ACKNOWLEDGEMENT

It is my pleasure to be indebted to various people, who directly or indirectly contributed in the

development of this work and who influenced my thinking, behavior, and acts during the
course of study.
I express my sincere gratitude to the members of Training and Placement Cell of RCC
Institute of Information Technology for allowing us to do the Winter Training at CETE,
Kolkata.
I am thankful to Mr. S. Mukherjee for his support, cooperation, and motivation provided to me
during the training for constant inspiration, presence and blessings. I also wish to express
my gratitude to the officials and other staff members of CETE, ERTL, Kolkata who rendered
their help during the period of my project work.

CERTIFICATE

This is to certify that Ms. Arpita Paul of RCC Institute of Technology has
completed her project on Tank Level Control using PLC & HMI during her training at
CETE, Kolkata (29.12.2014 to 09.01.2015)

-------------------(S. Mukherjee)

What is a Programmable Logic

Controller (PLC)?

A PROGRAMMABLE LOGIC CONTROLLER (PLC) is an industrial computer control

system that continuously monitors the state of input devices and makes
decisions based upon a custom program to control the state of output devices.
Almost any production line, machine function, or process can be greatly
enhanced using this type of control system. However, the biggest benefit in
using a PLC is the ability to change and replicate the operation or process while
collecting and communicating vital information.
Another advantage of a PLC system is that it is modular. That is, you can mix and
match the types of Input and Output devices to best suit your application.

History of PLCs
The first Programmable Logic Controllers were designed and developed by
Modicon as a relay
re-placer for GM and Landis.

These controllers eliminated the need for rewiring and adding additional
hardware for each new configuration of logic.

The new system drastically increased the functionality of the controls while
reducing the cabinet space that housed the logic.

The first PLC, model 084, was invented by Dick Morley in 1969

The first commercial successful PLC, the 184, was introduced in 1973 and was
designed by Michael Greenberg.

What Is Inside A PLC?

The Central Processing Unit, the CPU, contains an internal program that tells the
PLC how to perform the following functions:

Execute the Control Instructions contained in the User's Programs. This

program is stored in "nonvolatile" memory, meaning that the program will not be
lost if power is removed

Communicate with other devices, which can include I/O Devices,

Programming Devices, Networks, and even other PLCs.

Perform Housekeeping activities such as Communications, Internal

Diagnostics, etc.

How Does A PLC Operate?

There are four basic steps in the operation of all PLCs; Input Scan, Program Scan,
Output Scan, and Housekeeping. These steps continually take place in a
repeating loop.
Four Steps In The PLC Operations
1.) Input Scan
Detects the state of all input
devices that are connected to the PLC
2.) Program Scan
Executes the user created
program logic
3.) Output Scan
Energizes or de-energize all
output devices that are connected to

These steps are continually

processed in a loop.

the PLC.
4.) Housekeeping
This step includes
communications with programming
terminals,
internal diagnostics, etc

Basic Ladder Logic Instructions

XIC Examine if Closed
Symbol

Definition

Examines a bit for an On condition

Use the XIC instruction in your ladder logic to determine if a bit is ON.
0 = False
1 = True

XIO Examine if Open

Symbol

Definition

Examines a bit for an off condition.

Use an XIO instruction in your ladder logic to determine if a bit if off.
1 = True
0 = False

OTL Output Latch

Usually we latch a signal with a condition and then unlatch it when a different
condition becomes true. Most of time the Latch / Unlatch go together.

Symbol

Definition

Turns a bit on when the rung is executed, and this bit retains its state when
the rung is not executed or a power cycle power occurs.
OTL is a retentive output instruction. OTL can only turn on a bit. This
instruction is usually used with OTU with both OTL and OTU addressing the same bit.
Ladder logic can examine a bit controlled by OTL as often as necessary.
When you assign an address to the OTL instruction that corresponds to the
address of a physical output, the output device wired to the screw terminal is
energized when the bit is set. When rung conditions become false, the bit remains
set and the corresponding output device remains energized.
Actuating the latch input turns the function on or causes it to change state.
The function then stays on even if the latch input is turned off. To turn the function
off, another input must unlatch which turns the function off.

OTU Output Unlatch

Symbol

Definition

Turns a bit off when the rung is executed, and this bit retains its state
when the rung is not executed or when power cycle occurs.
OTU is a retentive output instruction. OTU can only turn off a bit. This
instruction is usually used with OTL with both OTL and OTU addressing the same
bit.
Ladder logic can examine a bit controlled by OTU as often as necessary.
When you assign an address to the OTU instruction that corresponds to
the address of a physical output, the output device wired to the screw terminal is
de-energized when the bit is cleared.
The unlatch instruction tells the controller to turn off the addressed bit.
Thereafter, the bit remains off, regardless of the rung condition, until it is turned
on.

OSR One-Shot Rising

Symbol

Definition

Triggers a one-time event.

The OSR instruction is a retentive input instruction that triggers an event

to occur only one time. Use the OSR instruction when an event must start based
on change of state of the rung from false to true.
When the input instruction goes from false to true, the OSR instruction
conditions the rung so that the output goes true for one scan. The output goes
false and remains false for successive scans until the input makes another false
to true transition.

Ladder Logic Timers

Introduction
Timers are very important in ladder logic programming. Timers gives the
precision in time. Timer on delay starts timing when instruction is true. Timers
are used to track time when instruction are on or off. They could also keep track
on a retentive base.

TON Timer On Delay

Symbol

Definition

Count time base intervals when the instruction is true.

The Timer On Delay instruction begins to count time base intervals when
rung conditions become true. As long as rung conditions remain true, the timer
adjust its accumulated value (ACC) each evaluation until it reaches the preset
value (PRE). The accumulated value is reset when rung conditions go false,
regardless of whether the timer has timed out.
Each Timer on Delay is made of a 3-word element.
Word 1 is the control word
Bit 0-12: Internal Use
Bit 13: Done (DN) this bit is on when the Accumulation value >= Preset
Value
Bit 14: Timer Timing (TT) this bit is on when the timer is timing
Bit 15: Enabled (EN), this bit is on when the timer is energized.
Word 2 stores the preset value. (PRE)
The programmer specifies this value. When the accumulated time reaches
the preset value the controller sets the done bit. When the accumulated value
becomes equal to or greater than the preset value, the done bit is set. Usually
preset value is from 0 - 32,767
If a timer-preset value is negative an error will occur.
Word 3 stores the accumulated value. (ACC)
This is the time elapsed since the timer was last reset. When enabled the
timer updates this continually.
Time Base: is the timing update interval, this can vary from 0 - 1 second.

TOF Timer Off Delay

Symbol

Definition

Counts time base intervals when the instruction is false.

The Timer Off Delay instruction begins to count time base intervals when
the rung makes a true to false transition. As long as rung conditions remain false,
the timer increments its accumulated value (ACC each scans until it reaches the
preset value (PRE). The accumulated value is reset when rung conditions go true
regardless of whether the timer has timed out.
Each timer address is made of a 3-word element.
Word 1 is the control word
Bit 0-12: Internal Use
Bit 13: DN- Done
Bit 14: TT - Timer Timing
Bit 15: EN - Timer is enabled
Word 2 stores the preset value. (PRE)
Specifies the value, which the timer must reach before the controller sets
the done bit. When the accumulated value becomes equal to or greater than the
preset value, the done bit is se.
Preset value is from 0 - 32,767
If a timer-preset value is negative an error will occur.
Word 3 stores the accumulated value. (ACC)
This is the time elapsed since the timer was last reset. When enabled the
timer updates this continually.
Time Base: is the timing update interval, this can vary from 0 - 1 second.

Ladder Logic Counters

Introduction
In this section we will cover the count up count down and reset instruction.
Counters are very essential in ladder logic programming. Counters are used to
index, increment or decrement values.

Definition
The following is a list of counter instructions
CTU-Count Up
CTD-Count Down
RES-Reset

CTU Count UP
Symbol

Definition

Increments the accumulated value at each false to true transition and

retains the accumulated value when the instruction goes false or when power
cycle occurs.
The CTU is an instruction that counts false to true transition. When this
transition happens the accumulated value is incremented by one count.
A CTU accumulation is reset by the RES instruction.
If the accumulation value is over the maximum range then the overflow
(OV) bit will be true.
Each counter address is made of a 3-word element.
Word 1 is the control word
Bit 0-7: Internal Use
Bit 10: UA - Update accumulation value.
Bit 11: UN - Underflow bit.
Bit 12: OV - Overflow bit.
Bit 13: DN - Done
Bit 14: CD - Count down is enabled.
Bit 15: CU - Count up is enabled.
Word 2 stores the preset value. (PRE)
Specifies the value, which the counter must reach before the controller
sets the done bit. When the accumulator value becomes equal to or greater than
the preset value, the done status bit is set. You can use this bit to control an
output device.
Preset value is from -32,768 to 32,767

If a timer-preset value is negative an error will occur.

Word 3 stores the accumulated value. (ACC)
This is the number of times of false to true transitions that have occurred
since the counter was last rest.

CTD Count Down

Symbol

Definition

Decrements the accumulate value at each false to true transition and

retains the accumulated value when the instruction goes false or when power
cycle occurs.
The CTD is an instruction that counts false to true transition. When this
transition happen the accumulated value is decrements by one count.
A CTD accumulation is reset by the RES instruction.
If the accumulation value is below the minimum range then the underflow
(UN) bit will be true.
Each counter address is made of a 3-word element.
Word 1 is the control word
Bit 0-7: Internal Use
Bit 10: UA - Update accumulation value.
Bit 11: UN - Underflow bit.
Bit 12: OV - Overflow bit.
Bit 13: DN - Done
Bit 14: CD - Count down is enabled.
Bit 15: CU - Count up is enabled.
Word 2 stores the preset value. (PRE)
Specifies the value, which the counter must reach before the controller
sets the done bit. When the accumulator value becomes equal to or greater than
the preset value, the done status bit is set. You can use this bit to control an
output device.
Preset value is from -32,768 to 32,767
If a timer-preset value is negative an error will occur.
Word 3 stores the accumulated value. (ACC)

RES Reset
Symbol
Definition

Resets the accumulated value and status bit of a timer or counter.

Use a RES instruction to reset timers or counters. When the RES
instruction is enabled, it resets the Timer On Delay, Retentive Timer, and Counter
Up, Counter Down instruction having the same address as the RES instruction.

Arithmetic Instructions in Ladder Logic

Introduction
Basic Ladder Logic instructions allow very simple logical decisions. Arithmetic
Ladder Logic instructions go beyond the simple true or false operation to give the
ability to more complex operations. It retrieves one or more value, perform an
operation and store the result in memory.

Definition
The following is a list of the comparison instructions

ADD-Adding
SUB-Subtract
MUL-Multiply
DIV-Division

ADD-Adding
Symbol

Definition
When rung conditions are true, this output instruction adds Source A to
Source B and stores the result at the destination address. Source A and
Source B can either be values or addresses that contain values,
however Source A and Source B cannot both be constants.
Carry (C), Sets if carry is generated; otherwise resets. Cleared For floating

value

Overflow (V), Sets if underflow; otherwise resets

Zero (Z), Sets if the result is Zero; otherwise resets
Sign (S), Sets if result is negative; otherwise resets

SUB-Subtract
Symbol

Definition
When rung conditions are true, the SUB output instruction subtracts
Source B from Source A and stores the result in the destination. Source
A and Source B can either be values or addresses that contain values,
however Source A and Source B cannot both be constants.

Carry (C), Sets if borrow is generated; otherwise resets. Cleared For

floating value
Overflow (V), Sets if underflow; otherwise resets
Zero (Z), Sets if the result is Zero; otherwise resets
Sign (S), Sets if result is negative; otherwise resets

MUL-Multiply
Symbol

Definition
Use the MUL instruction to multiply one value (source A) by another
(source B) and place the result in the destination. Source A and Source
B can either be constant values or addresses that contain values,
however Source A and Source B cannot both be constants.
The math register contains the 32-bit signed integer result of the
multiply operation. This result is valid at overflow.

Carry (C), Always reset

Overflow (V), Sets if overflow; otherwise resets
Zero (Z), Sets if the result is Zero; otherwise resets
Sign (S), Sets if result is negative; otherwise resets

DIV-Divide
Symbol

Definition
When rung condition is true, this output instruction divides Source A by
Source B and stores the result in the destination and the math register.
The value stored in the destination is rounded. The value stored in the
math register consists of the unrounded quotient (placed in the most
significant word) and the remainder (placed in the least significant
word).
Source A and Source B can either be constant values or addresses that
contain values, however Source and Source B cannot both be constants.
Carry (C), Sets if carry is generated; otherwise resets. Cleared For floating

value

Overflow (V), Sets if division by zero or overflow; otherwise resets

Zero (Z), Sets if the result is Zero; otherwise resets, undefined if overflow
Sign (S), Sets if result is negative; otherwise resets; undefined if overflow.

Ladder Logic Comparison

Instructions
Introduction
This chapter give the definition of comparison instructions and the way they are
used. In general comparison instruction are used to test a pair of values to
energize or de-energize a rung.

EQU - Equal
Symbol

Definition

Test whether two values are equal or not.

If source A and Source B are equal, the instruction is logically true. Source
A must be an address. Source B can either be a program constant or an address.
Negative integers are stored in two's complement.

NEQ Not Equal

Symbol

Definition

Test whether one value is not equal to a second value.

If Source A and Source B are not equal, the instruction is logically true. If
the two values are equal, the instruction is logically false.
Source A must be an address. Source B can be either a program constant
or an address. Negative integers are stored in two's complement.

LES Less Than

Symbol

Definition

Test whether one value is less than a second value.

If Source A is less than the value at source B the instruction is logically
true. If the value at source A is greater than or equal to the value at source B, the
instruction is logically false.
Source A must be an address. Source B can either be a program constant
or an address. Negative integers are stored in two's complement.

LEQ Less Than or Equal

Symbol

Definition

Test whether one value is less than or equal to a second value.

If value at source A is less than or equal to the value at source B, the
instruction is logically true.
If the value at source A is greater than or equal to the value at source B,
the instruction is logically false.
Source A must be an address. Source B can either be a program constant
or an address. Negative integers are stored in two's complement.

GRT Greater Than

Symbol

Definition

Test whether one value is greater than the second value.

If the value at source A is greater than the value at source B, the
instruction is logically true.
If the value at source A is less than or equal to the value at source B, the
instruction is logically false.
Source A must be an address. Source B can either be a program constant
or an address. Negative integers are stored in two's complement.

GEQ Greater or Equal

Symbol

Definition

Test whether one value is greater or equal to a second value.

If the value at source A is greater than or equal the value at source B, the
instruction is logically true.
If the value at source A is less than to the value at source B, the
instruction is logically false.
Source A must be an address. Source B can either be a program constant
or an address. Negative integers are stored in two's complement.

HMI - Human Machine Interface

Human Machine Interface
Human Machine Interface aim at a better Human-machine interaction. Any
automation system is said to be blind without HMI. HMI gives the ability to the
operator, and the management to view the plant in real time. Add to that the
ability to have alarm management that can warn the operator of a problem. It
cam even log and print all the alarms in real time, which can help the
management to improve the production and efficiency.
Today there exists many Human Machine Interface softwares that could be used
to monitor, supervise and control process. What we are presenting here is just an
overview of what could be achieved with most of these softwares.
So what are the main functionalities of an HMI. Well the HMI's main functionality
is to monitor, supervise, and control processes. This could be used in a variety of
industries such as food processing, sawmills, botteling, semiconductors, oil and
gas, automotive, chemical, pharmaceutical, pulp and paper, transportation,
utilities, an more. HMI software provides the process knowledge and control
needed to perfect the products companies make and the processes they
manage. It is said that a control without an HMI is a blind control.
Human Machine Interface can display texts, pictures, bar graphs, bitmap and
animated pictures. More importantly it can also display System messages,
reports, alarms, trends and manipulate string values and calculate boolean
operations and more complex math operations. This flexibility reduces the task
that the PLC
More and more manufacturing designers are recognizing the benefits of using
Human Machine Interface to control and to operate their controls.

TANK LEVEL CONTROL

Objective
The overhead Tank is to be filled by a Pump. The pump will automatically start
when the water level of Over Head Tank reaches below Low Level and stop when
the level reaches High Level. Dry run is to be checked by the Low Level sensor of
the Under Ground Tank. In that case Pump will not run. Run time monitoring of
the pump in Second and minute is recorded and Reset Switch is also provided.
Provision of Manual Start/Stop switch is incorporated which will totally override
the automatic system. Provisions are also made for various alarms, such as
Underground Tank Empty Alarm and Pump run time exceeded 10 Minutes (If
pump runs continuously for 10 Minutes).

Justification
Automatic water level monitor came into existence because of human error and
inconsistence that is associated with manually operated water pumping
machine. This is because it takes time for individual who is manually operating
the water pump to turn off the pumping machine and this may cause water
spillage and at times the individual might not know that the water level has drop
so low until the tank is completely empty. This was the problem that leads to the
development of the ideal of an automatic water level control and automatic
pump short down.

Sensors
UG_LL : Low Level Sensor Underground Tank (B3:0/0)
OH_LL : Low Level Sensor Overhead Tank (B3:0/4)
OH_HL : High Level Sensor Overhead Tank (B3:0/5)
(Theses sensors give open contact when they are inside water and they give
close contact when they are outside water.)

Sensor Positioning
Inductive Proximity sensors were used to sense presence of water at required levels. The
sensors are
UG_LL : Low Level Sensor Underground tank (B3:0/0),
OH_LL : Low Level Sensor Overhead tank (B3:0/4),
OH_HL : High Level Sensor Overhead tank (B3:0/5)
are placed as shown below in Figure.
(Theses sensors give open contact when they are inside water and they give close
contact when they are outside water.)

Flow Diagram

Fig : Flow Chart of Tank Level Control

Tank Level Control Estimation of HMI

using Graphics

The implementation of the process should provide the features:

1. Water comes below OH_LL, the Pump will start.
2. The Pump will stop when water will rise above OH_HL.
3. Level MIMIC will show.
For the First case: The Pump will start when water comes below low level of Overhead
Tank only when there is water above low level of Underground Tank.

For the Second case: The Pump will stop when water will rise above high level of
Overhead Tank.
For the Third case: Level MIMIC based on flow rate will show where Tank capacity is 1000
L and Flow rate is 125 L/Min.

The following Blinking Alarms are provided:

1. Underground Tank Empty.
The Alarm will blink when water comes below low level of Overhead Tank but the
Underground tank is Empty.

2. Pump run time exceeded 10 Minutes

Here, Alarm will blink when Pump run time exceeds 10 Minutes in case pump
runs continuously for 10 Minutes.

Conclusion