Industrial Electronics
Contents
1. RESULTS Table 1 Hondi 40 45 50 55 60 65 70 75 80 85 90 95 RH RH RH RH RH RH RH RH RH RH RH RH Humidified impedance Dehumidified impedance Table 2 ifm NN ERES V Vsensorl Ba 1 or oro RRA Lve qp d ft ft Table 3 DP cwitch venne 0082 0164 0246 0328 0409 TONY P em nm a KL 62001 KL 62001 Readout E 7 7 9 D RN RN RN O Drs pinl om a a Pint KL 64005Vol6 o o o o Table 4 Deech seas OI 0573 0655 0737 0819 See prm s E E mun KL 62001 KL 62001 Readout a a O E d pinl Eee a a a S nu KL 64008Vol ooo Industrial Electronics 26 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 9 HALL CURRENT SENSOR MAGNETIC DEVICE DESCRIPTION The SY 03 Characteristics PARAMETER SAMBOL Nominal input If current F S Linear range Output voltage Vh Zero current offset Vo Linearity p Power supply Vcc Rating Resoponse time Trr Thermal characteristics Hystersis error Insulation resistance Operation temperature Ta Storage temperature Ts R2 35 7K SENSOR 3 3 0 T a pa pa m Tau ut 3t pe E AZvO CHARACTERISTICS OY 3A DC 0 OY 6A DC 4V OY 1 at If within OY 0 04V at If 0 within Y 1 of Vh at If F S OY 15V DC within Y 5 3 u S Max2. Industrial Electronics 39 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 13 CONTROL SYSTEM FOR MOTORS WITH EMERGENCY BACKUP PURPOSE OF EXPERIMENT 1 Understand motor s PLC Commands 2 Learn about I O MAP of PLC PREPARATION 1 FXGP WIN RELATED KNOWLEDGE 1 One should be able to understand basic commands of PLC 2 One should be able to understand the basics of motors controlling logic and basic sequence circuit 3 One should be able to design PLC I O MAP ACTIVATION CONDITION 1 Build motor s start stop circuit by using four input switches operation stop 2 PLC I O MAP is configured below Inputs STOP SWITCHM2 J X3 Switch S 4 EMERGENCY X4 Swiths 4 Outputs po MLM Y3 S MOTORIO EMERGENCY LAMP Y4 LampL3 BUZZER YS Buzzer Bl Industrial Electronics 40 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering PROGRAM PRACTICE 1 Execute the FXGP WIN and open the Project window and the program window 2 Write a program using PLC I O MAP 3 Write ladder program as shown below AID 001 0 000 Y UD AU ADS AA 4 y DOT O00 3I We vt Yoo iai a y 3 Yooo On pue Yo04 Yo05 END EXECUTION OF PROGRAM USING SIMULATOR Execute the program by converting and then writing to the plc Follow the steps use
3. 3 FXGP WIN RELATED KNOWLEDGE T One should be able to understand basic commands of PLC 8 One should be able to understand the basics of motors controlling logic and basic sequence circuit 9 One should be able to design PLC I O MAP ACTIVATION CONDITION 5 Build motor s start stop circuit by using four input switches operation stop 6 PLC I O MAP is configured below Indirect Variable Name I O Allocation TE NENNEN LADDER DIAGRAM Industrial Electronics 44 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering WORKING DESCRIPTION CONCLUSION Industrial Electronics 45 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 16 TIMERS USING PLC A driven coil sets internal PLC contacts NO and NC contacts available Various timer resolutions are possible from 1 to 100 msec but availability and quantity vary from PLC to PLC Timer Resolution Peo Fm TX TXu PG 100 msec 6 200 i TO 55 TO 62 TO 199 10 msec 24 31 T32 55 T32 62 T200 245 Retentive 1 msec 2 62 1 4 quam Selectable timers taken from the main range of 100 msec timers 56 56 TO 199 2 46 2 55 200 245 IA J Timers operate by counting clock pulses 1 10 and 100 msec The timer output contact is activated when the count data reaches the value set by the constant K
4. 000 pulses per second 2 channel Pulse Width Modulated PWT outputs 2 channel 32 bit High Speed Counters HSC counts up to 10 000 Hz 4 channel Intemupt Inputs channel pube measurement inputs capable of measuring frequency anc pulse wicdth of incoming pulses up to 10 000 Hz Real time Clock Calendar for programming scheduled ON OFF events 6016 Words 16 bit of EEPROM Program Memory expandable to 8190 Worcs with optional IC M2018P 1700 Words 16 bit of programmable EEPROM for users data expandable to 7750 Words with optional IC M2018P Built in 16 channes of PID computation engines let TIOOM PLCs directly provide PID type digital control for process automation One Independent R5232 port for connection to a host PC for programming or monitoring One independent R5485 port for networking or for connecting to extemal peripherals such as LCD display and R3485 based analog VO cards etc Industry Standard Protocols Both R5232 and R5485 serial port simultaneously support multiple communication protocols as follow i Native ASCH based Host Link Commands ij MODBUS RTU protocols ii MODBUS ASCII Protocols iv OMRON C 20H Host Link Commands Watch Dog Timer WDT which resets the PLC if the CPU malfunctions due to hardware or software emor A system reset by WDT can be determined by the STATUS T command 1 2 Special Digital l Os Four of the first 8 ON OFF inputs of the T100M PLC can be configured as speci
5. Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering 6 In the absence of magnetic field adjust the VR 10K to make the output voltage Vo OV 7E Move the magnet toward Hall sensor observe and record the side of Hall having no reaction 8 Move the magnet toward Hall sensor observe and record the distance between magnet and Hall if a change occurs at the output 9 Change the poles of magnet and repeat Steps 7 and 8 Digital hall IC l set the Module KL 64001 on the Trainer KL 62001 2 Connect the Vo3 in HALL EFFECT Digital SENSOR area to the DCV INPUT and switch power ON 3 Move the magnet toward the Hall IC and try to find out which side the Hall has no response 4 Record the distance between magnet and Hall if the change occurs at output 5 Change the polarities of magnet and record the output variation of Hall IC Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 6 ANALOG HALL SENSOR DESCRIPTION The Hall sensor in Figure 1 is an analog element and the equivalent circuit is shown in Figure 2 Since the bridge arms are not balance the 13K resistor is for the compensation The VR 10K in Figure 1 acts as an adjuster for the offset of differential amplifier q 12V Differential amplifier Figure 2 The equivalent circuit of analog Hall sensor Fig Analog Hall IC shows a Hall detector
6. Figure on KL 64001 and KL 62001 breadboard 2 Connect the Vol to KL 62001 STATUS DISPLAY amp DCV INPUT and the E to 3 Complete the following connections on KL 62001 Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering SIGNAL TO SECTION AREA SECTION AREA SIGNAL SELECT MANUAL SINGLE MANUAL MANUAL SINGLE GND CHIP SELECT CHIP 4 Switch power ON and the display should be ON 5 Set STATUS DISPLAY amp DCV MODE switch to DCV position and RANGE to 20V 6 Cover the phototransistor window with hand and record the output voltage Vol Vol V 7 Lighten the phototransistor with fluorescent lamp and record the output voltage Vol Vol V 8 Adjust the distance between source and phototransistor and complete Table 1 Results Table 1 L9 Jl pol lol ol l1 Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 2 PHOTO INTERRUPTOR PHOTO COUPLER OBJECT DETECTOR DISCRIPTION Figure shows an object detector using a fixed distance photo coupler In normal situation the detector receives light signal from LED and the output voltage Vo is low If an object passes through the window and blocks the light beam the collector current Ic decreases and the output Vo rises to a high potential The two inverters act as a wave shaper Figure Object detec
7. Industrial Electronics 47 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering b Output YO to become de energized 1 e output YO will turn OFF 5 Hence it can be seen that timer T1 is part of a cut throat circuit in that when it does time out it immediately de energizes itself 6 With timer T1 dropping out its normally closed contact will close and for as long as input XO is closed the operation will be constantly repeated 7 Line 9 Hence the output YO will be continuously OFF for 1 sec and then ON for 1 sec LAB ASSIGNMENT Design a system controlling three motors with conditions 1 All the three motors should operate for 1 second 2 When motor 1 is on the others two should be off i e only one motor should operate at a time CONCLUSION Industrial Electronics 48
8. The overall duration or elapsed time for a timers operation cycle is calculated by multiplying the present value by the timer resolution 1 e A 10 msec timer with a present value of 567 has actually been operating for 567 10 msec 567 _ 0 01 sec 5 67 seconds Timers can either be set directly by using the constant K to specify the maximum duration or indirectly by using the data stored in a data register ex D For the indirect setting data registers which are battery backed latched are usually used this ensures no loss of data during power down situations If however the voltage of the battery used to perform the battery backed service reduces excessively timer malfunctions may occur On certain programmable controllers driving a special auxiliary coil redefines approximately half of the 100 msec timers as 10 msec resolution timers The following PLC s and timers are subject to this type of selection FXO FXOS driving M8028 ON timers T32 to 55 24 points are changed to 10 msec resolution FXON driving M8028 ON timers T32 to 62 31 points are changed to 10 msec resolution Industrial Electronics 46 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering PROGRAM FOR OPERATING A BUZZER FOR 1ms 1 Build buzzer s start stop circuit by using one input switch a 1ms timer and a buzzer as an output 2 Execute the FXGP WIN and open the Project window and the program wi
9. at di dt 100A uS within Y 0 1 J within Y0 08 J Typical at RL 10KQ within 0 02V at If 100A gt 0 500M O Min at 500V DC 10 J 70 J 15 J 85 J E d 8 Vot R 3 34 3 A From the charateristics we know the input current If is 0 3A so that output voltage Vh is 0 4V for the proportion of the value of output voltage to input current so that Industrial Electronics 27 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering Vol R2 R9 RI1 DVi 0 75i1D AV 3V Vo R5 R4 DVol 10K 10K D 3V 3V When the input current change from 0 3A output voltage is 0 3V R3 R6 are DC offsetadjustment The input current is 0 adjusting is knob make the output voltage 1s 0 PROCEDURE 1 On the KL 62001 main Trainer jSSELECT block in the SMANUAL SINGLE CHIPj aera put the SMANUALj to i GNDj and in the j STATUS DISPLAY amp DCV MODE area push on the DCV and the range on the 20V The main unit provides the power supply to the module 2 Turn on the power supply put the voltage in 10V current in 100mA Connecting the main unit power supply to KL 64008 Vin and Vin Kept the voltage in same adjust the current to 0 mA Adjust R3 make Vol output is OV and adjust R6 make Vo21 output voltage is OV Change the power supply current to 1A adjust the R9 make Vo21 voltage to 1V Above adjustment 1s for
10. controllers are being used The drection pin is turned ON when the motor moves in the negative direction and tumed OFF when the stepper motor moves in the positive direction The STEPMOVEABS command makes it extremely simple to position the motor at an absolute location while the STEPMOVE command let you implement incremental move in either directions for each channel Interfacing to 5V Stepper Motor Driver Inputs some stepper motor drivers accept only SV signals from the stepper motor controller In such case you need to determine whether the drivers inputs are opto isolated If they are then you can simply connect a 2 2K current limiting resistor in series to the path from the PLC s output to the drivers inputs as shown in the following diagram Stepper Motor Driver 12 24V DC Power Supply for PLC T100MD1616 PLC CUTFUTS i Calculszuan 10m R V 5HT DH eg tor Vera Fim 24 5001 1 5 Select RoIK2 Rating 192200 DIEN Lise Clay mesistor Figure 1 1 However if the stepper motor driver input is only 5v CMOS level and non opto isolated then you need to convert the 12 24V outputs to 5V This can Industrial Electronics 34 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering be achieved using low cost transistor such as 2N4403 A better way is to use an opto isolator with logic level output as shown in Figure 1 2 This provides a galvanic isol
11. lighting because the CDS resistance don t have to much range the voltage through CDS make R1 and R2 divided the voltage let the Vbl have a potential This potential enough make Q1 turn on and make Vb2 potential get down The Q2 is a PNP transistor when B voltage Vb get down and lower to Emitter voltage Vcc a Vbe Bias the Q2 will turn so the LED is lighting 5 4 5V 2 5v R35 o Aw s E ME E 9 SENSOR 23 m K 29 s d Cac m EI 283906 A muri mh d ne E So cos LI aw 2N3804 Ia 9 vons TI 2 p 2 Rt gt l RS jn LED1 iK sim P 1005 R F 2 we uw g naz exl te 150 1 E Fig 1 CDS light controlled circuit Opposite when you used the hand covered lighting of the CDS received the CDS resistance will increased it make the Vbl1 voltage get down suddenly When Vbl lower 0 7V the QI cut off It will make the Vb2 voltage increased and Q2 Base voltage increases also make the Q2 cut off and LED turn off It means the CDS received light the LEDI will be lighting If the CDS is not received the light the LED also turn off Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering PROCEDURE 1 Find the CDS connect terminal 2 Used the meter measuring the CDS on the normal lighting the resistance 1s Ohm 3 When used the hand covered CDS what change about the resistance increase or re
12. of simulator to monitor our program Industrial Electronics 37 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan START SWI STOP Swit TCH Bow 0 E Bot l Electrical Engineering CH MOTOR z OPERAT LOM LAMP Rd as rs MOTOR Ie E an H H H H Bow 3 L E LG IS GLOFA PLC Simulator PeRGGEEEEEEEEETS pem l 3 The above figure shows that when simulator is in RUN mode and start switch is pressed the output related to operation lamp and motor status are activated which means that program is working properly LAB TASK 1 Implement the above lab in FXGPWIN and also configure the hardware 2 Also mentioned that in what sequence the hardware is connected 3 Also implement the above ladder with set and reset command as discussed in class in GMWIN STAET_SWI TCH SWITCH Bow n l 4 OPERATION En Row l STOP LAMP Row z I b STOP SWIT CH Row 3 Row 4 Browse Im utvariables Browse global variables ee Comments OT VAR OXO 2 2 BOOL san OPERATION_LAMP VAR 36 Q0 2 1 BOOL START SWITCH VAR 88 0 0 2 BOOL STOP LAMP VAR OX0 2 0 BOOL Row 7 STOP SWITCH VAR 60 2 0 BOOL SWITCH A VAR 60 0 0 BOOL Industrial Electronics 38 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering LADDER DIAGRAM WORKING DESCRIPTION CONCLUSION
13. the actuator side PLCs operate electric motors pneumatic or hydraulic cylinders magnetic relays solenoids or analog outputs The input output arrangements may be built into a simple PLC or the PLC may have external I O modules attached to a computer network that plugs into the PLC PLCs are well adapted to a range of automation tasks These are typically industrial processes in manufacturing where the cost of developing and maintaining the automation system is high relative to the total cost of the automation and where changes to the system would be expected during its operational life PLCs contain input and output devices compatible with industrial pilot devices and controls little electrical design is required and the design problem centers on expressing the desired sequence of operations PLC applications are typically highly customized systems so the cost of a packaged PLC is low compared to the cost of a specific custom built controller design On the other hand in the case of mass produced goods customized control systems are economic due to the lower cost of the components which can be optimally chosen instead of a generic solution and where the non recurring engineering charges are spread over thousands or millions of units A microcontroller based design would be appropriate where hundreds or thousands of units will be produced and so the development cost design of power supplies input output hardware and necessary testing and ce
14. using an analog Hall IC LT110 The output of this Hall element is directly proportional to the distance from the magnetic field The analog signal is amplified by the differential amplifier U3 Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering PROCEDURE A l Complete the circuit of Figure on KL 64001 and KL 62001 breadboard 12V Differential 2 Connect the Vo4 to KL 62001 STATUS DISPLAY amp DCV INPUT 3 Complete the following connections on KL 62001 SECTION AREA SIGNAL TO SECTION AREA SIGNAL MANUAL SINGLE MANUAL SINGLE SELECT CHIP MANUAL SELECT CHIP GND 4 Switch power ON and the display should be ON 5 Set STATUS DISPLAY amp DCV MODE switch to DCV position and RANGE to 20V 6 Inthe absence of magnetic field adjust the VR 10K to make the output voltage Vo 0V 7 Move the magnet toward Hall sensor observe and record the side of Hall having no reaction 8 Move the magnet toward Hall sensor observe and record the distance between magnet and Hall if a change occurs at the output 9 Change the poles of magnet and repeat Steps 7 and 8 Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering Analog hall IC l Set the Module KL 64001 on the Trainer KL 62001 Connect the Vo4 in HALL EFFECT Analog SENSOR area to the DCV INPUT and switch power O
15. 107 TBASIC commands STEPSPEED STEPMOVEABS STEPCOUNTABS STEPMOVE STEPSTOP STEPCOUNT t is essential to understand the difference between a steppe motor Controller and a steppe motor rer A stepper motor Driver comprises the power electronics circuitry that provicles the voltage curent and phase rotation to the stepper motor coils Industrial Electronics 33 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering The T100M s built in Stepper Motor Controller on the other hand only generates the requred number of pulses and sets the direction signal according to the defined acceleration and maximum puling rate specified by STEPSPEED and STEPMOVE commands You cannot directly connect the pulses to the steppe motor You wil need a stepper motor diver which you can buy from the motor vendor Depending on the power output the number of phases of the stepper motor and whether you need micro stepping the driver can vary in size and cost Most steppe motor dives have opto solated inputs which accept a direction signal and stepping pulse signal from the Stepper Motor Controller In this case the T100M is the stepper Motor Controller which wil supply the required pulse and direction select signals to the driver Note that the digital output 1 and 2 automatically become the direction select signals for Stepper controller 1 and 2 respectively when the steppe
16. 2 The magnitude of negative output is proportional to sensed humidity The R17 is for gain adjustment and the R14 is for zero level calibration Figure 2 shows the characteristic of humidity sensor Figure 1 Humidity transducer circuit Industrial Electronics 23 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering 40 T el e L ed e EL E 4 Nn 9 T 10 K 40 FL k Figure 2 Characteristic of HOS201 HYGROMETER In Figure 1 we measure the output voltage of Vol6 using DMM or AD converter Using DMM the voltage reading must divide by 100 mV to obtain the value of humidity Using AD converter the readout represents the value of humidity The operating range of HOS201 is from 55 to 100 RH and a tolerance of Y3 RH PROCEDURE A Basic measurement 1 Set the Humidity Transducer Module KL 64005 Block 16 on the Trainer KL 62001 Supply the power 2 Using scope measure and record the signal at Vf2 f Hz Vp p V 3 Using scope measure and record the signal at SENSOR16 f Hz Vp p V B Impedance measurement 1 Connect the DMM probes to HOS201 lead wires Industrial Electronics 24 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering 2 Set humidity disk with water hygrometer and HOS201 in the Thermostatic Complete Table 1 using the fan and water 3 4 P
17. D gt KL 64005 GND 2 Using 25 pin cable connect the RS 232 interface to any serial port of personal computer 3 Set the AD590 Transducer Module KL 64005 on the Trainer KL 62001 4 Repeat Steps 2 to 3 from section A 5 Set the DIP switches to the value of 4095 6 Turn on KL 62001 7 Complete Table 3 8 When the temperature exceeds the setting the potential at OUT CONTROL pin4 should be LOW and the alarm buzzer is turned on Previous Steps are used to display the temperature values of the AD590 transducer through the single chip microcomputer 9 Connect the SINGLE CHIP amp EPROM OUT CONTROL CTRL to the GND 10 Boot the computer using the KL 62001 disk At A gt type CD BASIC lt ENTER gt Then type YOURBASIC lt ENTER gt At OK type LOAD KLPLOTER lt ENTER gt At OK type RUN lt ENTER gt 11 The screen will display Select Monochrome or Color display M C M monochrome C color default C Select RS232 ON COMI or COM2 1 2 1 COM1 2 COM2 default COM2 12 After your selections the screen shows 9 functions 1 Acquire Data Industrial Electronics 20 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Load Data Save Data Plot Data Sample Times 10000 Range Voltage 25to5 5 sample Rate HR MN SC gt MAX Print Data 9 EXIT Se Ie MAP ue ex do 13 Select function 1 by typing 1 1 lt ENTER gt Electrical Engineering b Change the temperature values a
18. Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering Federal Urdu University of Arts Science amp Technology LAE MAN UAL SEVENTH SEMESTER INDUSTRIAL ELECTRONICS BASIC ELECTRICAL amp ELECTRONICS LAB DEPARTMENT OF ELECTRICAL ENGINEERING i Prepared By Checked By Approved By i Engr Asad Jamal Engr M Nasim Khan Dr Noman J afri Lecturer Lab Electrical Senior Lab Engineer Electrical Dean FUUAST Islamabad FUUAST Islamabad FUUAST Islamabad Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering Registration No Roll No Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering CONTENTS WI NN PREXI MI TY SENSOR E INTRODUCTION TO PLC S MN LLL I m m I UJ NJ m m m Oo Ul Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 01 PHOTO TRANSISTOR DISCRIPTION The circuit of figure is a light controlled switch using a phototransistor When incident light 1s absent the resistance across C and E is high and the output voltage Vo is high If incident light applied the output voltage will reduce in response to incident illumination Figure A light controlled switch PROCEDURE 1 Complete the circuit of
19. LECT area to GND on the Module KL 62001 4 Connect the Vol5 on KL 64005 to the DCV INPUT on KL 62001 5 Insert the AD590 into the Thermostatic Container Read and record the readout for each temperature setting in Table 2 6 Compare the settings with the readouts C Computer interface and control Figure shows the functional blocks of module KL 62001 The transducer output 0 to 5 VDC applies to inputs of the 12 bit A D converter and then 1s converted to digital signals to the PIO chip or the single chip microcomputer 8031 according to control signals The PIO chip is a interface for transmitting the digital signals to a buffer card in a personal computer The RS 232 is a communication interface for communication between the single chip 8031 and serial ports of the personal computer Refers to the KL 62001 USER S MANUAL for details KL 62001 CUT circuit SELECT mo jH SIGNAL 25Pin CABLE COMPUTER INTERFACE To buffer card 25Pin CABLE RS 232C To communication port OUT ALARM Load unit Figure Functional diagram of KL 62001 1 Complete the connections as follows SECTION AREA SIGNAL TO SECTION AREA SIGNAL Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering MANUAL MANUAL SELECT axcrp nu CHIPSSELECT aca GND pecan HIP OUTCONTROL 1 AMPLIFIER Penance SIN IN oi MN CONTROL A D IN gt KL 64005 Vol5 a eaten CONTROL GN
20. N Move the magnet toward the Hall IC and try to find out which side the Hall has non response Record the distance between magnet and Hall if the change occurs at output Change the polarities of magnet and record the output variation of Hall IC Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 7 TEMPERATURE SENSOR DESCRIPTION The AD590 is an excellent sensor for temperature to current conversion due to its good linearity with a transduction ratio of 1 A K The circuit of Figure 1 is the AD590 transduction circuit with two different transduction outputs the 10mV K at U1 PIN6 and the 100mV J at Vol15 The UI acts as a voltage follower The output of U1 can obtain the voltage of 10mV K by adjusting the R2 for R2 R3 10K In many applications the Celsius scale is more convenient than absolute temperature The relationship of these two temperature scales is K C 273 2 and 273 2 K 0 C In other words if the temperature is at 273 2 K O C the output voltages at Vfl and U1 should be 2 732V and OV respectively In order to yield the 2 732V stabilized voltage a voltage regulator which consist of R6 CRI R7 R8 R9 and U3 is used Figure 1 AD590 transducer circuit A digital thermometer shown in Figure 2 is built with the AD590 transducer module and the Industrial Electronics Federal Urdu University of Arts Science a
21. able to understand motor s starting method 2 One should be able to understand basic sequence circuit 3 One should be able to design PLC I O MAP ACTIVATION CONDITION 1 Build motor s start circuit by using two input switches start stop Output consists of output coil for electronic contact maker operation lamp and stop lamp Initially stop lamp must glow 2 If start input switch is turned on motor gets started and then operation lamp turns on whereas stop lamp turns off 3 If one turns on stop lamp during operation motor stops and lamp turns on and operation lamp turns off 4 PLC I O MAP is configured below Indirect Variable Name START SWITCH Push Switch S 2 Inputs Outputs PROGRAM PRACTICE 1 Execute the GMWIN and open the Project window and the program window 2 Write a program using PLC I O MAP 3 Write ladder program as shown below Industrial Electronics 36 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXECUTION OF PROGRAM USING SIMULATOR 1 To verify what was mentioned above one uses a simulator which is characteristic of GLOFA t perform an experiment to check whether there is any abnormality in the circuit and its activation 2 Simulator starts when one clicks the icon m on Basic tool bar When one clicks on this icon firstly following window opens If one clicks OK than simulator starts and we can use inputs and outputs
22. al inputs such as High Speed Counters Intemupts and Pulse Measurement Some of the first 8 outputs can also be configured as PWM and the stepper controller pulse outputs If these special l Os are not used then they can be used as ordinary ON OFF type I O in the ladder diagram Note that f two special functions share the same I O then only one of them can be active at any one time The location of these special I O are tabulated as follows Industrial Electronics Electrical Engineering 32 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering Special Inputs B Oe we eee ee R WE NE J an AE NM a LN Note A pin defined as a special input cannot simultaneously act as another special input E g Pin 3 cannot be used as high speed counter and at the same time seres as a pulse measuring pin Special Qutputs Output Stepper pulse output PWM output NE PENNE Direction for Ch 1 m These special l O therefore share the same electrical specifications as the ON OFF type WO which have already been described in the Installation Guide 1 3 Stepper Motors Controller Outputs Technical Specifications No of Channels Max Pulse Rate pps 20000 single channel running 10000 twa channels running Maximum Load Current 1A 24V DC Velocity Profile Trapezoidal Defined by STEPSPEED accelerate from 1 8 max pps to max pps decelerate from max pps to 1 8 max pps 2 7 2 1x
23. ation between the PLO and the stepper motor driver 5V OV Steppers supply i og Logic output 12 24V DC W Optoisolator Power Supply pwy Ne pisiusia iac TETEITETE or PLC Quality Technology 1 OUTPUTS To 5Y CMOS stepper driver input 2K2 resistor mA max 2 2K 1 4 PWM Outputs Pulse Width Modulation PWT is a highly efficient and convenient way of controlling output voltage to devices with large time constants such as controlling the speed of a DC motor the power to a heating element or the position of a proportional valve PW works by first tuming the output to full voltage for a short while and then shutting it off for another short while and then turning it on again and so on in accurate time intervals This can be illustrated in the following diagram The average voltage seen by the load is determined by the duty cycle of the PWM wave form The duty cycle is defined as follow a Duty Cycle x 100 Period a b Frequency 1 period Hz 1 4 Industrial Electronics 35 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 12 MOTOR START STOP CONTROL PROGRAM PURPOSE OF EXPERIMENT 1 Understand motor s starting principle using PLC 2 Learn about I O MAP of PLC 3 Understand the structure and principle of PLC SIMULATOR PREPARATION 1 PC FXGPWIN Installed 2 PC GMWIN Installed RELATED KNOWLEDGE 1 One should be
24. calibration voltage output to make it is an calibrated current detector p xev IA duc uds Change the terminals of power supply to any other current circuit willknow the circuit current are how many Attention the current can not over 3A Industrial Electronics 28 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT No 10 PREXIMITY SENSOR DESCRIPTION As Fig 1 is used the capacititive type proximity switches for the experimental circuit SENSOR 22 12V n P ida GND Fig 1 Capacititive type proximity switches SPECIFICATION D C Current 10 30VDC Max Ripple 10 Real Dis lt 80 Sr Magnetic hysteresis lt 15 Sr Accurancy lt 5 The sensor is on the S SHIGH position when they are no metal approach through the U3 a Schmitt reverser the Vo22 point 1s low position that why the buzzer no alarm When the metal objector near the sensor the LED turn on and output become low level through the reverser become high position than the transistor turn on the buzzer alarm Industrial Electronics 29 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering PROCEDURE l set the Module KL 64008 on the Trainer KL 62001 and connect the power source 2 Plug in the capacitive proximity switch to the module Switch the power on gt When no metal approach the proximity switch what voltage on t
25. ctor using a fixed distance photocoupler In normal situation the detector receives light signal from LED and the output voltage Vo is low If an object passes through the window and blocks the light beam the collector current Ic decreases and the output Vo rises to a high potential The two inverters act as a wave shaper Figure Object detector EXPERIMENTS AND RECORDS 1 Complete the circuit of Figure on KL 64001 and KL 62001 breadboard 2 Connect the Vo2 to KL 62001 STATUS DISPLAY amp DCV INPUT and the to GND Connect the output CK to COUNTER input or Oscilloscope input 3 Complete the following connections on KL 62001 SECTION AREA SIGNAL TO SECTION AREA SIGNAL SELECT MANUAL SINGLE MANUAL SELECT MANUAL SINGLE GND CHIP CHIP 4 Switch power ON and the display should be ON 5 Set STATUS DISPLAY amp DCV MODE switch to DCV position and RANGE to 20V Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering 6 In the absence of object between emitter and detector measure and record the output voltage Vo2 V 7 In the presence of object between emitter and detector measure and record the output voltage Vo2 V 8 Cuta sheet of paper to a pulse shape and move it between emitter and detector and record the output waveform Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engi
26. d in the previous lab SUMMARY OF LOGIC USED PROGRAM SUMMARY Industrial Electronics 4 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 14 WATER LEVEL CONTROL SYSTEM PURPOSE OF EXPERIMENT 3 Understand motor s PLC Commands 4 Learn about I O MAP of PLC PREPARATION 2 FXGP WIN RELATED KNOWLEDGE 4 One should be able to understand basic commands of PLC 5 One should be able to understand the basics of motors controlling logic and basic sequence circuit 6 One should be able to design PLC I O MAP ACTIVATION CONDITION 3 Build motor s start stop circuit by using four input switches operation stop 4 PLC I O MAP is configured below Indirect Variable Name I O Allocation TE ed PROGRAM PRACTICE 4 Execute the FXGP WIN and open the Project window and the program window 5 Write a program using PLC I O MAP 6 Write ladder program as shown below Industrial Electronics 42 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering LADDER DIAGRAM WORKING DESCRIPTION CONCLUSION Industrial Electronics 43 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 15 MOTORS LOAD DISTRIBUTION CONTROL SYSTEM PURPOSE OF EXPERIMENT 5 Understand motor s PLC Commands 6 Learn about I O MAP of PLC PREPARATION
27. duce in the same time the CDS resistance 1s Ohm 4 Geta 60W bulb lighting to CDS what change about the resistance a increase or reduce in the same time the CDS resistance 1s Ohm 5 Can you used the CDS design a sample automatic lighting circuit 6 Set the Module KL 64009 on the Trainer KL 62001 and connect the power source 7 On the KL 62001 main Trainer SSELECT block in the SMANUAL SINGLE CHIP area put the SMANUAL to i GNDj and in the SSTATUS DISPLAY amp DCV MODE area push on the iSDCV and the range on the 20V 8 Adjusting the R1 make the LED just on the lighting position Used the voltmeter measuring the Vb1 Vb2 V023 3 points voltage value and record on the Table 9 Used the hand covered the lighting of the CDS received even the CDS didnjjt received lighting but in this time the LED is turn jSON or jSOFF MEASURING THE Vbl Vb2 V023 the 3 points voltage and record on the Table 10 If CDS and R1 R2 change the position than when the CDS received the lighting which the LED is turn j ON or jSOFF RESULTS STATUS Vbl Vb2 V023 LED1 STATUS CONCLUSION Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 4 SENSORS OBJECT DETECTOR PURPOSE OF EXPERIMENT 1 To work On KL 62001 Trainer 2 To build Circuit on KL 64001 DISCRIPTION OF EXPERIMENTAL CIRCUITS Figure shows an object dete
28. he output and Vo22 4 When the metals approach the proximity switch how long the distance the buzzer will be alarm Industrial Electronics 30 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 11 INTRODUCTION TO PLC S BASICS A programmable logic controller PLC or programmable controller is a digital computer used for automation of electromechanical processes such as control of machinery on factory assembly lines amusement rides or lighting fixtures PLCs are used in many industries and machines Unlike general purpose computers the PLC is designed for multiple 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 or non volatile memory A PLC 1s an example of a real time system since output results must be produced in response to input conditions within a bounded time otherwise unintended operation will result The main difference from other computers is that PLCs are armored for severe conditions such as dust moisture heat cold and have the facility for extensive input output I O arrangements These connect the PLC to sensors and actuators PLCs read limit switches analog process variables such as temperature and pressure and the positions of complex positioning systems Some use machine vision On
29. lot the impedance vs humidity curve using the data in Table 1 5 Compare the curve in Step 4 to the curve in Figure 2 and explain the difference 6 Compare the humidified impedance to the dehumidified impedance and explain the difference C Conversion voltage measurement Set the Humidity Transducer Module KL 64005 Block 16 on the Trainer KL 62001 supply the power Connect the HUMIDITY SENSOR leads to SENSOR IN Repeat Step 2 in experiment B Complete Table 2 p e den em Plot V sensorl6 vs humidity Vu4 pin6 vs humidity and Vo16 vs humidity curves D Computer control 1 Complete the following connections SECTION AREA SIGNAL TO SECTION AREA SIGNAL SINGLE CHIP amp OUT CONTROL 1 AMPLIFIER ALARM SIN IN EPROM KL 64005 Vol6 POTENTIO METER VRI KL 64005 GND POTENTIO METER VR3 POTENTIO METER VR2 gt A D CONVERTER CONTROL A D IN POTENTIO VR3 SELECT GND METER MANUAL SINGLE CHIP 2 Repeat Steps 1 and 2 in experiment C 3 Complete Table 3 4 Connect the SINGLE CHIP amp EPROM OUT CONTROL CTRL to the GND This step performs the data communications between the transducer circuit and the personal computer via the RS 232 port Industrial Electronics 25 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering 5 Follow the steps for the RS 232C control in experiment temperature AD590 computer control and proceed the following steps 6 Note 1V 10 RH
30. mp Technology Islamabad Pakistan Electrical Engineering 7135 A D converter Since the transduction output of the AD590 transducer is 100mV J such that the full scale voltage of the A D converter must be set to 20V KL 62001 STAUS DISPLAY amp DCV KL 64005 AD590 TRANSDUCER Vo15 MODOLE vr 7135 AD CONVERTER Figure 2 Digital thermometer PROCEDURE A Characteristics and transduction circuit of the AD590 1 Place Module KL 64005 Block 15 on the Trainer KL 62001 2 Measure the resistance between U1 pin3 GND with the DMM and adjust the R2 for the resistance value of 1OKQ 3 Adjust the R8 to make Vf1 2 732V 4 Putthe AD590 in the Thermostatic Container The pins of AD590 must be isolated from water Measure and record the output voltages at U1 pin6 and Vol5 for each temperature setting in Table 1 5 From Table 1 the voltage difference between U1 pin6 and Vo15 V 6 Construct the conversion curve of AD590 transducer using data in Table 1 7 Review the curve in Step 6 calculate and record the temperature to voltage transduction ratio mV J B Digital thermometer 1 Place module KL 64005 on KL 62001 2 Repeat Steps 2 to 5 from section A Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering 3 Set the MODE switch to the SENSOR position the RANGE switch to the J position and connect MANUAL SE
31. nd observe the temperature curve on the screen 1V 104J c If the screen displays the error message Device Timeout in 600 please d retry from Step 12 for a correct selection of the RS232 port 14 Type 9 lt ENTER gt to exit RESULTS Table 1 Upn J J Loves o o go og o pg pg o Vo15 V 10 20 a0 AQ 50 60 70 g0 eg 100 T Table 2 Industrial Electronics 21 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering Tempera 30 40 so 60 70 80 90 100 Readout TT po ojo o Table 3 DIP switch 0819 1638 2457 3276 4095 Settings GOD COD GOED 40gJ S0 I KL 62001 readout o Temperature oo o o rourconrrotpnt fourconrrotpia Kcewswuse Industrial Electronics 22 Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 8 HUMIDITY SENSOR DESCRIPTION The circuit of Figure 1 is a humidity transducer circuit for this experiment This circuit consists of four sections The first section 1s an oscillator consisted of U5 and U6 The U6 Wein oscillator generates a sine wave The US acts as an amplitude limiter to limit the sine wave at 250 Hz and 0 5 Vrms The second section serves amplification filtering and rectification It consists of U4 C1 and CR
32. ndow 3 Write ladder program as shown below 000 g 4 pE tier K10 TU 4H h_f t 0 b END PROGRAM FOR TURNING A DEVICE ON OFF AT A CONTROLLED RATE In this example the Output YO will be ON for 1 sec and then OFF for 1 sec It will be used to describe how a PLC ladder can be produced modified and tested Then using a Mitsubishi FX2NPLC the program will be downloaded run and monitored The ladder diagram for the circuit and its explanation 1s given below 000 T1 0 a C _ ID E1U Td 5 MM MT1 ETO 1 Line 0 a On closing the input switch X0 the timer TO will be enabled via the normally closed contact of timer T1 b Timer TO will now start timing out and after 1 sec the Timer will operate This means 1 Any TO normally open contacts jj will close 11 Any TO normally closed contacts j j will open 2 Lines 5 and 9 There are two TO contacts which are both normally open therefore both of them will close causing the following to occur a Timer T1 will become enabled and start timing out b Output YO will become energized i e output YO will turn ON 3 Line 5 After timer T1 has been energized for 1 sec it will also operate and its normally closed contact will open causing Timer TO to dropout 4 With Timer TO dropping out its normally open contact will now re open causing a Timer T1 to dropout even though T1 has just timed out
33. neering EXPERIMENT No 5 DIGITAL HALL SENSOR DESCRIPTION Figure 3 Digital Hall circuit shows the circuit The block diagram of IC 3503 is shown in Figure 4 Block diagram of IC 3503 The internal power regulator Vref provides a constant current to the Hall element X and a regulated voltage to amplifiers The output transistor 1s an open collector configuration which can sink the current up to SmA When a magnet is placed in close proximity with a magnetic field as shown in Figure 5 The sensing method for Hall and magnet its output 1s inversely proportional to the strength of and the proximity to the magnetic field To determine its output state high or low the output must be amplified by a differential amplifier The amplified output 1s then send to a Schmitt latch which determines the output state To reverse the output state a magnetic field of opposite polarity should be added Refer to Figure 6 for the output voltage versus distance characteristics of IC 3503 PROCEDURE A l Complete the circuit of Figure on KL 64001 and KL 62001 breadboard Zi Connect the Vo4 to KL 62001 STATUS DISPLAY amp DCV INPUT 3 Complete the following connections on KL 62001 SECTION AREA SIGNAL TO SECTION AREA SIGNAL MANUAL SINGLE MANUAL SINGLE SELECT CHIP MANUAL SELECT CHIP GND 4 Switch power ON and the display should be ON 5 Set STATUS DISPLAY amp DCV MODE switch to DCV position and RANGE to 20V Industrial Electronics
34. rtification can be spread over many sales and where the end user would not need to alter the control Automotive applications are an example millions of units are built each year and very few end users alter the programming of these controllers However some specialty vehicles such as transit busses economically use PLCs instead of custom designed controls because the volumes are low and the development cost would be uneconomic Very complex process control such as used in the chemical industry may require algorithms and performance beyond the capability of even high performance PLCs Very high speed or precision controls may also require customized solutions for example aircraft flight controls Programmable controllers are widely used in motion control positioning control and torque control Some manufacturers produce motion control units to be integrated with PLC so that G code involving Industrial Electronics 3l Federal Urdu University of Arts Science amp Technology Islamabad Pakistan a CNC machine can be used to instruct machine movements citation needed 1 1 Introduction A Standard T100MD PLC features the following 1 2 3 4 3 6 7 a 3 10 11 12 13 i 14 zm m 4 to 8 channels of 10 bit Analog Inputs 4 on TIOOMD1616 1 to 2 channels of 8 bit Analog outputs 2 channel programmable Motion Controllers for controlling stepper motors up to 20
35. tor PROCEDURE 1 Complete the circuit of Figure on KL 64001 and KL 62001 breadboard Emitter 2 Connect the Vo2 to KL 62001 STATUS DISPLAY amp DCV INPUT and the to GND Connect the output CK to COUNTER input or Oscilloscope input Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering 3 Complete the following connections on KL 62001 SECTION AREA SIGNAL TO SECTION AREA SIGNAL SELECT MANUAL SINGLE MANUAL SELECT MANUAL SINGLE GND CHIP CHIP 4 Switch power ON and the display should be ON 5 Set STATUS DISPLAY amp DCV MODE switch to DCV position and RANGE to 20V 6 In the absence of object between emitter and detector measure and record the output voltage Vo2 V 7 In the presence of object between emitter and detector measure and record the output voltage Vo2 V 8 Cuta sheet of paper to a pulse shape and move it between emitter and detector and record the output waveform Industrial Electronics Federal Urdu University of Arts Science amp Technology Islamabad Pakistan Electrical Engineering EXPERIMENT NO 3 CDS SENSOR DESCRIPTION In this experimental circuit we used CDS can change the light stronger or week to resistance value characteristics and get the purpose of light controlled circuit As the Fig 1 circuit the CDS is under the normal lighting operation Adjusted the R1 make the LED 1 just from the dark to
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