CX 2ndpart

INDUSTRIAL AUTOMATION SECTION
Programmable Logic Controller 2 (FAD 30502)

Page 1 Programmable Logic Controller_2
1. Practical 1
HOW TO START A NEW PROGRAM WITH CX-PROGRAMMER

1. Select FILE then NEW
The new program window below will arise.

Figure1

2. Before press OK make sure in the Settings.. of the Device Type are set as below :

Select CQM1H
SelectSYSMAC
WAY



Figure2

3. After you ensure that the CPU setting is correct, press OK. Then Figure1 will arise again.
Do not press OK, make sure that the Network Type settings is as in the Figure 3 and 4 below.

Figure 3

CPU 51 according to
the PLC



Figure 4

4. Press OK for Network Setting. Then when Figure 1 arise again, press OK for validation the PLC
types and settings. The next window will appear.



You may start build the ladder.

5. Those are the icons to build the ladder

For SFT, TIM, CNT, END, etc use this icon.

To delete or copy, the keyboard is very useful.

6. Once the ladder is ready, it can be transfer to the plc. But, before that the PLC should connected to
the computer in order to communicate between them. This can be made by pressing:

Work online button or choose PLC then Work Online

This window will appear, just answer YES

7. When the PLC and the computer are connected you may transfer the program to the PLC. By
pressing the Transfer to PLC button or choose PLC then Transfer then To Plc.


The Download Options window will appear, select include program then press OK

Then, this window will appear, press YES .

This will change the PLC to the Program mode, press YES

The program will be downloaded and one the downloading process success, you will be asked to
return the PLC to the RUN mode, press YES.



If the step is not existed, you can turn the PLC to run mode by pressing this button

Well, you may test your program now.

Remark: To edit the program you must work Offline.


2. Practical 2
Packaging Line Control (Apple Conveyor)

Operation :

When PB1 (START Push Button) is pressed, the box conveyor moves. Upon detection of box
present, the box conveyor stops and the Apple conveyor start. Part sensor will count for 10 apples.
Apple conveyor stops and box conveyor starts again. Counter will be reset and operation repeats
until PB2 (STOP Push Button) is pressed.

Input Devices Output Devices
00000 START Push Button (PB1) 10000 Apple Conveyor
00001 STOP Push Button (PB2) 10001 Box Conveyor
00002 Part Present (SE1)
00003 Box Present (SE2)


Instruction :

1. Build:
a. PLC input and output wiring.
b. PLC program
i. Ladder
ii. Instruction list table
2. Connect input and output wiring
3. Test the program


DRL - B
PUSHER - A
3. Practical 3
CLAMPING AND DRILLING UNIT

This is a drilling section where two actuators involve (two pneumatic cylinders). The first actuator
(cylinder A) pushes the part under the drilling operation. The drilling process is done by pneumatic
B. After drilling, cylinder A must not return until drill feed unit has reached its start position. The
sequence will begin where a start button is pressed. Each cylinder is controlled by a single solenoid
valve.



Using REED Switches Using LIMIT Switches


INPUT LIST

OUTPUT LIST

The Operation will be done in two types of sequence:
1. STEP by STEP
2. AUTO
The view of the system based on the following diagram:

Input Device Symbol Address
Start button ( push button NO) Start Pb 00000
Stop button ( push button NC ) Stop Pb 00005
Auto/Manual selector switch AutoManu 00006
Step by Step pushbutton ( NO ) Steper 00015
Reed switch Cylinder A ( +ve ) NO MS2 00002
Reed Switch Cylinder A ( -ve ) NO MS1 00001
Reed switch Cylinder B ( +ve ) NO MS4 00004
Reed switch Cylinder B ( -ve ) NO MS3 00003

Output Device Symbol Address
Valve Cylinder A Y1 10001
Valve Cylinder B Y2 10013


PRACTICAL:
4. Build:
a. PLC input and output wiring.
b. PLC program (You are required to use SHIFT REGISTER Function)
i. Ladder
ii. Instruction list table
5. Connect input and output wiring
6. Test the program


4. Practical 4
== Car Park Control ==

This is simple car park control system that allows only a maximum of 100 cars parking
space. Every time a car comes in, the PLC will automatically add one through sensor
S1. Any car that goes out will automatically be subtracted by one through sensor S2.
When 20 cars are registered, the car park full sign will be lighted to inform on coming
vehicles not to enter.


1. Practical procedures
i. Get the required equipment
ITEM QNTY.
PLC OMRON CQM1H 1
Programming terminal 1
Push button 2
Relay 1
Wires as needed

ii. Do the wiring for PLC input & output
iii. Write the program to the PLC
iv. Testing the program


5. Practical 5
ANALOG INPUT AND OUTPUT SETTING

The Analog Input Output Modules for OMRON CQM1H

Analog Input Modules CQM1-AD041
The CQM1-AD041 Analog Input Unit retrieves four analog signals from sensors or
measuring equipment. This unit is used in combination with a power supply unit.

Analog Output Modules CQM1-DA021
A single Analog Output Unit makes two-point digital-to-analog possible at a speed of
0.5ms/two points. This unit is used in combination with a power supply unit.


System Configuration Example



Using Inner Boards CQM1H-MAB42 (Analog I/O Board)

The Analog I/O board is an inner board with 4 analog inputs and 2 analog outputs.
The signal ranges that can be used for each of the 4 analog inputs are -10V to 10V, 0V to
10V, 0V to 5V, and 0 to 20mA. Each inputs signal range can be set independently.
The signal ranges that can be used for each of the two analog output points are -10 to 10V
and 0mA to 20mA. Each outputs signal range can be set independently.




Installation of the Inner Board

The Analog I/O board can only be
mounted in slot 2 (right slot) of the
CQM1H-CPU 51/61 CPU unit

Board connectors

Pin Arrangement for CN1 (Analog Input)


Pin Arrangement for CN2 (Analog Output)

Analog Input connections



Analog Output connections


ANALOG INPUT AND OUTPUT DATA AND CONVERTED VALUE





APPLICATION PROCEDURES


6. Practical 6
Air Condition Control
The closed loop block diagram for an air condition system controlled by PLC is as follow:
SP
Temp.
sensor +
-
P
V
E=SP-PV
Feedback signal
Air Cond System
Air Cond System
PLC

In this application, the analogue input signal is used to control discrete output signal. The
aircond will be On if the room temperature is more than 24C and turn Off if the
temperature drop below 24C.

The measurement range of the temperature sensor RTD Pt100 is 0C to 100C


The temperature transmitter converts the resistance value received from RTD into 0 to
10V analog signal.
Using the programming console; configure the analog input channels (IR 232, IR 233,
IR 234, IR 235) to receive 0-10Vdc.
DM 6611 : 0000-0000-0101-0101

The PLC analog input module converts the analog signal received from the temperature
transmitter into digital signal. Refer to analog I/O specification for details.
If the transmitter send 10V, what will be the corresponding value stored in
the memory?

If the transmitter send 2.5V, what will be the corresponding value stored in
the memory?


List the PLC input and output devices
Discrete input list
Address Tag Description
Start Start the system (N/O contact)
Stop Stop the system (N/C contact)

Discrete output list
KM1 Air Cond

Analog input list
Room_temp Temperature signal from transmiter



Draw the PLC input and output schematic wiring diagram
PLC discrete input wiring

PLC discrete output wiring

0V 24V 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15


PLC analog input wiring


Design the PLC program
Ladder

Start & stop the system:

Store the analog signal receives from temperature transmitter connected to
channel IR 232 into data memory DM 0000.

Since the raw data received is between to .. Hex, we need to
convert this data into engineering unit between 0C to 100C in BCD.
Use the instruction BCD(24) to convert Hex value in DM 0000 into
BCD value which is stored in DM 1000.


Use the instruction DIV(33) to divide the BCD value stored in DM
1000 with . to get the engineering unit 0C to 100C in BCD.
Store the results in DM 1010.

Use the instruction CMP(20) and the related flag (more than : SR 255.05)
to control the aircond based on the following conditions.
If the temperature is more than 24C; turn On the aircond.
If the temperature is less than 24C; turn Off the aircond.

Using calculator, convert BCD format of 24C into Hex format.
Hex. Use the instruction MOV(21) to store this value in DM
1011.


Use the instruction BCD(24) to convert setpoint value in Hex (DM
1011) into BCD value which is stored in DM 1012.

If the temperature is more than 24C (setpoint); turn Off the aircond.
If the temperature is less than 24C (setpoint); turn On the aircond


Instruction List / Mnemonic

Address Instruction Operands
00000
00001
00002
00003
00004
00005
00006
00007
00008
00009
000010
000011
000012
000013
000014
000015
000016
000017
000018
000019
000020
000021
000022


Practical procedures
v. Get the required equipment
ITEM QNTY.
PLC 1
PC + programming cable 1
Push button 2
Contactor 1
DC voltage injector 1
Wires as needed

vi. Do the wiring for PLC discrete input & output
vii. Do the wiring for analog input
viii. Program mode. Clear the memory of the PLC
ix. Write the program to the PLC
x. Check the program (level 0)
xi. Run mode. Run the PLC
xii. Test the program by injecting DC voltage (0 to 10V) to the analog input channel
to simulate signal received from the transmitter. DO NOT INJECT MORE THAN
10V. THE PLC ANALOG INPUT WILL BE DAMAGED.


7. Practical 7
Flow Control

The sensors are used to detect different level of the reservoir. We want to control the
speed of discharge base on the level of the reservoir. If sensor 1 is On (reservoir at high
level), the flow control valve will be opened 95%. If sensor 2 is On (reservoir at medium
level), the flow control valve will be opened 50%. If sensor 3 is On (reservoir at low level),
the flow control valve will be opened 25%.

Sensor 1, sensor 2 and sensor 3 are magnetic level switch (i.e discrete sensors). Flow
control valve receives 0 to 10V analog signal from the PLC analog output module to
control its percentage of opening (i.e analog output device). If it receives 0V, the it will be
fully closed. If it receives 10V, then it will be fully opened. If it receives 5V, then it will be
half opened.
Product
Discharge
Flow Control
Valve
Sensor 1
Sensor 2
Sensor 3
Reservoir
V
a
l
v
e
C
o
n
t
r
o
l
l
e
r


The PLC program written in the CPU use digital signal between 0 to 07FF. The PLC
analog output module converts the digital signal into 0 to 10V analog signal. This analog
signal will be sent to the valve controller that open and close the valve accordingly. (0V :
fully closed / 10V : fully opened)


8. Practical 8

Conveyor with a weight detector

The diagram shows a conveyor system with a weight detector and 3-phase AC motor. The
system is designed to move the conveyor belt at a certain speed when a specific value of
weight is on the conveyor. If the weight exceeds the preset value, the conveyor speed
increases to move the material off the belt at a faster rate. If the weight falls below the
preset value, the conveyor speed is reduced. The system will cut off if the weight less than
2 kg.

LOAD CELL
CONTROLLER
CONVEYOR
SET POINT
OUTPUT
HOPPER
VALVE
MOTOR


List the PLC input and output devices
Input list
Address Label Description
Start Start the system
Stop Stop the system
S1 Reset the system

Output list
Address Symbol Description
H1 Indicator light Low speed
H2 Indicator light High speed
H3 Indicator light System off

Data storage
Address Symbol Description
Set point data : 5 kg(Hex)

Data from weight sensor for comparison purpose
(Hex)
Data from variable speed drive purpose (Hex)
Data weight 1 : 6 kg(Hex)
Data weight 2 : 10 kg(Hex)
Data-weight 3 : 2 kg(Hex)
Data-speed 1 :1000 rpm(Hex)
Data-speed 2 : 1500 rpm(Hex)


Draw the PLC input and output schematic wiring diagram
PLC input wiring

PLC output wiring

0V 24V 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15


Design the PLC program
Ladder

Start & stop the system:

Store the data to the appropriate address:
Set point = 400 Hex

Weight 1 = 4CC Hex and Weight 2 = 7FF Hex


Compare data between Analog Input and set point. When data less than set point,
Indicator light H1 lit ON (Test the range from 2kg to 4kg)

Move the data for Normal speed = 55C Hex to address Analog Output.

Data comparison for 6kg< Analog Input< 10Kg


Move the data for High speed = 7FF Hex to address Analog Output

Compare data, if the weight less than 2kg = 199 Hex the system will cut OFF.

System reset


2. Practical procedures
xiii. Get the required equipment
ITEM QNTY.
PLC 1
PC + programming cable 1
Push button 3
Indicator light 3
Analog Input and Output Simulator 1
Fused isolator 1
Thermal overload relay 2
Wires as needed

xiv. Do the wiring for power circuit
xv. Do the wiring for PLC input & output
xvi. Write the program to the PLC
xvii. Run mode. Run the PLC
xviii. Switch ON supply for control circuit (48Vac) and test the program:
Start
Stop
Thermal overload relay
xix. Switch ON supply for power circuit (415Vac) and test the program
xx. During the program testing, monitor the bit status (ON/OFF).



APPENDIX

PLC input and Output wiring



PRACTICAL REPORT FORMAT:

a. PLC Input and Output List (discrete and analog)
b. PLC Input and Output wiring
c. Ladder diagram
d. Conclusion

CX 2ndpart

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INDUSTRIAL AUTOMATION SECTION

Programmable Logic Controller 2 (FAD 30502)

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