Basic Automation

Corporate CommunicationsNestlé Milkpak Ltd.

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BasicAutomation.

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Automation Technology.Automation is a Technology , which use the methods for controlling industrial processes automatically.

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Corporate Communications

Processes Parameters.

Nestlé Milkpak Ltd.

Processes Parameters.Temperature.Pressure.Level.Flow.Weight.Conductivity.Humidity.Density.Viscosity.Volume.

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Basic Processes Parameters.Temperature.Temperature is measurement of average kinetic energy in a substance or object.Units. Celsius (°C) , Fahrenheit (°F) , Kelvin (K). EtcPressure.Pressure is force per unit area applied in a direction perpendicular to the surface of an object. Gauge pressure is the pressure relative to the local atmospheric or ambient pressure.Units. Bar , PSI , kg/cm2 etc

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Flow.To move or run smoothly with unbroken continuity as in the manner characteristics of a fluid. Flow rate.The amount of fluid ,that flow in a given time.Units. m3/s , liter/sec , etcLevel.Relative Position or rank on a scale.Units . Meter ,Foot ,Inch etc.

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Process Transmitter & Controller


Process Transmitter & Controller1-PLC (Programmable Logic Controller).2-Temperature Transmitter.3-Pressure Transmitter.4-Level Transmitter.5-Flow Transmitter.6-Conductivity & PH Meter.7-Sensor s & Switches.8-Pneumatics Devices.9-Motors & Encoder.10-Variable Frequency drive.

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1-PLC (Programmable Logic Controller)


1-PLC (Programmable Logic Control)Manufacturer of PLC.Allen Bradley.SiemensMitsubishi.Omron.ABB

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Allen Bradley PLC Types.SLCCompact LogicControl LogicFlex LogicMicro LogicFlex I/OPoint I/O

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Siemens PLC Types.Simatic S5Simatic S7

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Communication Protocols.Ethernet .Control net.Device net.Profibus.Optical Fiber.RS-232

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A PLC Network that communicate with Nodes on different Communications Protocols.

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Simple Compact Logic Communication Network.

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1-Rack or bank2-Slot3-Channel

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Identification of rack , slot and channel.




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Power Supply of Compact Logix.

Every PLC have its own Power supply with a unique # like that compact logix 1769-L32E have 1769-PA4 Power supply etc.




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1-PLC (CPU) Model 2-Selector Switch3-Memory card Slot4-Ethernet Port5-Serial Port

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Controller Parts.




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Digital Input Module




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Digital Output Module




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Active & Passive Devices.Active Devices. 4-wire device (transducer ,Transmitter etc).which have Power line [ +ve & -ve ] & signal line [ +ve , -ve ] through separate cables. In this event device (transducerTransmitter etc). is active devicePassive Devices. 2 wire devices (transducer ,Transmitter etc),means 24vdc is required to maintain the current loop of 4-20mA dc through 24vdc power supply. signal is both through the same pair of cable. In this event devices (transducer ,Transmitter etc) , is passive device




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Analog Input Module




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Analog Output Module




PLC Troubleshooting

If your application unexpectedly stop running , check ok light on the front of the controller. if it’s flashing red, the controller has major fault.

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If controller ‘s I/O light is solid green, controller is communicating with all its module.

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Controller Communication status




If I/O Light is flashing green, controller is not communicating at least one of its module.

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Check all the link that it is properly connected to nodes.Check Power supply voltage ,that required to node. 25





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Link Status Indicator.




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Network Status Indicator.




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Serial Port Status Indicator.


2-Temperature Transmitter.


Manufacturer of Temperature TransmitterEndress+HauserHoney well Rosemount Weidmuller

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Types of Temperature Transmitter RTD (Pt100) Thermocouple Thermistor

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RTD ( Resistance Temperature detector )

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Introduction.An RTD (Resistance Temperature Detector) is basically a temperature sensitive resistor. It is a positive temperature coefficient device, which means that the resistance increaseswith temperature. There are some types like negative temperature coefficient device , which means that the resistance decrease with temperature.




Temperature Coefficient of resistance ( α)

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The temperature coefficient of resistance, for RTDsis normally defined as the average resistance changeper °C over the range 0˚C to 100°C divided by R at 0°C. The temperature coefficient is expressed in ohms/




RTD & R/I Converter.

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In industries we use 4-20mA signal , so we use R/I converter to change resistance into 4-20mA signal .R/I converter available in different ranges.




Calibration.

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Set the temperature on Oil both and wait till temperature meet to set point and value stable.Insert the Temperature sensor in the oil both and compare the both value of oil both and temperature sensor display.Acceptable Tolerance is Plus/Minus 1 degree.




Troubleshooting.Always check the R/I converter range before installation.Check the resistance of RTD. Calibrate it with standard oil bath. First confirm that RTD or R/I converter faulty.

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ThermocoupleIntroduction.A thermocouple is a junction between two different metals that produces a voltage related to a temperature difference. Thermocouples are a widely used type of temperature sensor for measurement and control , and can also be used to convert heat gradient into electricity.




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Thermocouple types & Emf (mv) against Temperature




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Thermocouple & mV/I Converter.




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Calibration.Set the temperature on Oil both and wait till temperature meet to set point and value stable.Insert the Temperature sensor in the oil both and compare the both value of oil both and temperature sensor display.Acceptable Tolerance is Plus/Minus 1 degree.




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Troubleshooting.Always check the mv/I converter range before installation.Check the mv of Thermocouple. Calibrate it with standard oil bath. First confirm that Thermocouple or mv/I converter faulty.




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ThermistorA thermistor is a type of resistor ,whose resistance varies significantly with temperature, more so than in standard resistors. The word thermistor is stand for thermal and resistor. Thermistor is generally made of a ceramic or polymer.




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Thermistor (NTC) table




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Types of Thermistor & R/I Converter.




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Troubleshooting.Always check the R/I converter range before installation.Check the KΩ of Thermocouple. First confirm that Thermistor or R/I converter faulty.


3-Pressure Transmitter


3-Pressure TransmitterManufacturer of Pressure TransmitterEndress+Hauser Nuqvafima Sensor technics

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Types of Pressure TransmitterStrain Gauge type Pressure Transmitter.Differential pressure Transmitter Absolute and gauge type Transmitter.

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Strain Gauge type Pressure Transmitter.Introduction. A strain gauge consists of a foil of resistive characteristics, which is safely mounted on a backing (Layer) material. When a known amount of stress in subjected on the resistive foil, the resistance of the foil changes accordingly. The change in the resistance can be calculated with the help of a Wheatstone bridge.




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Working of Strain Gauge Pressure Transmitter.If the ratio of the two resistances in the known leg (R2 / R1) is equal to the ratio of the two in the unknown leg (Strain gauge / R3), then the voltage between the two midpoints will be zero and no current will flow through the galvanometer. If the bridge is unbalanced through strain gauge ,when pressure applied thus current will flow.




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Calibration Of strain Gauge Pressure Transmitter Strain Gauge Pressure Transmitter are mostly pre calibrated. We can check it on Zero and span Pressure and check 4-20mA output with reference the minimum and maximum pressure written on the transmitter.




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Troubleshooting.Check the Supply voltage properly.Check pressure is not out of range which mention on transmitter.Check sensor diaphragm ,may be it is damage.




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Differential pressure TransmitterDifferential transformers (DTs) use a variable inductance principle to infer displacement. A linear variable differential transformer (LVDT) is the most popular type of DT, and a sectional diagram is shown in part (a) of the figure below.




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Working of Differential pressure TransmitterAn LVDT consists of three symmetrically spaced coils wound onto an insulated holding. The magnetic core can move within the holding and provides a path for the magnetic flux linkage between the primary and the secondary coils. The motion (from a mechanical input) changes the characteristics of the flux path and the changes can be detected in the circuit.




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Calibration Of differential Pressure TransmitterWe can Calibrate Transmitter by giving Zero and span range against 4-20mA signal through menu.We can also calibrate it through Hart Communicator using 250 Ω resistance in series.




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Troubleshooting.Check air supply is properly connected on High and Low positionWhich is mention on transmitter. Check calibration range is proper and unit also.Transmitter mounting should be proper.Line can also blockage if pressure not display properly.Check pressure is not out of range.




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Absolute and Gauge Pressure Transmitter.The process pressure deflects the metal diaphragm with a fill fluid transmitting the pressure to a resistance bridge. The bridge output voltage, which is proportional to pressure, is then measured and processed.




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Calibration of Absolute and Gauge Pressure Transmitter.There are two method to calibrate it , through Zero / Span button or using Hart Calibrated.




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Troubleshooting.Check air supply is properly connected. Check calibration range is proper and unit also.Transmitter mounting should be proper.Line can also blockage if pressure not display properly.Check pressure is not out of range.


4-Level Transmitter


4-Level Transmitter.Manufacturer of Level TransmitterEndress+Hauser burkert Pulsar

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4-Level Transmitter


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Types of Level TransmitterUltrasonic.Capacitance.Radar type.Hydrostatic.


4-Level Transmitter


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Ultrasonic Level Transmitter.Introduction.Non-contact ultrasonic level sensors emit ultrasonic (20 kHz to 200 kHz) acoustic waves from a transducer which also detects and measures the reflected waves. This type of sensor is ideal for measuring bulk solids such as sand, cement, grain, rice and plastic pellets as well as liquids with high viscosity such as slurries, heavy oil, grease and latex.


4-Level Transmitter


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Working of Ultrasonic Level Transmitter.Short ultrasonic impulses in to range of 10 to 70 kHz are emitted by the transducer to the measured product, reflected by the product surface and received again by the transducer. The time from emission to reception of the signals is proportional to the level in the vessel


4-Level Transmitter


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Calibration .Mostly Ultrasonic Level Transmitter are calibrated with the Tank height.Set the tank height for 4 mA signal it is Zero calibration , for span calibration set the tank full height.Change the output units for tank level according to requirement.


4-Level Transmitter


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Troubleshooting .Check the supply voltage according to the transmitter which is mention on transmitter.Check Calibration range is proper according to that height which u want to measure. Check mounting position is proper like mention in instruction manual.Check Loop Connection is proper , always insure it is active or passive loop.Always insure that sensor condition is normal ,because sensor can also damage.


4-Level Transmitter


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Capacitance Level Transmitter.Introduction.Often called RF due to the radio frequency signals that are applied to the capacitance circuits, these type of sensors are excellent for measuring a wide range of liquids, slurries and solids. Capacitance level sensors can be used to measure media with dielectric constants between 1.1 and 90.


4-Level Transmitter


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Working of Capacitance Level Transmitter.A basic capacitor can be constructed by dipping two parallel conductive plates into a dielectric liquid . If the capacitance is measured as the plates are gradually immersed, it will be seen that the capacitance changes in proportion to the depth by which the plates are immersed into the dielectric liquid.


4-Level Transmitter


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Calibration .Calibration of capacitance level transmitter can be done by Zero span switch on transmitter. Press Zero when tank is empty and press span when tank is full.Calibration can also be perform if transmitter can communicate on Hart protocol ,because value ( μf ,Pf etc) can be read when tank is full or zero , so adjust these value for zero span calibration.


4-Level Transmitter


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4-Level Transmitter


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Radar Level Transmitter.Introduction. Radar level sensors are ideal for use in environments where temperature varies and in moist, dusty or vaporous environments. The microwaves are able to penetrate temperature and vapour layers that can be problematic for other types of water level sensor. Objects with high dielectric constants such as metal and conductive water will reflect microwaves. Conversely, media with low dielectric constants (glass, plastics, food stuffs, paper) will absorb the microwaves by varying degrees.


4-Level Transmitter


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Working of Radar Level Transmitter.A radar signal is emitted via an antenna, reflected on the product surface and received after a time t.The difference is directly proportional to the distance. A large frequency difference corresponds to a large distance and vice versa.


4-Level Transmitter


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Calibration .Mostly Radar Level Transmitter are calibrated with the Tank height.Set the tank height for 4 mA signal it is Zero calibration , for span calibration set the tank full height.Change the output units for tank level according to requirement.


4-Level Transmitter


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Troubleshooting.Check the supply voltage according to the transmitter which is mention on transmitter.Check Calibration range is proper according to that height which u want to measure. Check mounting position is proper like mention in instruction manual.Check Loop Connection is proper , always insure it is active or passive loop.Always insure that sensor condition is normal ,because sensor can also damage.


4-Level Transmitter


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Hydrostatic Level Transmitter.Hydrostatic pressure is what is exerted by a liquid when it is at rest. The height of a liquid column of uniform density is directly proportional to the hydrostatic pressure. The formula for calculating the hydrostatic pressure of a column of liquid in SI units is: Hydrostatic Pressure (Pa, N/m2) = Height (m) x Density(kg/m3) x Gravity(m/s2)


4-Level Transmitter


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Calibration.Calibration of this type of transmitter tank height is necessary Formula is that 1meter height = 100mbar pressure.If u want to measure the 5 meter tank level ,so u put the value of 500mbar in span calibration and 0 mbar in zero calibration.


4-Level Transmitter


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5-Flow Transmitter


5-Flow TransmitterManufacturer of Flow TransmitterEndress+Hauser Diesel Honeywell Mettler Toledo

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5-Flow Transmitter


Types of Flow TransmitterMag Flow transmitter.Mass Flow Transmitter.

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5-Flow Transmitter


Mag Flow Transmitter

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PrincipleFaraday’s Law of Electromagnetic Induction: “When a moving conductor is placed in the magnetic field, voltage is induced.”Induced voltage is proportional to the fluid flow.


5-Flow Transmitter


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Not suitable for gases or non conductive liquids, A minimum conductivity required is 5 μS/cm

Mag Flow Transmitter

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5-Flow Transmitter


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CalibrationFor Calibration of Flow Transmitter .Give the value in transmitter parameter of flow for 4mA.Give the value in transmitter parameter of flow for 20mA.Change the value as u required like that kg/h ,l/h etc.Give the density of liquid which need to measure.


5-Flow Transmitter


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TroubleshootingCheck the supply voltage according to the transmitter which is mention on transmitter.Check Calibration range is proper according to that height which u want to measure. Check mounting position is proper like mention in instruction manual.Check Loop Connection is proper , always insure it is active or passive loop.Always insure that sensor condition is normal ,because sensor can also damage.


5-Flow Transmitter


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Mass Flow TransmitterPrinciple.

When fluid is moving through the sensor's tubes,

Coriolis forces are induced in both the inlet and outlet legs of both flow tubes. These forces cause the flow tubes to twist in opposition to each other.


5-Flow Transmitter


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Mass Flow meter mostly use for gases.AccuracyMass flow (liquids): ±0.35% Mass flow (gases): ±0.75%

Mass Flow Transmitter


5-Flow Transmitter


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Calibration Flow meter.


5-Flow Transmitter


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6-Conductivity & PH Transmitter


6-Conductivity TransmitterManufacturer of Conductivity TransmitterEndress+Hauser Honeywell ΩMetrohm

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Types of Conductivity Transmitter.

Condumax ( ElectrodeType ) Indumax (Inductive Type )




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Conductivity.Introduction.Conductivity is the total dissolve able salts contained within a liquid solution. Because pure water does not contain salts it has a conductivity measurement of zero. By adding dissolve able elements to the water, electricity is able to move through the solution giving it a conductivity rating.




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Condumax TypeCondumax is a two-electrode conductivity sensor for high-temperature applications. This conductivity sensor is designed for industrial and power plant applications (e.g. condensate The measuring range of the sensors depends on the cell constant k.k = 0.01 cm-1: 0.04 ... 20 μS/cmk = 0.1 cm-1: 0.1 ... 200 μS/cm




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Calibration.

Conductivity sample

Conductivity sample

Access the calibration mode parameter calibrate it on zero calibration first .Put the value of standard solution in parameter and read it on span calibration.




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Inductive Type Conductivity Transmitter.Indumax conductivity transmitter is a highly resistant inductive conductivity measuring cell for standard, Ex and high-temperature applicationsMeasuring range from 0 to 2000 mS/cm




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Calibration.Access the calibration mode parameter calibrate it on zero calibration first .Put the value of standard solution in parameter and read it on span calibration.

Conductivity sample

Conductivity sample




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PH Meter.Introduction.The pH meter measures the electrical potential between the mercuric chloride of the reference electrode and its potassium chloride liquid, the unknown liquid, the solution inside the glass electrode, and the potential between that solution and the silver electrode.




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7-Sensors & Switches


7-Sensors & SwitchesManufacturer of sensors & SwitchesPepperl+FuchsSick Honeywell

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Types of Sensors

Metal Sensors Magnetic Sensors Photo Sensors

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Metal Detector ( Proximity Sensor)A high-frequency magnetic field is generated by coil L in the oscillation circuit. When a target approaches the magnetic field, an induction current (eddy current) flows in the target due to electromagnetic induction. As the target approaches the sensor, the induction current flow increases, which causes the load on the oscillation circuit to increase. Then, oscillation attenuates or stops. The sensor detects this change in the oscillation status and generate output.




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TroubleshootingCheck the supply voltage ,that it is according to the supply which is mention on the sensor.Always insure that it is NPN or PNP type. Check sensor front side ,that may be it is damage.Position of metal which need to detect must be in the calibration range.Check that there is any liquid or material on the sensor which can effect to detection.




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Magnetic SensorMagnetic sensors are actuated by the presence of a permanent magnet. Their operating principle is based on the use of reed contacts, which consist of two low reluctance ferro-magnetic reeds enclosed in glass bulbs containing inert gas. The reciprocal attraction of both reeds in the presence of a magnetic field, due to magnetic induction, establishes an electrical contact.




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Troubleshooting.Check the supply voltage ,that it is according to the supply which is mention on the sensor.Always insure that it is NPN or PNP type. Check sensor front side ,that may be it is damage.Position of metal which need to detect must be in the calibration range.Check that there is any liquid or material on the sensor which can effect to detection.




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Photo Sensor.A Photoelectric Sensor consists primarily of an Emitter for emitting light and a Receiver for receiving light. When emitted light is interrupted or reflected by the sensing object, it changes the amount of light that arrives at the Receiver. The Receiver detects this change and converts it to an electrical output. The light source for the majority of Photoelectric Sensors is infrared or visible light (generally red, or green/blue for identifying colors).




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Troubleshooting.Adjustment is most important in these sensor .




Types of Switches. Electrode type Limit switches

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Electrode Switches.Introduction.Relay energizes when liquid level drops below low level electrode and de-energized when level reaches high level electrode .




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TroubleshootingCheck all electrode because , mostly electrode damage all or any one of them.Level position must be clear , that from which level need to measure.Check the position of level electrode ,that it is according to level measuring position.




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Limit Switches A mechanical limit switch interlocks a mechanical motion or position with an electrical circuit. A good starting point for limit-switch selection is contact arrangement. The most common limit switch is the single-pole contact block with one NO and one NC set of contacts; however, limit switches are available with up to four pole




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Troubleshooting.Check that supply is coming on one contact ,that is mention on Limit switch .If limit switch not operate then check and set its operating position.You can also check by removing from line and check it on manual operate.


8-Pneumatics Devices.


8- Pneumatics Devices. Manufacturer of Pneumatics Devices.Festo Lasani Samson

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8-Valves & Pneumatics.


Types of Pneumatics Devices.

Valves.Cylinders.Regulators.

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Types of Valves.

Regulating Valves.Actuator valves. Solenoid valves.

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Regulating Valves.

112P/P Positioner

I/P Positioner

Regulating valve




Calibration of Regulating Valves.

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Give 4-20 mA from simulator and check Zero to span calibration.Leak detection system (flange) must be install for zero calibration.




TroubleshootingCheck main air supply that must be according to that pressure which is mention on valve.Check there is no any leakage in valve positioner or regulator.Check the signal according to operating value.Check its zero and span operating position.

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Actuator Valves.

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TroubleshootingCheck main air supply that must be according to that pressure which is mention on valve.Check there is no any leakage in actuator .Check its ON and OFF operating position.

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Solenoid valves.

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A solenoid valve is an electromechanical valve for use with liquid or gas. The valve is controlled by an electric current through a solenoid: in the case of a two-port valve the flow is switched on or off.




TroubleshootingCheck the supply voltage.Check the coil resistance to confirm it is normal.Check its mechanical fitting is normal.

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Types of Cylinder.Single acting.Double acting.

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Troubleshooting.Check main air supply that must be according to that pressure which is mention on valve.Check there is no any leakage in cylinder .Check its ON and OFF operating position.

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Types of Regulators.Regulator mostly use in industry to regulate the air pressure It is available in many pressure ranges and types.

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Troubleshooting.Ensure maximum pressure Supply of regulator.Filter must be clean some time it is block due to dust.Check there is no any leakage in regulator.

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9-Motors & Encoders.


9-Motors & Encoders.Manufacturer of MotorsSiemens. ABB

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Types of Motors.AC Motors.DC Motors.

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Types of AC Motors.Classification Based On Principle Of Operation.Synchronous Motors.Asynchronous Motors. Classification Based On Type Of Current. Single PhaseThree Phase Classification Based On Speed Of Operation. Constant Speed. Variable Speed. Adjustable Speed.




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Classification Based On Structural Features.Open.Enclosed.Semi-enclosed.Ventilated.Pipe-ventilated.Riveted frame-eye etc.




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Introduction.An AC motor is an electric motor driven by an alternating current. It commonly consists of two basic parts, an outside stationary stator having coils supplied with alternating current to produce a rotating magnetic field, and an inside rotor attached to the output shaft that is given a torque by the rotating field.




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Motor Parts.




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Speed Of an Inductor Motor.




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Name plate of an inductor Motor.




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Motor Star Connection.




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Troubleshooting.Check Motor resistance at U (U1,U2) V (V1,V2) and W (W1,W2)Resistance should be same with each other ,if there is difference between them ,so that cause of motor unbalancing and overload. Check motor short with megger at (U1,V1) ( U2,V2) ,(V1,W1) etc on 500 or 1000 volt and ensure there is no beam(short signal) on Megger.




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Motor Delta Connection.




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Troubleshooting.Check Motor resistance at U (U1,U2) V (V1,V2) and W (W1,W2)Resistance should be same with each other ,if there is difference between them ,so that cause of motor unbalancing and overload. Check motor short with megger at (U1,V1) ( U2,V2) ,(V1,W1) etc on 500 or 1000 volt and ensure there is no beam(short signal) on Megger.




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Star Delta connection of Motor.




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Troubleshooting .

Starting up of the squirrel cage motor via K1 and K3 in star connection. . Actuating S2 switched K3 and the timing relay K4 (starting delay). K1 is switched by means of K3 closer. K1 holds itself alone above its closer. Following the adjustment period the opening contact of K4 switches K3 off whilst K2 is switched on by means of the opening contact of K3.




Manufacturer of EncodersSiemens. ABB

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Types of Encoders.Incremental EncoderAbsolute Encoder

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Absolute Encoder.Position or angular encoder which – after power ON – immediately makes available the position of the axis as an absolute actual value. An absolute information is thus available on the momentary angular or linear position at any time. using Grey code system.




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Troubleshooting.Check output of Encoder by moving the encoder .Mostly encoder output is 0-10 VDC , so check by moving the encoder that encoder give output 0-10 VDC.




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Incremental Encoder.An incremental encoder (incremental position encoder) is generally a pulse encoder, sin/cos encoder, or resolver. Homing is required to determine the absolute position.




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Troubleshooting.Check output of Encoder by moving the encoder .Mostly encoder output is 24 VDC output , so check by moving the encoder that encoder give output pulse of 24 VDC.


10-VFD (Variable Frequency Drive)


10- Variable Frequency Drive.

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Manufacturer of EncodersAllenbradley ( Power Flex). Danfoss (VLT). Telemechanique ( Altivar ) Sew (Eurodrive) Siko.




Types of variable frequency drive

Types with respect to Kw.Types with respect to I/O Voltage.

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Drive FundamentalIntroduction.Motor Loads are classified into two main groups depending on how their torque requirement varies with operating speed.The following paragraphs deal with the various Load types found in the industry. Motor Load groupsConstant Torque Load.Variable Torque Load.




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General Grounding Requirement




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Open the Covering




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Main Power & Motor Connection.




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I/O Terminal Position.




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Installation / Control Wiring




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Encoder Interface.




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I/O Wiring Example.




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I/O Wiring




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I/O Wiring




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I/O Wiring




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Troubleshooting




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Troubleshooting




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AUTOMATION CONTINUE EXCELLENCE




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THANK YOU

Basic Automation

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