PLC Lab Manual
Contents
1. Start the three phase induction motor via star delta connection using PLC Start and reverse the direction of the three phase induction motor via star delta connection using PLC 1 Basic Information 1 1 Semi automatic Star Delta Starter Semi automatic and fully automatic starters require three contactors to connect the motor windings first in star and then in delta The power circuit diagram showing the scheme is given in Fig 5 1 Fig 5 1 Power circuit diagram for a star delta starter Whenever one has to make connections for a star delta starter it is advantageous to draw the winding diagram as shown in the right hand side of Fig 5 1 It helps to remember that for delta connection finishing end of one winding is to be connected to starting end of the other winding as shown in the figure The three phase supply is then given at the three junctions Now let us refer to the power circuit diagam of the starter as given in Fig 5 1 The sequence of operation of the contactors is as follows First the contactor A will close for star connections then the main contactor M will close and lastly contactor A will open and contactor D will close for delta connection When star contactor is first closed winding terminals A2 B2 C2 get connected together through the contacts of contactor A and thus the windings get connected in star Now when the main contactor is closed supply reaches terminals Al B1 C1 and therefore the motor windings are ener2. 220V 50Hz QO WC oa Contactor Contactor Main _ O O om D aS dee oO OO Star 2 Download and operate your program PLC Lab Manual 35 Part 2 Semi automatic Star Delta Starter with reversing the direction 1 bor the following star delta control system sketch the ladder diagram The input output diagram of the PLC is shown in the figure Wi L1 W U1 L2 aa L3 we we U1 V Sec l a gt a a ee S E mcb3x10A Sg EE V1 Main Contactor g 3 d Delta Contactor E 3 e 220V 50Hz et ee ee SE A en E E COIL do d 4 COIL p g S s ba i i R e SE Le l Star Contactor 1 3 5 Delta Contactor DE 3 5 S 220V 50Hz 220V 50Hz ll ee Sone COIL d d d COIL d d d A2 2 4 6 ae 2 4 6 Overload Stop sed NVR NVR Sat Ta Star F aa d Star R R S F R Delta T y l D d 3 14 J 2 T3 Le 220V 50H 7 Z F R 220V 50Hz 220V 50Hz igs See cot LS Pe eat N K K K K K c 5 5 5 5 z 5 2o d e s s g Ss Ss aS Ef X1 Star F xo _Star R 2 Download and operate your program PLC Lab Manual 36 Experiment 6 Programming PLC Via SFC OBJECTIVES After successfully completing this laboratory you should be able to Build self starting system for generators using PLC Us
3. ON push button is kept pressed because there is S P Star Main Delta contactor contactor contactor Fig 5 2 Control circuit for a semi automatic star delta starter When the ON push button is released contactor S gets de energised its auxiliary contacts come back to their original positions as shown in Fig 5 2 Opening of S1 does not make any difference in operation as the main contactor is now held through its own contact However closing of contact S2 causes energisation of the delta contactor Thus now the main contactor and the delta contactor are energised simultaneously and the motor runs with its windings connected in delta Whenever the motor is to be stopped the OFF push button is pressed both the contactors M and D are de energised as holding through auxiliary contact of M is broken Similar action takes place when the control contact of the overload relay opens 1 2 Semi automatic Star Delta Starter In a three phase induction motor the rotor tends to rotate in the same direction as the revolving magnetic field produced by the stator windings The direction of the revolving field depends upon the phase sequence of the supply voltage If the phase sequence of supply to the motor windings is changed by interchanging two phase leads the direction of the revolving fields is reversed Thus the direction of rotation of a three phase induction motor can be reversed if the two supply phase leads to the motor terminals are intercha
4. can be extended to 128 points They are indicated with Y sequence in Octal numbering mode Internal Auxiliary Relays Single bit variables They are indicated with M sequence in Decimal numbering mode ranging from MO to M1279 M1000 and above are used for system flags and special purpose auxiliary relays Steps Single bit variables indicated by S sequence in Decimal numbering mode ranging from SO to 127 Timers Indicated by T sequence in Decimal numbering mode ranging from TO to T127 Each timer has a 16 bit holding register for its preset value as well as a single bit variable representing its contact Counters Indicated by C sequence in Decimal numbering system Similar to Timers each counter has a holding register and a single bit contact There are 128 16 bit counters ranging from CO to C127 and there are 13 32 bit counters indicated as C235 to C238 C241 C242 C244 C246 C247 C249 C251 C252 and C254 These later counters are referred as high speed counters Data Registers 16 bit variables indicated by D sequence in Decimal numbering PLC Lab Manual 18 1 4 mode ranging from DO to D599 and from D1000 to D1143 D1000 and above are special purpose registers Index Registers Two pointers indicated by E and F They are D1028 and D1029 respectively These memory locations are reached easily using their names However one may reach them by means of the PLC device addresses specified by Delta This method is use
5. include in these transitions the signal from X3 as well in order to protect the pistons in case of failure of the vertical motion In other words you will not allow the motion of the horizontal direction unless the vertical piston is in its UP position 1 3 Generator Self Starting System Figure 6 1 shows control circuit diagram for generator self starting in this circuit if the remote contact is closed first the fuel pump is run via relay R1 after some time delay the self is run via timer T and relay R2 When the generator is run it will return feedback voltage of 220VAC to the control circuit which will operate relay R3 which will disconnect the self from the control circuit f LTL FUSE 3A i 12VDC 220VAC Ki T R1 T R2 j R3 Ai EN At Ai 12VDC 12vDC Fa 12VDC 220VAC COIL R1 col LC T coL LR2 COIL R3 A A Q Fa O a Zz CO ba S a u LL CW Bi Remote Signal Fig 6 3 Generator self stating control diagram 220VAC T meb 16A PLC Lab Manual 39 1 4 Automatic change over switch ATS One of the most commonly used circuit in power networks is change over switch circuit which transfer the power flow from the main power source to the stand by source which may be generator set The are two types of change over switch the first one is manual and the second one is automatic operated Figure 6 4 shows the power circuit of change over switch consists of two mechanically interlocked cont
6. the wooden board wiring ducts and mounting rails assemble and arrange the control board as shown in figure 1 1 16 2 i 14 3 14 3 42 e Fig 1 1 The power circuit diagram for a direct on line starter PLC Lab Manual 4 Part 2 1 Assemble the components of the circuit shown in figure 1 2 on the control board and make the required wiring and connections mcb 1x10A L 220VAC e SW1 L2 L1 220V 50H cor LAL O Q N g Fig 1 2 Energizing and de energizing relay using on off switch 2 Once you are finished with the connections call the instructor to check it for you and make sure that it is correct 3 Connect the circuit to the power source and try to change the position of the switch SW1 What is your observation Part 3 1 Assemble the components of the circuit shown in figure 1 3 the control board and make the required wiring and connections mcb 1x10A L 220VAC o 220V 50Hz COIL N o Fig 1 3 Energizing and de energizing relay using on pushbutton and off pushbutton 2 Once you are finished with the connections call the instructor to check it for you and make sure that it is correct PLC Lab Manual 5 3 Connect the circuit to the power source and try to operate the motor by pressing ON push button is pressed and also stop the motor by pressing the OFF push button What is your observation Part 4 1 Assemble the components of the circuit shown in figure 1 4 the co
7. A 5V Foo T s m se mmm emm og m a mmm ms mmm mn mmm nm mmm B Fig 2 6 DC input type PLC wiring wm m mmm a mmm nm mmm zm mmm sw PLC Lab Manual 9 1 3 2 Input Point Wiring All versions of the DVP PLC have Input Output circuits that can connect to a wide variety of field devices DC Input PLCs have two modes of operation SINK and SOURCE Sink Current flows into the common terminal S S source Current flows out of common terminal S S For example we simply connect the common terminal S S to the supply source By adding the switch between the supply and the input we have completed the circuit Below are two circuit diagrams showing both the sinking and sourcing inputs Sinking woe Sourcing input p zr z nr iE s d i Sourcing Fig 2 7 Sinking and sourcing inputs Input Point Loop Equivalent Circuit Wiring Loop DC Type DC Signal IN SINK Mode Wiring Loop DC Type DC Signal IN SOURCE Mode Source Type 1 3 3 Output Point Wiring There are three kinds of DVP Series PLC outputs Relay SSR and Transistor All relays used in DVP series PLC have passed the standard of IEC 947 5 1 under AC 15 the rated current and voltage specification for a cycle test of 6050 times PLC Lab Manual Bd CR LOAD bei 29 POWER UL _ O RELAY OUTPUT LED a Fig 2 8 Rely output type PLC wiring DVP oth FH eh LT LOAD CH 0 5A below LE
8. D trigger ir TRANSISTOR OUTPUT Fig 2 9 Transistor output type PLC wiring Be careful with the connection of the common terminals when wiring output terminals For example when wiring DVPI4ESOOR note that there are six normally open SPST relays available They are organized into 4 groups with individual commons The figure below shows the relays and the internal wiring of the PLC Note that each group is isolated from the other groups CO YO C1 Y1 C2 Y2 C3 Y3 Y4 Y5 Fig 2 10 relays groups and the internal wiring of the PLC PLC Lab Manual 11 Relay Output Wiring Methods Yu YOY f 3 e vee it fcilyatys tvelv7 Fig 2 11 Relay Output Wiring Methods 1 Surge absorbing diode increases relay contact life 2 Emergency stop use an external switch 3 Fuse 5 to 10A for every 4 output points to protect the PLC s 4 output circuit 5 Surge absorber reduces noise on AC inductive loads 6 Unused terminal do not connect 7 DC supply 8 Neon lamp 9 AC supply 1 1 0 Incandescent lamp 1 Mutually exclusive outputs Use external hardware interlocks as well as those in the PLC program for maximum safety Transistor Output Wiring Methods YA GE LI ISIS ACOVYO Y1 Ci Y4 Y5 Y6 Y7 e f Fig 2 12 Transistor Output Wiring Methods PLC Lab Manual 12 1 DC supply 2 Emergency stop 3 Fuse 4 If YO is used as a pulse train output with PLSY use a pull up resistor to ensur
9. PLC Lab www infoPLC net seess see VVVVVVP Ss AS ehre hah KENE a3 A TEAT AN LAN SEL egeszesseh KEES aE VE VE H ats i bh LW Include CD ROM e S Soe A KA A ES Se geg GE Ki EEN KANN PET A Lah d Tore Ek D X 00 A PLC Lab Manual Experiment 1 Experiment 2 Experiment 3 Experiment 4 Experiment 5 Experiment 6 Table Of Contents Operating a simple loads using relays switches and pushbuttons PLC Input Output Wiring Methods Programming the PLC Via Ladder logic Position control for satellite dish DC motors Starting Three Phase induction Motors Via Star Delta Starter Programming PLC Via SFC 14 26 30 36 PLC Lab Manual 3 Experiment 1 Operating a simple loads using relays switches and pushbuttons OBJECTIVES After successfully completing this laboratory you should be able to Identify the basic components of the control board Assemble and arrange a simple control board Explain the operation of electromagnetically controlled circuits Operate a simple loads using relays switches and pushbuttons 1 Equipments 3xl0A mcb 230V coil 50Hz 10A Relay Green and red indicator lamp NO and NC pushbuttons ON OFF switch Toggle switch 1 0 2 Flexible wires Single phase power source 42x55 cm wooden board Mounting rails Wiring ducts panel type Terminals 2 Procedure Part 1 1 Using
10. R 1xl0A mcb 230V coil 50Hz 10A Relay Green and red indicator lamp NO and NC pushbuttons ON OFF switch Flexible wires Satellite dish motor Single phase power source Control board 3 Procedure Part 1 Position control using internal set point 1 Assemble the components of the control circuit on the control board and make the required wiring and connections as shown in the following figure x4 ad SA mcb 1x10A Ri Ga 2 e Ce Su swe N o 0V 50Hz L g so O e a CT ssis ftxa ve x6 x7 E e 24VDC 24GND o COIL COIL GREEN PLC Lab Manual 29 2 Make the required wiring and connections for the power circuit as shown in the following figure 24V GND 3 Assuming that the set point is available in data register D1 start a new project in Wpl and in the Ladder diagram window sketch a program represents the position control problem of the satellite dish motor illustrated in the previous section 4 Download and operate your program Part 2 Position control using External set point 1 Using tow pushbuttons PB1 and PB2 to increase and decrease the set point develop a ladder diagram represents this position control problem 2 Download and operate your program PLC Lab Manual 30 Experiment 5 Starting Three Phase induction Motors Via Star Delta Starter OBJECTIVES After successfully completing this laboratory you should be able to
11. actors CM for the main source and CG for the generator Mains 1 2 3 vor yp GG 220V 50Hz 9 To Load Fig 6 4 Power circuit diagram for a change over switch Figure 6 5 shows the circuit used to control the power transfer from the main circuit to the generator The default case is that the loads is connected to the main source CM is connected but if at least one of phases is lost the control circuit will change the state that is the loads should be transferred to the generator via CG contactor GENERATOR REMOTE START TM3 Mains Generator F2 NV F2 A R 220V ey 2b RST giw R 220V MAIN Fi RCM mu J mm Se Rca GENERATOR F G i CG RCG E RCM CM TM1 l TM4 A1 A A1 A Al A Al Al A INV cM mu Rom Xmm RM TM2 X TM4 RCG CG A2 A2 A2 A2 A2 A2 A2 A2 A2 A2 e GEET ME e NG NVR 60sec 10min 10min 60sec Fig 6 5 Control circuit diagram for a change over switch PLC Lab Manual 40 2 Equipments RS DVPI4ESOOR 1xl0A mcb 230V coil 50Hz 10A Relay 24V coil 50Hz 10A Relay Green and red indicator lamp NO and NC pushbuttons ON OFF switch Flexible wires Single phase power source Control board 3 Procedure 1 Itis desired to implement the above illustrated generator self starting system shown in figur
12. ault that the target PLC is connected to the PC through COMI You may change this default sitting from Option Comm port To download your program click on Communication gt PLC Select Write PLC from the drop menu and click OK 6 To operate the program the PLC is placed in the RUN mode from Communication PLC Run Part 2 DC motor reversing circuit 1 Starting a new project in Wpl In the Ladder diagram window sketch a program represents the following control circuit PLC Lab Manual 23 2 Download your program click on Communication gt PLC Select Write PLC from the drop menu and click OK 3 Operate the program the PLC is placed in the RUN mode from Communication PLC Run Part 3 Sliding Gate system 1 Starting a new project in Wpl In the Ladder diagram window sketch a program represents the following control system for a sliding gate Flusher Limit switch 2 E Stop Up Down Photocell Limit switch 7 The program should satisfy the following conditions The motor should be overload protected The gate should stop in case of pressing stop pushbutton In case of pressing Up pushbutton the gate should move up to max limit limit Switch 2 PLC Lab Manual 24 In case of pressing Down pushbutton the gate should move down to max limit imit switch 1 Incase any one passed the photocell interrupts the down state and activates the up state The flusher lamp to be operated in th
13. click on RUN Naw Office Document zi 3 Open Office Document Ka Set Program Access and Defauts Astat A A Wunttied pant Designate the location where WPLSoft is to be installed www infoPLC net PLC Lab Manual 15 2 Type the name of a program Folder document or gt Internet resource and Windows will open it for you Open D wolisetup exe Cancel Browse The program show the dialog box explaining the WPLSoft copyright Please click Next to proceed with the installation jig WPLSoft 2 09 Beta InstallShield Wizard x Welcome to the InstallShield Wizard for WPLSoft 2 09 Beta The Installshield Vizard wil instal WWPLSot 2 09 Beta on your computer To continue click Next WARNING This program is protected by copyright lawe and international treaties Enter the user name and the organization then click Next gt ig WPL Soft 2 09 Beta InstallShield Wizard Customer Information Please enter your information User Name fuser Organization o ooo Install this application for e Anyone who uses this computer all users Only for me user Boot CSJ zen Click Next to comtinue or click Change to install to a different folder www infoPLC net PLC Lab Manual ji WPLSoft 2 09 Beta InstallShield Wizard Destination Folder Click Next to install to this folder or click Change to install to a different folder Click Install to conti
14. counting is not performed After the counter has counted out the count value and the status of the contact will not change until the RST instruction is executed A negative number cannot be used as a set value When the set value is 0 the same processing as for is performed The instruction CNT uses 16 bit registers to accumulate counted values in the valid counters domain CO to C127 On the other hand the instruction DCNT uses 32 bit registers for high speed counters Timers When the operation result of instructions preceding the TMR instruction are on the coil of timer turns on and counts up to the set value When the timer times out counted value gt set value the timer contacts are toggled In the following example the output YO is activated 3 seconds after activating the input XO TMR TO K30 Delta PLCs support 128 timers TO to T127 The timer will be reset when the operation result of instructions preceding the TMR instruction change from ON to OFF Moreover The RST instruction may be used to reset the timer values Timers use 16 bit registers and a negative number 32768 to 1 cannot be set as a set value Other useful functions In the User manual you will find plenty of functions that facilitate data movement arithmetic comparison and other operations similar to instructions provided for traditional microprocessors For example the instruction MOV K14 DO moves the decimal value 14 to data register DO An
15. e 6 3 using PLC the I O addresses of the PLC are assigned as shown in Figure 6 6 Draw the I O connection diagram for this system XO Automatic Operation xO Manual Operatiom X1 ATS remote contact gt XO Alarm rest gt X2 Feedback 220VAC S Figure 6 6 The I O addresses of the PLC ATS Remote Contact a en eae Ai M w I l a N 220V 50Hz L L Generator Feedback Q E a O be 24VDC S 220VAC GEN 5 st gt CH N G E N 7 220V 50Hz a 24GND Figure 6 7 The I O connection diagram of the PLC PLC Lab Manual 4 2 Once you are finished the drawing call the instructor to check it for you and make sure that it 1s correct 3 Using Sequential Function Charts SFCs develop a program to operate the previous generator self starting system 4 Once you are finished the program call the instructor to check it for you and make sure that it is correct 5 Download and operate your program and operate the system
16. e down state Required mechanical and electrical interlocks to be used Xf Stop gt X2 Up BR X3 Down gt ro CHU k OL PL Zi 1 C2 Down ge Ao at Y2 Flusher gt 44s mg AG ioe ee X7 Photocell gt 24V DC 220V AC 2 Download and operate your program Part 4 Water Pump system 1 Starting a new project in Wpl In the Ladder diagram window sketch a program represents the following control system for a water pump NC COM n MIN Level NO MAX Level MAX Level Electric float MIN Level Water tank Electric pump Cm f NC MAX Level cM PE O MIN Level NO SS SE DS SOO MAX Level jad Jab cll sos MIN Level Water well The system consists of one water pump and controlled via two float switches The system should satisfy the following conditions The pump should run if and only if the well is full and the tank is empty The pumps should be protected against o Phase failure o Changing the phase sequence o Under voltage The pump should run after a time delay of 5 seconds The system should be controlled by two float switches see figure 1 PLC Lab Manual 2 Download and operate your program Y2 GREEN LAMP 220V AC 25 PLC Lab Manual 26 Experiment 4 Position control for satellite dish DC motors OBJECTIVES After successfully completing this laboratory you should be able to to convert a si
17. e the output current is greater than 0 01A for correct operation 5 If Y1 is used with PWM use a pull up resistor to ensure the output current is greater than 0 01A for correct operation 6 Mutually exclusive outputs use external hardware interlocks as well as those in the PLC program for maximum safety 7 Unused terminal do not connect 2 Equipments RS DVPI4ESOOR 1x10A mcb 230V coil 50Hz 10A Relay Green and red indicator lamp NO and NC pushbuttons ON OFF switch Flexible wires Single phase power source Control board 3 Procedure 1 Assemble the components of the control circuit on the control board and make the required wiring and connections as shown in figure 2 13 mcb 1x10A D GE QD 220V 50Hz dr zZ 24VDC o 220V 50Hz 24GND Fig 2 13 The power circuit diagram for a direct on line starter PLC Lab Manual 13 2 Make the required wiring and connections for the power circuit as shown in figure 2 14 24V GND 3 Once you are finished with the connections call the instructor to check it for you and make sure that it is correct PLC Lab Manual 14 Experiment 3 Programming the PLC Via Ladder logic OBJECTIVES After successfully completing this laboratory you should be able to to convert a simple electrical ladder diagram to a PLC program Know the difference between physical components and program components sketch the ladder programs using
18. ed electrically by means of electric valves Figure 6 1 An educational covering machine There is a horizontally sliding plate driven by piston Y3 which has two proximity switches X5 and X4 to indicate the end of the forward and backward piston strokes PLC Lab Manual 37 respectively Initially the plate is driven forward by triggering a push button XQ Getting a signal from X5 the plastic container headed by a foil cover is manually placed in a dedicated hole made in this horizontally moving plate Since this feeding process is manually done the significance of the forward proximity sensor X5 may be ignored The operator gets the information of the plate position visually without the need for X5 However if this part 1s automated then X5 is essential sensor The covering process is initiated by pressing the push button XO again the piston Y3 moves the plate backward so that the container is centered under an aluminium plate which is kept at a temperature by means of a heater and a thermostat The proximity sensor X4 helps indicating the completion of the backward stroke and thus the container is exactly under the ironing plate Triggered by this sensor a vertically mounted piston Y4 presses the ironing plate over the covering foil and the container Due to heat the edges of the container starts to melt causing the foil to stick with the container circumference This process spends 3 seconds after which the vertical
19. fication gt wt 19t 247 ae SCHER Z VANAX Output Module Specification om wer r 2082 Mag S0 50Hz 523 LOAD CORE EER ERS Sone TEES vs DOIT ON OU ATA IOUR MCU Version gt V5 5 IIE SUIR2 12700904 Ue 1A ELEC TONICS INC WADEIR YEXAXY Fig 1 2 Delta programmable logic controller name plate Serial Number Explanation 3ZESOOR 2 T 3 100004 par Production number Production week Production year 2003 Production factory TaoYuan Plant Version type Production model PLC Lab Manual Model Explanation DVPLIIDINIOIUIL 2 Product Series DVP Series E e Inputs Outputs points unit O8 60points 1 2 CO ON AININ Models E Main Processing Unit Base Unit A Extension Unit S S TYPE Main Processing Unit Model Types Standard A D D A Functions Inextensible Digital Input X input extend Digital Output Y output extend Digital Input Output X Y extend TH SS CO x 0 7 2 Upgrade Model R Relay T Transistor N No Output Module 00 DI 11 AC Input DC Input DC Input H TYPE L TYPE H TYPE Fig 2 2 Delta programmable logic controller name plate model explanation Features of the DVP PLC Fig 2 3 Features of the DVP PLC DIN rail clip DIN rail 35mm Direct mounting holes cover Programming port cover RS 232 Extension port I O terminals I O terminals Input indicators 9 10 11 12 13 14 15 Output indicators Status
20. ful when these memory locations are monitored or preset at run time by an external devise such as a personal computer The device addresses table of Delta PLCs is illustrated in Table 2 1 It is not a traditional memory map where each location is byte width However the location size depends on the variable type Table 2 1 Device address table of Delta PLCs Device Range Effective Range Address 0 1023 0 127 0000 03FF 0 377 Octal 0 177 Octal 0400 04FF Y 0 377 Octal 0 177 Octal 0500 05FF 0 255 0 127 0600 06FF 0 1279 0 1277 0800 0CFF C0055 0 127 235 238 241 0E00 OEFF 242 244 246 247 249 251 252 254 pn Im 0 599 1000 1143 1000 14FF Ladder logic and mnemonic programming The instructions from a ladder diagram mnemonic or SFC are translated to machine code that can be stored in the PLC memory Each horizontal rung on the ladder in a ladder program represents a line in the program and the entire ladder gives complete program in ladder language There are three basic symbols used in ladder logic The first one is NO NC contacts NO contact is an instruction that tells the processor to look at a specific bit in its RAM memory If the bit is 1 the instruction is true and if it is 0 the instruction is false The determining factor in choosing which bits in its memory to look at is the address It could be some auxiliary bit M a timer contact T a counter contact C a state b
21. gised in star connection For delta connection first the star contactor should open before the delta contactor is closed If delta contactor gets closed while star contactor is still ON dead short circuit takes place at the outgoing leads of over load relay through contactor D and S This is taken care of by providing interlocking of auxiliary contacts between contactors S and D When star contactor PLC Lab Manual 31 opens and delta contactor closes motor winding terminals A2 B2 C2 get connected to B1 Cl Al through the closed contacts of contactor M and the motor runs in delta connection In a semi automatic starter the motor runs in star connection as long as ON push button is kept pressed When ON push button is released the motor gets connected in delta and continues to run till the OFF push button is actuated or over load relay trips The control diagram for a semi automatic starter is shown in Fig 5 2 Explanation of control operation is as follows When ON push button is pressed contactor S gets energized and it connects the motor windings in star connection Refer power diagram in Fig 5 1 Simultaneously the auxiliary contact S1 closes and S2 opens Closing of S1 causes energisation of contactor M which is then kept energized through its own auxiliary contact M1 Opening of contact S2 provides interlocking 1 e the delta contactor cannot get energized as long as contactor S is energized Contactor S remains energized as long as the
22. indicators POWER RUN ERROR I O terminal cover I O terminal cover I O terminal nameplate panel I O terminal nameplate panel RS 485 Communication port PLC Lab Manual 8 LA Wiring Guidelines EPO x4 x5 x6 x7 Hut DVP 14E3S DVP 14E3 DC Power IN DC Signal IN AC Power IN DC Signal IN 24VEYO LY1 LYO LL SW Paolcolc _ 1246 co ci c2 c3 Y5 Fig 2 4 DVP 14ES PLC terminal layout 1 3 1 Power Input Wiring Figures 2 5 and 2 6 show various possible external power connections for DVP PLC When wiring AC power the Live cable should be connected to the L terminal and the Neutral cable should be connected to the N terminal When wiring DC power the positive cable should be connected to the terminal and the negative should be connected to the terminal At no time should the power supply terminals be connected to any other terminal on the PLC AC Input Type r Le BR 100 240VAC Ls LLIN 2 SV OA SF EE T Fig 2 5 AC input type PLC wiring The 24V supply output is rated at 0 4 Amperes DO NOT connect external power supply to this terminal FUSE Protection there are internal fuses on all DVP PLCs However the fuse does not guarantee the prevention of DVP PLC damage but it will provide added protection DC Input Type J i H i D 4 a l i i 4 i I 20VDC 26VDC i jE DEN 7 GE n 2 5
23. ing SFC to program the PLC 1 Basic Information 1 1 Sequential Function Chart SFC An SFC is bipartite directed graph that contains steps represented by rectangles transitions represented by bars and directed arcs connecting steps to transitions and transitions to steps The dynamics of a system described by an SFC is represented by the movement of markers A marker represented as a small dot is placed in a step to indicate that the step is active The current location and distribution of markers m an SFC is called its marking The marking of an SFC defines the state of the system The initial state of a system modeled by an SFC is represented by a step with double border Outputs of an SFC are combined to steps A Boolean variable combined to step equals 1 when step 7 is active Transitions represent potential evolutions of the SFC A transition is enabled if each step preceding it is active An enabled transition is fired if its receptivity is true The receptivity of a transition is a level action logic condition Figure 4 1 illustrates the SFC of an RS flip flop which is assumed to be initially in the reset state 1 2 SFC Example Our introductory simple example is the derivation of the SFC which models the behavior of the educational covering machine shown in Figure 6 1 The moving parts of the machine are driven by linear pistons Pistons may provide linear or angular motion through compressed oil or air whose flow may be controll
24. it S or it might be connected to an external input X AU Normally Open Contact NC contact plays the same role as the previous one except that if the bit addressed is 1 the instruction is false and 1f it is O the instruction is true AU Normally Closed Contact The second symbol is output for outputting to the output module If the instructions to the left on its rung have a true path to the leftmost vertical rail then the PLC will set the bit to which it is referenced via the address to 1 If no complete true path is available it will set the bit to O YO Device Output PLC Lab Manual 19 1 5 The third symbol is special instruction boxes Along with the basic logic instructions addressed in the previous part PLCs are microprocessor based and they facilitate a wide area of useful built in functions like timers counters comparators CNT CO K10 Counter Example Let us assume that we have two inputs buttons and three output devices connected to a PLC terminals X1 X2 Y1 Y2 and Y3 respectively Assume also that the PLC is loaded with the program shown in Figure 2 5 _ _ o tas ys Y2 X1 Y3 X2 The program has 3 rungs which are explained as follows Rung 1 If we push on button X1 its associated internal bit labeled X1 is logic 1 true Thus when the processor executes this rung via the input instruction it sees the rung s input condition as
25. mple electrical ladder diagram to a PLC program Know the difference between physical components and program components sketch the ladder programs using the tools available in WPLSoft Download the program to the PLC operate the program via placing the PLC in the RUN mode 1 Basic Information In the satellite dish motor position control system there are two set points and two sensors limit switches used to feedback the position information to the controller In the general case the system may have almost continuous set points Thus a special sensor is required to report the position information back to the controller One cheep method is to fix a small permanent magnet to one side of the motor shaft and use a magnetic sensor to count the number of revolutions of the rotor as illustrated in Figure 4 1 _ Magnetic Sensor Figure 4 1 Magnetic sensors used in satellite dish motors The position information precision provided by these magnetic sensors is not adequate in more professional position control applications Optical encoders on the other hand are more common in these applications and capable of generating hundreds or thousands of pulses per rotor revolution Figure 4 2 depicts a 1000 pulse resolution optical encoder and its internal structure Position control using DC motors is based on feedback as illustrated in Figure 4 3 In the literature there are many tools developed to design continuous or digital controller
26. nged This phase reversal to the motor terminals 1s accomplished by two contactors PLC Lab Manual 32 The power diagram for reversing the direction of rotation of the motor and the associated control circuits are shown in Fig 5 3 Ly Ls La Fig 5 3 Reversing direction of rotation of a three phase induction motor a Power diagram b and c Control circuit diagrams It may be seen from 5 3 a that phase reversal to motor terminals has been done by interchanging phase L2 and phase L3 leads at the upper terminals of the reverse contactor R The forward and reverse contactor are mechanically interlocked i e if one of them is closed the other cannot close This is done to avoid dead short circuit in case both the contactors closing simultaneously Electrical interlocking has also been provided by using control contacts Electrical interlocking is essential even if mechanical interlocking of contactors is provided This is because if the coil of contactor which is mechanically interlocked not to close is energized its coil gets burnt The coil gets burnt as it draws large current due to less reactance in this case Reactance of coil is less as reluctance to flux path increases due to large air gap between the electromagnet and the locked armature of contactor Forward reverse starters may be designed for either Forward Reverse Operation or Forward Off Reverse Operation The control diagram in Fig 5 3 b is a simple circuit for For
27. ntrol board and make the required wiring and connections mcb 1x10A L 220VAC GO 220V 50Hz Fig 1 4 Energizing and de energizing relays using toggle switch 1 0 2 2 Once you are finished with the connections call the instructor to check it for you and make sure that it 1s correct 3 Connect the circuit to the power source and try to change the positions of the switch SW 1 1 0 2 What is your observation PLC Lab Manual 6 Experiment 2 PLC Input Output Wiring Methods OBJECTIVES After successfully completing this laboratory you should be able to Read and explain the nameplate of DELTA s PLC DVP Series Model Make different types of PLC input wiring Make different types of PLC output wiring 1 Basic Information 1 1 DELTA s PLC DVP Series Model Explanation DELTA s PLC DVP Series has main processing units and extension units The main processing units offer 14 60 points and the extension units offer 8 32 points The maximum input output can be extended up to 128 points It also can be used on applications according to INPUT OUTPUT points power sources output modules digital analog exchanges A D amp D A converter In addition DVP SS Series has the special modules AD DA PT TC XA used for extending its functions and the maximum special modules can be extended up to 8 units Nameplate Explanation Aner Programmable in PLC Model yonet DVP3Z2ES00R2 Input Power Supply Speci
28. nue WPLSoft 2 09 Beta InstallShield Wizard Ready to Install the Program The wizard is ready to begin installation WPLSoft 2 09 Beta InstallShield Wizard Installing WPLSoft 2 09 Beta The program features you selected are being installed Click Finish to complete the installation 16 PLC Lab Manual 17 1 3 WPLSoft 2 09 Beta InstallShield Wizard i x InstallShield Wizard Completed The InstallShield Wizard has successfully installed Wl Gott 2 09 Beta Click Finish to exit the wizard DELTA s PLC DVP Series has main processing units and extension units The main processing units offer 14 60 points and the extension units offer 8 32 points The maximum input output can be extended up to 128 points It also can be used on applications according to INPUT OUTPUT points power sources output modules digital analog exchanges A D amp D A converter In addition DVP SS Series has the special modules AD DA PT TC XA used for extending its functions and the maximum special modules can be extended up to 8 units Delta PLC memory map In the previous section we introduced two types of memory variables in Delta PLCs the input relays and the output relays In Delta PLCs there are total of 8 memory location types as described below Input Relays Single bit variables and can be extended to 128 points They are indicated with X sequence in Octal numbering mode Output Relays Single bit variables and
29. other example the instruction CMP D7 K23 M0 compares the value of D7 with the decimal number 23 If larger MO will be set else if equal M1 will be set otherwise if smaller then M2 will be set PLC Lab Manual 21 2 Equipments RS DVPI4ESOOR 1xl0A mcb 230V coil 50Hz 10A Relay Green and red indicator lamp NO and NC pushbuttons ON OFF switch Flexible wires Single phase power source Control board 3 Procedure Part 1 DC motor set reset circuit 1 Assemble the components of the control circuit on the control board and make the required wiring and connections as shown in the following figure mcb 1x10A LG Ohn D OV 50Hz dr 24VDC 2 220V S0Hz 220V 50Hz COIL 24GND g GREEN 2 Make the required wiring and connections for the power circuit as shown in the 24V GND following figure 3 Starting a new project in Wpl you will be prompt to specify the memory capacity of the target PLC model and a title for the project as shown below PLC Lab Manual 22 Steps Setting bd Memory Capacity 2000 Steps 4000 Steps C 16000 Steps Project Title Tank Filling Control Cancel 4 Specify 4000 steps for the DVPI4ESOOR PLC model and write down a suitable project title then click OK In the Ladder diagram window sketch the program shown below using the tools available in the common tools bar Internal Relay R1 Relay Green Lamp Red Lamp 5 Wpl assumes by def
30. piston should be released and then the horizontal plate should be driven forward to start a new cycle This is accomplished by utilizing two proximity sensors X2 and X3 to signal the end of the vertical piston down and up strokes respectively The evolution of the SFC is as illustrated in Figure 6 2 while the machine signals are Summarized in Table 6 1 Note that in the transition from S10 to S11 we utilized the signal from the sensor X5 Figure 6 2 SFC of the educational covering machine PLC Lab Manual 38 Table 6 1 Signals of the educational covering machine Siena Type bemp OOU Input Trigger push button switch Input Down stroke limit switch of the vertical piston Input Up stroke limit switch of the vertical piston Input Backward stroke limit switch of the horizontal piston Input Forward stroke limit switch of the horizontal piston Output Horizontal piston Output Vertical piston If you want to ignore the sensor as we mentioned above you have to replace the transition condition to rising edge of XO and not the high level of XO This is due to the fact that arrival to S10 is conditioned by the level of XO and it is likely that this state will be a transient state if the departure is also conditioned by the high level value of XO However what is expected from the system is that the user will press the input push button and have a time to raise his hand before pressing it again Moreover it is a good idea to
31. that meets some design parameters such as overshoot rise time settling time and steady state error However we prefer here to simplify the problem by assuming that the mechanical and time constants of the system are zeros That is the motor system responds instantaneously to its input voltage This is justifiable when the motor is coupled by high ratio step down gear box In this case we do not have to design a linear voltage driver for the motor and we may use the circuit shown in Figure 4 4 to drive the motor The control circuit should instruct the relays to feed the motor with the DC forward polarity when the error signal is positive or reverse polarity when the error signal is negative PLC Lab Manual 27 St aes Man oui Light _ sensor Coded Mask Disk Lens LED Position sensor Figure 4 3 Feed back position control Once the error signal equals zero relays disconnect the power supply of the motor It is difficult and impractical to realize this controller using traditional relay control circuits To T 24V R1 R1 GND Figure 4 4 Power circuit of the system Conversely speaking when implemented using a PLC Figure 4 5 illustrates the hardware connection of the control circuit PLC Lab Manual 28 wee op ee XO X41 X2 X3 DVP 14ES 24V YO Y1 Y2 7 Y3 1 4 124G ico C1 c2 c3 Y5 Figure 4 5 PLC based position control 2 Equipments DVPI4ESOO
32. the tools available in WPLSoft Download the program to the PLC operate the program via placing the PLC in the RUN mode 1 Basic Information 1 1 Introduction PLCs are special computers designed to operate in the industrial environment with wide ranges of ambient temperature and humidity They have a number of different programming languages which include Ladder logic Mnemonic instructions and Sequential Function Charts Ladder logic is the main programming method used for PLCs It is a graphical language which has been developed to mimic relay logic The decision to use the relay logic diagrams was a strategic one By selecting ladder logic as the main programming method the amount of retraining needed for engineers and tradespeople was greatly reduced a software tool called Wpl runs on a personal computer allows users to sketch the ladder diagram and then transfers its compiled code serially to the PLC Such a software tool is more convenient and it supports mnemonic and SFC programming languages as well 1 2 WPLSoft Installation and setup Start up your computer to Windows 95 98 2000 NT ME XP system Insert WPLSoft CD into the CD ROM disk or download installation program from http www delta com tw product em plc plc_main asp If the installation program is downloaded from the website it needs to be saved in the designated directory after uncompressing and then the installation can be started Click START and then
33. true Therefore it puts a 1 in the output bit Y1 This ladder program line is converted to mnemonic instruction as LD X1 OUT Y1 Rung 2 The processor works through the inputs from left to right and the output instruction sees a true condition only when it sees a true path via input instructions to the left rail If you push both push buttons connected to terminals X1 and X2 then the processor sees their associated bits logic 1 and hence puts a 1 in the output bit Y2 If none or one push button is pushed the input conditions to the left of the output instruction do not produce a true path This type of program rung is called an AND because both push buttons X1 AND X2 must be pushed to activate the output This rung is converted to mnemonic instruction as LD X1 AND X2 OUT Y2 Rung 3 This type of instruction is an OR gate because there are two pathes that will turn the output either push button X1 OR X2 is pushed It is implemented in mnemonics as LD X1 OR X2 OUT Y3 Functions on PLCs Counters PLC Lab Manual 20 When the operation result of instructions preceding the CNT instruction has changed from OFF to ON 1 is added to the count value When the counter has counted out count value set value the state of the counter contacts are toggled In the following example the output YO is activated after entering 5 clock pulses at input When the operation result of the instructions preceding the CNT instruction remain on
34. ward Off Reverse operation The motor can be run in forward or reverse direction by pressing FOR or REV push buttons When say the FOR push button is pressed contactor F gets energized and is held energized through its auxiliary contact F1 As the interlocking contact F2 is now open the reverse contactor R can not be energized even if the REV push button is pressed When the motor is to be reversed the motor is to be stopped first by pressing the STOP push button which de energises contactor F only then the motor can be run in reverse direction by pressing the REV push button Control circuit in Fig 5 3 c is for direct reversing of the motor In this circuit for reversing there is no need to first press the STOP push button Direction of rotation of the motor can be changed by pressing the respective push button This is accomplished by using interlocking through NC contacts of the push button in the coil PLC Lab Manual 33 circuits of the contactors Assume that motor is running in forward direction when contactor F is energized through closed contact F1 NC contact of reverse push button and normally closed contact R2 of reverse contactor R When it is desired to reverse the motor direction REV push button is pressed its NO contact closes whereas its NC contact which is in series with coil of contactor F opens Contactor coil of F is thus de energized and its holding circuit is also released De energization of F also leads to closing of its au
35. xiliary contacts F2 The reverse contactor R is thus energized through NO contact of REV push button NC of FOR push button and NC contact F2 of contactor F The contactor R remains energized through its auxiliary contact R1 Similar action takes place when the motor is to again run in forward direction by pressing FOR push button Induction motors can be safely reversed by direct reversing method as the inrush current is not significantly more than when it is started direct from rest Direct reversing is also used for bringing a motor to standstill quickly using reverse torque acting as a brake 2 Equipments RS DVPI4ESOOR 1xl0A mcb 230V coil 50Hz 10A Relay Green and red indicator lamp NO and NC pushbuttons ON OFF switch Flexible wires Single phase power source Control board 3 Procedure Part 1 Semi automatic Star Delta Starter 1 For the following semi automatic star delta control system sketch the ladder diagram The input output diagram of the PLC is shown in the figure WI L1 w2 U1 L2 dk L3 w2 w2 Ut V2 U2 wm D e e e A ES mcb3x10A SCH KV V1 Main Contactor 7 a Delta Contactor 7 s Star Contactor 1 5 220V 50Hz OM 220V S0Hz D hee fee GC AKT ow COIL S COIL COIL A2 Q Q Q Q Q Q 2 4 2 4 6 se 6 A2 Overload U1 Wwe D D Cog D D e PLC Lab Manual Delta 220V 50Hz COIL 220V 50Hz COIL
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