The document discusses automation and how to get started with automation. It can be divided into two main sections: 1) It classifies automation into industry automation (discrete, process, hybrid) and products (power, motion, field devices, control/monitoring). Discrete industry uses PLCs and closed/open loop control while process uses large I/O, instruments, and SCADA. 2) It provides steps to get started with automation from basics of electrical circuits to PLC programming to industrial communication. It covers electrical components, control circuits, motors, and programming basics. Automation combines electrical, mechanical, and software systems to control equipment and processes.

1. Automation
By:Mahmoud Hussien

2. How to start with automation
Automation can be divided to two classes
1-industry : can be classified according to
A-discrete
B-process
C-hybrid (two step control)
2-products:can be classified according to
(power(low voltage)-motion-field devices-control monitoring)

3. Process vs discrete industry
 Process industry: closed loop control
 Food industry
 oil and gas production lines
 Sequence machines
 Discrete industry: open& closed loop
 Packaging
 Machine tools
 Injection machines
 Car production lines
Do independent control to achieve a
specific task.
Raw
material
Do some
process
Final
product

4. Process vs Discrete industry
 Discrete industry:
 I/O low
 Micro compact PLC
 HMI
 Motion protocols
 Vector control VFD
 Process industry:
 I/O huge
 Instruments
 Scada
 Wide industrial protocols
 VFD

5. products
 Power low voltage
 Supply
 Loads
 Transformer
 Circuit breakers
 Control components
 Switches
 Panel accessories
 Field devices
 Sensors
 Actuators
 Transmitters
 Transducers

6. products
 control
 PLC
 Classic control
 Control instruments
 DCS
 Motion
 AC drive
 Servo drive
 Monitoring
 HMI
 SCADA

7. How to start with automation
 Step 1(basics)
 basic of electrical laws.
 Basic of electrical circuits
 Basic of electrical installation
 Basic knowledge of control components
 Ac induction motors
 Dc motors

8. How to start with automation
 Step 2(logic control)
 Classic control
 Use sensors ,counters and timers in sequential control
 Step 3 (motor starter)
 Star-delta connection
 Soft starter
 Ac motor inverse direction

9. How to start with automation
 Step 4(motion)
 Ac drive
 Servo drive
 CNC
 Step 5 (Basic programming)
 PLC
 Numbering system
 PLC memory management
 HMI

10. How to start with automation
 Step 6(industrial communication)
 PLC with VFD
 PLC with field devices
 Step 7 (advanced level)
 SCADA
 Remote I/O
 Industrial network

11. Control types
 Automatic control
 Manual control:
ac
ac

12. Electrical sources
 Ac supply
 Single phase: line & neutral
 Three phase: 3 lines & neutral
 Dc supply
+
-
L1
L2
L3
N

13. Basic electrical laws
 V=I*R
 P=V*I
 Power loss=i2*R
Where
V:is the voltage supply
I:is the current
P:is the power

14. Loads
 Motors
 Induction motors
• Single phase
• Three phase
 Servo motors
 Stepper motors
 Dc motors
 Pneumatic cylinders
 Hydraulic cylinders

15. Loads power calculation
 Motor
 Ac motor single phase I(load)=s*1000/v I(load)=4.5*S (V=220v)
 AC motor three phase I(load)=(S*1000)/(0,866*380)=1.5*S
we are considering HP=KVA ………..P.F=1
 DC motor I(load)=power/I
 Pneumatic and hydraulics is deal as dc motors

16. Cables colors
 Red color: for 110 or 220 volts
 Blue color: for 12 or 24 volts
 Black color: for ground or neutral
 Orange color: its mean take current from another panel
 For control cables :low thickness –low current
 For power cables: huge thickness-high current
 There are a relation between cable diameter and current
 Cable diameter depends on current,environment

17. Control components
 Circuit breaker
 Over load
 Phase sequence
 Fuses
 Contactor
 Relay
 Limit switch
 Switches
 sensors

18. Control component selection
 Circuit breaker
 Short circuit current
 Time
 Voltage
 Current =1.25*rated current
 Over load
 Current=1.2*rated current
 voltage

19. Control component selection
 contactor
 Rated current
 Voltage
 Coil voltage
 No .of . Connected open and close
 relay
 Current
 Voltage
 No .of . Connected open and close

20. Control component selection
 Limit switch
 Controller supply
 sensors
 Controller supply
 Connection type
 Switches
 Open or close
 current
 preasure

21. Control component
 Contactor
 Test :coil resistance not equal zero
 Normally open test
 Normally close test

22. Control component
 Circuit breaker

23. Control component
 Phase sequence

24. Control component
 Over load

25. Control component
 Relay

26. Control component
 Limit switch

27. Control component
 Switches

28. Panel component
 Supply
 Power supply
 Main circuit breaker
 Branch circuit breaker
 Phase sequence
 Over load
 Fuse
 Contactor(relays)
 Controller(plc –VFD-DCS)
 Wires
 Bars

29. Classic control circuits
 Power circuit
 Circuit breaker
 Phase sequence
 Over load
 Fuse
 contactor

30. Classic control circuits
 control circuit
 Phase sequence
 Closes contact Over load
 Contactor
 Switches
 Sensors
 Limit switches

31. Exercises
 Start motor , draw power circuit and control circuit that stop when release my
hand
 Start -stop motor , draw power circuit and control circuit
 Start – with two switches and stop from one switch
 Start with one switch stop from another and emergency switch
draw power and control circuit.

32. Emad Elsheikh
32
KM1
A1
A2
S1
NO
S2
NC
KM1
13
14
L / +
N / -
Power Circuit Control Hardwire Circuit
L2
N
PE
L1
L3
M
3 ~
U V W
1
2
KM1
3
4
5
6
Q1
I> I> I>
1
2
3
4
5
6
Controlling 3 Phase Motor ( Relay
Control)

33. Emad Elsheikh
33 Start - Stop Operation
Supply
3 Ф
Cable
stop
start
4
14
3
13
L1
L1
T1 T2 T3
L2 L3
aux
A1
A2 ~ac
KM1 KM1 Contactor
Thermal
Overload
3-ph
Induction
Motor
Controlling 3 Phase Motor ( Relay
Control)