Study of SCADA

DEPARTMENT OF ELECTRICAL AND EECTRONICS ENGINEERING
MARINE AUTOMATION LAB
EX NO:1 STUDY OF SCADA SYSTEM,PLC AND LADDER PROGRAMMING

INTRODUCTION
The S7-1200 controller provides the flexibility and power to control a wide variety of
devices in support of your automation needs. The compact design, flexible configuration, and
powerful instruction set combine to make S7-1200 a perfect solution for controlling a wide
variety of applications.
The CPU combines a microprocessor, an integrated power supply, input and output
circuits, built-in PROFINET, high-speed motion control I/O, and on-board analog inputs in a
compact housing to create a powerful controller. After you download your program, the CPU
contains the logic required to monitor and control the devices in your application. The CPU
monitors the inputs and changes the outputs according to the logic of your user program, which
can include Boolean logic, counting, timing, complex math operations, and communications with
other intelligent devices.
To communicate with a programming device, the CPU provides a built-in PROFINET

port. With the PROFINET network, the CPU can communicate with HMI panels or another
CPU. To provide security for your application, every S7-1200 CPU provides password
protection that allows you to configure access to the CPU functions.
PLC controller used to this project is S7-1200 1214C AC/DC/RLY with version 3.0
and MLFB number is 6ES7 214-1BE31-OXBO.
DETAILS:
 Digital inputs in the controller is14 and Voltage is 24

 Digital output in the controller is 10 and Voltage is 24
 Back plane is available to connect extra I/O modulus and communication modules
 Analog input in the controller is two
 Input power supply to the controller is 120/240 VAC
 Three communication modules and eight I/O expansion modules can be used
 Modbus communication board, analog output board and analog input board can be used
PLC LANGUAGES
The function of all programming languages is to allow the user to communicate with the
programmable controller (PC) via a programming device. They all convey to the system, by
means of instructions, a basic control plan. Ladder diagrams, function blocks, and the sequential
function chart are the most common types of languages encountered in programmable controller
system design. Ladder diagrams form the basic PC languages, while function blocks and the
sequential function charting are categorized as high-level languages.
The basic programmable controller languages consist of a set of instructions that will
perform the most common type of control functions like relay replacement, timing, counting,
sequencing, and logic. High level languages are used for analog control, data manipulation,
reporting, and other functions that are not possible with the basic instruction sets.
The language used in a PC dictates the range of applications in which the controller can
be applied. Depending on the size and capabilities of the controller, one or more languages may
be used. Here are some typical combinations of the languages;
1. Ladder diagram (LAD).

2. Function blocks diagram (FBD).
Ladder Language
LAD is a graphical programming language. The representation is based on circuit

diagrams. To create the logic for complex operations, you can insert branches to create the logic
for parallel circuits. Parallel branches are opened downwards or are connected directly to the
power rail. You terminate the branches upwards. LAD also provides "box" instructions for a
variety of functions, such as math, timer, counter, and move.
Function blocks diagram
In FBD programming, you can drag the "Negate binary input" tool from the "Favorites"
toolbar or instruction tree and then drop it on an input or output to create a logic inverter on that
box connector. You can also right-click on the box input connector and select "Insert input". Box
inputs and output can be connected to another logic box, or you can enter a bit address or bit
symbol name for an unconnected input. When the box instruction is executed, the current input
states are applied to the binary box logic and, if true, the box output will be true.
STEP 7 Basic PROGRAMMING SOFTWARE
STEP 7 Basic provides a user-friendly environment to develop controller logic,

configure HMI visualization, and setup network communication. To help increase your
productivity, STEP 7 Basic provides two different views of the project: a task-oriented set of
portals that are organized on the functionality of the tools (Portal view), or a project-oriented
view of the elements within the project (Project view). Choose which view helps you work most
efficiently. The Portal view provides a functional view of the project tasks and organizes the
tools according to the tasks to be accomplished. You can easily determine how to proceed and
which
task to choose.
1) Portals for the different tasks.
2) Tasks for the selected portal.
3) Selection panel for the selected Action.
4) Changes to the Project view.
The Project view provides access to all of the components within a project.
1) Menus and toolbar.

2) Project navigator.
3) Work area.
4) Task cards.
5) Inspector window.
6) Changes to the Portal view.
7) Editor bar.
With all of these components in one place, you have easy access to every aspect of your
project. For example, the inspector window shows the properties and information for the object
that you have selected in the work area. As you select different objects, the inspector window
displays the properties that you can configure. The inspector window includes tabs that allow
you to see diagnostic information and other messages.
By showing all of the editors that are open, the editor bar helps you work more quickly
and efficiently. To toggle between the open editors, simply click the different editor. You can
also arrange two editors to appear together, arranged either vertically or horizontally. This
feature allows you to drag and drop between editors.
To help you to find more information or to resolve issues quickly and efficiently, STEP 7
Basic provides intelligent point-of-need assistance. For example, some of the tool tips in the
interface (such as for the instructions) "cascade" to provide additional information. A black
triangle alongside the tool tip signifies that more information is available.
STEP 7 Basic provides a comprehensive online information and help system that
describes all of the SIMATIC TIA products that you have installed. The information system
opens in a window that does not obscure the work areas. Click the "Show/hide contents" button
on the information system to display the contents and undock the help window. You can then
resize the help window.
SYSTEM REQUIREMENTS
To install the STEP 7 software on a PC running Windows XP, or Windows 7 operating system,
you must log in with Administrator privileges.
Hardware/software Requirements
Processor type : Intel Pentium i3, 2.5 GHz or similar
RAM : 4 GB
Available hard disk space : 10 GB on system drive C:\
Operating systems : Windows XP Professional
SP3
Windows 2003 Server R2 StdE SP2
Windows 7 (Professional, Enterprise, Ultimate) SP1
Windows 10 Pro
Graphics card : 32 MB RAM, 24-bit color depth
Screen resolution : 1024 x 768.
Network : 20 Mbit/s Ethernet or faster.
Optical drive : DVD-ROM
CPU OPERATING MODES
The CPU has three modes of operation: STOP mode, STARTUP mode, and RUN mode.
Status LEDs on the front of the CPU indicate the current mode of operation.
 In STOP mode, the CPU is not executing the program, and you can download a project.
 In STARTUP mode, the CPU executes any startup logic (if present). Interrupt events
are not processed during the startup mode.
 In RUN mode, the scan cycle is executed repeatedly. Interrupt events can occur and
be processed at any point within the program cycle phase.
Note
You cannot download a project while the CPU is in RUN mode. You can download your
project only when the CPU is in STOP mode.
The CPU supports the warm restart method for entering the RUN mode. Warm restart
does not include a memory reset, but a memory reset can be commanded from the programming
software. A memory reset clears all work memory, clears retentive and non-retentive memory
areas, and copies load memory to work memory. A memory reset does not clear the diagnostics
buffer or the permanently saved IP address. All non-retentive system and user data are initialized
at warm restart.
You can specify the power-up mode of the CPU complete with restart method using the
programming software. This configuration item appears under the Device Configuration for the
CPU under Startup. When power is applied, the CPU performs a sequence of power-up
diagnostic checks and system initialization. The CPU then enters the appropriate power-up
mode. Certain detected errors will prevent the CPU from entering the RUN mode. The CPU
supports the following power-up modes: STOP mode, "Go to RUN mode after warm restart",
and "Go to previous mode after warm restart".
The CPU does not provide a physical switch for changing the operating mode. Use the
CPU operator panel in the online tools of STEP 7 Basic to change the operating mode (STOP or
RUN). You can also include a STP instruction in your program to change the CPU to STOP
mode. This allows you to stop the execution of your program based on the program logic.
CPU MEMORY AREAS
The CPU provides the following memory areas to store the user program, data, and
configuration:
 Load memory is non-volatile storage for the user program, data and configuration. When
a project is downloaded to the CPU, it is first stored in the Load memory area. This area
is located either in a memory card (if present) or in the CPU. This nonvolatile memory
area is maintained through a power loss. The memory card supports a larger storage
space than that built-in to the CPU.
 Work memory is volatile storage for some elements of the user project while executing
the user program. The CPU copies some elements of the project from load memory into
work memory. This volatile area is lost when power is removed, and is restored by the
CPU when power is restored.
 Retentive memory is non-volatile storage for a limited quantity of work memory values.
The retentive memory area is used to store the values of selected user memory locations
during power loss. When a power down occurs, the CPU has enough holdup time to
retain the values of a limited number of specified locations. These retentive values are
then restored upon power up.
An optional SIMATIC memory card provides an alternative memory for storing your
user program or a means for transferring your program. If you use the memory card, the CPU
runs the program from the memory card and not from the memory in the CPU.
The CPU supports only a preformatted SIMATIC memory card. To insert a memory
card, open the top CPU door and insert the memory card in the slot. A push-push type connector
allows for easy insertion and removal. The memory card is keyed for proper installation. Check
that the memory card is not write-protected. Slide the protection switch away from the "Lock"
position.
Use the optional SIMATIC memory card either as a program card or as a transfer card:
 Use the transfer card to copy your project to multiple CPUs without using STEP Basic.
The transfer card copies a stored project from the card to the memory of the CPU. You
must remove the transfer card after copying the program to the CPU.
 The program card takes the place of CPU memory; all of your CPU functions are
controlled by the program card. Inserting the program card erases all of the internal load
memory of the CPU (including the user program and any forced I/O). The CPU then
executes the user program from the program card. The program card must remain in the
CPU. If you remove the program card, the CPU goes to STOP mode.
USER PROGRAM BLOCKS
The CPU supports the following types of code blocks that allow you to create an efficient
structure for your user program:
 An organization block (OB) is a code block that typically contains the main program
logic. The OB responds to a specific event in the CPU and can interrupt the execution of
the user program. The default for the cyclic execution of the user program (OB 1)
provides the base structure for your user program and is the only code block required for
a user program. The other OBs perform specific functions, such as for startup tasks, for
handling interrupts and errors, or for executing specific program code at specific time
intervals.
 A function block (FB) is a subroutine that is executed when called from another code
block (OB, FB, or FC). The calling block passes parameters to the FB and also identifies
a specific data block (DB) that stores the data for the specific call or instance of that FB.
Changing the instance DB allows a generic FB to control the operation of a set of
devices. For example, one FB can control several pumps or valves, with different
instance DBs containing the specific operational parameters for each pump or valve. The
instance DB maintains the values of the FB between different or consecutive calls of that
FB, such as to support asynchronous communication.
 A function (FC) is a subroutine that is executed when called from another code block
(OB, FB, or FC). The FC does not have an associated instance DB. The calling block
passes parameters to the FC. The output values from the FC must be written to a memory
address or to a global DB if other components of your user program need to use these
values. The size of the user program, data, and configuration is limited by the available
load memory and the work memory in the CPU. There is no limit to the number of blocks
supported; the only limit is due to memory size
WORKING PROCEDURE:
Select TIA portal 16.0 and double click on it as shown in the red color mark in the below image
Double click on create new project as shown in the below image

.
Select the project name ''1'' and select the location path to save project ''2'' then click create ''3''
as shown in the below image
1
2
3
Double click on device and network as show in the image
Click add new device as shown in the red color mark

Click Controller ''1'' and ''2'' SIMATIC S7 1200 as shown in the below image
1
2
Click on CPU ''1'' and ''2'' CPU 1214C DC/DC/DC then select the required ''3'' MLFB number
and click add ''4''.
The below image shows the PLC controller configuration image and just follow the below
procedure to communication
Double click on the RJ 45 symbol in the controller ''1'' ,now properties of the controller will be
open and Ethernet configuration also open if it is not opened just click on the Ethernet address
and change IP address as require''2'' as shown in the below image.
2
Analog module selection:
 Double click the module block (1) given below the diagram
 And also got the catalog in right side column and click the signal boards folder(2).
 After select the signal boards folder(2) go to click AQ(3) and select the
module folder(4)and module(5)simultaneously.
2
1
3
4
5
Now the Analog Module was created inside the PLC module in shown below the diagram.
Now save the program settings to enter the (CTRL+S) function. Then go to compile operation to
click the Red color mark in below diagram.
Then go to downloading the program settings for click the online tab(1) and also select the
download to device option(2).
1
Another one option for download the program goes to click download icon nearer to the compile
icon (or) Enter the following shortcut key for CTRL+L.
Then automatically open the Extended to download device window and do the following
procedure simultaneously.
 Select the PN/IE into the Type of the PG/PC Interface(1).

 And also select the PG/PC Interface(2).
 Then select the show all compatible devices(3).
 Finally click the Start Search option(4).
1
2
4
Then go to select target device window and select the plc device(1). And then click the load
Button(2).
If you are using first time of downloading the program in plc in contains following procedures.
In Software synchronization before loading to a device window in open and then click the
Continue without synchronization option is shown below the Figure.
Then goes to load preview window to click the load option is marked in Red color block.
And also goes to Load Results window tick the start all and click the Finish option in given
figure.
Programming Method in PLC:
Click PLC-1 in the project tree ''1'' then click program block ''2'' and click main OB1 ''3'' as
shown in the below image
1
2
3
Now the below image shows (Object Block1) OB1 is created.
Now select the network as shown in the below image ''1'' and just double click on normally
open ''2'' as shown in the below image
1
Below image shows normally open is added
Select the ''1'' in below image and add the output coil in network. Then double click on the both
NO contact and output coil to enter their addresses simultaneously(2).
NOTES:
In Digital input starts from I0.0
In Digital output starts from Q0.0

1
Right Click the PLC_1 in Project tree then Go to "Download to device"[1] option and the
Hardware and Software (only changes)[2].
1 2
If you are first time to download the program in plc it shows the below window then click the
Continue without synchronization option
Load preview window will open, select "Load" option.

In load results windows, select "start all" option and then select "finish" option.
For make an online process goes to click the Monitoring on/off icon is shown below the image.
Then below the image shows the online mode of the PLC
EXPERIMENT NO: 1
AIM:
To study about the AND_GATE operation using SIEMENS S7-1200 PLC via TIA
Portal Software.
APPARATUS REQUIRED:
 PLC Trainer kit

 Personal Computer Installed with TIA Portal Software
 Ethernet cable
 Patch chords
OPERATIONS:
 In AND_GATE operation is used to make the multiple operation of 2 inputs.

Now using A&B are 2 inputs and C is the output.
 Now generatding the following formula to create the AND_GATE operation is
given below.
A.B = C
TRUTH TABLE & SYMBOL OF AND_GATE:
A
A B C
C
0 0 0
B
0 1 0
1 0 0
1 1 1
Notes:
0 - LOW ; 1 - HIGH
Programming Method in PLC:
1) Click PLC-1 in the project tree ''1'' then click program block ''2'' and click
main OB1 ''3'' as shown in the below image
2) Now the below image shows (Object Block1) OB1 is created.

Now write an AND_GATE operation for make a 2 inputs like A and B .It is created by using two
Normally open contacts. And their addresses are A(I0.0) and B(I0.1).
3) And the only one output can be used in this program that is C and their address is
(Q0.0). The given below image can be shows the AND_GATE operation program.
4) Then save the program to press (CTRL+S) function it will be saved.
5) After saved the program go to online mode to click GO Online icon directly.
6) After click the online mode goes to select the Monitoring ON/OFF Icon.
7) Finally the two inputs [(I0.0),(I0.1)] are goes to HIGH the output [Q0.0] will goes to
HIGH. It can be represented in Green color indications in below the Figure.
RESULT:
Thus the S7-1200 PLC based AND_GATE operation was studied and created
successfully through TIA portal.
Experiment no 2:
INTRODUCTION
The “Lift control system” is one of the applications of PLC. PLC’s are solid state device in built
by Micro controller and Relay. The PLC operates by the software’s the ladder logics functions.
The PLC interface with the PC via RS 232 cables the and the lift control system get the inputs,
outputs from PLC.
LIFT CONTROL SYSTEM

PC PLC UNIT
WORKING PRINCIPLE
There are three floors and each floor has one requesting switch. Whenever the switch is
pressed the lift comes to that floor and remains in that floor for the given particular time
period.
STEPPER MOTOR
The stepper motor in the trainer kit produces the required rotating motion to the bottle
platform. The stepper motor windings Coil 1, Coil 2, Coil 3, Coil 4 can be cylindrically excited with
the DC current to run the motor in clockwise direction. By reversing the phase sequences Coil
1, Coil 4, Coil 3, Coil 2. The 4 coils of the stepper motor are arranged in a fashion to rotate in
steps.
The steps angle for rotation of stepper motor is governed by number of stator and rotors.
Step Angle = 360 / NS×NR

The Material platform stepper motor axis connected together exhibit
synchronism. The stepper motor operates in a two modes of operation as it is
given.
i. Single step operation
For a single step operation energised each coil step by step for that consider the below given
table at the time of moving the first decimal data (1) Coil 1 is energised, then coil 2 for second
decimal data and so on. This process repeated again and again to acheive the required job.
Coil 1 Coil 2 Coil 3 Coil 4 Decimal Value

1 0 0 0 1
0 1 0 0 2
0 0 1 0 4
0 0 0 1 8
Double Step Operation
Double step operation energised 2 coils simultaneously and repeat same for step by step at
that time of moving the first decimal data (3) Coil 1 & 2 are energised. Then coil 2 & 3 for
second decimal data (6) and so on.
Coil 1 Coil 2 Coil 3 Coil 4 Decimal Value

1 1 0 0 3
0 1 1 0 6
0 0 1 1 12
1 0 0 1 9
,
Wiring for Stepper Motor:
Blue - Coil 1
Red - Coil 2
Green - Coil 3
Orange - Coil 4
Specifications
Torque - 2Kg
Voltage - 12V
Inductive Sensor
This inductive sensor is used to monitor the lift position, when it senses the output of the sensor
will be given to the PLC input.
Specifications
Voltage - 230V
Current - 100mA.
,
BLOCK DIAGRAM
LIFT CONTROL SYSTEM

LIFT CONTROL SYSTEM
I/P PULSE TO PLC
FLOOR SENSOR 1,2,3. REQUEST SWITCH 1,2,3.

PLC
STEPPER MOTOR DRIVER BOARD

I/P PULSE TO PLANT STEPPER MOTOR
UNIT 1UNIT 2
POWER SUPPLY
LIFT FRONT PANEL DIAGRAM
LIFT CONTROL SYSTEM (VPAT-20P)
FLOOR 3
24V DC REQUEST SWITCH 3
+
FLOOR INDICATOR 3
-
INPUTS
RS1
FLOOR 2
RS2
REQUEST SWITCH 2
RS3
FS1 FLOOR INDICATOR 2

FS2
FS3
OUTPUTS FLOOR 1
COIL1
REQUEST SWITCH 1
COIL2
FLOOR INDICATOR 1
COIL3
COIL4
COM
Program Description
I1, I2, I3 - Requestion switch.
I4, I5, I6 - Sensor Inputs
Q2, Q3, Q4, Q5 - Output for stepper motor.
I1, I2, I3 are the requestion switches I4, I5, I6 are the sensor placed in each floor. The other
coils used in the program are the set coil, reset coil, Positive transition coil, negative transition
coil arein memory location.
The timer functions are used to produce the required time delay.
Bit sequence function is used to drive the stepper motor.
Whenever the requirement switch I1, is pressed the setcoil M1 is energized and bit sequence
outputs are enabled then the stepper motor rotates.
When the motor reaches the respective floor, the switch I4 gets closed and energizes both
positive transition coil & negative transition coil.
The positive transition coil energize one more set coil, which is used to enable the
timer. This timer is used to give time delay for the lift in each floor.
The negative transition coil which was energized is used to reset the requestion.
The above functions are repeated in each floor.
Conditions For rotation Of Motor
Consider the lift is in ground floor, when the requestion is given from first floor or second floor
the motor has to move forward.
If the lift is in top floor then it has to move in the reverse direction.
If the lift is in middle floor then according to the requestion, lift will move in forward or
reverse direction.
WIRING DIAGRAM
LADDER DIAGRAM
LIFT CONTROL SYSTEM VPAT - 20
LIFT CONTROL SYSTEM VPAT – 20
LIFT CONTROL SYSTEM VPAT-20
CONTACT AND COIL DETAILS:
I1 - REQUEST SWITCH 1
I4 - FLOOR SENSOR 1
I5 - FLOOR SENSOR 2
I6 - FLOOR SENSOR 3
I7 - MANUAL FORWARD
I8 - MANUAL REVERSE
Q1 - MOTOR COIL 1
Q2 - MOTOR COIL 2
Q3 - MOTOR COIL 3
Q4 - MOTOR COIL 4
M6 - FORWARD ENABLE
M7 - REVERSE ENABLE
RESULT
Thus the LIFT CONTROL SYSTEM was studied successfully by using Ladder Logic
program.
EQUIPMENT NO: 3 SYNCHRO
TRANSMITTER & RECEIVER PAIR
A synchro is an electromagnetic transducer commonly used to convert an angular
position of a shaft into an electric signal.
The basic synchro is usually called a synchro transmitter. Its construction is similar to
that of a three phase alternator. The stator (stationary member) is of laminated silicon steel and
is slotted to accommodate a balanced three phase winding which is usually of concentric coil
type (Three identical coils are placed n the stator with their axis 120 degree apart) and is Y
connected. The rotor is a dumb bell construction and wound with a concentric coil. An AC
voltage is applied to the rotor winding through slip rings. Ref. Fig. No.1A.
Let an AC voltage Vr (t) = Vr sin Wct … (1) be supplied to the rotor of the synchro
transmitter. Thisvoltage causes a flow of magnetizing current in the rotor coil which produces a
sinusoidally time varying flux directed along its axis and distributed nearly sinusoidal, in the air
gap along stator periphery. Because of transformer action, voltages are induced in each of the
stator coils. As the air gap flux is sinusoidally distributed, the flux linking any stator coil is
proportional to the cosine of the angle between rotor and stator coil axis and so is the voltage
induced in each stator coil.
The stator coil voltages are of course in time phase with each other. Thus we see that the
synchro transmitter (TX) acts like single phase transformer in which rotor coil is the primary and
the stator coils form three secondaries.
Let Vs1 N, Vs2 N and Vs3 respectively be the voltages induced in the stator coils S1, S2
and S3 with respect to the neutral. Then for the rotor position of the synchro transistor shown in
fig.No.1 where the rotor axis makes an angle 0 with the axis of the stator coil S2.
Let Vs1N = KVr sin Wct cos (0+120) (2)
Vs2N = KVr sin Wct cos (0) (3)
Vs3N = KVr sin Wct cos (0+240) (4)
The three terminal voltages of the stator areVs1s2 = Vs1N – Vs2N

= 3 KVr sin (0=240) sin Wct (5)
Vs2S3 = Vs2N – Vs3N
= 3 KVr sin (0+120) sin Wct (6)
= 3 KVr sin (0) sin Wct (7)
When 0 is zero from equation (2) and (3) it is seen that maximum voltage is induced in the stator
coil s2 while it follows from equation (7) that the terminal voltage Vs3s1 is zero. This position
of rotor is defined as the electrical zero of the Tx and is used as a reference for specifying the
angular position of the rotor.
Thus it is seen that the input to the synchro transmitter is the angular position of its rotor
shaft and the output is a set of three single phase voltages given by equation (5), (6) and (7). The
magnitudes of these voltage are functions of a shaft position.
The classical synchro systems consists of two units.

1. Synchro transmitter (Tx)
2. Synchro rceiver (Tr)
The synchro receiver is having almost the same constructional features. The two units
are connected as shown in figure No.2. Initially the winding S2 of te stator of transmitter is
positioned for maximum coupling with rotor winding. Suppose its voltage is V. The coupling
between S1 and S2 of the stator and primary (Rotor) winding is a cosine function. Therefore the
effective voltages in these winding are proportional to cos 60 degrees or they are V/2 each. So
long as the rotors of the transmitters and receivers remain in this position, no current will flow
between windings because of voltage balance.
When the rotor of Tx is moved to a new position, the voltage balance is disturbed.
Assume that the rotor of Tx is moved through 30 degrees, the stator winding voltages will be
changed to zero, 0.866V and 0.866V respectively. Thus there is a voltage imbalance between
the windings causes currents to 1 flow through the close circuit producing torque that tends to
rotate the rotor of the receiver to a new position where the voltage balance is again restored.
This balance is restored only if the receiver turns through the same angle as the transmitter and
also the direction of the rotation is the same as that of Tx.
The Tx Tr pair thus serves to transmit information regarding angular position at one point
to a remote point.
System Description and Operation

The system set up is made up of synchro transmitter and synchro receiver on a single
rigid base provided with suitable swithes and anodized angular plates. The system also contains
a step down transformer for providing excitation to the rotors. Suitable test points for rotor (R1
and R2) and stator (S1, S2 and S3) for both Tx and Tr are provided.
Experiment No.1 :
AIM: Study of synchro transmitter
In this part of the experiment we can see how, because of the transformer action, the
angular position of the rotor of synchro transmitter is transformed into a unique set of stator
voltages.
Procedure:
1. connect the mains supply to the system with the help of cable provided. Do not
connected any patch cords to terminals marked “S1, S2 and S3”
2. Switch on mains supply for the unit.
3. Starting from zero position, note down the voltage between stator winding terminals i.e
Vs1s2, Vs2s3 and Vs3s1 in a sequential manner. Enter readings in a tabular form and
plot a graph of angular position of rotor voltages for all three phases.
4. Note that zero position of the stator rotor coinsides with Vs2s1 voltage equal to zero
voltage. Do not disturb this condition.
Experiment No.2 :
AIM: Study of synchro transmitter and receiver pair.
Procedure
1. Connect mains supply cable.
2. Connect S1, S2 and S3 terminals of transmitter to S1, S2 and S3 of synchro receiver by
patch cords provided respectively.
3. Switch on SW1 and SW2 and also switch on the mains supply.
4. Move the pointer i.e rotor position of synchrono transmitter Tx in steps of 30 degrees
and observe the new rotor position. Observe that whenever Tx rotor is rotated, the Tr
rotor follows it for both the directions of rotations and their positions are in good
agreement.
5. Enter the input angular position and output angular position in the tabular form and plot
a graph.
Precautions
1. Handle the pointers for both the rotors in a gentle manner
2. Do not attempt to pull out the pointers
3. Do not short rotor or stator terminals
FRONT PANEL VIEW OF SYNCHRO TX

AND TR
Note: 1) Connect S1, S2, S3 of synchro transmitter to S1, S2, S3 of synchro receiver
respectively by mans of patch cords.
2) SW1 & SW2 are switches for rotor supply (excitation) of synchro TX &
TR.
TOP VIEW OF SYNCHRO
TRANSMITTER & RECEIVER
SYNCHRO TRANSMITTER ROTOR POSITION VERSUS STATOR VOLTAGES FOR THREE PHASES
(Vsls3, Vsls2, VS2S3)
Sr.No. Position rotor Stator / Vs3S1 Terminal VS1S2 Voltages (RMS)

degrees VS2S3
1 00 0.1 60.3 59.8
2 30 33.8 34.5 68.6
3 60 58.9 1.1 60.7
4 90 69.1 33.7 34.9
5 120 60.1 59.1 0.4
6 150 36.2 68.9 32.6
7 180 0.9 60.3 59.3
8 210 33.9 34.8 68.9
9 240 59.1 0.3 59.6
10 270 68.8 33.5 34.9
11 300 59.7 60 0.4
12 330 33.5 69.2 35.1
TYPICAL
RESULTS FOR
Sr. Angular position in degrees Angular position in degrees synchro
No. synchro transmitter I/P receiver O/P
1 0.0 0.5
2 30.0 30.5
3 60.0 61.0
4 90.0 89.0
5 120.0 119.0
6 150.0 148.0
7 180.0 178.0
8 210.0 209.0
9 240.0 240.0
10 270.0 269.0
11 300.0 299.0
12 330.0 329.0
EQUIPMENT NO: 4
PID
CONTROLLER
INTRODUCTION:
This trainer is specially designed to study about the analog PID controller with the
configuration of P, PI and PID. It consists of simulated block like controller, process, motor
drive and waveform generator. Internal of the controller block are error detector, adder
calibrator (fine tuning 10 turn) pot meter are provided for proportional gain, integral time and
derivative time constant and in waveform generator built-in synchronized square and triangle
signal source are provided with level and frequency controls. It enables the student to study
the response of PID on “CRO” and an important feature of this system is that the simulated
blocks are designed to be operated at frequency suitable for CRO viewing, and for real time
processing, DC motor controller is provided along with this trainer provided with digital
indicator for set RPM and current RPM features and temperature control as an optional
feature. Technical Specifications:
Built in Signal Sources

Square Wave : Amplitude - 1V (p-p)
Frequency - 10 Hz to 40 Hz
Triangular Wave : Amplitude - 1V (p-p)
Frequency -10 Hz to 40 Hz
Simulated Process : Delay
Integrato
r
Time Constant I &

Time Constant II
Error Detector
Gain
Controller Configuration: P,PI,PD & PID
Proportional band: 5% to 50 %
Controller gain: 2 to 20
Integral Time Constant: 10 to100msec
Derivative time constant: 0.2 to 20msec
Experiments
 Open & Closed loop response of simulated process like delay, integrator, and time
constant.
 Study and performance evaluation of Closed loop response of P,PI,PD and PID
controller.
OBJECTIVE:
To study the performance characteristics of an analog P, PI and PID controller
under open loop and closed loop systems.
EXPERIMENTAL UNIT:
This is a very well designed and compact unit for class room experiments on the study
of proportional-integral-derivative controllers. It comprises of a flexible process, a PID
controller, signal sources, a DVM and a stabilized power source for all the sub-systems. The
various sections along with their specifications are described below.
Process or plant
In a practical situation the process or plant is that part of the system which
produces the desired response under the influence of command signal. Usual proc esses
are higher order, nonlinear functions having inherent dead time or pure time delay. In
process control studies such plants are commonly modeled by transfer functions of the
form
1
Gp(S) = θs
Ke
s 1
Where,  is the time delay in sec  is the effective time constant and K is the
controller gain.
In the present system, the process is an analogue simulation through a few basic
building blocks which may be connected suitably to form a variety of processes or
plants. These blocks are,
a) Integrator - having an approximate transfer function of 1/s
b) Simple pole - two identical units, each having a transfer function of 1 /(1+0.0155s)
c) Pure time delay - a time delay of about 5.64 msec. generated by a high order
multiple pole approximation of the delay function.
Note that all the above blocks, except pure time delay, have 180° phase shift between input and
output.
Controller:
The controller for the process is an analog Proportional-Integral-Derivative
(PID) circuit in which the PID parameters are adjustable. The values may be set within
the following range through 10 turn calibrated potentiometers:
Proportional Gain, Kc : 2 to 20
Proportional Band : 5% to 50%
Integral Time Constant, Ti : 10 - 100 msec.
Derivative Time Constant, Td : 2 - 20 msec.
It may be mentioned that although in an industrial PID Controller it is common
to adjust the above parameters directly, but in the educational environment convenience
and simplicity is more important. In the present unit, therefore, it is the proportional,
integral and derivative gains viz. Kc, Ki and Kd, which are made variable through 10
turn potentiometers calibrated from 0 to 1.
The PID block has a phase angle of 0° between its input and output.
Error Detector:
The error detector is a unity gain inverting adder which adds the command signal
with the feedback signal. To ensure negative feedback it would therefore be necessary
to have (2n+1) phase shift in the forward path, for n = 0, 1, 2...
Uncommitted Amplifier:
It is a unity gain inverting amplifier. This amplifier may be inserted in the loop,
if required, to ensure a proper phase angle.
Signal Sources:
The signal source comprises of a low frequency square and triangular wave
generator having adjustable amplitude and frequency. The square wave is used as
command input to the system, while the triangular wave is used for external x-deflection
in the CRO. This arrangement gives a perfectly steady display even up to very low
frequencies and is convenient for CRO measurements.
BACKGROUND SUMMARY
Introduction:
The performance of a physical system is not always good enough for a given
application. In such a situation the characteristics of the system needs to be modified.
This is referred to as ‘Compensation Design’. Standard procedure available for
compensation includes time and frequency domain designs of a variety of compensation
networks. Such design methods have been successfully used in many practical dynamic
control systems. The performance of the system is evaluated in terms of a set of
performance specifications e.g. rise time, peak time, settling time, peak percent overshoot
and steady state error in the time domain, and gain margin phase margin, closed loop
bandwidth etc in the frequency domain.
Fig 1: Block diagram of the Overall system
Another approach towards improving the performance of systems has been
through elementary control actions - called control terms - inserted in the forward path of
an existing control system. The block diagram of Fig.1 shows the location of such a
controller in a unity feedback system. The controller work comprise of two or three of
the following control terms:
(a) Proportional, P
(b) Integral, I
(c) Derivative, D
The resulting controller may then turn out to be a P, PI or PID controller.
The two, and three-term controllers indicated above have been used more
commonly by process industries e.g. petroleum, chemical, power, food etc., for the
control of temperature, pressure, flow and similar variables. A common feature of these
systems is their sluggish response which calls for accurate and slow integration and
sensitive differentiation. Although near ideal electronic differentiator and integrator
circuits are difficult to achieve except with high impedance operational amplifiers and
good quality component, PI and PD controller valves have existed in the pneumatic and
hydraulic environments for a long time.
In the present unit attempt has been made to expose the students to the study and
design of PID controllers using simulated systems. The speed of response has been
deliberately scaled up to have a fast and easy viewing on CRO.
Structure of PID Controller:

The equation of a PID controller is given by.
de(t)
m (t) = Kc e(t) + Ki e(t)dt  Kd 2
 dt
Where,
e(t) = error signal
m(t) = P1D output or plant input
Kc = Proportional gain
Ki = Integral gain
Kd = Derivative gain
1n the Laplace domain, the above equation is written as
Fig.2. Block Diagram of PID Controller
Ki
M(s) = Kc E(s) + E(s) + sKd E(s)
s
The above equation is represented as a block diagram of PID controller as shown in Fig.
2. An alternative representation of the above equation which is more commonly used in
process control literature is as follows:
 1 
M(s) = Kc 1 Td sE(s) 3
 Ti s 
Where,
Ti = K c
Integral time constant
Ki
Td = K d
Derivative time constant
Kc
It is easy to develop the structure of PD, and PI controllers from above, by
substituting Ki = 0 and Kd = 0 respectively. A special terminology used in process
control literature is given below to facilitate better understanding.
1
Proportional Band = x 100%
Kc
Reset Rate
Ki 1 per minute
Kc  T i
=
Derivative Time Constant = Td
In the present unit, the three gains are adjustable in the following range with the
help of calibrated 10-turn potentiometers.
Kc : 0 to 20
Ki : 0 to 1000
Kd : 0 to 0.01
Characteristics:
From Eq. (2), the transfer function of the PID controller may be written as
M (s) K s s 2 K c s K i 4
GPID (s)  
s
E(s)
Ks (s  1)(s  2)
Where 1 and 2 are the two zeros of the PID controller transfer function.
Fig. 3 Bode diagram of PID controller

The above transfer function has a pole at the origin and two real zeros for Kc2 >
4KdKi Notice that a properly designed PID controller should not, in general, have a pair
of complex conjugate zeros which may result in reduced damping. Bode diagram of the
PID controller is shown in Fig. 3. It may be seen that the controller gain increase without
limits as the frequency is decreased. This is due to the integral term, and it results in a
reduction of steady state error. However, the negative phase angle introduced by the
controller at low frequencies has a destabilizing effect as well. The corner frequency 1,
should therefore be so located that large negative phase angle occurs at sufficiently low
frequencies only, where the plant already has a good stability margin.
Again, the Bode diagram of the controller (Fig. 3) shows an increased gain at high
frequencies accompanied by a positive phase angle. The positive phase angle has a
stabilizing effect while the large gain at high frequencies makes the system respond more
to fast or sudden changes. The overall system then becomes relatively more stable, as it
is capable of taking `anticipatory' action in the presence of signals having fast variations.
Design:
The PID Controller can be designed both in the frequency domain and in the s-
plane, through the classical or trial-and-error design procedure. The method needs the
pole-zero locations or frequency-phase responses of the plant, for its implementation. A
large number of process control systems are however characterized by,
Incomplete or inaccurate plant equation
Extremely slow response
Presence of time delays
High order transfer function
Limited possibility of experimentation for identification of the plant and need for fine
trimming the compensator at site
In such a situation alternative simpler techniques of setting the controller parameters (KC,
Ti Td), or tuning, are of great practical value. Presented below are three techniques of
tuning a PID controller aimed at obtaining a satisfactory step response of the overall
system.
Trial-and-error tuning
This is a simple and systematic method for on-line tuning of a PID controller. The
method assumes that the three parameters Kc, Ki and Kd are available for adjustment.
Following are the steps for its implementation.
1.
Disconnect or reduce derivative and integral block signals by setting Ki and Kd
to zero.
2.
Starting from a low value increase Kc, gradually till Sustained oscillation sets
in. This condition is tested by small disturbances generated by varying the reference
signal a little. The value of- proportional gain so obtained is called ultimate gain, Kcu.
3.
Set Kc to 1/2 of the value obtained in step 2.
4.
Increase K, gradually until sustained oscillations start again. Set Ki to 1/3 of
this value.
5.
Increase Kd gradually until sustained oscillations start again. Set Td to 1/3 of
this value.
The above method, though very simple in operation, has the following limitations:
(i)A number of systems which are, or may be approximated to, first or second order
transfer functions without time delay do not oscillate. Step 3 is then not possible and the
method fails.
(ii) Open loop unstable systems cannot be handled by this method.
(iii) Tuning of very slow systems by this method is extremely time consuming.
(iv) Sustained oscillations may not be acceptable or may be risky in some physical
processes such as a large chemical process.
(b) Continuous Cycling Method

In this method, given by Ziegler and Nichols, the first step is to determine
experimentally the value of ultimate gain, Kcu as suggested in the previous method. The
time period of the resulting sustained oscillations is referred to as ultimate period P u
Based on the values of Kcu and Pu the controller settings are obtained from Table I below
which is essentially empirical in nature.
Controller Kc Ti Td
P 0.5 Kcu - -
PI 0.45 Kcu 0.833 Pu -
PID 0.6 Kcu 0.5 Pu 0.125 Pu
Table 1: Empirical values for tuning the controller

Some variation in the coefficient settings have also been suggested by various
workers. In case the above values should be taken as the `initial settings' and should
invariably be followed by fine-tuning via trial-and-error. Most of the limitations of the
first method are still present in this method; however the continuous cycling method is
less time consuming.
Fig 4 Step response of (a) Type – 0 (b) Type – 1 system

c) Process Reaction Curve Method
This is a second on-line tuning method proposed by Ziegler and Nichols and is very
attractive because it is based on a simple experimentation. The plant is modeled as a first
order function with time delay. The open loop step response of the plant, called reaction
curve of the process, is experimentally obtained.
Typical step responses for Type-0, and higher type number systems are shown in Fig.
4(a) and 4(b) respectively. The step responses are characterized by two parameters.
(i) Slope S of the tangent drawn at the point of inflection
(ii) Time T at which the tangent intersects the X-axis.
The values of S and T are obtained graphically as shown in Fig. 4. If the input step change
was M then the PID parameters are given by the Table 2 below.
Controller Kc Ti Td
P M/ST - -
PI 0.9 M/ST 3.33 T -
PID 1.2 M/ST 2T 0.5 T
Table 2: Tuning Parameters using Process Reaction Curve.
Once again, the above values are empirical in nature and therefore fine tuning of
the parameters may be needed in specific cases. The values of Ki and K d may be
calculated from Eq. (2) for implementation on the present unit.
Although the process reaction curve method based on a single experimentation is
fast and simple, it does have some limitation as given below:
(i) The step response obtained in the open-loop may not be satisfactory in case the
system is highly nonlinear or open loop unstable.
(ii) Accuracy is limited due to the graphical procedure involved.
In conclusion it may be said that any method used to calculate the parameters
must be followed by a fine tuning on the operational process.
EXPERIMENTS:
STUDY OF PID RESPONSE
Aim:
To study the response of a PID controller under calibration mode.
Apparatus Required:
 PID controller trainer kit.
 CRO.
 CRO probes.
 Patch cards
Self Calibration of CRO:

 Keep amplitude knob in 2V position in channel 1.
 Keep traces at center using X-Y position.
 Choose calibrate set 2V.
 Give 2V input which is available in CRO for calibrating purpose to channel 1.
 Verify 2V / 1 deviation in screen.
 Digital panel meter for motor control.
STUDY OF P CONTROLLER
Connection details
 Connect the output of the generator (square wave) to the input of P controller.
 Keep P controller knob at zero position initially (0.00) rotate anticlockwise
fully.
 Connect the output of P controller to the positive terminal of CRO.
 Connect negative terminal of CRO to GND of the trainer (channel 1).
Step: 1
 Switch ON the trainer.
 Connect CRO (channel 2) positive terminal to the waveform generator
(square wave).
 Connect negative terminal of CRO to the GND of the trainer (channel 2).
 Set amplitude of square wave as 0.1 V (P-P) & time period as 25msec in
square wave generator by varying amplitude knob.
 Connect the output of the square wave generator to the input of the P controller.
 Verify that the P controller pot in zero position.
 Now vary the P controller pot from min to max position and the
response (square wave amplitude) of the P controller.
Calculate the gain by using this formula.
Input = 0.1 V (P-P).
Output = 2.0 V (P-P).
Kc(max) = P-P square wave output / square wave input.
= 2.0/0.1
= 20V.
Result:
Thus the response of a P controller under calibration mode was studied and the gain
was calculated.
STUDY OF I CONTROLLER
Connection details
 Connect the output of the generator (square wave) to the input of I controller.
 Keep I controller knob at zero position initially (0.00) rotate anticlockwise fully.
 Connect the output of I controller to the positive terminal of CRO.
Step: 1
(triangular wave)
 Set amplitude of square wave as 0.1 V (P-P) & time period as 70msec in
 Connect the output of the triangular wave generator to the input of an I
controller.
 Verify that the I controller pot in zero position.
 Now vary the I controller pot from min to max position and the response
(square wave amplitude) of the P controller.
CALCULATION
Input = 1 V (P-P).
Output = 1.2 V (P-P).
Ki (max) = 4*f* (P-P) triangular wave output amplitude in volts / p-p square wave input
amplitude in volts.
= 4*40*1.2/1
= 192 sec.
Integral Time Constant Ti = Kc/Ki
= 2/192 (Kc=2)
= 10.4 msec
Ti = Kc/Ki
= 20/192 (Kc=20)
= 104 msec
Result:
Thus the response of I controller under calibration mode was studied and the gain was
calculated.
STUDY OF D CONTROLLER
Connection details
 Connect the output of the generator (triangular wave) to the input of D
controller.
 Keep D controller knob at zero position initially (0.00) rotate anticlockwise
fully.
 Connect the output of D controller to the positive terminal of CRO.
Step: 1
(square wave)
 Set amplitude of triangular wave as 0.84 V (P-P) & time period as 70msec in
 Connect the output of the square wave generator to the input of the D controller.
 Verify that the D controller pot in zero position.
 Now vary the D controller pot from min to max position and the
response (square wave amplitude) of the D controller.
CALCULATION
Input = 1 V (p-p)
Output = 7.5 V (p-p)
Kd(max) = P-P square wave output / 4* f* (P-P) triangular wave input
= 7.5 / 4* 40 * 1
= 0.046
Derivative Time Constant (Td) = Kd/Kc

= 0.046/2 (Kc=2)
= 23 msec
Td = 0.046/20 (Kc=20)
= 2.3 msec
Result:
Thus the response of a D controller under calibration mode was studied and the gain
was calculated.
Ex.No.1 CLOSED LOOP RESPONSE
OF P CONTROLLER
Aim
To find the peak overshoot and steady state error of a P controller.
Apparatus Required
 CRO
 CRO probes Patch cards
P
ro  Set the amplitude of the square wave at 1V (P-P) and frequency to a low value.
Connect the output of waveform generator (square wave) to the error
ce detector input.
 Connect the P controller output to the adder input.
d  Connect the adder output the delay input.
Connect the delay output to the time constant1 input.
u  Time constant1 output is connected to the amplitude input.
re  The amplitude output is connected to error detector feedback input.
Ensure that the circuit will from a closed loop control.
 Connect the CRO (channel1) positive terminal to the amplitude output.
 Connect the negative terminal (channel1) of the CRO to GND.
 Connect the CRO (channel 2) positive terminal to the triangular output.
 Vary the potentiometer of the P controller from minimum to maximum
position and note down the peak overshoot & steady state error from the
graph.
 Calculate % of steady state error and peak overshoot value.

Model Graph
Tabular Column
SI.No. Kc X Y Steady % of
state error overshoot
1 1 0.5 0.58 0.5 16
Calculation
Input = 1V (P-P) square wave low frequency
Kc = 0 to max.
Steady State Error = (P-P) input – x / (P-P) input = (1-0.5)/1
% Overshoot = y-x / x *100
=[(0.58-0.5)/0.5]*100=16%
Patching diagram
Result
Thus the peak overshoot and steady state error of a P controller was founded out and the
graph of time Vs amplitude was plotted.
Ex.No.2 CLOSED LOOP RESPONSE OF
PI CONTROLLER
Aim
To find the peak overshoot and steady state error of a PI controller.
Apparatus Required
 CRO
 CRO probes
 Patch cards
Procedure
 Set the amplitude of the square wave at 1V (P-P) and frequency to a low value.
 Connect the output of waveform generator (square wave) to the error detector input.
 Connect the P & I controller output to the adder input.
 Connect the adder output the delay input.
 Connect the delay output to the time constant1 input.
 Time constant1 output is connected to the amplitude input.
 The amplitude output is connected to error detector feedback input.
 Ensure that the circuit will from a closed loop control.
 Vary the potentiometer of the P controller from minimum to maximum position and
note down the peak overshoot & steady state error from the graph.
 Calculate % of steady state error and peak overshoot value.
Model Graph
Tabular Column
Steady % of
S.No Ki X Y state overshoot
error
1. 0.9 0.6 0.66 0.4 10%
Calculation
Kc= 0.6
Steady State Error = (P-P) input – x / (P-P) input =(1-0.6)/1=0.4
% Overshoot = y-x / x *100 =[(0.66-0.6)/0.6]*100= 10%
Patching diagram
Result
Thus the peak overshoot and steady state error of a PI controller was founded out and the
graph of time Vs amplitude was plotted.
Ex.No.3 CLOSED LOOP RESPONSE OF
PID CONTROLLER
Aim
To find the peak overshoot and steady state error o a PID controller.
Apparatus Required
 PID controller trainer kit
 CRO
 CRO probes
 Patch cards
Procedure
 Set the amplitude of the square wave at 1V (P-P) and frequency to a low value.
 Connect the output of waveform generator (square wave) to the error detector input.
 Connect the P, I & D controller output to the adder input.
 Connect the adder output the delay input.
 Connect the delay output to the time constant1 input.
 Time constant1 output is connected to the amplitude input.
 The amplitude output is connected to error detector feed back input.
 Ensure that the circuit will from a closed loop control.
 Vary the potentiometer of the P controller from minimum to maximum position and
note down the peak overshoot & steady state error from the graph. Calculate % of steady
state error and peak overshoot value.
Model Graph
Tabular Column
Kd X Y Steady % of
Sl.No state overshoot
error
1. 0.9 0.72 0.76 0.28 5.55
Calculation
Kc = 0.6 , Ki=0.006,
Steady State Error = (P-P) input – x / (P-P) input
= 1 – 0.72/ 1 = 0.28
% Overshoot = y-x / x *100

= 0.76-0.72 /0.72 * 100 = 5.55%
Patching diagram
Result:
Thus the peak overshoot and steady state error of a PID controller was founded out and
the graph of time Vs amplitude was plotted.
Appendices:
Circuits used in PID Controller:
Hydraulic manual
1
Hydraulic manual
Symbols of hydralic supply elements:
2
Hydraulic manual
Ex no: 05
Aim: Symbols of hydraulic components

To study Symbols of hydraulic components
Pump unit (simplified) :
Simplified representation of the detailed pump unit . The component does not
have tank connections in the circuit diagram.
Adjustable parameters:
Max. pressure: 0.01 ... 40 MPa (6)

Flow: 0 ... 500 l/min (2)
Internal leakage: 0 ... 100 l/(min*MPa) (0)
Fixed displacement pump:

The fixed displacement pump delivers a constant volumetric flow rate
dependent upon the revolutions and the displacement volume.
Revolution: 0 ... 3000 1/min (1320)

Displacement: 0.001 ... 1 Liter (0.0016)
Max. Pressure: 0.1 ... 40 MPa (6)
Variable displacement pump:

The revolutions of the variable displacement pump can be changed under
operating conditions. The pump delivers a variable volumetric flow rate dependent upon
the variable revolutions and the displacement volume.
Adjustable parameters
Revolution: 0 ... 3000 1/min (1320)
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Hydraulic manual

4
Hydraulic manual
Tank:
The tank is integrated into the pump unit and has a pressure of 0 MPa. It can be
inserted into the circuit diagram as an independent component.
Pump unit:
The pump unit supplies a constant volumetric flow. The operating pressure is
limited by the internal pressure relief valve. The pump unit has two tank connections.

Flow: 0 ... 500 l/min (2.4)
Internal leakage: 0 ... 100 l/(min*MPa) (0.04)
Proportional amplifier, 1-channel:

The amplifier is used to control proportional valves. For this purpose, nominal
values (voltage signals) from 0 V to +10 V are transformed into the necessary magnetic
current for the proportional valves. In Fluid SIM the amplifier is coupled to the
respective valve with the help of a label. The maximum current at the amplifier output is
hereby automatically adjusted in relation to the coupled valve. A step current relative to
the maximum current can be specified, in order to compensate the positive overlap of
proportional valves. The amplifier requires a power supply of 24 V.
5
Hydraulic manual
6
Hydraulic manual
Proportional pump:
The revolutions of the variable displacement pump can be changed
proportionally from zero to maximum through a voltage signal between 0 V and 10 V
and the assistance of a proportional-amplifier. The pump delivers a variable volumetric
flow rate dependent upon the variable revolutions and the displacement volume.
Max. Revolution: 0 ... 3000 1/min (1320)

Hydraulic reservoir:
The reservoir enables the performance of a hydraulic system to be optimized. For
example, it can be utilized as an energy reservoir and for the absorbance of pressure
surges or flow fluctuations. Reservoirs are capable of absorbing a defined volume of
fluid under pressure and releasing it again with minimal losses. The construction consists
essentially of a pressure resistant container, generally a gas charge of nitrogen and a
separator e.g. a piston, a membrane or a bubble elastomer.
Hydraulic fluid only starts to flow into the reservoir when the fluid pressure is greater
than the gas-preload pressure.
Volume: 0.01 ... 100 Liter (0.32)

Gas pre-charge pressure: 0 ... 40 MPa (1)
Hydraulic reservoir:
The reservoir enables the performance of a hydraulic system to be optimized. For
example, it can be utilized as an energy reservoir and for the absorbance of pressure
surges or flow fluctuations. Reservoirs are capable
7
Hydraulic manual
of absorbing a defined volume of fluid under pressure and releasing it again with
minimal losses. The construction consists essentially of a pressure
8
Hydraulic manual
resistant container, generally a gas charge of nitrogen and a separator e.g. a piston, a
membrane or a bubble elastomer. Hydraulic fluid only starts to flow into the reservoir
when the fluid pressure is greater than the gas- preload pressure.
Volume: 0.01 ... 100 Liter (0.32)

Gas pre-charge pressure: 0 ... 40 MPa (1)
Diaphragm accumulator with shutoff block:

Stores the pressure and is equipped with a pressure relief valve to prevent overpressure.
Nominal pressure: 0 ... 35 MPa (6)

Gas pre-charge pressure: 0.1 ... 35 MPa (1)
Hose with quick-action coupling:

The hose is available in 3 lengths: 600 mm, 1500 mm, and 3000 mm. The pressure loss
in a hose is taken into account by specifying a hydraulic resistance. In Fluid SIM no
pressure loss is simulated with simple connections between two components.
Hydraulic resistance: 1e-7 ... 100 MPa*min2/l2 (0.012)
Filter:
The filter limits the contamination of the fluid respecting a certain tolerance value in
order to reduce the risk of damage at the components. Adjustable parameters
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Hydraulic manual
10
Hydraulic manual
Cooler:
An unacceptable fall in the hydraulic fluid's viscosity can be avoided through the
use of a cooler.

Heater:
The hydraulic fluid's optimal viscosity can be reached quickly through the use of a
heater.
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Hydraulic manual
Distance rule:
The distance rule is a device for attaching switches at the cylinder. The labels at the
distance rule define links to the actual proximity switches or limit switches in the
electrical circuit.
Configurable cylinders:
The configurable cylinder can be customized via its properties dialog. Almost any
combination of piston type (single-acting, double-acting), the specification of the piston
rods (double ended, with magnetic coupling or slide) and the number (none, one, two) is
possible. An end position cushioning (without, with, adjustable) can also be defined.
FluidSIM automatically adjusts the symbol according to the preset configuration.
In addition, a load to be moved (including possible static and sliding friction) and a
variable force profile can be defined in the properties dialog. In the component library
from FluidSIM there are several pre-configured cylinders that can be inserted in your
circuit and directly used. Should no suitable symbol be available, then simply choose the
component with the most similarity to the required component, open the properties
dialog and adjust the configuration accordingly.
Max. stroke:1 ... 5000 mm (200)

Piston position: 0 ... Max. stroke mm (0) Piston
diameter: 1 ... 1000 mm (16)
Piston rod diameter: 0 ... 1000 mm (10)
Mounting angle: 0 ... 360 Deg(0)
Moving mass: 0 ... 10000 kg (0)
Static friction coefficient:0 ... 2 (0)
Sliding friction coefficient: 0 ... 2 (0)
Force:-1000000 ... 1000000 N (0)
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Hydraulic manual
Hydraulic motor:
The hydraulic motor transforms hydraulic energy into mechanical energy. Adjustable
parameters

Friction: 0.01 ... 100 N*m*s/rad (0.0128)
Moment of inertia: 0.0001 ... 1 kg*m2 (0.0001)
External torque: -1000 ... 1000 Nm (0)
Semi-rotary actuator:
The semi-rotary actuator is controlled by alternately switching the pressure. In the end
positions the swivel cylinder can activate switches or valves via labels.
Rotation angle: 1 ... 360 Deg(180)

Friction: 0.01 ... 100 N*m*s/rad (0.1)
Initial position: Left, Right (Left)
Configurable directional valves:

Configurable 2/n way valve:
The configurable 2/n way valve is a way valve with two connections, where both its
body elements and its operation modes are user-definable.
Additionally, the hydraulic connections can be closed with blind plugs. Adjustable
parameters
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Hydraulic manual
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Hydraulic manual

The configurable 3/n way valve is a way valve with three connections, where both its
body elements and its operation modes are user-definable. Additionally, the hydraulic
connections can be closed with blind plugs.

The configurable 4/n way valve is a way valve with four connections, where both its
parameters

The configurable 5/n way valve is a way valve with five connections, where both its
parameters

The configurable 6/n way valve is a way valve with six connections, where both its body
elements and its operation modes are user-definable.
parameters
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Hydraulic manual
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Hydraulic manual
The configurable 8/n way valve is a way valve with eight connections, where both its
body elements and its operation modes are user-definable. Additionally, the hydraulic
connections can be closed with blind plugs.
Mechanically operated valves:
3/2-way hand-lever valve:
In normal position the connection P is closed and A to T opened. When manually

actuated T is shut off and P to A opened.
This valve is derived from a configurable 3/n way valve.
4/2-way hand-lever valve (i):
In normal position the connection P is open to B and A to T. When manually actuated the
valve is set to parallel position.
This valve is derived from a configurable 4/n way valve
4/2-way hand-lever valve (ii):
In normal position the connection P is open to A and B to T. When manually actuated the
valve is set to crossover position.
4/3-way hand-lever valve with shutoff position
(i):
In normal position all connections are closed. When manually actuated the valve is set to
parallel or crossover position.
4/3-way hand-lever valve with shutoff position
(ii):
In normal position all connections are closed. When manually actuated the valve is set
to crossover or parallel position.
This valve is derived from a configurable 4/n way valve. You find this valve in the
component library “Frequently used Way Valves”, under the Library menu.
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Hydraulic manual
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Hydraulic manual
4/3-way hand-lever valve with bypass position

(i):
In normal position the connections A and B are closed and P to T opened. When
manually actuated the valve is set to parallel or crossover position. This valve is
derived from a configurable 4/n way valve.
4/3-way hand-lever valve with bypass position
(ii):
In normal position the connections A and B are closed and P to T opened. When
manually actuated the valve is set to crossover or parallel position. This valve is
4/3-way hand-lever valve with floating

position (i):
In normal position the connections A and B are open to T. When manually actuated the
valve is set to parallel or crossover position.
4/3-way hand-lever valve with floating
position (ii):
In normal position the connections A and B are open to T. When manually actuated the
valve is set to crossover or parallel position.
2/2-way stem-Actuated valve (ii):
If the cylinder piston actuate the stem, the flow from P to A is shut off. This valve is
2/2-way stem-Actuated valve (ii):

If the cylinder piston actuate the stem, the flow from P to A is shut off. This valve is
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Hydraulic manual
Mechanically operated valves:
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Hydraulic manual
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Hydraulic manual
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Hydraulic manual
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Hydraulic manual
Nozzle:
The nozzle represents a hydraulic resistance. Adjustable

parameters
Throttle valve:
The setting of the throttle valve is set by means of a rotary knob. Please note that by the
rotary knob no absolute resistance value can be set. This means that, in reality, different
throttle valves can generate different resistance values despite identical settings.
Opening level: 0 ... 100 % (100)

Orifice:
The orifice represents a hydraulic resistance. Adjustable
parameters
Orifice, adjustable:
The orifice represents a variable hydraulic resistance.
Opening level: 0 ... 100 % (100)

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Hydraulic manual
Shutoff valve:
The shutoff valve can be manually opened or closed. The hydraulic resistance relates to
the completely opened valve.
Opening level: 0 ... 100 % (100)

One-way flow control valve:

The setting of the One-way flow control valve is set by means of a rotary knob. A check
valve (see check valve) is located parallel to the throttle valve. Please note that by the
rotary knob no absolute resistance value can be set. This means that, in reality, different
throttle valves can generate different resistance values despite identical settings.
Opening level: 0 ... 100 % (100)

Check valve:
If the inlet pressure at A is higher than the outlet pressure at B, then the check valve
allows the flow to pass, otherwise it blocks the flow.
Check valve with pilot control

If the input pressure is higher than the output pressure, the check valve opens. Otherwise
it is shut. In addition, the check valve can be opened via a control line, allowing flow in
both directions.
Area ratio: 1 ... 10 (5)
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Hydraulic manual
Check valve, spring loaded:

If the inlet pressure at A is higher than the outlet pressure at B and the nominal pressure,
then the check valve allows the flow to pass, otherwise it blocks the flow.
Nominal pressure: 0.001 ... 40 MPa (0.1)

Check valve with pilot control, spring loaded:

If the input pressure is higher than the output and nominal pressure, the check valve
opens. Otherwise it is shut. In addition, the check valve can be opened via a control line,
allowing flow in both directions.

Area ratio: 1 ... 10 (5)
Pilot to close check valve:

If the inlet pressure at A is higher than the outlet pressure at B, then the check valve
allows the flow to pass, otherwise it blocks the flow.
Additionally, the check valve can be closed using the pilot line X. Adjustable
parameters
Area ratio: 1 ... 10 (5)

Pilot to close check valve, spring loaded:

If the inlet pressure at A is higher than the outlet pressure at B and the nominal pressure,
then the check valve allows the flow to pass, otherwise it
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Hydraulic manual
blocks the flow. Additionally, the check valve can be closed using the pilot line X.

Area ratio: 1 ... 10 (5)
2- way flow control valve:

If the pressure is sufficient, the preset flow is maintained to a constant level in the
direction of the arrow.
The hydraulic resistance relates to the completely opened valve. Adjustable parameters
Nominal flow: 0.01 ... 500 l/min (1)

3- way flow control valve:

With sufficient pressure, the preset flow rate is kept constant in the direction of the
arrow. The surplus hydraulic fluid is drained at connection T using a pressure
compensator. The inlet pressure pA is load dependent, i.e it changes with the outlet
pressure pB. Therefore a parallel circuit of several 3-way flow control valves is not
possible. In this case, the inlet pressures would be defined by the valve with the lowest
inlet pressure. Compared to the 2-way flow control valve, the 3-way flow control valve is
admittedly more efficient in its energy consumption.
The hydraulic resistance relates to the completely closed pressure compensator.

Nominal flow: 0.01 ... 500 l/min (1)

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Hydraulic manual
Shuttle valve:
If one of the two input pressures is larger than zero, the shuttle valve opens (OR
function) and the higher input pressure becomes the output pressure. Adjustable
parameters
Two-pressure valve:
If both input pressures are larger than zero, the two-pressure valve opens (AND function)
and the higher input pressure becomes the output pressure. Adjustable parameters
Flow divider valve:

The flow divider valve divides the flow from P into two equal flows at A and
B. This is achieved using two measuring orifices and two variable control resistors.
The control resistors are unified in a pressure compensator. The hydraulic resistance
relates to the resistance of the individual measuring orifices and control resistors.
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PRESSURE CONTROL VALVES

Pressure relief valve:
In normal position the valve is closed. If the opening pressure is reached at P, T opens.
When the pressure drops below the preset level, the valve closes again. The flow
direction is indicated by the arrow.

Pressure relief valve:

In normal position the valve is closed. If the opening pressure is reached at P, T opens.
When the pressure drops below the preset level, the valve closes again. The flow
direction is indicated by the arrow.

Pressure relief valve with pilot control:

The valve is closed in the idle position. The hydraulic fluid drains off at T, when the
pressure difference at the connections P and T exceeds the nominal pressure. If the
pressure falls below the preset value, the valve closes again. The flow direction is
marked with an arrow.
The pilot operated pressure relief valve consists of a pilot stage and a main stage. When
open, there is less volumetric flow at the pilot stage that leads to connection Y.
The hydraulic resistance relates to the completely opened valve. Adjustable
parameters
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Hydraulic manual
Hydraulic resistance: 1e-7 ... 100 MPa*min2/l2
(0.01) Shutoff/counteracting valve:
If the opening pressure is reached at the control line connection, the valve opens from P
to T.

2-way pressure reducing valve:

The pressure regulator valve regulates the pressure at connection A to the preset
operating pressure and equalizes the pressure fluctuations. The valve closes when the
pressure at connection A exceeds the operating pressure. The setting of the real
components is component dependent and cannot be changed.
Nominal pressure: 0.01 ... 40 MPa (1)

2-way pressure reducing valve, adjustable:

The pressure regulator valve regulates the pressure at connection A to the preset
operating pressure and equalizes the pressure fluctuations. The valve closes when the
pressure at connection A exceeds the operating pressure.

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Hydraulic manual
3-way pressure reducing valve:

The pressure reducing valve maintains a constant output pressure despite fluctuating
input pressure. The hydraulic fluid is drained off at T when the pressure at connection
A exceeds the operating pressure.
The hydraulic resistance relates to the completely opened valve. Adjustable
parameters

Closing pressure compensator:

The pressure compensator represents a pressure dependent hydraulic resistance. The
pressure compensator closes when the pressure difference X-Y exceeds the nominal
pressure. A pressure regulating valve is implemented by the combination of connections
A and X. The pressure balance is also a component of 2-way flow control valves.
The nominal pressure setting of the real components is component dependent and cannot
be changed.

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Hydraulic manual
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Hydraulic manual
Closing pressure compensator, adjustable:

pressure compensator closes when the pressure difference X-Y exceeds the nominal
pressure. A pressure regulating valve is implemented by the combination of the
connections A and X.

Opening pressure compensator:

pressure compensator opens when the pressure difference X-Y exceeds the nominal
pressure. A pressure relief valve is implemented by the combination of connections P
and X. The pressure balance is also a component of 3-way flow control valves.
The nominal pressure setting of the real components is component dependent and cannot
be changed.

Hydraulic resistance: 1e-7 ... 100 MPa*min2/l2
(0.01) Opening pressure
compensator, adjustable:

pressure compensator opens when the pressure difference X-Y exceeds the nominal
pressure. A pressure relief valve is implemented by the combination of connections P
and X.
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Hydraulic manual

Opening cartridge valve:

The 2/2-way cartridge valve is a 2/2-way valve. It is fitted with two working ports and
the two switch positions “closed” and “open”. Whether or not the cartridge valve is open
or closed depends on the effective areas A, B and X, the adjacent pressures pA, pB and
pX, as well as the spring force.
A+B=X is valid.
If pA*A + pB*B > pX*X + F, then the valve opens, otherwise it is closed.
The valve therefore operates purely pressure dependent and can, with the appropriate
control, assume directional-, flow- and pressure functions. The spring force is specified
by means of the nominal pressure. This is the minimum pressure, with pressureless
connections at B and X, necessary at connection A to open the valve.
Whether the valve has one (A=B) or two (A <> B) effective areas can be specified in the
properties window. The relevant symbol is automatically depicted.
Area: 0 ... 100 qcm (6)

Nominal pressure: 0 ... 1 MPa (0.1)
Opening cartridge valve:

or closed depends on the effective areas A, B and X, the adjacent pressures pA, pB and
pX, as well as the spring force.
A+B=X is valid.
If pA*A + pB*B > pX*X + F, then the valve opens, otherwise it is closed.
by means of the nominal pressure. This is the
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Hydraulic manual
minimum pressure, with pressureless connections at B and X, necessary at connection A to open

the valve.
Whether the valve has one (A=B) or two (A <> B) effective areas can be specified in the
properties window. The relevant symbol is automatically depicted.
Area: 0 ... 100 qcm (6)

Closing cartridge valve:

or closed depends on the effective areas A and X, the adjacent pressures pA, and pX, as
well as the spring force. A=X is valid.
If pA*A > pX*X + F, then the valve closes, otherwise it is open.
by means of the nominal pressure. This is the minimum pressure, with pressureless
connections at B and X, necessary at connection A to open the valve.
Area: 0 ... 100 qcm (6)

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Hydraulic manual
MEASURING INSTRUMENT AND

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Hydraulic manual
SENSORS
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Hydraulic manual
Manometer:
The manometer measures the pressure at its connection.
Pressure indicator:
An optical signal is activated when the pressure at the connection to the pressure display
exceeds the preset switching pressure.
Switching pressure: 0.0001 ... 40 MPa (3)

Color: 16 standard colors (Dark red)
Flow meter:
The flow meter measures the flow rate. Either the current flow or the total quantity
flowed can be displayed. The component image is automatically adjusted accordingly.
Flow meter:
The flow meter measures the flow rate. Either the current flow or the total quantity
flowed can be displayed. The component image is automatically adjusted accordingly.
Flow meter, analog:

This symbol represents the hydraulic part of the analog flow meter. The analog flow
meter measures the volumetric flow and transforms it into a proportional electrical
voltage signal. In the process, only flow rates in the specified pressure ranges are
considered. Within this range, the flow rate in
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Hydraulic manual
the voltage range from 0 V to 10 V is represented, i.e. the minimum volumetric flow
delivers 0 V and the maximum volumetric flow 10 V. Adjustable parameters
Analog pressure sensor:

The pressure switch takes the pressure and actuates the associated electrical pressure
switch if the preset switching pressure is exceeded. Adjustable parameters
Switching pressure: 0.0001 ... 35 MPa (3)
Pressure sensor, analog:

This symbol represents the hydraulic part of the analog pressure sensor. The analog
pressure sensor measures the adjacent pressure and transforms it into a proportional
electrical voltage signal. In the process, only pressures in the specified pressure ranges
are considered. Within this range, the pressure in the voltage range from 0 V to 10 V is
represented, i.e. the minimum pressure delivers 0 V and the maximum pressure 10 V.
Flow meter:
The flow meter consists of a hydraulic motor connected to an RPM gauge. Adjustable
parameters

Friction: 0.01 ... 100 N*m*s/rad (0.1)
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Hydraulic manual
Ex no: 02
Calculate the volumetric flow rate of a hydro pump.

Aim:
The student calculate the volumetric flow rate of a hydraulic pump
Information
Displacement volume V (also known as delivery rate or swept volume) is a Measure of
the size of the pump. It designates the liquid volume which is delivered by the pump per
revolution (or stroke).
The delivered liquid volume per minute is designated volumetric flow rate q. This
result from displacement volume V and speed in rpm n:
q = n .V
Calculate the volumetric flow rate of a gear pump.
Solution:
Given
Speed n = 1450 rpm (From motor Name Plate) Displacement volume
V = 2.8 cubic cm (per revolution)
Desired
Flow rate q in l/min.
Calculation
Q=n.v =1450min^-1*2.8cm^3
=4060cm^3/min
=4.06dm^3/min
=4.06 l/min
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Hydraulic manual
Ex
no:03. Calculate the efficiency of a hydro
Aim: pump
The student calculate the efficiency of a hydro pump
Theory:
Mechanical power is converted to hydraulic power by pumps, during which
power losses occur that
are expressed in terms of the pump’s degree of efficiency.
Effective power Phyd generated by the pump depends upon operating pressure p and
effective
Volumetric flow rate qeff. Effective power is calculated with the equation:
Phyd = p. qeff
Volumetric efficiency is the relationship between the pump’s effective
volumetric flow rate and its
Theoretically calculated volumetric flow rate.
Nvol=qeff/qth
qeff =Vth . n.ηvol
Calculate the efficiency of a hydro pump.
Given
Speed n = 1450 rpm
Displacement volume V = 6.5 cubic cm (per revolution) Effective
volumetric flow rate qeff=8.6l/min at 100bar
Desired
Efficiency η vol
Calculation
Qth=6.5cm^3*1450min^-1=9.4l/min
Neff=qeff/qth
=8.6/9.4
=0.92
=92%
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Hydraulic manual
Ex no: 03
AIM: DRAW THE CHARACTERISTIC FOR A

PRESSURE RELIEF VALVE
. To teach the student how to draw the characteristic for a
Pressure relief valve
PROCEDURE:
. Drawing the hydraulic circuit diagram
. Practical assembly of the circuit
. Setting a maximum pressure of 50bar
. Establishing the opening pressure of the pressure relief valve
. Determining the various measured values and entering them into the table
. Drawing the pressure/flow rate characteristic
. Drawing conclusions
Exercise:
Owing to a change in the production process, a package lifting device is now required
to lift heavier packages than those for which it was originally designed. It has been observed
that the stroke speed is now lower. Using the pressure/flow rate characteristic for the pressure
relief valve, determine the pressure at which flow diversion of the pump output begins.
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Hydraulic manual
Circuit diagram:
0Z1 Hydraulic power pack

0Z2 Pressure gage
1V Shutoff valve
1S Flow sensor
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Hydraulic manual
working pressure 35 40 42.5 45 47.5 50 bar

Flow rate q l/min
48
Hydraulic manual
CONCLUSION:
Every pressure relief valve has a certain opening pressure at which point diversion of the
flow through the valve begins. The difference between opening pressure and maximum pressure
is 5 bar in this case. When the preset maximum pressure is reached, the entire pump delivery is
discharged via the pressure relief valve.
49
Hydraulic manual
Ex no: 04
Determine the times pressure and forces during the advance and
return strokes of a single-acting cylinder.
Aim:
To determine the times pressure and forces during the advance and return strokes
of a single-acting cylinder.
Procedure:
.Drawing the hydraulic circuit diagram
. Determining the necessary components
. Measuring the travel pressure and travel time for the advance and
return strokes
. Calculating the required advance-stroke pressure
. Calculating the advance-stroke speed and time
Exercise:
For this exercise, the cylinder is bolted onto the base plate on the left of the profile plate
and loaded with the weight. When the cylinder is connected up, it is essential that the upper
connection is connected to the tank. Once the circuit has been assembled, the PRV 0V2 should
first be fully opened. The hydraulic power pack should then be switched on and the PRV 0V2
slowly closed. The piston rod will then travel to its upper end position. Continue to close the
PRV until the pressure gauge 0Z2 indicates 50bar. Now switch off the hydraulic power pack. It
can be demonstrated by briefly opening the shut-off valve that the non-return valve prevents the
weight from lowering further and that return flow of hydraulic fluid during the return stroke can
take place only via the 2/2- way valve 1V.The piston rod can retract only when the pump is
switched off. This is arranged intentionally in systems like the one shown here. This ensures that
the hydraulic power pack is switched off during lengthy standstill periods.
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Hydraulic manual
Circuit diagram:
51
Hydraulic manual
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Hydraulic manual
Advance-Stroke Speed : Vadv = 𝒒
𝑨𝑷𝑵
CONCLUSION:
The back pressure is considerably lower than the hydraulic resistance. A cylinder motion
can take place only if this case applies. The value of the
back pressure depends on the hydraulic resistances. These are very low when fluid is
discharged into the tank.
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Hydraulic manual
Ex no: 05
Determine the times, pressures and forces during the advance and
return strokes of a double acting cylinder.
Aim:
To determine the times, pressures and forces during the advance and
return strokes of a double acting cylinder
PROCEDURE:
 Drawing the hydraulic circuit diagram
 Determining the necessary components
 Practical assembly of circuit
 Measuring the travel and back pressures and transfer time for
the advance and return strokes
 Calculation of advance and return-stroke speeds
 Comparison of calculated and measured values
EXERCISE:
Once the circuit has been assembled and checked, the hydraulic power pack
should be switched on and the system pressure set on the pressure relief valve 0V to 50 bar.
Pressure sensors should be used to measure the travel and back pressures. Pressure gauges are
sluggish in operation and would give incorrect readings. When the hand lever of the 4/2-way
valve is actuated, the piston rod of the cylinder will advance until the lever is released or the
piston rod runs against the stop. When the lever is released, the piston rod will immediately
return to its retracted end position. Before the pressures and times are measured, the piston rod
should be advanced and retracted several times to expel any air which may have entered the
piston-rod chamber during the previous exercises.
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Hydraulic manual
CIRCUIT DIAGRAM:
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Hydraulic manual
Tabulation:
Advance stroke Travel pressure p1S1 Travel time tadv
Return stroke Back pressure p1S1 Travel time tadv
Characteristic data required for calculation:

Piston area: APN =
Piston annular area: APR =
Stroke length: s =
Pump output: q = 2 l/min
Formula:
𝑨𝑷𝑵
Area ratio: α=
𝑨𝑷𝑹
Advance stroke speed: 𝑉𝑎𝑑𝑣 = q/APN

𝑨𝑷𝑵
Advance stroke time: tadv=s/vadv
Return stroke speed: vret=q/APR
Return stroke time: tret= s/vret
Ratio travels speed: Vadv/Vret =
Ratio of travel times: tadv/tret =
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Hydraulic manual
Conclusion:
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Hydraulic manual
The travel speed ratio is equal to the area ratio a of the cylinder. The speed ratio is equal
to the reciprocal of the area ratio.
Ex no:
06 Use hydraulic accumulator as a
Aim: power source
To use the accumulator to power advance and strokes of the cylinder after the
pump is switched off.
Procedure:
.. Drawing the hydraulic circuit diagram
. Determining the necessary components
. Determining the number of working cycles possible after the pump is switched off.
. Drawing conclusions
. Explaining the design and mode of operation of a diaphragm accumulator
. Naming possible applications of an accumulator
Exercise :
A heavy cold-store door is opened and closed by a hydraulic cylinder. A
hydraulic accumulator is to be installed to allow the door to be closed in the case of an
electrical power failure. This will permit the cold-store door
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Hydraulic manual
to be opened and closed a number of times. A 4/2-way valve is to be used to activate the
cylinder. This valve should be connected up in such a way that the piston rod is
advanced with the valve in its normal position.
No provision will be made here for the safety cut-out which is essential
to prevent persons from becoming trapped in the door. This cut-out function is normally
provided by an electrical control device for the hydraulic system.
Be sure to follow the operating instructions for the accumulator. After
switching off the control system, do not dismantle the hydraulic components until you
have relieved the pressure in the accumulator and isolated this from the control system
by means of the built-in shut-off valve.
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Hydraulic manual
Circuit diagram:
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Hydraulic manual
System pressure Opening Closing
50bar
25bar
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Hydraulic manual
Accumulators are used for the followings:

. Compensation for leakage losses
. Energy reserve in emergencies
. Compensation for peaks in flow rate demand
. Cushioning of switching jolts
Conclusion:
Without the accumulator fitted, the door will remain in its instantaneous position after
a power failure and it will no longer be possible to move it. This diaphragm accumulator
allows the door to be opened 2 x and closed 1 x with a system pressure of 20 bar and opened 4
x and closed 3 x with a system pressure of 50 bar. The higher the hydraulic pressure with
which the accumulator is charged, the more times the door can be opened and closed.
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Hydraulic manual
EXERCISE:07
Determine the cylinder advance-stroke time with and

without a load.
Aim:
Measure the cylinder advance stroke time with and without load
Exercise:
A double-acting cylinder is used to open and close a bulkhead door Closing must
be carried out smoothly and at a constant adjustable speed. The speed is adjusted by
means of a one-way flow control valve. A pressure relief valve must be fitted to provide
counter-holding and prevent the heavy door from pulling the piston rod out of the
cylinder during the closing operation.
Measure the following:
t ® = Cylinder advance-stroke time p1Z1 =
Cylinder travel pressure
p1Z2 = Cylinder back pressure p0Z2 =
System pressure
The applied load now be varied. Initial settings should be such as to achieve an
advance-stroke time of 5 s with a system pressure of 50 bar but without an applied load
or counter holding. 10 bar back pressure should subsequently be set.
When dismantling the circuit, ensure that no pressurized fluid is trapped
(p1Z2 = 0 bar).
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Hydraulic manual
Circuit diagram:
64
Components list:
Tabulation:
Load Poz2 P1z1 P1z2 t-

Without load
With load
CONCLUSIONS:
The travel time becomes shorter as the load increases. The piston
is pulled out by the load. Without counter-holding, the movement is
uncontrolled and jerky. A constant advance-stroke speed is obtained only
with counter-holding. The generation of a counter pressure clamps the
piston hydraulically. The travel and back pressures remain constant,
which means that the travel speed also remains constant.
A circuit with counter-holding is advisable both with and without

a load. It is also possible to adjust the counter-holding to suit the load.
65

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DEPARTMENT OF ELECTRICAL AND EECTRONICS ENGINEERING

MARINE AUTOMATION LAB

EX NO:1 STUDY OF SCADA SYSTEM,PLC AND LADDER PROGRAMMING

To communicate with a programming device, the CPU provides a built-in PROFINET

 Digital inputs in the controller is14 and Voltage is 24

1. Ladder diagram (LAD).

LAD is a graphical programming language. The representation is based on circuit

Function blocks diagram

STEP 7 Basic PROGRAMMING SOFTWARE

STEP 7 Basic provides a user-friendly environment to develop controller logic,

1) Menus and toolbar.

CPU MEMORY AREAS

USER PROGRAM BLOCKS

Double click on create new project as shown in the below image

Click add new device as shown in the red color mark

 Select the PN/IE into the Type of the PG/PC Interface(1).

Programming Method in PLC:

In Digital input starts from I0.0

In Digital output starts from Q0.0

Load preview window will open, select "Load" option.

 PLC Trainer kit

 In AND_GATE operation is used to make the multiple operation of 2 inputs.

TRUTH TABLE & SYMBOL OF AND_GATE:

2) Now the below image shows (Object Block1) OB1 is created.

4) Then save the program to press (CTRL+S) function it will be saved.

HIGH. It can be represented in Green color indications in below the Figure.

LIFT CONTROL SYSTEM

Step Angle = 360 / NS×NR

synchronism. The stepper motor operates in a two modes of operation as it is

Coil 1 Coil 2 Coil 3 Coil 4 Decimal Value

Double Step Operation

Coil 1 Coil 2 Coil 3 Coil 4 Decimal Value

LIFT CONTROL SYSTEM

I/P PULSE TO PLC

FLOOR SENSOR 1,2,3. REQUEST SWITCH 1,2,3.

STEPPER MOTOR DRIVER BOARD

LIFT CONTROL SYSTEM (VPAT-20P)

FS1 FLOOR INDICATOR 2

I1, I2, I3 - Requestion switch.

I4, I5, I6 - Sensor Inputs

Q2, Q3, Q4, Q5 - Output for stepper motor.

Bit sequence function is used to drive the stepper motor.

The above functions are repeated in each floor.

Conditions For rotation Of Motor

The three terminal voltages of the stator areVs1s2 = Vs1N – Vs2N

The classical synchro systems consists of two units.

System Description and Operation

FRONT PANEL VIEW OF SYNCHRO TX

Sr.No. Position rotor Stator / Vs3S1 Terminal VS1S2 Voltages (RMS)

Built in Signal Sources

Time Constant I &

Structure of PID Controller:

Fig.2. Block Diagram of PID Controller

Fig. 3 Bode diagram of PID controller

(b) Continuous Cycling Method

PI 0.45 Kcu 0.833 Pu -

PID 0.6 Kcu 0.5 Pu 0.125 Pu

Table 1: Empirical values for tuning the controller

Fig 4 Step response of (a) Type – 0 (b) Type – 1 system

Self Calibration of CRO:

% Overshoot = y-x / x 100 =[(0.66-0.6)/0.6]100= 10%