INTRODUCTION

1. INTRODUCTION
1.1 History :The primordial Greek mathematician Archimedes invented a type of an elevator
before 230 B.C. It uses ropes and pulleys and it could lift one person. The elevators were
in use in the early 1800s. By 1840 hydraulic and steam powered elevators which were
ropes very slow and the carrying them often broke.
The first elevator with a safety device was invented by Elisha G. Otis in 1854,
which was having an automatic safety device, which prevent the elevator from falling in
case of the rope breaks. The worlds first electric lift started working in 1889. Automatic
elevators were introduced in the residential buildings in 1890s.

1.2 Importance of Elevator System :In the 1800s, new iron and steel production processes revolutionized the world of
construction. With sturdy metal beams as their building blocks, architects and engineers
could erect monumental skyscrapers hundreds of feet in the air.
These towers would have been basically unusable if it weren't for another technological
innovation that came along around the same time. Modern elevators are the crucial
element that makes it practical to live and work dozens of stories above ground. High-rise
cities like New York absolutely depend on elevators. Even in smaller multi-story
buildings, elevators are essential for making offices and apartments accessible to
handicapped people. An elevator (lift in British English) is a type of
vertical transport equipment that efficiently moves people or goods between floors
(levels, decks) of a building, vessel, or other structure. Elevators are generally powered by
electric motors that either drive traction cables or counterweight systems like a hoist, or
pump hydraulic fluid to raise a cylindrical piston like a jack.
In agriculture and manufacturing, an elevator is any type of conveyor device used
to lift materials in a continuous stream into bins or silos. Several types exist, such as the
chain and bucket bucket elevator, grain auger screw conveyor using the principle
of Archimedes' screw, or the chain and paddles or forks of hay elevators. Whether it be a
residential or commercial application, every day many people depend on the safe and
reliable operations of vertical transportation systems. It is of critical importance to the
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owners and ultimately to the tenants, guests or visitors who travel throughout residences
and buildings each day. Deciding on a competent maintenance company is a complicated
decision. Elevator maintenance can be provided by manufacturers, installation companies
or Independents.
Today, many new elevators run on proprietary computer-based software that requires
specialized tools for proper maintenance that only the manufacturer or company that
installed the lift can provide. If your home or building has proprietary equipment you will
have limited maintenance service options and generally will have to pay a premium for
elevator maintenance. One advantage of using OEM (Original Equipment Manufacturer)
maintenance is the ability to provide spare parts quickly and reduce overall downtime for
repairs. In addition, with OEM manufacturer maintenance you deal with the organization
that designed the equipment and know it operating systems the best. Usually,
manufacturer's maintenance contracts are the most risk-free choice but you may pay a
premium.
Elevator manufacturing companies actively pursue maintenance contracts for
elevator equipment they did not manufacture. The service contracts they offer are
comparable to service contracts you would consider with the actual OEM manufacturer of
equipment in your home or building. An advantage of using another manufacturer may be
to save money or obtain better service in a specific geographic area. Most companies and
manufacturers also offer a variety of discounts for contracts covering multiple buildings
with the same owner or property manager.
Independent elevator maintenance companies are located in most areas of the country.
Independents often charge less for their maintenance programs than manufacturers. When
considering an independent you will want to investigate the company's level of technical
expertise of your specific equipment and ability to provide spare parts to avoid extended
downtimes.
Large facilities such as universities and medical facilities provide in-house maintenance
for elevator equipment to reduce overall maintenance costs. The decision to self maintain
elevator equipment should be based on local code requirements, economics and the
availability of skilled labor. Other factors to consider include the ability to obtain spare
parts and manage major components repairs. Due to the increased liability exposure and
technical expertise needed to maintain the elevator equipment properly, using other
maintenance options is recommended for most customers. Many elevator companies will
not service elevator equipment that is being maintained by non-certified elevator
mechanics without conducting a complete inspection and bringing it up to a maintainable
level. Sometimes, it may be impossible to take on a service contract due to increased
exposure to lawsuits.

Knowing the different types of elevator contract options can greatly increase the
chances of saving money and finding a maintenance agreement that meets your home or
building's requirements. The more risk you are willing to assume, the lower the cost of
services will be. Most elevator companies offer different types of elevator maintenance
contracts. These contracts offer you a range of coverage options and discount
opportunities.

Survey and Report Contract :Coverage under a survey and report contract consists of quarterly, semi-annual or
annual inspection of all major equipment components. The inspection does not include
maintenance, repair work or dismantling equipment that necessitate elevator mechanics.
Maintenance or replacement recommendations may be completed by the owner or by
selected contractors under the property manager's coordination. Most jurisdictions require
regular basic servicing so this type of contract is not an option. This type of contract also
makes it extremely difficult for a building owner to avoid liability if an accident should
occur.

Oil and Grease (O & G) or Examination & Lubrication Contract :O & G contracts include lubrication of moving parts and minor adjustment on a
regularly scheduled basis. When additional services are needed, the service company
reports potential problems to the customer with an estimated cost to then schedule all
repairs, once approved, to be paid by the home or building owner. The cost for the O & G
contract is relatively low but when you include repairs, the entire yearly cost is usually
much higher and more complicated to budget. O & G agreements also generate additional
paper work, as the customer must coordinate with the service company on all repairs.
Liability exposure to claims in the event of shut downs, accidents or injuries are even
greater because the owner is responsible for the approval of having parts repaired and
replaced. Customer satisfaction with this type of agreement is usually very low.
A variation of an O & G contract lists specific items of equipment that are covered and not
covered in the contract, such as controllers, elevator machines, motor-generator sets, and
cables, etc. This type of contract will only have value if the contract clearly stipulates the
work to be covered and the parts to be supplied including frequency of examinations and
trouble calls to be answered. These service agreements also generate additional paperwork
and the customer must coordinate with the service company on what is covered in the
contract and what will be done under repair orders at a later date. It is important to know
what is and what is not covered in this variation of service contract.
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 Full Maintenance Contract or Agreement (FMC or FMA) :A full maintenance contract or agreement is written to allow the elevator service
company to take total care of the elevator equipment identified in the maintenance
agreement. This contract acts like an insurance policy and allows the home or building
owner to budget total yearly costs and eliminate concerns relating to elevator repairs as
they become necessary. Shut downs are limited because the maintenance contractor
assumes all responsibility and determines the amount of service visits required to keep the
elevator system operating safely. If an accident should occur, the elevator maintenance
company may be responsible for defending itself against accident claims and will exhaust
every effort to ensure safe operating condition.
Once a maintenance contract has been chosen that will work best for your elevator you
will need to find an elevator company. The company you select will then perform
maintenance services under the type of contract you have specified. But here's where your
troubles can begin. You must understand what is not covered and how those services will
be billed and what steps can be taken to control overall maintenance costs.

1.3 Construction of Elevator System :Most of the elevators operate automatically. A person brings an elevator to a
certain floor by pushing a button that has been installed on the wall outside the shaft or
inside the cabin. Most of the elevators in buildings of 5 or more floors are lifted by steel
cables. There are two types of traction elevators, gearless and geared traction.
Gearless traction systems are employed in the buildings of more than 10 floors. They
travel at 120 to 600 meters per minute. The hoisting ropes lift the cage, fit around a sheave
(pulley)

that

is

connected

to

the

driving

motor.

Geared traction elevators travel at a speed of 140 meters per minute. The operation is
similar to that of a gearless traction system. However, the motor of geared traction
elevator operates a reduction gear, which turns the sheave. This gear decreases the speed
at which the sheave would otherwise turn. Fig. (1.1) shows typical elevator system

 ELEVATORS AND CONVEYING SYSTEMS GENERAL :This chapter establishes the minimum safety requirements for, and governs the
design, construction, installation, alteration, maintenance, inspection, test and operation
of,elevators, dumbwaiters, escalators, moving walks, industrial lifts and loading ramps,
mechanical
parking equipment, console or stage lifts, power operated scaffolds, amusement
devices, and special hoisting and conveying equipment. This chapter and all the
provisions of this code for new installations shall also apply to elevators in existing
buildings moved to new hoistways. High-rise buildings elevators shall also conform to the
provisions of Section 403 of this code.
Exception: Personnel and material hoists used for construction operations subject
to the Except as otherwise provided for in this code, the design, construction, installation,
alteration, repair and maintenance of elevators and other conveying systems and their
components shall conform .
A change in use of an elevator from freight to passenger, passenger to freight, or
from one freight class to another freight class shall comply No piping or ductwork of any
kind shall be permitted within hoistway or elevator enclosures except:
1. As required for the elevator installation; and
2. Low voltage wiring less than 50 volts required for fire alarm systems required
by this code. A mirror shall be installed in each self-service passenger elevator in multiple
dwellings. Such mirror shall be affixed and maintained in a manner sufficient to enable
persons entering such elevator to view the inside thereof prior to entry to determine
whether any person is in the elevator Car switch operation. Elevators with car
switch operation (manual operation) shall be provided with a signal system by means of
which signals can be given from any landing whenever the elevator is desired at that
landing.
The following devices shall be prohibited
1.The installation of manlifts is prohibited.
2.The installation of sidewalk elevators located outside the street line is prohibited

Approved equipment Buffers, PA interlocks, elevator entrances, wedge shackles, and

elevator governors shall be approved by the commissioner.
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Construction documents. Applications for elevator, escalator, moving walkway

and stairway, dumbwaiter, and similar equipment shall contain construction documents
that include the following:
1. The location of all machinery, switchboards, junction boxes, and reaction
points, with loads indicated;
2. The details of all hoistway conditions including bracket spacing;
3. The estimated maximum vertical forces on the guide rails on application of the
safety device;
4. In the case of freight elevators for class B or C loading, the horizontal forces on
the guide-rail faces during loading and unloading; and the estimated maximum
horizontal forces in a postwise direction on the guide-rail faces on application
of the safety device;
5. The size and weight per foot of any rail reinforcements where provided;
6. Compliance with the accessibility features of this code;
7. The details of capability of the withstanding forces (impact) on door entrance
assembly and retaining devices;
8. The withstanding hourly fire rating of the hoistway and the hoistway door
assembly;
9. The impact loads imposed on machinery and sheave beams, supports and floors
or foundations;
10. The impact load on buffer supports due to buffer engagement at the maximum
permissible speed and load;11. Where compensation tie down is applied, the
load on the compensation tie down supports; and
12. The total static and dynamic loads from the governor, ruper and tension
system.

HOISTWAY ENCLOSURES :Hoistway enclosure protection. Elevator, dumbwaiter and other hoistway
enclosures shall have a fire-resistance rating not less than that specified shall be
constructed in accordance. Openings in hoistway enclosures shall be protected as
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Hardware on opening protectives shall be of an approved type installed as tested, except

that approved interlocks, mechanical locks and electric contacts, door and gate electric
contacts and door-operating mechanisms shall be exempt from the fire test requirements.
Number of elevator cars in a hoistway. Where four or more elevator cars serve all
or the same portion of a building, the elevators shall be located in at least two separate
hoistways. Not more than four elevator cars shall be located in any single hoistway
enclosure. Elevators that service different risers shall be located in separate hoistways.
An approved pictorial sign of a standardized design shall be posted adjacent to
each elevator call station on all floors instructing occupants to use the exit stairways and
not to use the elevators in case of fire. The sign shall read: in fire emergency, do not use
elevator. use exit stairs. The emergency sign shall not be required for elevators that are
part of an accessible means of egress complying. Elevator car to accommodate ambulance
stretcher. In buildings five stories in height or more, at least one elevator shall be provided
for Fire Department emergency access to all floors. Emergency power shall be provided in
accordance. Such elevator car shall be of such a size and arrangement to accommodate a
24-inch by 76-inch (610 mm by 1930 mm) ambulance stretcher in the horizontal, open
position and shall be identified by the international symbol for emergency medical
services (star of life). The symbol shall not be less than 3 inches (76 mm) high and shall
be placed on both jambs of the hoistway entrances on each floor.
Emergency doors. Where an elevator is installed in a single blind hoistway or on
the outside of a building, there shall be installed in the blind portion of the hoistway or
blank face of the building, an emergency door in accordance. Common enclosure with
stairway. Elevators shall not be in a common shaft enclosure with a stairway.

ELEVATOR EMERGENCY OPERATIONS :Emergency power. In buildings and structures where emergency power is required
or furnished to operate an elevator, the operation shall be in accordance.
Manual transfer. Emergency power shall be manually transferable to all elevators in each
bank.
One elevator. Where only one elevator is installed, the elevator shall automatically
transfer to emergency power within 60 seconds after failure of normal power.
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Two or more elevators. Where two or more elevators are controlled by a common
operating system, all elevators shall automatically transfer to emergency power within 60
seconds after failure of normal power where the emergency power source is of sufficient
capacity to operate all elevators at the same time. Where the emergency power source is
not of sufficient capacity to operate all elevators at the same time, all elevators shall
transfer to emergency power in sequence, return to the designated landing and disconnect
from the emergency power source. After all elevators have been returned to the designated
level, at least three elevators shall remain operable from the emergency power source.
Where emergency power is connected to elevators, the machine room ventilation
or air conditioning shall be connected to the emergency power source. Fire fighters
emergency operation. Elevators shall be provided with Phase I emergency recall operation
and Phase II emergency in-car operation in accordance. Elevator in readiness.
Requirements for elevator in readiness shall be as defined in High-rise buildings. Except
as provided in high-rise buildings as defined . all floors shall be served by at least one
elevator that shall be kept available for immediate use by the Fire Department during all
hours of the night and day, including holidays, Saturdays and Sundays. There shall be
available at all times a person competent to operate the elevator. However, an attendant
shall not be required for buildings with occupied floors of 150 feet (45 720 mm) or less
above the lowest level of the fire department vehicle access that have elevators with
automatic or continuous pressure operation with keyed switches meeting the requirements
as modified by so as to permit sole use of the elevators by the Fire Department. Number
of Elevators. A number of elevators shall be kept available at every floor for the sole use
of the Fire Department as required This requirement shall apply to the following types of
buildings:
1. High-rise buildings with occupancies classified in Groups A, B, E, I, F, H, M
and S;
2. Buildings with Group B occupancies with a gross area of 200, 000 square feet
( 18581 m2 );
3. Buildings with a main use or dominant occupancy in Group R-1 or R-2.
Three or fewer elevators. Where a floor is serviced by three or fewer elevator
cars, every car shall be kept available for sole use by the Fire
Department.3003.3.2.2 More than three elevators. Where a floor is serviced by
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more than three elevator cars, at least three elevator cars with a total rated
load capacity of not less than 6,000 pounds (2722 kg) shall be kept available for sole
use by the Fire Department. Such cars shall include not more than two cars that
service all floors and at least one other car in another bank servicing that floor. If
the total load capacity of all cars servicing the floor is less than 6,000 pounds (2722 kg),
all such cars shall be kept available for sole use by the Fire Department. Operation and
control. Elevators that are kept for the sole use of the Fire Department and that have
automatic or continuous pressure operation shall be controlled by keyed switches meeting.
Other elevator cars. In high rise buildings classified in occupancy groups A, B, E, F, H, I,
M and S, in low-rise buildings classified in occupancy group B with a gross area of
200,000 square feet (18 581 m2) or more and in buildings classified in occupancy group
R-1or R-2, all other automatically operated cars shall have manual operation capability.

HOISTWAY VENTING :Plumbing and mechanical systems. Plumbing and mechanical systems shall not be
located in an elevator shaft.Exception: Floor drains sumps and sump pumps shall be
permitted at the base of the shaft provided they are indirectly connected to the plumbing
system.
Control of smoke and hot gases. Hoistways of elevators shall be provided with any one of
the following means to prevent the accumulation of smoke and hot gases in case of fire in
Accordance.Vents in the hoistway enclosures. Hoistway enclosures may be vented in
accordance with the following:
1. Location of vents:

1.1. The vents in the side of the hoistway enclosure below the elevator machine
room floor or in the roof of the hoistway shall open either directly to the outer
air or through non-combustible ducts to the outer air.

1.2. The vents in the wall or roof of an overhead elevator machine room through
the smoke hole in the top of the elevator hoistway shall be vented to the outer
air through non-combustible ducts.
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2. Area of vents. The area of vents in the hoistway or the elevator machine room
and the smoke hole shall be not less than 3 percent of the area of the hoistway
nor less than square feet (0.28 m2) for each elevator car, whichever is greater.
Such vents Shall comply with the following requirements:

2.1. Open Vents. Of the total required vent area, not less than one-third shall be
permanently open or equipped with an openable hinged damper. The smoke
hole shall be permanently open.

2.2. Closed Vents. The two-thirds closed portion of the required vent area either in
the hoistway enclosure or in the elevator machine room may consist of windows
or skylights glazed with annealed glass not more than -inch (3.2 mm) thick.
A closed damper that opens upon the activation of a smoke detector placed at the
top of the hoistway shall be considered closed.

Mechanical ventilation of the hoistway enclosure. Hoistway enclosures may be

mechanically vented. The system of mechanical ventilation shall be of sufficient capacity
to exhaust at least 12 air changes per hour of the volume of such hoistways through a roof
or an approved location on an exterior wall other than the lot line wall. Such system shall
comply with the following requirements:
1. The smoke detector shall be placed at the top of the hoistway and shall activate
the mechanical ventilation system.

2. Such mechanical ventilation system shall not pass through the overnight
sleeping areas of a hotel, multiple dwelling, hospital, or similar buildings.

3. Such mechanical ventilation system shall be equipped with a manual shut-off in

or near the elevator control panel at the designated level.
Air pressurization of hoistway enclosure. Hoistways may be air pressurized.Where
such system is utilized, the air shall not cause erratic operation of the landing or car door
11

equipment, traveling cables, selector tapes, governor ropes, compensating ropes, or any
other components sensitive to excess movement or deflection.
Alternate means. The commissioner may accept alternate means to prevent the
accumulation of smoke and hot gases in the hoistways and machine rooms in case of fire.

CONVEYING SYSTEMS :Conveying systems shall comply with the provisions of this section.Escalators and
moving walks. Escalators and moving walks shall be constructed of approved
noncombustible and fire-retardant materials. This requirement shall not apply to electrical
equipment, wiring, wheels, handrails and the use of 1/28-inch (0.9 mm) wood veneers on
balustrades backed up with noncombustible materials.
Enclosure. Escalator floor openings shall be enclosed except where Exception 2 is
satisfied. Where provided in below-grade transportation stations, escalators shall have a
clear width of 32 inches (813 mm) minimum. Exception: The clear width is not required
in existing facilities undergoing alterations.Conveyors and related equipment shall comply
Conveyors and related equipment connecting successive floors or levels shall be enclosed
with fire barrier walls and approved opening protectives complying Conveyor safeties.
Power-operated conveyors, belts, and other material-moving devices shall be equipped
with automatic limit switches, which will shut off the power in an emergency and
automatically stop all operation of the device.Amusement devices shall also comply with
rules of the department.

MACHINE ROOMS :An approved means of access shall be provided to elevator machine rooms and
overhead machinery spaces. Elevator machine rooms that contain solid-state equipment
for elevator operation shall be provided with an independent ventilation or airconditioning system to protect against the overheating of the electrical equipment. The
system shall be capable of maintaining temperatures within the range established for the
elevator equipment. The elevator machine room serving a pressurized elevator hoistway
shall be pressurized upon activation of a heat or smoke detector located in the elevator
12

machine room. Machine rooms and machinery spaces. Elevator machine rooms and
machinery spaces shall be enclosed with construction having a fire-resistance rating not
less than the required rating of the hoistway enclosure served by the machinery. Openings
shall be protected with assemblies having a fire-resistance rating not less than that
required for the hoistway enclosure doors.
Sprinklers are not permitted in elevator machine rooms. Plumbing systems not
related to elevator machinery shall not be located in elevator equipment rooms. Elevator
machinery noise control in multiple dwellings. Gear-driven machinery, gearless
machinery, and motor generators located in an elevator machinery room or shaft on a roof,
or on a floor other than a floor on grade, shall be supported on vibration isolator pads
having a minimum thickness of inch (12.7 mm).

SERVICE EQUIPMENT CERTIFICATES :No service equipment shall be placed in operation until a service equipment
certificate of compliance has been obtained in accordance with the provisions of this code.
Posting of inspection certificate. At the time a service equipment certificate of compliance
is issued, an inspection certificate issued by the commissioner shall be posted. No such
inspection certificate shall be issued for elevators that are not subject to periodic
inspections pursuant to this code. The inspection certificate shall be in such form as the
commissioner shall determine by rule and shall be posted in a frame with a transparent
cover in the car of every passenger and freight elevator and on or near every escalator and
moving walk and power operated scaffold.
Alternate posting locations. In lieu of posting the inspection certificate in those
locations specified in this section, the inspection certificate may be kept in the on-site
building managers office. In such case, the building managers office must be open
during normal business hours. In addition, notice must be posted in each location and kept
in a frame with a transparent cover, or a plaque with an indelible inscription, stating that
the inspection certificate is located in the building managers office and identifying the
location of such office.
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Temporary use certificates. The commissioner may issue temporary use

certificates for any equipment or device regulated by this code, except power-operated
scaffolds, provided that such partial use and operation may be made safely and without
endangering public health, safety, and welfare and provided further that such temporary
use certificate shall not be issued for a period of more than thirty calendar days, subject to
renewal for additional thirty-day periods at the discretion of the commissioner. Temporary
use certificates for elevators shall also be conditioned upon compliance with the
following:
1. The class of service to be permitted shall be designated on the temporary use
certificate.

2. The hoistway shall be enclosed throughout in an enclosure complying or with a

temporary enclosure in accordance with the requirements for workers'
elevators (temporary elevators) of the Industrial Code of the State of New
York, No.23.Posting of temporary use certificate. The temporary use certificate
shall be posted in a conspicuous location on, or adjacent to, the device covered
by the certificate and shall state that the device has not been finally approved
by the commissioner.

ELEVATOR, AMUSEMENT, AND OTHER DEVICE OPERATORS :With the exception of automatic operation, continuous pressure elevators and
sidewalk elevators, every passenger and freight elevator with a rise of more than one story
shall be in the charge of a designated competent operator, who shall be at least 18 years
old, free from serious physical or mental defects, and selected with consideration of his or
her abilities to perform his or her duties in a careful and competent manner. Such
designated competent operator shall be instructed in accordance with requirements of
department rules.

Operators of amusement devices shall meet the requirements of rules of the

department. Other devices regulated by this code shall, when deemed necessary by the
commissioner to protect public safety, be in the charge of a designated competent operator
14

conforming to such qualifications as the commissioner may prescribe, except that

operators for workers' hoists shall be assigned as required by the applicable provisions. If
the commissioner finds that any person engaged in operating an elevator, amusement, or
other device is not competent to operate the elevator, amusement or other device, the
owner, agent or lessee of such elevator, amusement, or other device shall, upon notice
from the commissioner, discontinue the operation of such device by such operator.

ELEVATOR BEING SERVICED :When an existing or new automatic passenger elevator in any building or structure
is being serviced by an elevator maintenance company, elevator maintenance personnel,
or other person and there are no maintenance personnel available to remain in the elevator
car, CAUTION sign tapes shall be placed across the car door jamb. One strip of
CAUTION sign tape shall be placed at a height of 18 inches (457 mm) above the car
floor and another strip of CAUTION sign tape shall be placed at a height of 54 inches
(1372 mm) above the car floor.The CAUTION sign tape shall be 3 inches (76 mm) in
width with the words CAUTION DO NOT ENTER repeated every 6 inches (152
mm). The lettering shall be black on yellow background. The letters shall be at least 2
inches (51 mm) high.

ACCIDENTS :The owner of any device regulated by this chapter shall promptly notify the
commissioner of every accident involving injury to any person requiring the services of a
physician or damage to property or to apparatus exceeding one thousand dollars on, about,
or in connection with such equipment, before commencing any repairs and shall afford the
commissioner every facility for investigating such accident or damage. The commissioner
shall make an investigation immediately thereafter, and shall prepare a full and complete
report of such investigation. Such report shall give in detail all material facts and
information available and the cause or causes as far as they can be determined. Such
report shall be a public record. When an accident involves the failure or destruction of any
15

part of the construction or operating mechanism of such equipment, no such equipment

shall be used until it has been made safe, and re-inspected by the commissioner; and the
commissioner may order the discontinuance of such equipment until a new service
equipment certificate has been issued by him or her for its use. No part shall be removed
from the premises of the damaged construction or operating mechanism until permission
to do so has been granted by the commissioner.

EXISTING INSTALLATIONS :Existing installations shall be modified in accordance with department rules.
inspection and testing elevators and Conveying Systems. Inspection and testing of
elevators and conveying systems shall be in accordance. Amusement devices. Inspection
and testing of amusement devices shall comply with rules of the department.

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The main parts of the elevator system are as follows:

Fig.(1.1): Elevator System

1) Control system : It gives smooth and fast operation of elevator system. It is the heart of the elevator
system. This system isolates the PLC from power supply of driving motor. Any faults in
the power supply side are prevented to appear on the PLC as the power levels at which
17

both circuits work is very much different. Also it controls the UP and DOWN motion of
the elevator.

2) The driving motor : It gives the power to the cage for UP and DOWN motion of the elevator. This
motor is usually an induction motor with the gear reduction arrangement.

3) Sheave : It is just a pulley with grooves around the circumference. The sheave grips the
hoist ropes, so when you rotate the sheave, the ropes move too. The sheave is connected to
an electric motor. When the motor turns one way, thesheave raises the elevator; when the
motor turns the other way, the sheave lowers the elevator.

4) The Counter Weight :The counter weight is nearly equal to the weight of the cage and about half of its
maximum passenger load. This decreases the load to be driven by the motor.

5) The Guiding Rails :These rails help the elevator move easily throughout. These rails are usually
applied grease in order to reduce the friction between the rails and the cage.

18

LITERATURE
SURVEY

19

2. LITERATURE SURVEY
2.1 Literature Review :

Study project on Microcontroller Based digital display of time table

Being related to the syllabus of microcontroller, microcontroller based was
the first choice. We contacted different people having knowledge about
microcontroller. After gathering the information we came to know that there was
little application of Electrical engineering. So the project was rejected.

Study project on Load flow analysis in MSEB

The entire load flow analysis was carried out in this topic. The project was
rejected as the permission was not granted by MSEB.

Project on distance protection of transmission line

We decided to do project on this topic but we came to know that this project
was already done by our previous batch so the project was rejected.

2.2 Finalization of the project :The technologies like PLC are emerging these days, which necessitates us to improve
the current equipment into more sophisticated and technically advanced form. The
elevator is one of such commodity. Thus we finalized project on PLC Based Elevator
Control.

2.3 Market Survey :The market survey includes gathering information about following devices which are
going to be used in the project
1)
2)
3)
4)
5)

DC Motor
Limit switches
Push buttons
Toggle switches
The output of PLC is 24 V DC; the motor of proper rating was not available.
So as per the requirement of PLC the design of motor was done.
20

PROBLEM
DEFINATION

21

3.PROBLEM DEFINATION
3.1 Objective of System :The objective of the project is the design and implementation of a three-level
elevator system controlled by a PLC.

3.2 Specification of System :-

Sr.No.

Component

Rating

Quantity

Allen Bradley Micrologix 1400

DI -20, DO-12, 24V 1

DC

DC Motor

24V DC, 30 rpm

Relay

24V DC , 2 C/O

Limit Switch

24V DC, 1NO,1NC

Push Button

24V DC, NO

Toggle Switch

24V DC

Pulley

V-Grooved

Diameter 6.5cm
7

Rope

8 Ft.

Iron Frame

1.5*2*4

Table 3.1 System Specifications

22

DESIGN OF SYSTEM

23

4. DESIGN OF SYSTEM

4.1 Hardware Design :4.1.1 Block Diagram :Working of elevator system is based on co-ordination of PLC with Hardware of
the elevator system. Fig (4.1) shows schematic block diagram of elevator system.
Hardware of Elevator system consists three main parts namely,
i)

Micrologix 1400.

ii)

Elevator.

iii)

Control Panel.

Fig.(4.1)Schematic Block Diagram of Elevator System

24

4.1.2 Elevator model :The basic aim in fabricating the elevator model is that it should be strong, sturdy
and overall cost effective. Sticking to this, we have decided to use mild steel (MS.),
instead of aluminum or wood. Aluminum structure is difficult to weld and is costly.
Experts are needed for welding aluminum materials. Also it is very hard to maintain the
sturdiness if nuts and bolts are used instead of weld. Wooden structure s flimsy and hence
it is not worthy. The only choice for us is to use MS, which can be easily fabricated,
welded; never the less the structure thus obtained will be a bit heavy.

1) Main Frame :To attain overall sturdiness the main frame is made up of L shape MS bars. The
frame measures about 1.5(L)x2(W)x4(H) ft.

2) The Elevator Cage :It is also made up of Wooden and measures about 15 x15x 20 cm. The elevator
cage moves in the main frame with the help of fiber clips and the fiber bars acting as
guidelines.

3) Counter Weight :It approximately balances the weight of cage. The counter weight is chosen in such
a way that the load on motor be minimized and thus motors function is only to transfer
load from one side to another. If counter weight is not taken into account, then winding
pulley arrangement is to be implemented. These will increase the load on motor and there
is possibility of misalignment of motor shaft.
4) Driving Motor :The motor used is permanent magnet direct current motor (PMDC), rated
for 24 volts. The rated speed of motor is approximately 30 rpm.

25

4.1.3 Fabrication detail

Frame :Dimensions :- Height:

ft.

Width:

1.5

ft.

Depth:

ft.

Weight :Material :-

12

kg

M.S.Angle Bars: 2 x 2x 2 cm.

Plywood: 1) Top Side: 2 x 1.5 ft
2) Bottom Side: 2 x 1.5 ft
3) Front Side: 1.5 x 4 ft

Plywood thickness : -12 mm

Elevator cage :- Height:

20cm

Width:

15cm

Depth:

15cm

Weight:

1 kg

Material:Plywood
Counter weight :- Weight: 1.2 kg.
Pulleys:-

Motor

shaft

pulley:

grooved

diameter

Counter weight pulley: V- grooved diameter 6.5cm.

26

6.5cm

4.1.4 Photographs of System :-

Fig (4.2)Front View

27

Fig (4.3)Side View

28

Fig(4.4)Top View

29

4.1.5 Control circuit :The whole design of the elevator depends on the control circuit. It consists mainly;
Limit Switches
Push Buttons (Call Buttons).
Toggle Switches (Door Switches).
+
1) Limit Switches :To sense the position of the elevator, that is the status on which floor it is situated
limit switches are mounted on every floor.

Fig. (4.5): Limit Switches Circuit

Fig. (4.5) shows how all limit switches are interfaced with PLC. The construction
of the limit is very simple. The limit switches have the roller contacts on their tips.
These can comfortably operate during the motion of the elevator in both the
directions i.e. up and down. When the elevator starts moving, on every floor it will operate
the limit switch. This will give a signal out to the PLC, with which the status check will be
done by the PLC. This will give the exact position of the elevator.
When the destination to the elevator is given by the PLC, it will make the
appropriate limit switch ON i.e. it will only sense the limit switch on that floor only. This
will make the elevator to move on to the destination correctly. The logic of up- collecting
30

and down collecting is also incorporated in the programming of the PLC. This will enable
the PLC to take input signals in between current operation. In electrical
engineering a limit switch is a switch operated by the motion of a machine part or
presence of an object.
They are used for control of a machine, as safety interlocks, or to count objects passing a
point. A limit switch is an electromechanical device that consists of an actuator
mechanically linked to a set of contacts. When an object comes into contact with the
actuator, the device operates the contacts to make or break an electrical connection.
Limit switches are used in a variety of applications and environments because of their
ruggedness, ease of installation, and reliability of operation. They can determine the
presence or absence, passing, positioning, and end of travel of an object. They were first
used to define the limit of travel of an object; hence the name "Limit Switch".

A limit switch with a roller-lever operator; this is installed on a gate on acanal lock, and
indicates the position of a gate to a control system.
Standardized limit switches are industrial control components manufactured with a variety
of operator types, including lever, roller plunger, and whisker type. Limit switches may be
directly mechanically operated by the motion of the operating lever. A reed switch may be
used to indicate proximity of a magnet mounted on some moving part. Proximity
switches operate by the disturbance of an electromagnetic field, by capacitance, or by
sensing a magnetic field.
Rarely, a final operating device such as a lamp or solenoid valve will be directly
controlled by the contacts of an industrial limit switch, but more typically the limit switch
will be wired through a control relay, a motor contactor control circuit, or as an input to
a programmable logic controller.
Miniature snap-action switch may be used for example as components of such devices
as photocopiers, computer printers, convertibletops or microwave ovens to ensure internal
31

components are in the correct position for operation and to prevent operation when access
doors are opened. A set of adjustable limit switches are installed on a garage door
opener to shut off the motor when the door has reached the fully raised or fully lowered
position. A numerical control machine such as a lathe will have limit switches to identify
maximum limits for machine parts or to provide a known reference point for incremental
motions.
2) Push Button :Push Buttons are used as Call Buttons. There are total 3 call buttons are provided.
On each floor one call switch is provided. Fig.(4.6) shows interfacing of inner and outer
call switches panel with PLC.
While moving from 1st floor to 3rd floor if we press the call button on 2ndfloor
and if lift is still to come to 2nd floor, then it will not stop on the 2nd floor, it will go to
3rdfloor and then come back to 2nd floor. For the simplicity we have not employed first
come first serve method.
Before proceeding to the next floor the elevator will stop for a given
predetermined delay. These anti-co operations are done with help of limit switches.
A push-button (also spelled pushbutton) or simply button is a simple switch mechanism
for controlling some aspect of a machine or aprocess. Buttons are typically made out of
hard material, usually plastic or metal. The surface is usually flat or shaped to
accommodate the human finger or hand, so as to be easily depressed or pushed. Buttons
are most often biased switches, though even many un-biased buttons (due to their physical
nature) require a spring to return to their un-pushed state. Different people use different
terms for the "pushing" of the button, such as press, depress, mash, and punch.

Uses :The "push-button" has been utilized in calculators, push-button telephones, kitchen
appliances, and various other mechanical and electronic devices, home and commercial.
In industrial and commercial applications, push buttons can be connected together by a
mechanical linkage so that the act of pushing one button causes the other button to be
released. In this way, a stop button can "force" a start button to be released. This method
of linkage is used in simple manual operations in which the machine or process have
no electrical circuits for control.
32

Pushbuttons are often color-coded to associate them with their function so that the
operator will not push the wrong button in error. Commonly used colors are red for
stopping the machine or process and green for starting the machine or process.
Red pushbuttons can also have large heads (called mushroom heads) for easy operation
and to facilitate the stopping of a machine. These pushbuttons are called emergency
stop buttons and are mandated by the electrical code in many jurisdictions for increased
safety. This large mushroom shape can also be found in buttons for use with operators
who need to wear gloves for their work and could not actuate a regular flushmounted push button. As an aid for operators and users in industrial or commercial
applications, a pilot light is commonly added to draw the attention of the user and to
provide feedback if the button is pushed. Typically this light is included into the center of
the pushbutton and a lens replaces the pushbutton hard center disk. The source of the
energy to illuminate the light is not directly tied to the contacts on the back of the
pushbutton but to the action the pushbutton controls. In this way a start button when
pushed will cause the process or machine operation to be started and a secondary contact
designed into the operation or process will close to turn on the pilot light and signify the
action of pushing the button caused the resultant process or action to start.
In popular culture, the phrase the button (sometimes capitalized) refers to a (usually
fictional) button that a military or government leader could press to launch nuclear
weapons.

33

.
Fig. (4.6) Call Switches Circuit

3) Toggle Switches :Instead of providing doors on each floor we have provided toggle switch on each
floor for simplicity. When all toggle switches are ON indicates that all doors are closed
while any toggle switch is OFF indicates that door on that respective floor is open.
Fig.(4.7) shows indicate that how door simulated switches are connected to the PLC.

Fig. (4.7): Door Switch Circuit

34

The door switches are simulated with help of the toggle switches, connected in series so
that it will give out a signal if any door of the elevator is open. If any of the doors is open
then the elevator will not operate, until and unless that door is closed. This gives an
additional safety feature that if anybody opens the door during elevator operation the lift
will stall and after closing the door it run again.
Electrical switches. Top, left to right: circuit breaker,mercury switch, wafer
switch, DIP switch, surface mount switch, reed switch. Bottom, left to right: wall switch
(U.S. style), miniature toggle switch, in-line switch, push-button switch, rocker switch,
microswitch.
In electrical engineering, a switch is an electrical component that can break an electrical
circuit, interrupting the current or diverting it from one conductor to another.

Description :The most familiar form of switch is a manually operated electromechanical device
with one or more sets of electrical contacts, which are connected to external circuits. Each
set of contacts can be in one of two states: either "closed" meaning the contacts are
touching and electricity can flow between them, or "open", meaning the contacts are
separated and the switch is nonconducting. The mechanism actuating the transition
between these two states (open or closed) can be either a "toggle" (flip switch for
continuous "on" or "off") or "momentary" (push-for "on" or push-for "off") type.
A switch may be directly manipulated by a human as a control signal to a system, such as
a computer keyboard button, or to control power flow in a circuit, such as a light switch.
Automatically operated switches can be used to control the motions of machines, for
example, to indicate that a garage door has reached its full open position or that a machine
tool is in a position to accept another workpiece. Switches may be operated by process
variables such as pressure, temperature, flow, current, voltage, and force, acting
assensors in a process and used to automatically control a system. For example,
a thermostat is a temperature-operated switch used to control a heating process. A switch
that is operated by another electrical circuit is called a relay. Large switches may be
remotely operated by a motor drive mechanism. Some switches are used to isolate electric
power from a system, providing a visible point of isolation that can be padlocked if
necessary to prevent accidental operation of a machine during maintenance, or to prevent
electric shock.

35

An ideal switch would have no voltage drop when closed, and would have no limits on
voltage or current rating. It would have zero rise time and fall time during state changes,
and would change state without "bouncing" between on and off positions.
Practical switches fall short of this ideal; they have resistance, limits on the current and
voltage they can handle, finite switching time, etc. The ideal switch is often used in circuit
analysis as it greatly simplifies the system of equations to be solved, but this can lead to a
less accurate solution. Theoretical treatment of the effects of non-ideal properties is
required in the design of large networks of switches, as for example used in telephone
exchanges.

Contacts :-

A toggle switch in the "on" position.

In the simplest case, a switch has two conductive pieces, often metal, called contacts,
connected to an external circuit, that touch to complete (make) the circuit, and separate to
open (break) the circuit. The contact material is chosen for its resistance to corrosion,
because most metals form insulating oxidesthat would prevent the switch from working.
Contact
materials
are
also
chosen
on
the
basis
of electrical
conductivity, hardness (resistance to abrasive wear),mechanical strength, low cost and
low toxicity.
Sometimes the contacts are plated with noble metals. They may be designed to wipe
against each other to clean off any contamination. Nonmetallicconductors, such as
conductive plastic, are sometimes used. To prevent the formation of insulating oxides, a
minimum wetting current may be specified for a given switch design.

36

 Toggle switch :-

Large toggle switch, depicted in circuit "open" position, electrical contacts to left;
background is 1/4" square graph paper

Bank of toggle switches on a Data General Nova minicomputer front panel.

Toggle switches with the shared cover preventing certain forbidden combinations
A toggle switch is a class of electrical switches that are manually actuated by a
mechanical lever, handle, or rocking mechanism.
Toggle switches are available in many different styles and sizes, and are used in numerous
applications. Many are designed to provide the simultaneous actuation of multiple sets
of electrical contacts, or the control of large amounts of electric current or mains voltages.
The word "toggle" is a reference to a kind of mechanism or joint consisting of two arms,
which are almost in line with each other, connected with an elbow-like pivot. However,
the phrase "toggle switch" is applied to a switch with a short handle and a positive snap37

action, whether it actually contains a toggle mechanism or not. Similarly, a switch where a
definitive click is heard, is called a "positive on-off switch".
Multiple toggle switches may be mechanically interlocked to prevent forbidden
combinations.

Electronic switches :-

Three push button switches (Tactile Switches). Major scale is inches.

A relay is an electrically operated switch. Many relays use an electromagnet to
operate a switching mechanism mechanically, but other operating principles are also used.
Solid-state relays control power circuits with no moving parts, instead using a
semiconductor device to perform switchingoften a silicon-controlled rectifier or triac.
The analogue switch uses two MOSFET transistors in a transmission gate arrangement as
a switch that works much like a relay, with some advantages and several limitations
compared to an electromechanical relay.
The power transistor(s) in a switching voltage regulator, such as a power supply unit, are
used like a switch to alternately let power flow and block power from flowing.
Many people use metonymy to call a variety of devices "switches" that conceptually
connect or disconnect signals and communication paths between electrical devices,
analogous to the way mechanical switches connect and disconnect paths for electrons to
flow between two conductors. Early telephone systems used an automatically
operated Strowger switch to connect telephone callers; telephone exchanges contain one
or more crossbar switches today.
Since the advent of digital logic in the 1950s, the term switch has spread to a variety of
digital active devices such as transistors and logic gates whose function is to change their
output state between two logic levels or connect different signal lines, and even
computers, network switches, whose function is to provide connections between
different ports in a computer network. The term 'switched' is also applied
to telecommunications networks, and signifies a network that is circuit switched,
38

providing dedicated circuits for communication between end nodes, such as the public
switched telephone network. The common feature of all these usages is they refer to
devices
that
control
a binary state
they
are
either on or off, closed or open, connected or not connected.

4) Emergency Stop Switch :This switch is very important concern with security of an elevator as well as of
user. When any fault is occurred, person can stop the elevator by pushing this emergency
stop switch. As soon as person realize the fault is occurred in the elevator system and he
press this emergency stop switch, which gives signal to PLC so as it cuts the supply to the
driving motor immediately. Fig. (4.8) shows connection of emergency switch with PLC.

EMERGENCY
SWITCH

PLC

Fig. (4.8): Emergency Stop Switch Circuit

The other use of this switch is that if person wants to land on the floor rather than
floor destination is given by him previously, he can press this switch. As soon as the floor
reaches in front of cage where he wants to land, he can push this button which cuts supply
to the driving motor so as the cage stops immediately in front of that floor.

A kill switch, also known as an emergency stop or e-stop, is a safety mechanism used to
shut off a device in an emergency situation in which it cannot be shut down in the usual
manner. Unlike a normal shut-down switch/procedure, which shuts down all systems in an
orderly fashion and turns the machine off without damaging it, a kill switch is designed
and configured to a) completely and as quickly as possible abort the operation, even if this
damages equipment and b) be operable in a manner that is quick, simple (so that even
a panicking operator with impaired executive function can activate it), and, usually, c) be
obvious even to an untrained operator or a bystander. Many kill switches feature a
39

removable barrier or other protection against accidental activation (e.g., a plastic cover
that must be lifted or glass that must be broken).
Kill switches are featured especially often as part of mechanisms whose normal operation
or foreseeable misuse may cause injury or death; designers who include such switches
consider damage to or destruction of the mechanism to be an acceptable cost of preventing
that injury or death.

Applications :A similar system, usually called a dead man's switch (for other names, see alternative
names), as its name suggests, is a device intended to stop a machine in case the human
operator becomes incapacitated, and is a form of fail-safe. They are commonly used
in locomotives, tower cranes, freight elevators, lawn mowers, tractors, jet skis, outboard
motors, snowblowers and snowmobiles. The switch in these cases is held by the user, and
turns off the machine if they let go.
Vehicles :On railways, an emergency stop is a full application of the brakes in order to bring
a train to a stop as quickly as possible, much like anemergency brake on a train.[1] This
occurs either by a manual emergency stop activation, such as a button being pushed on the
train to start the emergency stop, or on some trains automatically, when the train
has passed a red signal or the driver has failed to respond to warnings to check that he/she
is still alert, which is known as a dead man's switch.
In large ships, an emergency stop button pulls the countershaft for the fuel pumps to the
stop position, cutting off the fuel supply and stopping the engines. With a controllable
pitch propeller, the stop button may declutch the engine from the propeller.
NASCAR (National Association for Stock Car Auto Racing) requires all their stock cars
to be equipped with a steering wheel-mounted kill switch, in case the accelerator
pedal sticks and the driver needs to shut down the engine.
Kill switches are also used on land vehicles as an anti-theft system and as an emergency
power off. Such devices are often placed in bait cars and configured so that observing
police can trigger the switch remotely.
A related concept is the dead man's switch, where the operator must be holding a button or
lever any time the vehicle is operating. A common example of this would be the kill
switches used by boaters wherein a cord connects the kill switch to the operator (usually
by the operator's life jacket), and if the operator is thrown overboard in an accident, the
cord will pull the switch and immediately shut down the vessel's engine. This prevents it
from becoming a run-away vessel that could impose a danger to other vessels or
swimmers at sea, and allows the operator to swim back to the vessel and re-board it.

40

 Machinery :The arrows indicate that the stop button must be turned to reset the switch before
the equipment can be restarted.On large industrial machines, an emergency stop button is
typically located on the panel, and possibly in several other areas of the machine. This
provides a rapid means to disconnect the energy source of the device to protect
workers.[2] For fail-safe operation, the emergency stop is button is a normally closed
switch which ensures that a broken wire will neither accidentally activate the emergency
stop nor prevent it from being activated. On machinery controlled by a Programmable
Logic Controller, the emergency stop is designed in a way that it overrides the output of
the controller.In some contexts, such as nuclear reactors or data centers, the emergency
stop is known as a scram switch.
In the European Union, most types of machinery are required to be equipped with an
emergency stop according to the Directive 2006/42/EC. Exceptions apply for machinery
in which an emergency stop would not lessen the risk as well as for portable handheld/hand-guided machinery.
A kill switch is also used for gasoline pumps or any other device that pumps large
amounts of explosive or flammable chemicals. Most vehicles nowadays also have a kill
switch that cuts power to the fuel pump if the vehicle is overturned. There is commonly a
single kill switch for all pumps at a pumping station. The kill switch is also used on such
things as industrial band saws and belt sanders. Kill switches are also found on school-use
electric powered tools such as drills and wood/metal lathes.

Forward and Reverse Operation Of Motor:

41

4.2 Software Design :-

4.2.1: Introduction :A PLC is a digitally operated electronic system, designed for use in an Industrial
Environment, which uses a Programmable Memory for the internal storage of useroriented instructions for implementing specific functions such as Logic, Sequencing,
Timing, Counting, and Arithmetic, to control, through Digital or Analog Inputs and
Outputs, various types of machines or Processes. Both the PLC and its peripherals are
designed so that they can be easily integrated into an industrial control system and easily
used in all their intended functions.
PLCs are used in many real world applications. If there is industry present,
chances are good that there is a PLC present. Most of the applications involving
machining, packaging, material handling, automated assembly or countless other
industries are probably already using them. Almost any application that needs some type
of

electrical

control

has

need

for

PLC.

A programmable

logic

controller, PLC or programmable controller is a digital computer used for automation of

typically industrialelectromechanical processes, such as control of machinery on
factory assembly lines, amusement rides, or light fixtures. PLCs are used in many
industries and machines. PLCs are designed for multiple analogue and digital inputs and
output arrangements, extended temperature ranges, immunity to electrical noise, and
resistance to vibration and impact. Programs to control machine operation are typically
stored in battery-backed-up or non-volatile memory. A PLC is an example of a
"hard" real-time system since output results must be produced in response to input
conditions within a limited time, otherwise unintended operation will result.

42

4.2.2: History:In the late 1960s PLCs were first introduced. The primary reason for designing such a
device was eliminating the large cost involved in replacing the complicated relay based
machine control systems. Bedford Associates (Bedford, MA) proposed something called a
Modular Digital Controller (MODICON) to a major US car manufacturer. Other
companies at the time proposed computer based schemes. The MODICON brought the
worlds
first
PLC
into
commercial
production.
When production requirements changed so did the control system. This becomes
very expensive when the change is frequent. Since relays are mechanical devices they also
have a limited lifetime, which required strict adhesion to maintenance schedules.
Troubleshooting was also quite tedious when so many relays are involved. Now picture a
machine control panel that included many, possibly hundreds or thousands, of individual
relays. The size could be mind-boggling and these relays would be individually wired
together in a manner that would yield the desired outcome which is very tedious.
These new controllers also had to be easily programmed by maintenance and plant
engineers. The lifetime had to be long and programming changes easily performed. They
also had to survive the harsh industrial environment. The answers were to use a
programming technique most people were already familiar with and replace mechanical
parts with solid-state ones. Before the PLC, control, sequencing, and safety interlock logic
for manufacturing automobiles was mainly composed of relays, cam timers, drum
sequencers, and dedicated closed-loop controllers. Since these could number in the
hundreds or even thousands, the process for updating such facilities for the yearly
model change-over was very time consuming and expensive, as electricians needed to
individually rewire the relays to change their operational characteristics.
Digital computers, being general-purpose programmable devices, were soon
applied to control of industrial processes. Early computers required specialist
programmers, and stringent operating environmental control for temperature, cleanliness,
and power quality. Using a general-purpose computer for process control required
protecting the computer from the plant floor conditions. An industrial control computer
would have several attributes: it would tolerate the shop-floor environment, it would
support discrete (bit-form) input and output in an easily extensible manner, it would not
require years of training to use, and it would permit its operation to be monitored. The
response time of any computer system must be fast enough to be useful for control; the
required speed varying according to the nature of the process.Since many industrial
processes have timescales easily addressed by millisecond response times, modern (fast,
43

small, reliable) electronics greatly facilitate building reliable controllers, especially

because performance can be traded off for reliability.
In 1968 GM Hydra-Matic (the automatic transmission division of General Motors)
issued a request for proposals for an electronic replacement for hard-wired relay systems
based on a white paper written by engineer Edward R. Clark. The winning proposal came
from Bedford Associates of Bedford, Massachusetts. The first PLC, designated the 084
because it was Bedford Associates' eighty-fourth project, was the result. Bedford
Associates started a new company dedicated to developing, manufacturing, selling, and
servicing this new product: Modicon, which stood for MOdular DIgital CONtroller. One
of the people who worked on that project was Dick Morley, who is considered to be the
"father" of the PLC The Modicon brand was sold in 1977 to Gould Electronics, and later
acquired by German Company AEG and then by French Schneider Electric, the current
owner.One of the very first 084 models built is now on display at Modicon's headquarters
in North Andover, Massachusetts. It was presented to Modicon by GM, when the unit was
retired after nearly twenty years of uninterrupted service. Modicon used the 84 moniker at
the end of its product range until the 984 made its appearance.
The automotive industry is still one of the largest users of PLCs.

4.2.3: Importance of PLC :A PLC monitors inputs, makes decisions based on its program, and controls
outputs to automate a process or machine. The mass manufacture of automobiles involves
many machines, all of which must be controlled. Earlier the control function of these
machines was performed by control relays.
Control relays were effective but suffered from several disadvantages. Relays are capable
of on off control, so many relays are needed to design complicated control systems,
making the relay control scheme so expensive. Control systems can be bulky, so a control
system requiring lots of relays takes lots of space. They are power hungry too, and this
high power consumption results leads in heat generation. When a relay fails, either due to
an opening of coil or due to a pitting of the hardwired, any change in control circuit needs
the

relays

to

be

rewired,

which

proves

to

be

very

costly.

In Hard-Wired Control Prior to PLCs, many of these control tasks were solved
with contactor or relay controls. This is often referred to as hardwired control. Circuit
diagrams had to be designed, electrical components specified and installed, and wiring
44

lists created. Electricians would then wire the components necessary to perform a specific
task. If an error was present the wires had to be reconnected correctly. A change in
function or system expansion required extensive component changes and rewiring. Wiring
between devices and relay contacts is done in the PLC program hard wiring, though still
required to connect field devices, is less intensive. Modifying the application and
correcting errors are easier to handle. It is easier to create and change a program in a PLC
than it is to wire and rewire a circuit.

4.2.4: Component of PLC :The controller consists of a built-in power supply, central processing unit
(CPU),memory, inputs, which you wire to input devices (such as pushbuttons, proximity
sensors, limit switches), and outputs, which you wire to output devices (such as motor
starters, solid-state relays, and indicator lights). Fig (4.9) shows functional block diagram
of Allen-Bradley Micrologix-1400.

Fig.(4.9):Block Diagram Of Allen Bradley Micrologix-1400.

45

Programmable controllers have grown throughout industrial control applications because

of the ease they bring to creating a controller: ease of programming, ease of wiring, ease
of installation, and ease of changing. PLCs span a wide range of sizes, but all contain six
basic components:

processor or central processing unit (CPU);

rack or mounting;
input assembly;
output assembly;
power supply;
programming unit, device, or PC/software

We will start with explaining the physical components you see when looking at a PLC
system and then explore what goes on inside each part, and how the components relate
to each other.

Rack Assembly :Most medium to large PLC systems are assembled such that the individual
components CPU, Input/Output, Power Supply are modules that are held together
within a rack.
In smaller PLC systems all of these components may be contained in a single housing or
brick these smaller systems are sometimes referred to as bricks or shoebox PLCs.

46

 Power Supply :The power supply provides power for the PLC system. The power supply provides
internal DC current to operate the processor logic circuitry and input/output assemblies.
Common power levels used are 24V DC or 120 VAC.

Processor (CPU) :The processor, central processing unit, or CPU is the brain of the PLC. The size and
type of CPU will determine things like: the programming functions available, size of the
application logic available, amount of memory available, and processing speed.
Understanding the CPU can be a complex subject and we will tackle that in other articles.

Input/Output Assembly :Inputs carry signals from the process into the controller, they can be input switches,
pressure sensors, operator inputs, etc. These are like the senses and sensors of the PLC.
Outputs are the devices that the PLC uses to send changes out to the world. These are the
actuator the PLC can change to adjust or control the process motors, lights, relays,
pumps, etc.
Many types of inputs and outputs can be connected to a PLC, and they can all be divided
into two large groups analog and digital. Digital inputs and outputs are those that
operate due to a discrete or binary change on/off, yes/no. Analog inputs and outputs
change continuously over a variable range pressure, temperature, potentiometer.

Programming Device :The PLC is programmed using a specialty programmer or software on a computer that can
load and change the logic inside. Most modern PLCs are programmed using software on a
PC or laptop computer. Older systems used a custom programming device.

47

4.2.5: Inputs :They examines state of physical components of user input devices like limit
switches, sensors, toggle switches, thermocouples, push buttons, etc.
Input signals from input devices through input relays are fed to A/D converter
through isolation circuit and filters. Filters are used to reduce the ripple contents and noise
from the input signals and isolation circuits are used to protect A/D converter and
processor from any fault occurrence at input side. A/D converter converts this analog
input into equivalent digital form which is suitable form for the CPU operation .CPU
process on this converted signals as per programmed. Fig (4.10) shows functional block
diagram of INPUTS of PLC.

INPUT
DEVICE

ELECRICAL
AND
OPTICAL
ISOLATION

FILTER

ANALOG

C
TO

INPUT
DEVICE

ELECRICAL
AND
OPTICAL
ISOLATION

FILTER

DIGITAL

CONV.
INPUT
DEVICE

ELECRICAL
AND
OPTICAL
ISOLATION

FILTER

Fig. (4.10): Input Working Circuit

The term PLC inputs refers to the devices and transducers which are entrusted with taking
in information about the physical world to the PLC. Keep in mind that it also refers to the
PLC hardware that connects to those devices, sensors and transducers. The PLC uses this
input information to make decisions based upon its program whether to energize and deenergize the outputs controlled by the PLC. It very important to know about the different
input types discussed below.

48

The two types of PLC inputs are commonly referred to DI and AI (Digital and Analog).
Analog inputs are those like temperature and pressure which span over a range of values.
Digital inputs are simply two states, like those of a switch position indicating as On or
Off.
Analog Inputs include temperature sensors/transmitters, current sensors, voltage sensors
and others that can convert a physical quantity to a electrical signal. These electrical
signals used for PLC input are typically 4-20ma or 1-5vdc.
Digital Inputs include push-buttons, limit switches, relay contacts, proximity switches,
photo sensors (On/Off), pressure switches and more. Digital inputs devices are available
in both DC as well as AC and some are voltage independent such as a switch contact.
A less common PLC input is the High Speed Counter (HSC). It is very similar to the
digital input type, but the hardware is capable of detecting rapid ON/OFF inputs. It is
common that 10KHz or 10,000 on/off transitions per second are within the abilities of
these input types. A photo optic eye counting parts on an high speed assembly line would
be example of when a HSC module would be needed.
A HSC PLC input module may also have quadrature capable inputs. This would be used
with an rotary encoder to sense speed and direction of a motor for instance.
Depending on the particular PLC, the different inputs discussed above will require a
separate hardware module for each type. However mixed I/O (input/output) modules or
cards are available and some smaller integrated PLC models have some I/O included.
PLC Digital Inputs have a LED indicator on the module itself for setup and
troubleshooting. Simply, if the LED is ON the input is ON.
If the LED is ON and it should not be, then you need to look at your wiring, the input
sensor position or adjustment, or the possibility that the input device may be defective.The
same applies if the LED is OFF and you expect to to be ON, with the addition of checking
input protecting fuses.
PLC Analog Inputs generally don't have a display on the module (I know that Automation
Direct's newest top of the line PLC does!) to aid in troubleshooting. In this case you are
going to need your multimeter or other suitable measurement tool.
49

The PLC input module itself would generally would be considered the last step in
troubleshooting the problem.
Now that you understand the differences and uses of Digital and Analog inputs, be aware
that the PLC input hardware is part of a system made of several different components that
comprise a PLC. These components consist of the CPU or the central processing unit, the
input and output modules, memory and power supply.

4.2.6: Outputs :They give signals to the output devices like solenoids, lights, power drives, etc.
Processed digital signal from CPU is then fed to D/A converter.
D/A converter convert this digital signal into equivalent analog output which is
first store in to the memory and then fed to the output device through isolation circuit
which protects mal-operation of output device due to improper programming and faults
occurred at D/A converter side .Fig (4.11) shows functional block circuit of OUTPUTS of
PLC.

DATA

DIGITAL

STORAGE

OUTPUT
DEVICE

TO
DATA

ANALOG

P
CONV.

ELECRICAL
AND
OPTICAL
ISOLATION

STORAGE

DATA
STORAGE

ELECRICAL
AND
OPTICAL
ISOLATION

OUTPUT

ELECRICAL
AND
OPTICAL
ISOLATION

OUTPUT

Fig. (4.11): Output Working Circuit

50

DEVICE

DEVICE

PLC Outputs are the control circuits of the PLC and also refers to the devices controlled
by the PLC. Be aware when talking about PLCs the devices like motors and lights are also
referred to as PLC Outputs. Devices called actuators convert the electrical signal of the
PLC to a physical movement for instance a valve solenoid stoke or a motor contactor.
With regards to the variable output, the I/P (current to pneumatic) actuator, is an example.
There are two types, the ON/OFF output and the variable output. Digital output (DO) are
for the ON/OFF in your control scheme. Some examples are motors that need just be ON
or OFF, Lighting, solenoid valves, door locks. Analog output (AO) are for variable level
or range of output between OFF or stopped and ON or full speed as for an electric motor
for instance. Examples of analog outputs are a VFD (Variable Frequency Drive), a valve
position actuator, and a industrial variable power supply.
Now lets touch on the types of control circuits within the PLC Output Module. PLCs have
four typical output types. Three are DO and the other is AO.
For the Digital Outputs they are transistor, relay, and the triac. Relay dry contacts are the
quick choice since they are voltage independent and they are a easy interface to a
customer's system. Relays generally have a higher current rating than transistors, but have
a mechanical life span that has to be considered.
Transistor types are for DC applications. They are smaller and thus offer higher I/O count
per unit of circuit board real estate. You may also choose them for faster switching speeds
and longevity over relays.
Triacs are the solid state choice for AC and may require additional circuity called
snubbers. Also keep in mind to check the leakage current spec of the transistor or triac to
make sure it will not have the the possibility of turning on your output when it is OFF!
The PLC Analog Output is usually configurable for loop or internally powered and
externally powered, a voltage (typically 0 to 10VDC) or current (typically 4-20ma). In this
case the PLC uses a DAC (Digital to Analog Convertor) to drive the output. Other
available Analog outputs supply these typical ranges: -5 to 5 vdc, -10 to 10 vdc, or 0-5
vdc.
You must be aware of the inductive loads that are switched by the PLC outputs. These
include, motor starters, solenoids, and relays. If these devices are too large for direct
51

connection a interposing relay will be be required. These inductive loads will produce a
sizable reverse voltage, known as Back EMF. This Back EMF and corresponding current
can damage the PLC outputs and therefore has to be redirected.
For protection, devices like MOVs (metal Oxide Varistors) and diodes are installed as
close to the inductive device as possible to suppress or divert these voltages. Without
surge suppression relay contacts can pit from arching, generate electrical noise and may
weld closed! Manufacturers often provide guidelines for choosing and even supplying
suppression devices, but others may already have the suppression built-in and will not
need a separate component.
As I mentioned above, inductive devices produce voltage spikes and snubbers are used for
thyristor (Triac ) PLC outputs. Snubbers for this use are RC circuits that reduce the
voltage rate of change as not to falsely trigger the triac .However, most industrial
applications have low enough voltage and current ratings they can be connected directly to
the PLC outputs and some have built-in protection anyway. Most industrial solenoids are
energized by 24Vdc and consume only about two to three hundred mA.
Finally, we must talk about sinking and source outputs. A source output will connect the
voltage to the load, its return or ground is always connected. A sinking output will connect
the load to its return or ground, it is always connected to its voltage source. Okay, do you
see a potential problem?! What happens in this case if the circuit is made complete by a
short to ground?! That is right! Unintentional turning on of the output! For this reason and
the fact that I just consider connecting a circuit to power to energize more logical, I prefer
sourcing outputs.
Remember that outputs come in two main flavors, DO and AO. You have to consider
what you are going to control and to choose the right combination of PLC output module
and supporting components such as interposing relays. Oh, one more tip, create a
spreadsheet of all your inputs and outputs and all their requirements before you buy
anything!

52

4.2.7 Processor :It performs the necessary task to fulfill the PLC function such as scanning of I/O
bus traffic control, program execution, communication between external devices and
peripheral components, etc. It also performs data handling execution and self-diagnostics.

4.2.8 Programming Devices (PC) :We can connect the Micrologix 1400 programmable controller to personal
computer (Programming Device) using a serial cable(RS-232) from personal computers
serial port to the microcontroller for download the executable program from PC to PLC.
Here the PC is the programming device which programs executive logic diagram using
software like RSLogix 500. Fig (4.12) shows interconnectivity between PC and PLC
using RS-232 connector. Optical Isolator is used as safety device due to which duplex data
transmission between PC and PLC can be achieve safe mode.

Fig. (4.12): Interconnectivity Between PC And PLC

4.2.9: Supply Unit:

It is DC supply unit which is of order of +5V, +12V, + 24V, etc., provide for
working of CPU, input modules and output modules of PLC. Also 230V AC supply is
available there.

53

4.2.10: Memory :-

Fig.(4.13): Memory Used In PLC

It is the library where the executable programs are stored. The executable program
functions as the operating system of PLC. Memory unit is the part of programmable
controller where process data from input modules are stored as well as control data from
output modules are stored.
The memories used on CPU PCB are semiconductor memories. One or more than
one memories are used in single PCB. The Micrologix 1400 programmable controller uses
two memories for storing processor files: RAM and EEPROM. The RAM provides easy
access storage (i.e., its data is lost on a power down), while the EEPROM provides longterm storage (i.e., its data is not lost on a power down). Fig (4.13) shows how the memory
is allocated in the micro controllers processor (PLC). The memory device that is used
depends on the operation being performed.

4.2.11: Use of Memory :The following description tells how memory is stored and accessed during the
following operations:

1) Download
2) Normal Operation
3) Power Down
4) Power Up

54

1) Download :When the processor file is downloaded to the micro controller, it is first
stored in the volatile RAM. It is then transferred to the non-volatile EEPROM,
where it is stored as both backup data and retentive data. Fig (4.14) shows
memories used during DOWNLOAD process.

Fig. (4.14): Memories Used During Download Process

2) Normal Operation :During normal operation, both the micro controller and your programming
device can access the processor files stored in the RAM. Any changes to retentive data
that occur due to program execution or programming commands affect only the retentive
data in the RAM. The program files are never modified during normal operation.
However, both the CPU and your programming device can read the program files stored
in RAM as shown in Fig (4.15).

Fig.(4.15): Memories Used During Normal Operation

55

2) Power Down :When a power down occurs, only the retentive data is transferred from the RAM to
the EEPROM. (The program files do not need to be saved to the EEPROM since they
cannot be modified during normal operation.) If for some reason power is lost before all
of the retentive data is saved to the EEPROM, the retentive data is lost. This may occur
due to an unexpected reset or a hardware problem. Fig (4.16) shows memories used
during POWER DOWN.

Fig. (4.16): Memories Used During Power Down

2) Power Up :-

Fig.(4.17): Program Files And Retentive Data Transmission

During power up, the micro controller transfers the program files from the
EEPROM to the RAM. The retentive data is also transferred to the RAM, provided it was
not lost on power down, and normal operation begins as shown in fig (4.17).
56

Fig.(4.18): Program Files And Back-Up Data Transmission

If retentive data was lost on power down, the backup data from the EEPROM is
transferred to the RAM and used as the retentive data as shown in fig (4.18). In addition,
status file bit S2:5/8 (retentive data lost) is set and a recoverable major error occurs when
going to run.

4.2.12: Data Transmission Between PC And PLC :Fig (4.19) shows schematic of RS-232 Cable which is used for interconnection
between 9-pin D-shell of PC to 8-pin Mini Din of PLC.

Fig.(4.19): Schematic Of Rs-232 Cable

57

Pin Description :Fig (4.20) shows pin configuration of Programming Device (PC) and Controller
used for serial data communication in between them.

[1] Data Terminal Ready (DTR) :When a PC COM port is turned ON, after going through a self test, it sends out
signal DTR to indicate that it is ready to communication. If there is a fault with the COM
port, this signal will not be activated. This is OUTPUT pin of PC COM port and an input
to its own modem.

Fig.(4.20): Data Communication Between PC And PLC

58

[2] Data Set Ready (DSR) :When modem of PC is turned ON and has gone though the self test, it asserts DSR
to indicate that it is ready to communicate. When this signal is inactive, indicating to the
PC that it cannot accept or send data.
[3] Request To Send (RTS) :When the PC has a byte to send, it asserts RTS to signal the modem of PLC that it
has a byte to transmit.

[4] Clear To Send :In response to RTS, when modem of PLC has room for storing the data it is to
receive, it sends out signal CTS to the PC to indicate that it can receive the data now.
Therefore it is OUTPUT from PLC and INPUT to the PC.

[5] Data Carrier Detect (DCD) :The modem asserts signal DCD to inform PC that valid carrier has been detected
and that contact between this modem of PC and modem of PLC is established. Thus DCD
is an INPUT to the PC and an OUTPUT from PLC.
[6] Ring Indicator (RI) :This is input to the PC indicates that the Telephone is ringing. It goes ON and
OFF in synchronization with the ringing sound. This is least often used, due to the fact
that modems take care of answering the phone. However if in a given system the PC is in
charge of answering the phone, this signal can be used.

4.2.13: Advantages of PLC :1) Smaller physical size than hard- Wire solutions.
2) Easier and faster to make changes.
3) PLCs have integrated diagnostics and override functions.
59

4) Diagnostics are centrally available.

5) Applications can be immediately documented; Applications can be duplicated
faster and less expensively.
6) Easily programmed or reprogrammed with a minimum of downtime.
7) Easily maintained.
8) Rugged enough to operate in an industrial environment.
9) Able to consume less power and require less cabinet and floor space than the relay
control system and Competitive in cost.

4.2.14: Specification of Allen Bradley micrologix-1400 :Preconfigured 4K programming and data memory to ease configuration (bit,
integer, timers, counters, etc).
Fast processing allows for typical throughput time of 1.5 ms for a 500-instruction
program.
Built-in EEPROM memory retains all of your ladder logic and data if the
controller loses power, eliminating the need for battery back-up or separate memory
module. Multiple input commons allow you to use the controller for either sinking or
sourcing input devices and multiple output commons provide isolation in multi-voltage
output applications.
RS-232 communication channel allows for simple connectivity to a personal
computer for program upload, download and monitoring using multiple protocols,
including DF1 Full Duplex.RTU slave protocol support using DF1 Half-Duplex Slave
allows up to 254 notes to communicate with a single master using radio modems, leasedline modems or satellite uplinks. Peer-to-peer messaging capability allows you to network
up to 32 controllers on a DH-485 (using a 1761-NET-AIC module).
Advanced communications networks, including Device Net and Ethernet/IP
through the 1761-NET-DNI and 1761-NET-ENI communication modules.
Controllers that have 24V dc inputs include a built-in high-speed counter (6.6 kHz).
60

Adjustable DC input filters allow you to customize the input response time and noise
rejection to meet your application needs.
Regulatory agency certifications for world-wide market (CE, C-Tick, UL, c-UL, including
Class 1 Division 2 Hazardous Location).
This little powerhouse is both inexpensive and compact, with footprints as small as
120mm x 80 mm x 40 mm (4.72" x 3.15" x 1.57"). The analog I/O circuitry is embedded
into the base controller, not accomplished through add-on modules, providing compact
and cost-effective analog performance.

4.3 Advantages and disadvantages of System :-

4.3.1 Advantages :1. Fast and Reliable in operation.

2. Less power consumption and highly efficient.
3. Less space is sufficient for control room due to minimization of relay panels
(which are essential in conventional elevator system).
4. User friendly.
5. Less maintenance and competitive in cost.
6. Programming of PLC is simple; no need of skilled programmer is required.
7. Due to these advantages it is became more popular in industrial, commercial
and residential field.

4.3.2 Disadvantages :1. Program failure due to program corruption may cause system collapse.
2. Construction of LADDER LOGIC becomes tedious as numbers of floors are
increased.

61

3. Though the programming is simple basic knowledge of programming with ladder

logic is necessary.
4. As the number of INPUTS and OUTPUTS are increased with the number of
floors, PLC of different configuration (higher version) must have to replace the
original PLC.

4.3.3 Application of System :

The PLC controlled elevator system become popular in the commercial,

residential and industrial sectors in cities and metros.

They are used in residential buildings consisting large number of floors.

They are extensively used in hospitals, schools and colleges.

They are used in commercial sectors like shopping malls, multiplexes, towers,
commercial buildings, etc.

They are used in industrial sectors like IT zones, processing industries, etc.

62

WORKING OF MODEL

63

5. WORKING OF MODEL

In all there are 3 floors. There are three limit switches provided, one on each floor
to sense the UPWARD and DOWNWARD motion. These limit switches are of roller
type.
An operating bracket for the limit switch is being provided on the elevator cage.
The position of operating bracket is so adjusted that when this bracket operates the limit
switch, the supply to the motor is cut off and then the lift will stop at the exact defined
level and there will not be any over rider. There is an arrangement of oblong holes
provided on the limit switch bracket so that they can be moved vertically up and down as
per desired position. Oblong holes are also provided on limit switch operating bracket
placed

on

elevator

cage,

so

that

they

can

be

adjusted

horizontally.

The elevator cage must travel a distance of 20 cm i.e. from one floor to another
in about 4-5 seconds; which is visible. Hence the motor pulley is designed of diameter
6.5cm, so that its periphery is 3.5cm and thus there is large area available for the contact
of rope i.e. the arc of contact of the rope with pulley is large. Also there is large arc of
contact of the rope with motor pulley. These pulleys are V-grooved and thus avoid
slipping of the rope from the pulley. These pulleys provide the tension to the rope on the
motor pulley and thus it enables the motor to move the lift UP and DOWN easily.
Four cross legs are also provided at the base of the main frame for balancing the
height of the frame. The operation of the lift will be tedious if doors are made on the
elevator cage. Hence instead of doors, toggle switches are provided on every floor. The
ON and OFF operation of the toggle switch indicates the closing and opening of the cage
door. Push buttons are also provided on each floor which is used for calling the lift from
any floor.

64

TEST & EXPRIMENTAL

RESULT

65

6. TEST & EXPRIMENTAL RESULT

6.1 Programming of PLC :6.1.1 Introduction :Programmingof PLC is one of the important part of the project. The hardware
operation of elevator system is directed by PLC PROGRAMMING, based on LADDER
DIAGRAMS.
The logic you enter into the micro controller makes up a ladder program. A ladder
program consists of a set of instructions used to control a machine or a process. Ladder
logic is a graphical programming language based on electrical relay diagrams. Instead of
having electrical rung continuity, ladder logic is looking forlogical rung continuity. A
ladder diagram identifies each of the elements in an electromechanical circuit and
represents them graphically. This allows you to see how your control circuit operates
before you actually start the physical operation ofyour system. Fig (6.1) shows ladder
diagram representation.

Fig. (6.1)Graphical Representation Ladder Logic

In a ladder diagram each of the input devices represented in series or parallel
combinations across the rung of the ladder. The last element on the rung is the output that
receives the action as a result of the conditional state of the inputs on therung. Each output
instruction is executed by the controller when the rung is scanned and the conditions on
the rung are true. When the rung is not scanned or the logic conditions on the rung do not
create a true logic path, the output is not executed. The programming device allows you to
enter a ladder logic program into the micro Controller. A Programmable Logic Controller,
or PLC, is more or less a small computer with a built-in operating system (OS). This OS is
highly specialized to handle incoming events in real time, i.e. at the time of their
occurrence.

66

The PLC has input lines where sensors are connected to notify upon events (e.g.
temperature above/below a certain level, liquid level reached, etc.), and output lines to
signal any reaction to the incoming events (e.g. start an engine, open/close a valve, etc.).
The system is user programmable. It uses a language called "Relay Ladder" or RLL
(Relay Ladder Logic). The name of this language implies that the control logic of the
earlier days, which was built from relays, is being simulated.

Programmable Logic Controller :A Programmable Logic Controller, or PLC, is more or less a small computer with a builtin operating system (OS). This OS is highly specialized to handle incoming events in real
time, i.e. at the time of their occurrence.The PLC has input lines where sensors are
connected to notify upon events (e.g. temperature above/below a certain level, liquid level
reached, etc.), and output lines to signal any reaction to the incoming events (e.g. start an
engine, open/close a valve, etc.).
The system is user programmable. It uses a language called "Relay Ladder" or RLL
(Relay Ladder Logic). The name of this language implies that the control logic of the
earlier days, which was built from relays, is being simulated.There are some other
languages also used 1. Sequential Function chart 2. Functional block diagram 3. structured
Text 4. Instruction List

The PLC's purpose life :The PLC is primarily used to control machinery. A program is written for the PLC which
turns on and off outputs based on input conditions and the internal program. In this aspect,
a PLC is similar to a computer. However, a PLC is designed to be programmed once, and
run repeatedly as needed. In fact, a crafty programmer could use a PLC to control not only
simple devices such as a garage door opener, but their whole house, including switching
lights on and off at certain times, monitoring a custom built security system, etc.
Most commonly, a PLC is found inside of a machine in an industrial environment. A PLC
can run an automatic machine for years with little human intervention. They are designed
to withstand most harsh environments.

History of PLCs
When the first electronic machine controls were designed, they used relays to control the
machine logic (i.e. press "Start" to start the machine and press "Stop" to stop the
67

machine). A basic machine might need a wall covered in relays to control all of its
functions. There are a few limitations to this type of control.

Relays fail.

The delay when the relay turns on/off.

There is an entire wall of relays to design/wire/troubleshoot.

A PLC overcomes these limitations, it is a machine controlled operation.

Recent developments :PLCs are becoming more and more intelligent. In recent years PLCs have been integrated
into electrical communications(Computer network|networks)i.e., all the PLCs in an
industrial environment have been plugged into a network which is usually hierarchically
organized. The PLCs are then supervised by a control centre. There exist many proprietary
types of networks. One type which is widely known is SCADA (Supervisory Control and
Data Acquisition).

Basic Concepts : How the PLC operates :The PLC is a purpose-built machine control computer designed to read digital and analog
inputs from various sensors, execute a user defined logic program, and write the resulting
digital and analog output values to various output elements like hydraulic and pneumatic
actuators, indication lamps, solenoid coils, etc.
Scan cycle :Exact details vary between manufacturers, but most PLCs follow a 'scan-cycle'format.
Overhead :Overhead includes testing I/O module integrity, verifying the user program logic
hasn't changed, that the computer itself hasn't locked up (via a watchdog timer), and any
necessary communications. Communications may include traffic over the PLC
programmer port, remote I/O racks, and other external devices such as HMIs (Human
Machine Interfaces).

68

 Input scan :A 'snapshot' of the digital and analog values present at the input cards is saved to an input
memory table.
Logic execution :The user program is scanned element by element, then rung by rung until the end
of the program, and resulting values written to an output memory table.
Output scan :Values from the resulting output memory table are written to the output
modules.Once the output scan is complete the process repeats itself until the PLC is
powered down.The time it takes to complete a scan cycle is, appropriately enough, the
"scan cycle time", and ranges from hundreds of milliseconds (on older PLCs, and/or PLCs
with very complex programs) to only a few milliseconds on newer PLCs, and/or PLCs
executing short, simple code.

Basic instructions :Be aware that specific nomenclature and operational details vary widely between
PLC manufacturers, and often implementation details evolve from generation to
generation.Often the hardest part, especially for an inexperienced PLC programmer, is
practicing the mental ju-jitsu necessary to keep the nomenclature straight from
manufacturer to manufacturer.
Positive Logic (most PLCs follow this convention) :True = logic 1 = input energized.
False = logic 0 = input NOT energized.
Negative Logic :True = logic 0 = input NOT energized
False = logic 1 = input energized.
Normally Open :(XIC) - eXamine If Closed.
This instruction is true (logic 1) when the hardware input (or internal relay
equivalent) is energized.
69

 Normally Closed :(XIO) - eXamine If Open.

This instruction is true (logic 1) when the hardware input (or internal relay
equivalent) is NOT energized.
Output Enable :(OTE) - OuTput Enable.
This instruction mimics the action of a conventional relay coil.
On Timer :(TON) - Timer ON.
Generally, ON timers begin timing when the input (enable) line goes true, and
reset if the enable line goes false before setpoint has been reached. If enabled until
setpoint is reached then the timer output goes true, and stays true until the input (enable)
line goes false.
Off Timer :(TOF) - Timer OFF.
Generally, OFF timers begin timing on a true-to-false transition, and continue
timing as long as the preceding logic remains false. When the accumulated time equals
setpoint the TOF output goes on, and stays on until the rung goes true.
Retentive Timer :(RTO) - Retentive Timer On.
This type of timer does NOT reset the accumulated time when the input condition
goes false.Rather, it keeps the last accumulated time in memory, and (if/when the input
goes true again) continues timing from that point. In the Allen-Bradley construction, this
instruction goes true once setpoint (preset) time has been reached, and stays true until a
RES (RESet) instruction is made true to clear it.
Latching Relays :(OTL) - OuTput Latch.
(OTU) - OuTput Unlatch.Generally, the unlatch operator takes precedence. That
is, if the unlatch instruction is true then the relay output is false even though the latch
instruction may also be true. In Allen-Bradley ladder logic, latch and unlatch relays are

70

separate operators.However, other ladder dialects opt for a single operator modeled after
RS (Reset-Set) flip-flop IC chip logic.
Jump to Subroutine :(JSR) - Jump to SubRoutine
For jumping from one rung to another the JSR (Jump to Subroutine) command is
used.

6.1.2: Operating cycle :With the logic program entered into the controller, placing the controller in the
Run mode initiates an operating cycle as shown in fig (6.2). The controllers operating
cycle consists of a series of operations performed sequentially and repeatedly, unless
altered by your program logic.

Fig.(6.2)Operating Cycle

71

[1] Input Scan : The time required for the controller to scan and read all input data; typically
accomplished within mseconds.
[2] Program Scan :
The time required for the processor to execute the instructions in the program. The
program scan time varies depending on the instructions used and each instructions status
during the scan time.

[3] Output scan :

The time required for the controller to scan and write all output data; typically
accomplished within mseconds.

[4] Service Communications :

The part of the operating cycle in which communication takes place with other
devices, such as an HHP or personal computer.

[5] Housekeeping and Overhead :

Time spent on memory management and updating timers and internal registers.
You enter a logic program into the controller using a programming device. The logic
program is based on your electrical relay print diagrams. It contains instructions that direct
control of your application.

6.1.3 Processor File :The processor provides control through the use of a program you create, called a
processor file. This file contains other files that break your program down into more
manageable parts. Most of the operations you perform with the programming device

72

involve the processor file with its two components created with it namely program files
and data files as shown in fig (6.3).

FIG.(6.3) Processor Files

The programming device stores processor files on hard disk (or floppy disk).Monitoring
and editing of processor files is done in the workspace of the computer. After you select a
file from disk and edit it, you then save the file hard to disk, replacing the originaldisk
version with the edited version. The hard disk is the recommended location for a processor
file as shown in fig (6.4).

Fig.(6.4)Saving Of Processor Files

Processor files are created in the offline mode using the programming device. These files
are then restored (downloaded), to the processor for online operation.

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[1] Program Files :Program files contain controller information, the main ladder program;
interruptsubroutines, and any subroutine programs.
These files are:
System Program (file 0) This file contains various system relatedinformation and userprogrammed information such as processor type, I/Oconfiguration, processor file name,
and password.
Reserved (file 1) This file is reserved.
Main Ladder Program (file 2) This file contains user-programmedinstructions defining
how the controller is to operate.
User Error Fault Routine (file 3) This file is executed when a recoverablefault occurs.
High-Speed Counter Interrupt (file 4) This file is executed when an HSCinterrupt
occurs. It can also be used for a subroutine ladder program.
Selectable Timed Interrupt (file 5) This file is executed when an STI occurs.It can also
be used for a subroutine ladder program.
Subroutine Ladder Program (files 6 15) These are used according tosubroutine
instructions residing in the main ladder program file or othersubroutine files.

[2] Data Files :Data files contain the status information associated with external I/O and all
otherinstructions you use in your main and subroutine ladder program files. In
addition,these files store information concerning processor operation. You can also use
thefiles to store recipes and look-up tables if needed.These files are organized by the
type of data they contain.
The data file types are:
Output (file 0) This file stores the state of the output terminals for thecontroller.
Input (file 1) This file stores the status of the input terminals for thecontroller.
Status (file 2) This file stores controller operation information. This file isuseful for
troubleshooting controller and program operation.
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Bit (file 3) This file is used for internal relay logic storage.
Timer (file 4) This file stores the timer accumulator and preset values andstatus
bits.rogramming
Counter (file 5) This file stores the counter accumulator and preset valuesand the status
bits.
Control (file 6) This file stores the length, pointer position, and status bits forspecific
instructions such as shift registers and sequencers.
Integer (file 7) This file is used to store numeric values or bit information.

6.2 Software used for programming :Here we usedRSLogix 500 to construct elevator program on PC. The
RSLogix family of IEC-1131-compliant ladder logic programming packages helps to
maximize performance, save project development time, and improve productivity. This
family of products has been developed to operate on Microsoft, Windows operating
systems. Supporting the Allen-Bradley SLC 500 and MicroLogix families of
processors, RSLogix 500 was the first PLC programming software to offer unbeatable
productivity with an industry-leading user interface. RSLogix 5 supports the AllenBradley PLC-5 family of programmable controllers. TheseRSLogix products share:
Flexible, easy-to-use editors, Common look-and-feel, Diagnostics and troubleshooting
tools, powerful, time-saving features and functionality.
RSLogix programming packages are compatible with programs created with Rockwell
Softwares DOS-based programming packages for the PLC-5 or SLC 500 and MicroLogix
families of processors, making program maintenance across hardware platforms
convenient and easy. Fig(23)shows how RSLogix500 looks like on PC monitor screen.

6.2.1 Features of RSLogix 500 :The RSLogix family of IEC-1131-compliant ladder logic programming
packages helps you maximize performance, save project development time, and improve
productivity. This family of products has been developed to operate on Microsoft
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Windows operating systems. Supporting the Allen-Bradley SLC 500 and

MicroLogix families of processors, RSLogix 500 was the first PLC programming
software to offer unbeatable productivity with an industry-leading user interface.
RSLogix 500 programming package is compatible with programs created with
Rockwell Software DOS-based programming packages for the SLC 500 and MicroLogix
families of processors, making program maintenance across hardware platforms
convenient and easy. Supporting the Allen-Bradley SLC 500 and MicroLogix
families of controllers, RSLogix 500 programming software helps you maximize
performance, save project development time, and improve productivity with an industryleading user interface.Developed to operate on Microsoft Windows 2000 or later
operating systems, RSLogix offers reliable communications, powerful functionality, and
superior diagnostics. RSLogix 500 offers:
Flexible, easy-to-use editors
Diagnostic and troubleshooting tools
Powerful, timesaving features and functionality
Convenient and easy maintenance across hardware platforms

[1] Powerful, Flexible Programming :Combine the ease of ladder logic with the power of Allen-Bradley software, and
you get a micro that makes it simple to program even the most difficult applications.

[2] Flexible communications :Both [Windows & NT] and A.I. Series (DOS) for the MicroLogix 1400
programming packages support Allen-Bradley DF1 full-duplex communications. Direct
PC connectivity to your controller through the RS-232 port eliminates the need for
additional hardware interface, and allows remote programming by phone modem.

[3] Streamlined editing features :It's easy to create, edit, monitor, and troubleshoot ladder logic programs with such
functions as:
Command line entry of instructions and parameters saves keystrokes and time
Search and replace for fast modifications
Cut, copy, paste, drag & drop lets you edit and re-use ladder logic
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[4] On-line context sensitive help :Guides you through common tasks and provides detailed instruction descriptions.
[5] Extensive documentation :Provide application comment for rungs, addresses, and instructions that can be
viewed on-line.
[6] Wide variety of reports :Include program listing (ladder logic), data table contents, cross-reference, and
documentation database listing.
[7] Available in five languages :The global design of this product supports English, French, German, Italian, and
Spanish language versions of application menus, prompts, messages, and all user
documentation.
[8] Family program :Our programming tools for the SLC 500, RS Logix 500, and A.I. Series can be
used to program all MicroLogix 1400 controllers. Programs for SLC 500s easily convert
for use on MicroLogix programmable controllers.
[9] Hand-Held Problem Solver :MicroLogix 1400 puts remarkable problem-solving capabilities at your fingertips
with an advanced, easy-to-use Hand-Held Programmer (HHP). This streamlined unit fits
right into your pocket and provides full programming support for the MicroLogix
controller while delivering among the most powerful troubleshooting capabilities in the
industry.
Search key simplifies address location.
Trace key reduces troubleshooting time by quickly locating the source of a faulty output.
Navigation keys let you move between rungs and from instruction to instruction, saving
time.Six user-selectable languages: English, French, German, Italian, Spanish, and
Japanese.
Textual fault messages convey information instantly, no need to look up codes.
EEPROM memory module lets you move programs to multiple controllers.

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6.3 Ladder diagram for elevator:

Main Program:

Floor Sensing Subroutine:

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Floor Calling Subroutine:

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6.4 Inputs & Outputs of PLC

INPUTS
I:0/10

Master Switch.

I:0/1

Limit Switch For 1ST Floor.

I:0/2

Limit Switch For 2ND Floor.

I:0/3

Limit Switch For 3RD Floor.

I:0/4

Push Button For 1ST Floor

I:0/5

Push Button For 2ND Floor.

I:0/6

Push Button For 3RD Floor.

OUTPUTS
Q1

UP motion of driving motor.

Q2

DOWN motion of driving motor.

Table 4.1: Inputs & Outputs of PLC

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CONCLUSION &
FUTURE SCOPE

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7. CONCLUSION & FUTURE SCOPE

7.1 Conclusion:
In this small attempt we have tried to control the elevator which is situated in a
three storied building with the help of a Programmable logic controller. We have tried to
reproduce the exact facsimile of the elevator PLCs are used in many real world
applications Almost any application that needs some type of electrical control has a need
for a PLC. The bigger process, the more is a need for a PLC. We can simply program the
PLC to count its inputs and give the required outputs. We have developed a system, which
is based on the electronic control of the PLC. With the help of PLC it is very easy to scan
inputs of the elevator to achieve faster operation.

7.2 Future Scope:

The elevator is not provided with generator back up. The door closure display is
not integrated; instead we have simulated the condition by having the toggle switch on
each floor. Digital displays may be included. Weight sensor can be added to indicate
overload condition. First come first serve method can be employed by making
changes in ladder programming.

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