pilot air must be fed to this valve
in order to switch the valve spool and
extend the double-acting press cylinder
(CYL01), which requires simultaneous
pressing of both buttons. The 4-way valve's
spring return function returns the spool to
its default position when either button is
released, supplying air to retract the press
cylinder.
Hydraulic systems in PLC :
hydraulic control of the mechanical device
allowed for successful completion. PLC
(Programmable Logic Controller,
sometimes known as PLC) is a digital
electronic system created for use in
industrial settings. combining computer,
automatic control, and property technology:
 The pressure works perpendicular to the
surface of the plane.
 The pressure at each point is the same
for all directions.
 The pressure given to some fluid in a
closed place propagates.
Where :
F1 = Force applied at A1
F2 = Force out at A2
r1 = small piston radius
r2 = big piston radius

Components of the Hydraulic System:

Motor Single Double
Clutch Hydrauli Valve :( Relie Hydrauli Acting Acting
(Coupling c Pump f Valve c Work cylinde workin
) 2. Direction Cylinder r g
Control Valve s cylinde
3. Flow r
Control Valve

Manometer
”
Oil Filter Hydrauli
c Fluid

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 Control Pneumatic and hydraulic instruments using PLC
Pneumatic and hydraulic instruments are
operated using PLC.
A double-acting pneumatic cylinder is to make a
continuous back-and-forth motion once a start
pushbutton is pressed until a stop pushbutton is
pressed. The cylinder should always be in the
retracted position when the cyclic action comes
to an end. The final control component is a 5/2-
DC double solenoid valve, and the controller is
a PLC. The PLC is connected to every input and
output device. For a better knowledge of the
PLC-controlled pneumatic system, you can
examine the pneumatic circuit, PLC wiring
diagram, and the Ladder program.

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PLC Pneumatic Circuit Control

Here we discuss about PLC Pneumatic Circuit Control with different examples. PLC ladder
diagram for single acting and double acting pneumatic cylinders

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Solenoid Valve: A 5
An electromechanically operated valve is a
5/2 solenoid valve. The characteristics of the
electric flow, the attractive field, the
component used to regulate the liquid, and
the type and properties of the liquid are all
different amongst solenoid valves.

(Self-Check 3.3)
1. What are the 5 basic operations of a PLC controller?
2. How is PLC used in fluid power control?
3. What is PLC in pneumatic system?
4. WHAT IS PLC in oil and gas?

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 Answer Key: 3.3
What are the 5 basic operations of a PLC controller?
Typically a PLC system has five basic components. These are the processor unit, memory, the power
supply unit, input/output interface section and the programming device.
How is PLC used in fluid power control?
The most common applied control systems today are PLC which will precisely control fluid level in a
tanks. PLC or programmable controller is a digital computer used for automation in electromechanical
processes, such as control of machinery on factory assembly lines, or lighting fixtures.
What is PLC in pneumatic system?
The lower machine (PLC control. system) includes the CPU and the number/analog input, the
number/analog output, and other modules. Used to control air pressure, temperature and speed to
achieve pneumatic measurement control, the.Dec
WHAT IS PLC in oil and gas?
PLC. A PLC, which stands for “Programmable Logic Controller,” is a computer that's been programmed
to control a process. A PLC receives information about process conditions and then sends information
to devices n a prodtio site in order to ntrol thm.

Job Sheet

Job Sheet -4.1

Job Perform of connect pneumatic valve to PLC?
Procedure: 1. Collect and wear the necessary clothing.
2. Collecting necessary tools and equipment.
3. Collect the Valve and PLC.
4. Wiring Connection from PLC to Solenoid.
5. The solenoid valve is connected to the digital output module of the
PLC.
6. A branch cable (spur) is used to connect from the solenoid to the
junction box in the field
7. The main cable (home run) is used to connect from the junction box to
the marshalling cabinet in the control room
8. Proper use and maintenance of equipment.
Personal Protective 1.Apron 01 Pc
Equipment (PPE): 2. Safety Shoe 01 Pc
Materials 1.PLC 01 pc
2. Solenoid Valve 01 pc
3.DC Power Supply 01 pc
4.Magnetic Contactor 01 pc
5.Selector Button Switch 03 pc
6.Cable 1.5 RM Some
7.Plight Lamp 02 pc
9.MCB TP 01 pc
Tools and 1. Combination Players 01 pc
Equipment: 2.Wire Stepper 01 pc
3.Philips Screwdriver 01 pc
4. Neon Tester 01 pc

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 Review of Competency

Performance Criteria Yes No

1. PLC is connected with PC using appropriate cable  

2. Interfacing between PC and PLC is checked  

3. Sensors are wired with PLC as per diagram  
4. Program is written and simulated  
5. Functions of sensors are checked using PLC  
6. PLC is connected with PC using appropriate cable  
7. Interfacing between PC and PLC is checked  
8. Wiring of Motor Controlling starters are performed  
9. Starters are connected with PLC  
10. Motor is connected with Magnetic Contactor  
11. Motor is controlled and operated using PLC  
12. PLC is connected with PC using appropriate cable  
13. Interfacing between PC and PLC is checked  
14. AC drive parameters are set as per requirement  
15. VFD, Servo drive and stepper drive functions are  
controlled with PLC
16. PLC is connected with PC using appropriate cable  
17. Interfacing between PC and PLC is checked  
18. Pneumatic and hydraulic instruments with PLC are  
integrated as per requirement
19. Pneumatic and hydraulic instruments are operated using  
PLC

Now, I feel ready to undertake my formal competency assessment.

Signed:

Date:

388