Jai lal meena (2)

Jaimeena25@gmail.com
COLLEGE OF TECHNOLOGY AND ENGINEERING
Maharana Pratap University of Agriculture and Engineering
UDAIPUR (RAJASTHAN)-313001, INDIA
A REPORT ON TRAINING
Taken at
“PYROTECH ELECTRONICS PVT. Ltd., UDAIPUR”
On
“GENERATOR CONTROL PANELS &
PLC PANELS”
Submitted in partial fulfillment for the award of degree of
Bachelor of Engineering
(20010-11)
Submitted to: Submitted by:
Dr. Navneet Agarwal Jai Lal Meena
Training Incharge. 3rd
Yr. (ECE)

ACKNOWLEDGEMENT
I would like to express my sincere gratitude to “Pyrotech Electronics Pvt. Ltd.,
Unit-2, Udaipur” for giving me an opportunity to undergo my Industrial
Training for four weeks for providing me knowledge of Purge Panels. I would
also like to thank technical experts, engineers and executives for explaining
practical aspects of the theoretical knowledge.
My greatest debt in creating this project goes to the Assistant Manager, HRD
Ms. Surabhi Soni (Project Incharge) who has given me the basic concepts of
Purge Panels. Thank you Ms. for encouraging me every step of the way.
I owe a personal thanks to Mr. P.C.Talesara(Director) who extended a full
support and cooperation during my training period.
Here I obtained practical knowledge. For this travel of knowledge & training, I
am grateful & thankful to Mr. Sunil Joshi (HOD, Electronics &
Communication Department, C.T.A.E. Udaipur) & Dr. Navneet Agarwal
(Training Incharge) for initiating my interest in training.
Last but not the least I m indebted to my parents and friends for their constant
encouragement and help in my endeavour.
Needless to say, without all the above help and suggestions my training would
not have been a success.
Amit Verma
3rd
Yr ECE

PREFACE
With the ongoing revolution in electronic and communication where
innovations are taking at the blink of eye, it is impossible to keep the pace with
the emerging trends.
Industrial approach to problem solving based on a broad understanding of
process and mode of operation of organization.
During this period, the student gets the real experience for working in the actual
Industry environment. Most of the theoretical knowledge that has been gained
during the course of their studies is put to test here. Apart from this student gets
an opportunity to learn the latest technology, which is immensely helps in them
in building their career.
I had the opportunity to have a real experience on many ventures, which
increased my sphere of knowledge to great extent. I got a chance to learn many
new technologies and was also interfaced to many instruments.

CONTENTS
Profile of the company
Introduction
Pyrotech group
Manufacturing facility
Products
Clients
Company visit
PLC Panels
Introduction
History
Development
Programming
PLC Hardware
Configuration Of Typical PLC
Working Of PLC
Advantages Of PLC
Application Of PLC system
PLC v/s Computer
PLC Disadvantages
Conclusion
Generator Control Panel
• General Description
• Controlling Our Machines
• Working
Bibliography

PROFILE OF THE COMPANY
Introduction
Pyrotech, Unit-2 provides complete solution for electronic process control
instruments to the industries. Presently it is manufacturing about 200 different
types of process control instruments. It has a strong R & D team, comprising of
more than 50 engineers.
It is a leading manufacturer of Electronic Process Control Instruments. Its
product range includes Signal Converters, Transmitters, Electrical Transducers,
Indicators, Flow Totalizer, Power Factor Correction Relays, Timers, Counters,
Alarm Annunciator, Temperature Scanners, Speed Measuring Systems, Temp-
Max Transmitters, Closed Circuit Television Systems and Special Instruments
like Surge Arresters, Test Benches, Selector Switches, Rpm Generators & pH
Measuring Systems etc. It is a distributor of L&T AC/DC drives, Siemens field
instruments,CCTV, Wireless Modems, Ultrasonic/Radar Level Transmitter. It
also undertakes PLC automation jobs for the process control industries.

Pyrotech Group
Pyrotech Group
(Control &
Instrumentation
Electronic & Sensor
Equipment)
Pyrotech
Electronic Pvt.
Ltd. Unit II
ISO 9001:2008
ISO
14001:2004
ISO
18001:2007
OHSAS
(Control &
Instrumentation
)
Pyrotech
Electronic
Pvt. Ltd.
Unit I
ISO
9001:2000
(Electricals
&
Electronics)
Tempsens
Instrument
ISO 9001:2000
(Temprature
Sensors)
Pyrotech
Marketing
& Project
Pvt. Ltd.
(Marketing
)
Pyrotech
Workspac
e Solution
Pvt. Ltd.
ISO
9001:2000
Industrial
Automation
Annuniciator
Bar
Graphindicato
r Tranducer
Scanner
Thermocouple
Resistance
Thermometers(RTD's
)
Services,
Marketing
PLC
Projects
Control
Room &
Control
Desk
Interior

Manufacturing Facility
CNC hydraulic press punch, system controller -siemens 840D model name -
aquila 1250, linear turret trumph type, multistation (11 station). This multitool
turret incorporates advantages such as:
(A) Reduced throughput cycle.
(B) High Accuracy
(C) Better Machinability
(D) Versality in punching hole.
Converized powder coating plant with 2 booth ro ro & 4 paint guns back to
back oven size 11mtr, 25 mtr length with omega loop conveyor, overall
conveyor length 120 mtr. this plant facilitate features like
(a)Reduced handling hassles
(b)Uniform thickness through the sheet
(C)Considerable reduction in time cycle

Well set material management department that looks after planning &
procurement, vendor development & support, quality improvement, cost
reduction, import substitution etc.
Sheet surface treatment shop
7 tank system (7000 liter capacity)
7 tank system (2500 liter capacity)
Hot seven tank process generates phosphated & chromatised sheet having good
resistance to oxidation and errosion. Being an automated conveyorised plant the
cycle time of each dip is precisely fixed.
Specialized designed programs and CAD software generate faster design output.
Our designers help you visualize your product in advance.

The product development process includes stringent internal testing. Each
enclosure is subjected to harsh environmental conditions. Extensive & rigorous
testing for paint, mechanical, electrical, calibration, measurement & functional
testing of panels is undertaken to ensure they meet our standards & customer's
requirements.
Fabrication shop is equipped with power press, arc / mig / tig / spot welding
machines, pneumatic riveting and grinding machines to ensure reliable process.

Stud welding machine bms-10n/2
model no.: p01050a00329-04
this new machine renders better finish to the sheet due to removal of depression
& burrs.
Wiring for plc - swing arms, mosaics, connectors etc. with suitable ferruling is
done. termination from 0.5 mm2 to 60mm2 is possible.

Products
PANELS & CONTROLS DESKS
MOSAIC PANEL & DESK
MIMIC PANEL
CONTROL PANEL
PLC PANEL
MARSHALLING PANEL
NETWORKING PANEL 19"
TRANSDUCER PANEL
19" RACK PANEL
MCC PANEL
PURGE & EXPLOSION PROOF
PANEL
JUNCTION BOX
METERING BOX
LIE/LIR
SHELTER PANEL
HT PANEL
NG & LAVT CUBICLE
TEST BENCH
COMPUTER CONSOLES

SYSTEM INTEGRATIONS – DISTRIBUTORSHIP
SYNELEC - LARGE VIDEO
SCREEN
SUPTEAM - MOSAIC TILE SYSTEM
WEIGEL - PANEL METERS
AND ACCESSORIES
WORKSPACE SOLUTION
INDUSTRIAL FURNITURE
OFFICE FURNITURE

Clients
ASEA BROWN BOVARILTD., BANGLORE, NEW DELGHI, BARODA
JINDAL POWER, RAIGARH
ALSTOM TRANSPORT
J.K. CEMENT WORKS, NIMBAHERA
AREVA,NOIDA
J.K. INDUSTRIES LTD.
KIRLOSKAR BROTHERS LTD. KRIBHCO
AMBUJA CEMENT
LARSEN & TOUBRO LIMITED, MUMBAI, CHENNAI, BARODA
BHABHA ATOMIC RESEARCH CENTRE
MCNALLY BHARAT ENGINEERING CO. LTD.
BENTLY NEVADA
METSO AUTOMATION (NELES AUTOMATION)
BHARAT ELECTRONICS LTD.
MTL SYSTEMS LTD. CHENNAI
BHARAT HEAVY ELECTRICALS LIMITED, BANGLORE, BHOPAL, HARDWAR,
HYDRABAD
NATIONAL FERTILISERS LTD., PANIPAT
BINANI CEMENT LTD.
NELCO LIMITED
BIRLA CORPORATIONLTD., CHITTOGARH
NUCLEAR POWER CORPORATION
BPCL
NATIONAL THERMAL POWER CORPORATION
BSES LIMITED
PESTICIDES INDIA LTD., UDAIPUR
CROMPTON GREAVES
PYRAMID CONTROL SYSTEMS (P) LTD.
DANIEL MEASUREMENT & CONTROL (I) PVT. LTD.
RELIENCE INDUSTRIES LTD.
DRDL, HYDERABAD
ROCKWELL AUTOMATION INDIA LTD.
ELECTRONICS CORPORATION INDIA LTD.
SECURE METERS LIMITED

ENGINEERS INDIA LTD.
SCHNIDER ELECTRIC INDIA LTD.
EMERSON PROCESS
SHREE CEMENT LTD.
FLS AUTOMATION INDIA LTD.
SIEMENS LTD. KOLKATTA, NEW DELHI , MUMBAI, GURGAON
GE FANUC SYSTEMS LTD., BANGLORE
SUZLON ENERGY LTD
GRASIM INDUSTRIES LTD.
TATA HONEWELL LIMITED., PUNE
GTRE, BANGLORE TATA LTD, HONEYWELL,PUNE
TECHNIP ITELY S.P.A.
INSTRUMENTATION LTD., KOTA
THE ASSOCIATED CEMENT COMPANIES LTD
INDIAN FARMERS & FERTILISER COOPORATIVE
THERMAX, PUNE
INDIAN OIL TANKING LTD.
TRF LTD
INDURE LTD.
TRIVENI ENGG. & INDUSTRIES LTD
ION EXCHANGE (INDIA) LTD.
WESTINGHOUSE, DELHI
JINDAL STEELS, RAIGARH
YOKOGAWA BLUE STAR, BANGLORE

COMPANY VISIT
A company involves various departments for the completion of suitable tasks
like designing, manufacturing, marketing etc. Theae departments involve
various processes to furnish the task. Pyrotech is also working with the same
concept for the manufacturing of the panels. A brief description of PEPL #2 is
given below.
Maketing:
This department of PEPL keeps an eye over the marketing areas, consumers and
competitors to stay tuned.
Design:
The design department of PEPL is well equipped with latest designing
softwares including AUTOCAD. Highly learned and qualified team of draftmen
and Engineers work to come up with the perfect panel design.
Purchase:
A separate department looks after the requirement and procurement of the
material and equipment.

Production:
PEPL has the motto “It’s not the less price that sells, it is the quality”. PEPL is
equipped with the latest technology in the production of control panel.
Storage:
Raw material is purchased according to the need of company and after
purchasing the raw material is sent at Unloaded room where it is examined as
weight, height etc.
Main raw material is Sheets.
These sheets are mainly of the following types:
Stainless steel (SS)
Aluminium
CRCA (Cold Rolled Cold Annealed)
HRCA (Hot Rolled Cold Annealed)

PROGRAMMABLE LOGIC CONTROLLER
INTRODUCTION
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 is 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.
Programmable logic controllers (PLCs) are members of the computer family
capable of storing instructions to control functions such as sequencing, timing,
and counting, which control a machine or a process. The PLC is composed of
two basic sections, the Central Processing Unit (CPU) and the Input/Output
(I/O) interface system. The PLC measures input signals coming from a
machine and through the internal program provides output or control back to the
machine.
Ladder logic is the programming language used to represent electrical
sequences of operation. In hardwired circuits the electrical wiring is connected
from one device to another according to logic of operation. In a PLC the devices
are connected to the input interface, the outputs are connected to the output
interface and the actual wiring of the components is done electronically inside

the PLC using ladder logic. This is known as soft wired.
PLC is a device that is capable of being programmed to perform a controlling
function. logic control system.
The PLC was first conceived by group of engineers from hydramatic division of
GM in 1968.This was designed to provide flexibility in control based on
programming and executing logic instruction.

HISTORY
The PLC was invented in response to the needs of the American automotive
manufacturing industry.
Before the PLC, control, sequencing, and safety interlock logic for
manufacturing
automobiles was accomplished using hundreds or thousands of relays, cam
timers, and drum sequencers and dedicated closed-loop controllers. The process
for updating such facilities for the yearly model change-over was very time
consuming and expensive, as electricians needed to individually rewire each
and every relay.
In the late 1960's 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. One of the people who worked on that project was
Dick Morley, who is considered to be the "father" of the PLC. Other companies
at the time proposed computer based schemes, one of which was based upon the
PDP-8. The MODICON 084 brought the world's first PLC into commercial
production.

DEVELOPMENT
Early PLCs were designed to replace relay logic systems. These PLCs were
programmed in "ladder logic", which strongly resembles a schematic diagram of
relay logic. This program notation was chosen to reduce training demands for
the existing technicians. Other early PLCs used a form of instruction list
programming, based on a stack-based logic solver.
Modern PLCs can be programmed in a variety of ways, from ladder logic to
more traditional programming languages such as BASIC and C. Another
method is State Logic, a very high-level programming language designed to
program PLCs based on state transition diagrams.
Many early PLCs did not have accompanying programming terminals that were
capable of graphical representation of the logic, and so the logic was instead
represented as a series of logic expressions in some version of Boolean format,
similar to Boolean algebra. As programming terminals evolved, it became more
common for ladder logic to be used, for the aforementioned reasons. Newer
formats such as State Logic and Function Block (which is similar to the way
logic is depicted when using digital integrated logic circuits) exist, but they are
still not as popular as ladder logic. A primary reason for this is that PLCs solve
the logic in a predictable and repeating sequence, and ladder logic allows the
programmer (the person writing the logic) to see any issues with the timing of
the logic sequence more easily than would be possible in other formats.

PROGRAMMING
Early PLCs, up to the mid-1980s, were programmed using proprietary
programming panels or special-purpose programming terminals, which often
had dedicated function keys representing the various logical elements of PLC
programs. Programs were stored on cassette tape cartridges. Facilities for
printing and documentation were very minimal due to lack of memory capacity.
The very oldest PLCs used non-volatile magnetic core memory.
More recently, PLCs are usually programmed using special application software
written for use on desktop computers, and connecting between the desktop
computer and the PLC such as via Ethernet or RS-232 cabling. Such software
allows entry and editing of the ladder-style logic, and then may provide
additional functionality to assist debugging and troubleshooting the software
(for example, by highlighting portions of the logic to show current status during
operation or via simulation). Finally, the software may allow uploading and
downloading of the program between the computer and the PLC, for backup
and restoration purposes. Alternately, specific devices known as programming
boards are used to hard wire the logic into the controller by the use of a
removable chip, such as an EEPROM, where the program is transferred to the
programming board from the workstation via serial or other bus logic.
.

PLC HARDWARE
A programmable logic controller consists of the following components:
• Central Processing Unit (CPU).
• Memory.
• Input modules.
• Output modules and
• Power supply.
A PLC diagram is shown in Figure.

Processor
I/P
O/P
Connection
Connection
from
to Industrial
Industrial
Equipment
Equipment
CH 1
CH 2
CH 3
CHn
CH n
CH 1
CH 2
CH 3
CHn
CH n
Programming Software
Processor
Mmmmmmm
mememomor
y
Power Supply

Configuration of Typical PLC
CPU
Like other computerized devices, there is a Central Processing Unit (CPU) in a
PLC. The CPU, which is the “brain” of a PLC, does the following operations:
• Updating inputs and outputs. This function allows a PLC to read the status of
its input terminals and energize or deenergize its output terminals.
• Performing logic and arithmetic operations. A CPU conducts all the
mathematic and logic operations involved in a PLC.
• Communicating with memory. The PLC’s programs and data are stored in
memory. When a PLC is operating, its CPU may read or change the contents
of memory locations.
• Scanning application programs. An application program, which is called a
ladder logic program, is a set of instructions written by a PLC programmer.
The scanning function allows the PLC to execute the application program as
specified by the programmer.
• Communicating with a programming terminal. The CPU transfers program
and data between itself and the programming terminal.
A PLC’s CPU is controlled by operating system software. The operating
system software is a group of supervisory programs that are loaded and stored
permanently in the PLC’s memory by the PLC manufacturer.

MEMORY
Memory is the component that stores information, programs, and data in a PLC.
The process of putting new information into a memory location is called
writing. The process of retrieving information from a memory location is called
reading.
The common types of memory used in PLCs are Read Only Memory (ROM)
and Random Access Memory (RAM). A ROM location can be read, but not
written. ROM is used to store programs and data that should not be altered. For
example, the PLC’s operating programs are stored in ROM.
A RAM location can be read or written. This means the information stored in a
RAM location can be retrieved and/or altered. Ladder logic programs are stored
in RAM. When a new ladder logic program is loaded into a PLC’s memory, the
old program that was stored in the same locations is over-written and essentially
erased.
The memory capacities of PLCs vary. Memory capacities are often expressed in
terms of kilo-bytes (K). One byte is a group of 8 bits. One bit is a memory
location that may store one binary number that has the value of either 1 or 0.
(Binary numbers are addressed in Module 2). 1K memory means that there are
1024 bytes of RAM. 16K memory means there are 16 x 1024 =16384 bytes of
RAM.
INPUT AND OUTPUT MODULES
A PLC is a control device. It takes information from inputs and makes decisions
to energize or de-energize outputs. The decisions are made based on the statuses

of inputs and outputs and the ladder logic program that is being executed.
The input devices used with a PLC include pushbuttons, limit switches, relay
contacts, photo sensors, proximity switches, temperature sensors, and the like.
These input devices can be AC (alternating current) or DC (direct current). The
input voltages can be high or low. The input signals can be digital or analog.
Differing inputs require different input modules. An input module provides an
interface between input devices and a PLC’s CPU, which uses only a low DC
voltage. The input module’s function is to convert the input signals to DC
voltages that are acceptable to the CPU. Standard discrete input modules
include 24 V AC, 48 V AC, 120 V AC, 220 V AC, 24 V DC, 48 V DC, 120 V
DC, 220 V DC, and transistor-transistor logic (TTL) level.
The devices controlled by a PLC include relays, alarms, solenoids, fans, lights,
and motor starters. These devices may require different levels of AC or DC
voltages. Since the signals processed in a PLC are low DC voltages, it is the
function of the output module to convert PLC control signals to the voltages
required by the controlled circuits or devices. Standard discrete output modules
include 24 V AC, 48 V AC, 120 V AC, 220 V AC, 24 V DC, 48 V DC, 120 V
DC, 220 V DC, and TTL level.
POWER SUPPLY
PLCs are powered by standard commercial AC power lines. However, many
PLC components, such as the CPU and memory, utilize 5 volts or another level
of DC power. The PLC power supply converts AC power into DC power to
support those components of the PLC.

PROGRAMMING TERMINAL
A PLC requires a programming terminal and programming software for
operation. The programming terminal can be a dedicated terminal or a generic
computer purchased anywhere. The programming terminal is used for
programming the PLC and monitoring the PLC’s operation. It may also
download a ladder logic program (the sending of a program from the
programming terminal to the PLC) or upload a ladder logic program (the
sending of a program from the PLC to the programming terminal). The terminal
uses programming software for programming and “talking” to a PLC.
WORKING OF PLC
Bringing input signal status to the internal memory of CPU
• The field signals are connected to the I/P module. At the output of I/P module
the field status converted into the voltage level required by the CPU is always
available.
• At the beginning of each cycle the CPU brings in all the field I/P signals from
I/P module & stores into its internal memory called as “PII”, meaning process
image input.
• The programmable controller operates cyclically meaning when complete
program has been scanned; it starts again at the beginning of the program.

I/O BUS
A PLC works by continually scanning a program. We can think of this scan
cycle as consisting of 3 important steps.
Step 1-Check Input Status-First the PLC takes a look at each input to determine
if it is on or off. In other words, is the sensor connected to the first input on
How about the second input How about the third... It records this data into its
memory to be used during the next step.
Step 2-Execute Program-Next the PLC executes your program one instruction at
a time. Maybe your program said that if the first input was on then it should turn
on the first output. Since it already knows which inputs are on/off from the
previous step it will be able to decide whether the first output should be turned
on based on the state of the first input. It will store the execution results for use
later during the next step.
Step 3-Update Output Status-Finally the PLC updates the status of the outputs.
It updates the outputs based on which inputs were on during the first step and
the results of executing your program during the second step. Based on the
example in step 2 it would now turn on the first output because the first input
was on and your program said to turn on the first output when this condition is
true.
Process Control and Automation
Process Control
“The process of recognizing the state of the process at all times, analyze the
information according to the set rules and guidelines and accordingly actuate
the control elements is referred to as process control.”

FUNCTIONALITY
The functionality of the PLC has evolved over the years to include sequential
relay control, motion control, process control, distributed control systems and
networking. The data handling, storage, processing power and communication
capabilities of some modern PLCs are approximately equivalent to desktop
computers. PLC-like programming combined with remote I/O hardware, allow
a general-purpose desktop computer to overlap some PLCs in certain
applications. Regarding the practicality of these desktop computer based logic
controllers, it is important to note that they have not been generally accepted in
heavy industry because the desktop computers run on less stable operating
systems than do PLCs, and because the desktop computer hardware is typically
not designed to the same levels of tolerance to temperature, humidity, vibration,
and longevity as the processors used in PLCs. In addition to the hardware
limitations of desktop based logic, operating systems such as Windows do not
lend themselves to deterministic logic execution, with the result that the logic
may not always respond to changes in logic state or input status with the
extreme consistency in timing as is expected from PLCs. Still, such desktop
logic applications find use in less critical situations, such as laboratory
automation and use in small facilities where the application is less demanding
and critical, because they are generally much less expensive than PLCs.
In more recent years, small products called PLRs (programmable logic relays),
and also by similar names, have become more common and accepted. These are
very much like PLCs, and are used in light industry where only a few points of
I/O (i.e. a few signals coming in from the real world and a few going out) are
involved, and low cost is desired. These small devices are typically made in a

common physical size and shape by several manufacturers, and branded by the
makers of larger PLCs to fill out their low end product range. Popular names
include PICO Controller, NANO PLC, and other names implying very small
controllers. Most of these have between 8 and 12 digital inputs, 4 and 8 digital
outputs, and up to 2 analog inputs. Size is usually about 4" wide, 3" high, and 3"
deep. Most such devices include a tiny postage stamp sized LCD screen for
viewing simplified ladder logic (only a very small portion of the program being
visible at a given time) and status of I/O points, and typically these screens are
accompanied by a 4-way rocker push-button plus four more separate push-
buttons, similar to the key buttons on a VCR remote control, and used to
navigate and edit the logic. Most have a small plug for connecting via RS-232
to a personal computer so that programmers can use simple Windows
applications for programming instead of being forced to use the tiny LCD and
push-button set for this purpose. Unlike regular PLCs that are usually modular
and greatly expandable, the PLRs are usually not modular or expandable, but
their price can be two orders of magnitude less than a PLC and they still offer
robust design and deterministic execution of the logic.

COMMUNICATION
PLCs have built in communications ports, usually 9-pin RS-232, but optionally
EIA-485 or Ethernet. Modbus, BACnet or DF1 is usually included as one of the
communications protocols. Other options include various fieldbuses such as
DeviceNet or Profibus. Other communications protocols that may be used are
listed in the List of automation protocols.
Most modern PLCs can communicate over a network to some other system,
such as a computer running a SCADA (Supervisory Control And Data
Acquisition) system or web browser.
PLCs used in larger I/O systems may have peer-to-peer (P2P) communication
between processors. This allows separate parts of a complex process to have
individual control while allowing the subsystems to co-ordinate over the
communication link. These communication links are also often used for HMI
devices such as keypads or PC-type workstations.

ADVANTAGES OF PLC
• Reduced space.
• Energy saving.
• Ease of maintenance.
• Economical.
• Greater life and reliability.
• Tremendous flexibility.
• Shorter project time.
• Easier storage, archiving and documentation.
• PLCs are armored for severe conditions (such as dust, moisture, heat, cold)
and have the facility for extensive input/output (I/O) arrangements.
• PLCs read limit switches, analog process variables (such as temperature and
pressure), and the positions of complex positioning systems.
• PLCs are used in many "real world" applications. If there is industry present,
chances are good that there is a plc present. If you are involved in machining,
packaging, material handling, automated assembly or countless other industries
you are probably already using them. If you are not, you are wasting money and
time. Almost any application that needs some type of electrical control has a
need for a plc.

APPLICATIONS OF PLC SYSTEM
• In industry, there are many production tasks, which are of highly repetitive
nature. Although repetitive & monotonous, each stage needs careful attention of
operator to ensure good quality of final product.
• Many times, a close supervision of the processes cause high fatigue on
operator resulting in loss of track of process control.
• Sometimes it’s hazardous also as in the case of potentially explosive chemical
processes.
• Under all such conditions we can use PLCs effectively in totally eliminating
the possibilities of human error.
• Some capabilities of PLCs are as follows:
1. Logic control
2. PID control
3. Coordination & automation
4. Operator control
5. Signaling and listing etc.
• In short, wherever sequential logic control & automation is desired the PLCs
are the best suited to meet the task. It includes simple interlocking functions to
complicated analog signal processing to PID control action in closed loop
control etc.
• Few examples of industries where PLCs are used for control & automation
purpose are listed below: -
1. Tyre industry.
2. Blender reclaimer.

3. Bulk material handling system at ports.
4. Ship unloader.
5. Wagon loaders.
6. Steel plants.
7. Blast furnace charging.
8. Brick-moulding press in refectories.
9. Galvanizing plant.
10. Dairy automation.
11. Pulp factory.
12. Printing industry etc.
• Today the PLCs are used for control and automation job in a single machine
and it increases up to full automation of manufacturing or testing process in a
factory.
In robotics:
PLC is used for two tasks in robotics:
1) As the controller or unprogrammble part of robot.
2) As an overall system controller.
In flexible manufacturing system:
The logical development from linking machines in this manner is to group
programmable machines into flexible manufacturing cells, each capable of
machining a variety of products under fully automatic control.
In factory automation:
The Austin-rover assembling plant.
The plant produces multi style car body from individual body panels .

The process consists of following activities:
1. Make up of sub assemblies from panels. Eg: doors, under frames
2. Tag sub assemblies together.
3. Pass tagged bodies to a main jig for automatic alignment & framing.
4. Conduct material transfer in which sub assemblies are selected, transported &
distributed to workstation by conveyor system
5. Maintain quality control by automatic monitoring & manual inspection of
each process.
The PLC tracks each component as it moves through the production area,
communicating this information to each appropriate robot as necessary. Data
send between PLC & robot includes handshaking signals to indicate robot busy
parked, action complete etc. Data in binary coded decimal form is used to send
component information & weld sequences from the PLC to root, which must
acknowledge receipt of the correct data before the PLC will allow it to
commence operation.
PLC PANEL

PLC VS COMPUTER
PLC
• Designed for extreme industrial environments.
• Can operation in high temperature and humidity. Er
• High immunity to noise.
• Integrated command interpreter (proprietary).
• No secondary memory available (in the PLC).
• Optimized for Single task.Optimized
• Task
Computer
• Designed mainly for data processing and calculation.
• Optimized for speed.
• Can’t operate in extreme environments.
• Can be programmed in different languages.
• Lost of secondary memory available.
• Multitasking capability.

PLC DISADVANTAGES
• In contrast to microcontroller systems that have what is called an open
architecture, most PLCs manufacturers offer only closed architectures
for their products.
• PLC devices are proprietary, which means that parts and software from
one manufacturer can t easily be used in combination with parts of
another manufacturer, which limits the design and cost options.
CONCLUSION
PLC is a device that is capable of being programmed to perform a controlling
function. The PLC was designed to provide flexibility in control based
programming and executing logic instruction. PLC allowed for shorter
installation time and faster commissioning through programming rather than
wiring.
The PLC have in recent years experienced an unprecedented growth as
universal element in industrial automation .It can be effectively used in
applications ranging from simple control like replacing a small number of relays
to complex automation problems.
Today the PLCs are used for control & automation job in a single machine & it
increases up to full automation of manufacturing / testing process in a factory

GENERATOR CONTROL PANEL
• 80-1600 Amps
• 208-600Vac, 50/60Hz rated
• MEC 20 Microprocessor-based Engine/Generator Controller
• Digital AC/DC Instrumentation
• Certifi ed to UL#508, CSA C22.2#14
Industrial Control Equipment Standards
• In compliance with NFPA Level 1 or 2
• Unit or Wall Mount
• Oil Pressure and Water Temperature Sensors included
• Optional expansion output module for fault output contacts
• Standard remote communication feature
• Optional remote annunciator

GENERAL DESCRIPTION
The UCS 200 series auto start generator control panel is the most
cost effective full featured control system available. Over 30 years
of design and manufacturing experience have led to the creation of
the UCS 200 panel family. One control panel can now meet your
generator set control requirements throughout the world. The
control center of the UCS 200 system is the MEC 20
Microprocessor based Engine Generator Controller. The MEC 20
gives the customer a compact, user friendly, ﬁ eld programmable
control package. The MEC 20’s complement of standard features
has previously only been available with costly and complicated PLC
based control systems or as an expensive option from
engine/generator packagers.
The UCS 200 family of control panels is available in three basic models:
Version “C” – (Control only version, no breaker, no current transformers)
– customized factory programming and options available
Version “S” – (Control only version, no breaker, no current transformers)
– available from stock, programming by customer
Version “KD” – Knockdown (unassembled)
All models are designed to meet or exceed NFPA 110 Level 1, CSA C282 and
IEC generator set requirements without adding optional features. Optional
features are available in the UCS 200 C model to meet your custom application
requirements. The UCS 200 S version is available from stock with standard
conﬁ guration.

Controlling Our Machines
Any complex piece of machinery requires a user interface to enable the user to
monitor its operations, check for efficient functioning, and intervene when
required. Machines overheat, slow down, speed up or generally vary in their
performance based on numerous factors such as fatigue, weather conditions, and
the wear and tear of components and parts.
In electrical machines, like generators, these varying changes constitute an
electrical signal. These signals can be intelligently processed to control the
performance of the machine. A lot of machines in urban environments (such as
signal lights and automatic doors) are completely self-managed due to such
controllers. They have sensors that can detect changes in physical attributes like
heat and speed and generate signals accordingly. Modern generators also have
similar sensors to detect changes in all kinds of various parameters. These can
be used to control the generator through a control panel.

Working
The control panel is becoming an increasingly complex piece of electronics
with a microprocessor that can manipulate input from sensors to help give
feedback to the machine to manage itself. One such feedback could be the
temperature, indicating overheating, other examples would be over/under speed
and low/high oil pressure. Typically, a heat sensor inside the generator would
sense the build up of heat in the generator body and pass this to the
microprocessor in the control panel. The microprocessor will then take effective
measures to regulate the performance of the machine including shutdowns if,
for example, the oil pressure is too low or the coolant temperature is too high,
leading to buildup of heat. In industrial situations, this functionality of control
panels is becoming increasingly critical. The microprocessor or microcontroller
is embedded in the circuitry inside the control panel and is programmed to take
in the sensor input and react to that with the programmed control rules.
Control panels can be combined with an Automatic Transfer Switch (ATS) to
maintain the continuity of electrical power. The ATS detects an outage of power

when your local grid fails. It signals the control panel to start the generator.
Depending on the type of generator being used, the control panel may activate
glow plugs (for diesel) for an adjustable length of time. It will then start the
generator using an automatic starter, similar to the one you engage when you
turn the keys in the ignition of your car in the morning. As soon as the engine of
the generator reaches an optimum speed, the starter is disengaged. The ATS
then switches to the generator power, and you can go back to business as usual,
without having to frantically scramble to figure out what caused power loss.
This aspect of a control panel makes it extremely useful in homes during bad
weather and in industrial situations for ensuring mission-critical continuity

Bibliography
Net links:
1. http://www.tanswa.net/purge-panels.html
2. http://www.pyrotechindia.com/purge_pnl.asp
3. http://www.exloc.com/purging_mm.html
4. http://www.ncsu.edu/ehs/www99/right/handsMan/compgas/purgereq.ht
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