ZEAL EDUCATION SOCIETY’S

ZEAL COLLEGE OF ENGINEERING AND RESEARCH

NARHE │PUNE -41 │ INDIA

LAB MANUAL

Academic Year: 2024-25

Semester: II

CLASS : BE
SUBJECT : PLC AND SCADA PROGRAMMING
SUBJECT CODE : 411501 (B)
LAB IN-CHARGE : PROF. SAYALI DHUMAL

DEPARTMENT OF ROBOTICS & AUTOMATION

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ZEAL COLLEGE OF ENGINEERING AND RESEARCH
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Program Outcomes
PO 1 Apply the knowledge of mathematics, science, engineering fundamentals and an
engineering specialization to the solution of complex engineering problems
Identify, formulate, review research literature, and analyze complex engineering problems
PO 2 reaching substantiated conclusions using first principles of mathematics, natural sciences
and engineering sciences.
Design solutions for complex engineering problems and design system components or
PO 3 processes that meet the specified needs with appropriate consideration for the public
health and safety, and the cultural, societal and environmental considerations.
Use research-based knowledge and research methods including design of experiments,
PO 4 analysis and interpretation of data and synthesis of the information to provide valid
conclusions.
Create, select, and apply appropriate techniques, resources, and modern engineering and
PO 5 IT tools including prediction and modeling to complex engineering activities with an
understanding of the limitations.
Apply reasoning informed by the contextual knowledge to assess societal, health, safety,
PO 6 legal and cultural issues and the consequent responsibilities relevant to the professional
engineering practice.
Understand the impact of the professional engineering solutions in societal and
PO 7 environmental contexts, and demonstrate the knowledge of, and need for sustainable
development.
PO 8 Apply ethical principles and commit to professional ethics and responsibilities and norms
of the engineering practice.
PO 9 Function effectively as an individual and as a member or leader in diverse teams, and in
multidisciplinary settings.
Communicate effectively on complex engineering activities with the engineering
PO 10 community and with society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective presentations, and give and
receive clear instructions.
Demonstrate knowledge and understanding of the engineering and management principles
PO 11 and apply these to one’s own work, as a member and leader in a team, to manage projects
and in multidisciplinary environments.
PO 12 Recognize the need for, and have the preparation and ability to engage in independent and
life-long learning in the broadest context of technological change

Program Specific Outcomes (PSOs)

PSO 1 Design and Development of robotic systems that are cost effective, environment friendly
to solve engineering and societal problems using advanced tools and techniques.
PSO 2 Model, program and build an error free, safe, and productive automation systems for
various manufacturing processes.
PSO 3 Apply domain knowledge of robotics and automation to provide solutions in
interdisciplinary areas to meet current industrial challenges.
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ZEAL COLLEGE OF ENGINEERING AND RESEARCH
NARHE │PUNE -41 │ INDIA

INDEX
Page
Sr. No List of Experiments
No.
01 Familiarization of PLC environment and establishing connections
Develop and test logic using PLC Ladder for;
 AND, OR and Latching operation
02
 Simple ladder logic program using timers
 Simple ladder logic program using counters
03 PLC programming for Electro-pneumatic system

04 PLC programming for Electro-hydraulic system

05 PLC programming for robotics and electro-mechanical system

06 Develop process control application using SCADA

07 Collect and analyze Industrial Control System (ICS) Cyber Attack Datasets

08 Interface SCADA with PLC for given application

09 Design of digital system in virtual simulation using SCADA

10 Designing a virtual HMI panel

 ZEAL EDUCATION SOCIETY’S
ZEAL COLLEGE OF ENGINEERING AND RESEARCH
NARHE │PUNE -41 │ INDIA

EXPERIMENT NO.: 01
Objective: Familiarization of PLC Environment and Establishing Connections.

Software used: WPL

Theory:
Familiarizing yourself with a Programmable Logic Controller (PLC) environment involves
understanding the basic components, software, and connections associated with PLC systems. Here's
a general guide to help you get started:

1. Understanding PLC Basics:

PLC Definition: A PLC is a digital computer used in industrial automation to control different
electro-mechanical processes, such as machinery on a factory assembly line.

Components: Key components include a CPU (Central Processing Unit), input and output modules,
memory, and communication ports.

Input/Output (I/O): PLCs interact with the physical world through digital or analog inputs and
outputs.

2. PLC Software:

Programming Software: PLCs are programmed using specific software. Common programming
languages include ladder logic, function block diagrams, and structured text.

Simulators: Some software provides simulation capabilities, allowing you to test your program
without connecting to actual hardware.

3. Hardware Setup:

PLC Rack: The hardware setup typically includes a rack where modules are mounted. These
modules include the CPU, input modules, output modules, and special function modules.

Power Supply: PLCs require a stable power supply for proper operation.

Wiring: Connect input devices (sensors) and output devices (actuators) to the respective PLC
modules.

4. Establishing Connections:

Communication Ports: PLCs often have communication ports such as RS-232, RS-485, or Ethernet.
Use these ports for programming, monitoring, and connecting to other devices.

Programming Cable: You might need a specific programming cable to connect the PLC to your
computer for programming and monitoring.
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Network Setup: If your PLC supports network communication, configure the network settings to
connect to other PLCs, Human Machine Interfaces (HMIs), or supervisory systems.

5. Programming Basics:

PLC Program Structure: Understand the structure of a PLC program, including inputs, outputs, and
control logic.

Addressing: Learn how to address inputs and outputs in your program. Understand the difference
between physical and symbolic addressing.

6. Testing and Debugging:

Online Mode: Connect the PLC to your programming software in online mode to download and test
your program.

Monitoring Tools: Use monitoring tools to check the status of inputs and outputs during program
execution.

Debugging: Learn how to identify and troubleshoot common programming errors.

7. Documentation:

Documentation Practices: Maintain proper documentation for your PLC programs, including
comments, ladder logic descriptions, and version control.

8. Safety Precautions:

Safety Guidelines: Adhere to safety guidelines when working with electrical components. Ensure the
power is off before making any physical connections.

Components:

1. SMPS:

If the current rating of SMPS is higher, then you can use a distribution terminal board too for DC
supply. This will properly segregate the DC supply to all the components requiring it. From this,
power the PLC.

2. Digital Outputs:

Then, coming to digital outputs, the same sink and source theory applies to it.

So, for example, if the common is 24V, connect 0V and PLC digital outputs to all the relays (relay
has two pins, so one pin will be 0V and the other pin will be PLC digital output).According to the
output you want at relay output (DC or AC), connect the wiring accordingly .For example, if
the relay output required is 230V AC, connect the line wire to the common and connect the NO wire
to the contactor’s line input. Connect the neutral wire to the contactor’s neutral input and thus, the
circuit is complete.
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3. Analog Inputs and Outputs

Now, analog input and analog outputs will be directly routed through terminal boards with respect
to PLC. If possible, use fused terminal boards for additional safety.

4. Terminal Boards

Coming back to the contactors, the output is connected to terminal boards where you can connect
your final output. Note down some general points while designing a PLC panel: Have a good
understanding of electrical ratings and standards, before choosing a component; for example,
a contactor. Many times, fuses are connected after the mains breaker switch to protect the panel from
any damage caused by the incoming three-phase supply. Also, transformers are used in many panels
to step down a voltage according to the requirements. Fuses are also installed after SMPS for
protecting PLC or other sensitive field devices. If three phase devices are used with earth points,
ensure to provide separate earthing (power and instrument) in the panel. Do not mix them up. In this
example, I have not shown terminal boards for PLC digital outputs; but even they are used normally
in many applications. Because there can be valves in the system which require 24V DC, and such
outputs require terminal wiring in the boards.

Result:

Conclusion:
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EXPERIMENT NO.: 02
Objective: Develop and test logic using PLC Ladder for;
 AND, OR and Latching operation.
 Simple ladder logic program using timers.
 Simple ladder logic program using counters.

Software used: WPL Soft / Codesys

Theory:
1. AND, OR, and Latching Operations:

AND Operation

In ladder logic, the AND operation is represented by placing two or more normally open contacts in
series. The output coil will be energized only if all the input conditions are true.

OR Operation

OR operation is represented by placing two or more normally open contacts in parallel. The output
coil will be energized if at least one of the input conditions is true.

Latching Operation

A latching relay is used to maintain the state of the output, even if the input conditions change. This
is achieved by using both normally open and normally closed contacts in parallel.

2. Simple Ladder Logic Program Using Timers:

Timers:

Timers in ladder logic are used to introduce time delays. There are two types: on-delay timers and
off-delay timers. On-delay timers start counting when the input condition is true and activate the
output after a specified time.

3. Simple Ladder Logic Program Using Counters:

Counters:

Counters are used to keep track of the number of times an event occurs. There are up-counters and
down-counters. Up-counters increment the count when the input condition is true.
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Logic Gates:
AND Operation

OR Operation

Result:
Ladder Diagram:

1. AND ladder diagram

2.OR ladder diagram

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3. Latching operation

4. Timer ladder diagram

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ZEAL COLLEGE OF ENGINEERING AND RESEARCH
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5.Counter ladder diagram

Conclusion:
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EXPERIMENT NO.: 03
Objective: PLC programming for Electro-Pneumatic system.
Software used: WPL
Theory:
The most used pneumatic actuation systems are electrically controlled systems. These systems are
called electro-pneumatic actuation systems. Electro-pneumatic control system is a combination of
electrical unit and pneumatic control unit both in one unit. A number of electro-pneumatic elements
are used in electro-pneumatic controls.
The following experiment can be performed with following example:
Double acting cylinder is used to perform pressing operation. Cylinder has to move forward when
PB1 button is pressed and return for set time of 20 seconds before it automatically returns to intial
position. Limit switch S2 is used for end sensing of the forward motion of the cylinder. Draw the
pneumatic circuit, PLC wiring diagram and ladder diagram to implement this task.

Ladder Diagram:

A pneumatic double acting cylinder is attached with a rammer.

A push button is placed in front of the rammer.
A 3/2 valve is attached to the inputs of the cylinder.

Program:
Rung 1: X1 start button NO contact connected to Y1 i.e. one of the inlets of the valve. X1 is latch
with NC of X2

Rung 2: X2 is the push button in front of the rammer and output is attached to Y2 which is another
inlet of the valve.

Conclusion:
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EXPERIMENT NO.: 04
Objective: PLC Programming for Electro- hydraulic systems.

Software used: WPL

Theory:
Programming a PLC for an electro hydraulic system involves writing a set of instructions that
control the operation of the system. In an electro hydraulic system, a PLC is often used to control the
movement of hydraulic cylinders, valves, and other components.

Example: -
Double acting cylinder is used to perform forward and return motion. Pneumatic cylinder is
advanced by pressing push buttons PB1. Cylinder is returned by pressing push button PB2. Draw the
pneumatic circuit, PLC wiring diagram and ladder diagram to implement this task.
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Ladder Diagram:

A pneumatic double acting cylinder is attached with a rammer.

A push button is placed in front of the rammer.
A 3/2 valve is attached to the inputs of the cylinder.

Program:
 PLC Wiring diagram and Ladder diagrams are shown in above Figure. When the push button
PB1 is pressed state of the address I1 turns to 1 and thus there will be output 01. The output
of 01 operates the solenoid Y1 and cylinder moves forward.
 When the cylinder reaches the extreme forward position, and Push button PB2 is operated,
the state of address I2 turns to 1 and thus there will be output 02. The output of 02 operates
the solenoid Y2 and cylinder return back to initial position.

Conclusion:
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ZEAL COLLEGE OF ENGINEERING AND RESEARCH
NARHE │PUNE -41 │ INDIA

EXPERIMENT NO.: 05
Objective: PLC Programming for robotics and electro mechanical system.

Software used: WPL Software.

Theory: The process of Automation is the use of Control System and Programmable controllers to
reduce the need for human work in production of goods and services which are needed in factories
and industries. Basically, a set of pre-defined jobs, executed sequentially and systematically with the
help of hardware and software.

Pick & Place system is widely used in automation industries to transfer the products from one
location to other. It is based on Pneumatics i.e. system powered by compressed air/inert gas.
Pneumatic System can be controlled manually or by automated solenoid valves. The entire process
of gripping and lifting the objects is controlled by PLC, which is programmed by ladder logic.

Ladder Diagram:
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Program:
A) Conveyor Operation: The objects/products are fed on one end of conveyor belt. The
conveyor motor is started for 10 sec. After 10 secs, the object reaches the other end of the
conveyor due to the movement of belt. Proximity sensor detects the presence of the object
and sends electrical signal to PLC.

B) Pneumatic System: The electrical signals are received by PLC, which is then send to
Directional Control Valve. This leads the inlet of pneumatic pressure from Directional
Control Valve to Double Acting cylinders. There are two pneumatic cylinders i.e. horizontal
and vertical. The horizontal cylinder moves back and forth, whereas, the vertical cylinder
move up and down. Gripper is located at the end of vertical cylinder for gripping object in
jaws.

Conclusion:
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ZEAL COLLEGE OF ENGINEERING AND RESEARCH
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EXPERIMENT NO.: 06
Objective: Develop process control application using SCADA.

Software used: Wonderware "In Touch"

Theory: SCADA stands for supervisory control and data acquisition. This process is a type of
software application program for control. SCADA is a central control system that includes controller
network interfaces, input / output, communication equipment and software.

Wonderware "In Touch" provides a unified integrated view of all your controls and information
resources. Wonderware software is used in various industries, including: automotive assemblies,
facilities management, food and beverage, CPG, mining and metals, electricity, oil and gas,
chemical, energy, and water and waste water.

Process Control Application:

Process control applications are industrial

applications that involve controlling fluids;
liquids, gases, dry solids, and slurry mixtures.
Industrial applications are designed to make a
profit so improving process control improves
profits.

1. Manufacturing: SCADA systems are used to

monitor and control production lines, track
inventory levels, optimize scheduling, and
ensure quality control in manufacturing
processes.

2. Power Generation: SCADA systems are employed in power plants to monitor and control the
generation, transmission, and distribution of electricity. They help operators manage power grids,
monitor equipment performance, and respond to grid disturbances.

3. Water and Wastewater Treatment: SCADA systems are utilized in water treatment plants and
wastewater treatment facilities to monitor and control processes such as pumping, filtration,
chemical dosing, and disinfection. They help ensure water quality, optimize energy usage, and detect
and respond to equipment failures.

4. Oil and Gas: SCADA systems are extensively used in the oil and gas industry to monitor and
control drilling operations, pipeline networks, and storage facilities. They help operators monitor
pressure, temperature, flow rates, and detect leaks or other anomalies.
5. Transportation: SCADA systems are employed in transportation systems such as railways,
airports, and traffic management centers. They help monitor and control train schedules, track
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vehicle locations, manage traffic signals, and ensure passenger safety.

6. Building Automation: SCADA systems are utilized in commercial buildings to monitor and
control HVAC systems, lighting, access control, and energy management. They help optimize
energy usage, improve occupant comfort, and ensure efficient building operations.

Example:

Automatic Water Handling and Transportation System.

Conclusion:
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ZEAL COLLEGE OF ENGINEERING AND RESEARCH
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EXPERIMENT NO.: 07
Objective: Collect and analyze Industrial Control System (ICS) Cyber Attack Datasets.

Theory: To collect ICS cyber-attack datasets, you may need to explore various sources such as
cybersecurity organizations, government agencies, research institutions, and industry-specific
reports. These sources often provide information on known cyber-attacks, vulnerabilities, and their
impacts on industrial control systems.

Once you have obtained the datasets, analysis can be performed using various techniques such as
statistical analysis, machine learning, and data visualization. The goal is to identify patterns, trends,
and common attack vectors to enhance the security of industrial control systems.

It's important to note that working with ICS cyber-attack datasets requires expertise in cybersecurity
and data analysis. It is recommended to involve professionals with domain knowledge and
experience in handling such datasets to ensure accurate analysis and interpretation of the findings.
Remember to adhere to legal and ethical guidelines when collecting and analyzing datasets, ensuring
that privacy and confidentiality are maintained throughout the process

Case:

The SCADA system installed in the plant monitors and controls various aspects of the water
treatment process. It collects data from sensors placed throughout the plant, such as flow meters,
pressure sensors, and water quality analyzers.

The SCADA system continuously receives real-time data from these sensors, including information
about water flow rates, pressure levels, pH levels, turbidity, and chlorine levels. This data is
displayed on the HMI in the control room, allowing operators to monitor the process parameters and
identify any abnormalities.
If the SCADA system detects an issue, such as a sudden drop in water pressure or a high level of
contaminants, it can trigger alarms and alert the operators. The operators can then use the SCADA
system to investigate the issue further, analyze historical data, and take appropriate actions to resolve
the problem.

For example, if the SCADA system detects a high level of contaminants in the water, the operators
can remotely activate additional filtration systems or adjust the chemical dosing to ensure proper
water treatment. They can also monitor the effectiveness of these actions through real-time data
displayed on the HMI.
Furthermore, the SCADA system can generate reports and historical trends based on the collected
data. This information can be used for analysis, optimization, and regulatory compliance purposes.

In summary, the SCADA system in a water treatment plant enables real-time monitoring, control,
and data acquisition of various process parameters. It helps operators ensure the efficient and safe
operation of the plant by quickly identifying issues, taking appropriate actions, and optimizing the
water treatment process.

Conclusion:
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EXPERIMENT NO.: 08
Objective: Interface SCADA with PLC for given application.

Software used: Wonderware "In Touch"

Example: Bottle Filling and Separation Plant Set-up.

Steps:
To interface SCADA (Supervisory Control and Data Acquisition) with a PLC (Programmable Logic
Controller) for a given application, you would typically follow these steps:

1. Determine the communication protocol: Check the compatibility of the SCADA software
(Intouch) and the PLC software (RXLogix) to ensure they support a common communication
protocol. Common protocols used for SCADA-PLC communication include OPC (OLE for Process
Control), Modbus, and Ethernet/IP.

2. Configure the PLC: Set up the PLC (RXLogix) to communicate with the SCADA system. This
involves configuring the communication parameters such as the IP address, port number, and
protocol settings. Consult the documentation or user manuals of both the PLC and SCADA software
for specific instructions on configuring the communication settings.

3. Configure the SCADA software: In the SCADA software (Intouch), create a new project or open
an existing one. Configure the communication settings to establish a connection with the PLC. This
typically involves specifying the PLC's IP address, port number, and communication protocol.
Again, refer to the software documentation for detailed instructions on configuring the SCADA
software.

4. Define tags and variables: Define the tags or variables in both the PLC and SCADA software that
will be used to exchange data between the two systems. These tags represent the process variables
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such as fill levels, temperatures, and control signals. Ensure that the tags are consistent and properly
mapped between the PLC and SCADA software.
5. Develop the HMI: Using the SCADA software (Intouch), design the human-machine interface
(HMI) screens that will display real-time data and allow operators to interact with the system. Create
graphical representations of the bottle filling and separation plant, including status indicators, alarms,
and control buttons.

6. Establish data exchange: Set up data exchange between the PLC and SCADA software. This
involves configuring data polling or event-driven mechanisms to retrieve data from the PLC and
update the SCADA system in real-time. The SCADA software should be able to read and write data
to the PLC tags defined earlier.

7. Test and validate: Test the communication and data exchange between the SCADA software and
the PLC. Verify that the HMI screens display real-time data from the PLC and that control
commands sent from the SCADA software are correctly executed by the PLC.

It is important to note that the specific steps and procedures may vary depending on the versions and
configurations of the Intouch and RXLogix software. It is recommended to consult the software
documentation and seek assistance from the software vendors or experts for detailed guidance on
integrating SCADA with the PLC for your specific bottle filling and separation plant application.

Conclusion:
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ZEAL COLLEGE OF ENGINEERING AND RESEARCH
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EXPERIMENT NO.: 09
Objective: Design of digital system in virtual simulation using SCADA
Software used: Wonderware "In Touch".
Theory:
The automation of protection of power system components at the laboratory level using
Programmable logic controller (PLC) along with supervisory control and data acquisition (SCADA)
System owns paramount importance for intelligent decision making, sensing, actuating, monitoring
and maintaining the record in the host server.
The control system has indication of over and under values of voltage, load and frequency, which
Can trigger malfunctioning of equipment and must be rectified. Furthermore, ground fault and
Inverse current indication is added to the system for monitoring and controlling purposes. The
Proposed system enhances the efficiency and safety of the expensive equipment and the personnel to
the next level and also introduces new standards of automated protection schemes.

A typical SCADA system contains operations for users, SCADA computer server, workstation,
Programmable controllers, communication networks, signals and field devices.

Steps for Designing of digital system in virtual simulation using SCADA

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Programming:

Conclusion:
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EXPERIMENT NO.: 10
Objective: Designing a virtual HMI panel.
Software used: DOPSoft (Delta)
Theory:
1. Install DOP Software: Download and install the DOP software from the official Delta Electronics
website according to the provided instructions.
2. Create a New Project: Open the DOP software and initiate a new project dedicated to your HMI
design.
3. Select HMI Model: Choose the specific Delta HMI model that corresponds to your hardware setup
within the software interface.
4. Set Project Properties: Define project properties such as screen size, resolution, and
communication settings, aligning them with your application requirements.
5. Design Screen Layout: Utilize drag-and-drop functionality to craft the layout of your HMI
screens, incorporating components like buttons, switches, text fields, and images.
6. Arrange and Customize Components: Organize the components on the screen to optimize user
interaction and customize their appearance to match your design preferences.
7. Configure Component Properties: Specify the behavior and functionality of each component,
including actions triggered by user interactions, data bindings, alarms, and screen navigation.
8. Program Functionality: Utilize scripting or programming tools provided by the DOP software to
implement desired functionality, such as communication with PLCs, data logging, and alarm
systems.
9. Test the Interface: Use the simulation mode within the DOP software to evaluate the functionality
and user experience of the HMI interface before deployment.
10. Optimize and Refine: Gather feedback and iteratively refine the design to enhance usability,
clarity of instructions, and overall user experience.
11. Documentation and Deployment: Document the finalized HMI design, including any unique
features or functionality, and deploy the project to the actual HMI hardware for real-world use.
12. Maintenance and Updates: Regularly review and update the HMI design as necessary to
accommodate changes in system requirements or user feedback, ensuring long-term effectiveness.
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Program:

Output:

Conclusion: