Lab Exercise 1 Simple Ladder Logic

Transcription

1 Lab Exercise 1 Simple Ladder Logic Table of Contents Page Objectives Lab 11 I. Wiring the Lights and Switches Lab 11 II. Series Operation (Logical AND) Lab 110 III. Parallel Operation (Logical OR) Lab 110 IV. Motor Start/Stop Lab 111 V. Timer Operation Lab 111 VI. Counter Operation Lab 111 VII. Flashing Lights Lab 112 VIII. Turn Signal Lab 112 Permission to copy and post these notes granted to instructors of a course that uses Programmable Logic Controllers: An Emphasis on Design and Application by Kelvin T. Erickson.

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3 Lab 1 1 Objectives This exercise is designed to provide working knowledge of the Allen Bradley ControlLogix, PLC5, or SLC500 (and the RSLogix software); the Siemens S7 (and the Step 7 software); the Modicon M340 (and the Unity software); or the GE PACSystems (and the Proficy software). The PLC is programmed for simple logical operations using ladder logic diagrams and the appropriate software tools. Lamp loads and switches are used to simulate input/output conditions and the ladder logic programs are verified for correct operation. I. Wiring the Lights and Switches Connect the lights and switches to the I/O modules. Typical connections to the modules are shown in Figures 1 12 (Note: these are not the actual connections; you need to figure that out). Use the appropriate figures depending on the PLC (M340, ControlLogix, PLC5, SLC500, S7300/400, or RX3i). A diagram of the switches and lights is shown in Fig. 13. Use the following connections: Tag/Symbol/ Variable Group (Slot) Channel AllenBradley ControlLogix Address PLC5/SLC500 Address Mod. S7 Channel Address Start_PB :I.Data.0 I:1/ I0.0 Stop_PB :I.Data.1 I:1/ I0.1 SW :I.Data.2 I:1/ I0.2 SW :I.Data.3 I:1/ I0.3 LA :O.Data.0 O:2/ Q4.0 LA :O.Data.1 O:2/ Q4.1 LA :O.Data.2 O:2/ Q4.2 LA :O.Data.3 O:2/ Q4.3 LA :O.Data.4 O:2/ Q4.4

4 Lab 1 2 Tag/Symbol/ Variable Modicon GE Mod. Channel Address Mod. Channel Address Start_PB 2 0 %I %I1 Stop_PB 2 1 %I %I2 SW3 2 2 %I %I3 SW4 2 3 %I %I4 LA1 3 0 %Q %Q1 LA2 3 1 %Q %Q2 LA3 3 2 %Q %Q3 LA4 3 3 %Q %Q4 LA5 3 4 %Q %Q5 Doublecheck your wiring before you apply power!!

5 Lab 1 3 Only needed if IN16 to IN31 connected IN1 IN3 IN5 IN7 IN9 IN11 IN13 IN15 GND0 IN17 IN19 IN21 IN23 IN25 IN27 IN29 IN31 GND IN0 IN2 IN4 IN6 IN8 IN10 IN12 IN14 GND0 IN16 IN18 IN20 IN22 IN24 IN26 IN28 IN30 GND1 To Switch/Light Board Fig. 1. Example ControlLogix IB32 Input Module Connection Diagram. Jumper Bar 0() 1() 2() 3() 4() 5() 6() 7() 8() 9() 10() 11() 12() 13() 14() 15() 15() Not used OUT0 OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7 OUT8 OUT9 OUT10 OUT11 OUT12 OUT13 OUT14 OUT15 Not used Not used Fig. 2. Example ControlLogix OB16I Output Module Connection Diagram.

6 Lab 1 4 A B C D E Not used Not used Not used Not used Input 00 Input 07 Input 10 Input 17 Common Fig. 3. Example PLC5 IBD Input Module Connection Diagram. A B C D E Output 00 Output 07 Output 10 Output 17 Common Fig. 4. Example PLC5 OBD Output Module Connection Diagram.

7 Lab 1 5 In 00 In 02 In 04 In 06 In 08 In 10 In 12 In 14 Com In 01 In 03 In 05 In 07 In 09 In 11 In 13 In 15 Com Fig. 5. Example SLC500 IB16 Input Module Connection Diagram. Out 01 Out 03 Out 05 Out 07 Out 09 Out 13 Out 15 Out 00 Out 02 Out 04 Out 06 Out 10 Out 12 Out 14 Com Fig. 6. Example SLC500 OB16 Output Module Connection Diagram

8 Lab volt labeled wire to switch/light board 1 21 I I2.0 I I2.1 I I2.2 I I2.3 I I2.4 I I2.5 I I2.6 I I V 24 V Common I I3.0 I I3.1 I I3.2 I I3.3 I I3.4 I I3.5 I I3.6 I I3.7 M M Fig. 7. Example S7 SM321 DI32x24V Input Module Connection Diagram. 24 V L(0) Q4.0 Q4.1 Q4.2 Q4.3 Q4.4 Q4.5 Q4.7 M(0) L(1) Q5.1 Q5.3 Q5.4 Q5.5 Q5.6 Q5.7 M(1) Note: Use Switch/Light Board with 24volt lamps Fig. 8. Example S7 SM322 DO16x24V Output Module Connection Diagram.

9 Lab V In1 In3 In5 In7 In9 In11 In13 In15 24V 24V In0 In2 In4 In6 In8 In10 In12 In14 Com Com Fig. 9. Example Modicon DDI V Input Module Connection Diagram. 24 V Out1 Out3 Out5 Out7 Out9 Out11 Out13 Out15 24V 24V Out0 Out2 Out4 Out6 Out8 Out10 Out12 Out14 Com Com Fig. 10. Example Modicon DDO V Output Module Connection Diagram.

10 Lab 1 8 In In17 In In18 In In19 In In20 In In21 In In22 In In23 In In24 Common Common 1724 In In25 In In26 In In27 In In28 In In29 In In30 In In31 In In32 Common Common 2532 Only needed if IN9 to IN16 connected Fig. 11. Example GE MDL /24V Input Module Connection Diagram. Out Out17 Out Out18 Out Out19 Out Out20 Out Out21 Out Out22 Out Out23 Out Out24 Out Out25 Out Out26 Out Out27 Out Out28 Out Out29 Out Out30 Out Out31 Out Out32 for for 1732 for for 1732 Fig. 12. Example GE MDL /24V Output Module Connection Diagram.

11 Lab 1 9 (or L1) Start_PB LA1 Common (or L2) Stop_PB LA2 SW3 LA3 SW4 LA4 LA5 Fig. 13. Switch and light board connections.

12 Lab 1 10 II. Series Operation (Logical AND) Two switches in series are used to control a lamp load. The circuit and the corresponding ladder logic is shown in Fig. 14. The input and output addresses are shown in the ladder logic. Follow the instructions in part A of the appropriate software programming guide (Modicon Unity, ControlLogix, PLC5, SLC500, S7300, S7400, or GE Proficy) to set up the processor project. Then follow the procedure in part B.1 to program and test the ladder logic. SW 3 SW 4 LA1 SW3 SW4 LA1 Fig. 14. Series switch circuit and its ladder logic equivalent. III. Parallel Operation (Logical OR) Connect two switches in parallel, as shown in Fig. 15, which is a logical OR condition. The instructions to program the PLC are in part B.2 of the appropriate software programming guide. Demonstrate the PLC operation to the instructor. SW 3 LA1 SW 4 Fig. 15. Parallel switch circuit.

13 Lab 1 11 IV. Motor Start/Stop Using the Start and Stop switches and one lamp, implement a motor start/stop circuit. The start switch is a normally open pushbutton switch and the stop switch is a normally closed pushbutton switch. Demonstrate the PLC operation to the instructor. V. Timer Operation Devise a ladder logic program to do the following: a. When a switch is closed, one lamp lights. b. Five seconds later, another lamp lights. The instructions to program the PLC are in part B.3 of the appropriate software programming guide. Demonstrate the PLC operation to the instructor. VI. Counter Operation Devise a ladder logic program to do the following: When a switch is closed five times, one lamp lights. The instructions to program the PLC are in part B.4 of the appropriate software programming guide. Demonstrate the PLC operation to the instructor.

14 Lab 1 12 VII. Flashing Lights. Devise ladder logic using two lamps and two timers to make the two lamps flash alternately. Choose any on/off period. Use one of the switches to turn the flashing lights on and off. Demonstrate the PLC operation to the instructor. You will need to use this ladder logic for anything flashing/beeping/cycling and so it appears in many contexts. VIII. Turn Signal. Devise ladder logic using SW3 and SW4 and timers to produce a turn signal indication (like the old Thunderbirds) with the five lamps. If SW3 is on, the lights should flash to show a left turn. The sequence should be,,,,, (where means a lamp is on and means lamp off). If SW4 is on, the lights should flash to signal a right turn. The right turn sequence should be,,,,,. If both switches are on, then no lamps should flash. The patterns should repeat as long as either switch is on. Each "pattern" in the sequence should be displayed. There should be a time interval for which no outputs are on. Choose any reasonable timing intervals. Demonstrate the PLC operation to the instructor.