Mechatronics

PLC Applications
Level Process Control

Job Sheets - Courseware Sample

85253-F0
Order no.: 85253-30
First Edition
Revision level: 05/2017

By the staff of Festo Didactic

© Festo Didactic Ltée/Ltd, Quebec, Canada 2008

Internet: www.festo-didactic.com
e-mail: [email protected]

Printed in Canada
All rights reserved
ISBN 978-2-89640-310-3 (Printed version)
Legal Deposit – Bibliothèque et Archives nationales du Québec, 2008
Legal Deposit – Library and Archives Canada, 2008

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 Safety and Common Symbols
The following safety and common symbols may be used in this manual and on
the equipment:

Symbol Description

DANGER indicates a hazard with a high level of risk which, if not

avoided, will result in death or serious injury.

WARNING indicates a hazard with a medium level of risk which,

if not avoided, could result in death or serious injury.

CAUTION indicates a hazard with a low level of risk which, if not

avoided, could result in minor or moderate injury.

CAUTION used without the Caution, risk of danger sign ,

indicates a hazard with a potentially hazardous situation which,
if not avoided, may result in property damage.

Caution, risk of electric shock

Caution, hot surface

Caution, risk of danger. Consult the relevant user documentation.

Caution, lifting hazard

Caution, belt drive entanglement hazard

Caution, chain drive entanglement hazard

Caution, gear entanglement hazard

Caution, hand crushing hazard

Notice, non-ionizing radiation

Consult the relevant user documentation.

© Festo Didactic 85253-30 III

 Safety and Common Symbols

Symbol Description

Direct current

Alternating current

Both direct and alternating current

Three-phase alternating current

Earth (ground) terminal

Protective conductor terminal

Frame or chassis terminal

Equipotentiality

On (supply)

Off (supply)

Equipment protected throughout by double insulation or

reinforced insulation

In position of a bi-stable push control

Out position of a bi-stable push control

IV © Festo Didactic 85253-30

 Table of Contents
Preface ................................................................................................................. VII
About This Manual ................................................................................................ IX
To the Instructor .................................................................................................... XI

Job Sheet 1 Familiarization with the Level-Process Training System ...... 1

Job Sheet 2 Basic Level Control ................................................................. 13

Job Sheet 3 Batch Process .......................................................................... 21

Job Sheet 4 Troubleshooting ....................................................................... 39

Job Sheet 5 PID Control (Optional) ............................................................. 47

Appendix A List of Equipment Required .................................................... 71

Appendix B Ladder Program Design .......................................................... 73

Appendix C Boolean Algebra and Digital Logic ........................................ 89

Appendix D Troubleshooting Procedures .................................................. 95

Appendix E Glossary of Terms ................................................................. 101

Appendix F Ladder Diagram Graphic Symbols ....................................... 107

© Festo Didactic 85253-30 V

 Preface
The Programmable Logic Controller, Basic Programming student manual
(P/N 88270) allowed the reader to become familiar with PLCs and ladder
programming. This was accomplished with the help of the Programmable Logic
Controller Training System (Model 3240).

The aim of the present series of PLC applications is to integrate the basic
principles previously acquired by designing small-scale systems that can be
found in the real world. Through practical examples, students will gain a strong
knowledge of the PLC field of study.

Each manual of the PLC applications series concentrates on a specific example

of PLC application that evolves along a path of increasing complexity. With each
manual, new components are added to the PLC module to create different
opportunities to learn.

We hope that your learning experience with the PLC Training System will be the
first step of a successful career.

We invite readers of this manual to send us their tips, feedback, and

suggestions for improving the book.

Please send these to [email protected].

The authors and Festo Didactic look forward to your comments.

© Festo Didactic 85253-30 VII

 About This Manual
Programmable Logic Controllers (PLC's) represent state-of-the-art
microprocessor-based electronics that make up technologically advanced control
systems with applications in virtually every segment of industry where automation
is required.

The present manual includes five Job Sheets that introduce students to PLC
control of the Level-Process Training System, Model 8075-6. Throughout the
manual, students will learn how to program, connect, operate, and troubleshoot
different configurations.

Prerequisite

Before performing the Job Sheets in this manual, it is recommended to review

the Programmable Logic Controller, Basic Programming student manual
(P/N 88270), which explains how to use the programming software and the most
common PLC instructions. If any difficulty is encountered while performing the
exercises, the programming software's user guide and help menu can assist
students in problem solving.

Safety considerations

Safety symbols that may be used in this manual and on the equipment are listed
in the Safety Symbols table at the beginning of the manual.

Safety procedures related to the tasks that you will be asked to perform are
indicated in each exercise.

Control systems can be harmful when not used properly. Before performing any
of the exercises in this manual, make sure that you respect the following general
guidelines:
• Put your safety glasses on.
• Avoid wearing any loose clothing (e.g., tie, long sleeves, jewelry).
• Have your hair tied out of the way if it is long.
• Clean your work area if necessary.
• Be careful not to spill water on the PLC and the system electrical
components.

Remember that you should never perform an exercise if you have any reason to
think that a manipulation could be dangerous to you or your teammates.

Systems of units

Units are expressed using the International System of Units (SI) followed by units
expressed in the U.S. customary system of units (between parentheses).

© Festo Didactic 85253-30 IX

 About This Manual

Appendices

Appendix A: List of Equipment Required, gives the list of equipment needed

to perform the exercises.

Appendix B: Ladder Program Design, presents two different methods that can
be employed to program a PLC ladder program.

Appendix C: Boolean Algebra and Digital Logic, shows the logical

relationships that can be employed with normally-open (NO) and
normally-closed (NC) contacts.

Appendix D: Troubleshooting Procedures, is a set of guidelines permitting

students to locate and correct PLC system failures.

Appendix E: Glossary of Terms, defines technical words and expressions

contained in this manual.

Appendix F: Ladder Diagram Graphic Symbols, depicts the main symbols

used in ladder diagrams.

X © Festo Didactic 85253-30

 To the Instructor
You will find in this Instructor Guide all the elements included in the Student
Manual together with the answers to all questions, results of measurements,
graphs, explanations, suggestions, and, in some cases, instructions to help you
guide the students through their learning process. All the information that applies
to you is placed between markers and appears in red.

Accuracy of measurements

The numerical results of the hands-on exercises may differ from one student to
another. For this reason, the results and answers given in this manual should be
considered as a guide. Students who correctly performed the exercises should
expect to demonstrate the principles involved and make observations and
measurements similar to those given as answers.

The instructor should be familiar with PLCs to recognize erroneous results. It is

advised that a complete run-through of each job sheet be included in the
instructor’s preparation for class. Each Job Sheet has several performance
objectives. The instructor should ensure that each student understands them.

© Festo Didactic 85253-30 XI

 Sample
Extracted from
the Job Sheets Student
and the Job Sheets Instructor
 Information Job Sheet 3

Batch Process

Batch processes

A batch process is a production method used to obtain a desired product by

batches and not in a continuous manner. This method is popular in the food and
chemical industries where specific conditions (temperature, pressure, and/or
ingredients relative quantities) must be obtained to ensure proper transformation.
PLCs are particularly useful in monitoring and controlling these conditions.
Figure 13 shows how a batch of dough is prepared in a bakery.

Figure 13. Example of batch process.

PLC program initialization

To avoid unexpected outcomes, it is good practice to start a program by setting

data files to precise values. This is particularly important with sensitive files such
as outputs or control bits.

A way to realize this in practice is to use a condition that is only true during the
first processor scan. With Micrologix Controllers from Allen-Bradley, S:1/15 is a
reserved status bit that is only actuated during the first pass. As an example,

© Festo Didactic 85253-30 21

Job Sheet 3 – Batch Process

Figure 14 shows how all outputs of slot 0 can be reset at the beginning of the

a
program.

The instruction CLR (clear) sets all the bits in a word to zero.

Figure 14. Outputs reset upon initial scan.

Timer On (TON) instruction

With Micrologix Controllers from Allen-Bradley, the TON instruction starts to

count time base intervals when the rung in which it is contained goes from false
to true. As long as the rung remains true, the TON instruction increases its
accumulated value until it reaches the preset value. If the rung becomes false,
the accumulated value is reset to zero regardless of whether or not the preset
value has been reached.

Figure 15 shows the data file of a timer instruction. The timer status bits that you
can use to control relay-type (XIO and XIC) instructions in your program are
(timer T4:0 given as an example):
• Done bit (T4:0/DN): Set to logic state 1 when the accumulated value
becomes equal to the preset value, and reset to logic state 0 when the
rung becomes false.
• Timer timing bit (T4:0/TT): Set to logic state 1 when the TON rung is
true and the accumulated value is less than the preset value.
• Timer enable bit (T4:0/EN): Set to logic state value 1 when the TON
rung is true.

The timer status words that you can use in your program's comparison
instructions are (timer T4:0 given as an example):
• Preset value word (T4:0.PRE): Final value the accumulated value must
reach to stop timing and set the done bit.
• Accumulated value word (T4:0.ACC): Value accumulated since the
timer was last reset to zero.

22 © Festo Didactic 85253-30

Job Sheet 3 – Batch Process

Figure 15. Timer instruction file.

Alarms

A good PLC program must be able to cope with all the possible states that the
system can be found in. This includes all the faulty conditions resulting from a
physical failure. For example, the high-level float switch of the Level-Process
Training System may stop working, causing water to spill from over the top of the
cylinder. If this situation occurs, the program should inform the operator, through
an alarm routine, that an unusual situation is happening. In this particular case, a
second float switch may be installed higher on the cylinder to set the alarm and
avoid damage if it ever gets triggered.

Alarms are particularly important when the system is not under direct operator
supervision. Serious alarms may require shutting down the whole process
automatically. Safety here is the main issue.

Be careful when performing maintenance work on any system where sources of

energy (electrical, mechanical, pneumatic, hydraulic, etc.) can cause you harm.
More sophisticated systems in the industry may require specific procedures,
including lockout and/or tagout, as shown in Figure 16.

© Festo Didactic 85253-30 23

Job Sheet 3 – Batch Process

Figure 16. Lockout / Tagout procedure.

Height-adjustable float switch

The height-adjustable float switch can be converted from NO to NC operation, as

shown in Figure 17. In this Job Sheet, we will assume that the switch is NO and
marking the normal water height desired for heating.

24 © Festo Didactic 85253-30

Job Sheet 3 – Batch Process

Figure 17. Changing float switch from NO to NC.

© Festo Didactic 85253-30 25

 Job Sheet 3

Batch Process

OBJECTIVE Implement a ladder program permitting batch process.

PROCEDURE

Make sure you are wearing appropriate protective equipment when performing
the jobs. You should never perform a job if you have any reason to think that a
manipulation could be dangerous for you or your teammates.

Also, be careful not to spill water on the system electrical components.

1. Connect the Level-Process Training System according to Figure 18. This

arrangement will be used in both parts of the procedure section (without and

a
with the alarm).

Some items connected will only be used in the second part of the procedure
section.

© Festo Didactic 85253-30 27

Job Sheet 3 – Batch Process

Start PLC module

Power
supply
EM_Stop Inputs Outputs
Alarm_RES Wall
outlet

Alarm float
switch
EN

HL float
switch

Capacitive
switch

Wall
outlet

Figure 18. Job Sheet 3 configuration.

Table 5. Job Sheet 3 PLC I/O connections.

PLC address PLC port Connected to

I:0/0 (START_PB) Input 0 Start Pushbutton

I:0/1 (HIGH_FS) Input 1 High-Level Float Switch (Adjustable)

I:0/2 (LOW_CS) Input 2 Low-Level Capacitive Switch

I:0/3 (ALARM_FS) Input 3 Alarm Float Switch

I:0/4 (EM_STOP) Input 4 Emergency Stop Pushbutton

I:0/5 (ALARM_RES) Input 5 Reset Pushbutton

O:0/0 (IDLING) Output 0 Nothing (LED indicates IDLE mode)

O:0/1 (PUMP) Output 1 Pump EN terminal

O:0/2 (HEATER) Output 2 Nothing (LED indicates heating process)

O:0/3 (MIXER) Output 3 Nothing (LED indicates mixing process)

O:0/4 (VALVE) Output 4 Solenoid Valve + Terminal

O:0/5 (ALARM_LED) Output 5 Nothing (LED indicates FAULT mode)

28 © Festo Didactic 85253-30

Job Sheet 3 – Batch Process

2. The ladder program that you are about to write will control a batch process in
which a liquid enters a tank until a given level is reached. The liquid is then
heated and mixed for a predetermined time period (30 seconds) after which it
is evacuated.

The system will work in four different states, as shown in Figure 19.

T1 T2 T3
(START_PB) (HIGH_FS) (TIMER/DN)

First
scan
S1 S2 S3 S4

T4
(LOW_CS)

Figure 19. State diagram of Job Sheet 3 (without the alarm).

• State 1 (IDLE): Begins when the program is started (upon first scan) or
after a cycle is completed (when the liquid level is low). Ends when the
START pushbutton is pressed.
• State 2 (FILL): Begins when the START pushbutton is pressed in IDLE
state. Ends when HIGH_FS is triggered.
• State 3 (HEAT): Begins when HIGH_FS is triggered in FILL state. Ends
when the timer is done (after 30 seconds).
• State 4 (EMPTY): Begins when the timer is done in HEAT state. Ends
when the capacitive switch stops detecting water.

Table 6 shows the different outputs that are triggered in each state.

Table 6. Actuated output per state.

State Actuated output(s)

IDLE (1) IDLING (O:0/0)

FILL (2) PUMP (O:0/1)

HEATER (O:0/2)
HEAT (3)
MIXER (O:0/3)

EMPTY (4) VALVE (O:0/4)

The ladder program should only use the RSLogix instructions part of the
following list:

CLR - XIC - XIO - OTE - TON

© Festo Didactic 85253-30 29

Job Sheet 3 – Batch Process

3. Start RSLogix Micro and write a ladder program satisfying all the previous
conditions. Refer to Appendix B if necessary.

4. Switch on the Level-Process Interface and the PLC.

5. Download your ladder program to the PLC.

Test and comment your ladder program. Correct the program if it does not
behave as expected.

6. Demonstrate the operation of the Level-Process Training System to your

instructor.

30 © Festo Didactic 85253-30

Job Sheet 3 – Batch Process

Batch process ladder program (no alarm, part 1).

© Festo Didactic 85253-30 31

Job Sheet 3 – Batch Process

Batch process ladder program (no alarm, part 2).

32 © Festo Didactic 85253-30

Job Sheet 3 – Batch Process

Batch process ladder program (no alarm, part 3).

7. Save and print your ladder.

Alarm Implementation

8. Modify the program of the first part of the procedures by creating a fifth state
called FAULT. The new program will work according to Figure 20 state
diagram. The system will be in State 5 (FAULT) when the alarm float switch
is triggered or when the emergency stop pushbutton is pressed. This state
actuates PLC output 5 (I:0/5) for indicating purpose. The system returns to
State 1 (Idle) when the reset pushbutton is pressed.

T9 S5 T8
(ALARM_RES) (ALARM_COND)

T5 T7
(ALARM_COND) (ALARM_COND)
T6
(ALARM_COND)
T1 T2 T3
(START_PB) (HIGH_FS) (TIMER/DN)
First
scan
S1 S2 S3 S4

T4
(LOW_CS)
Figure 20. State diagram of Job Sheet 3 (with the alarm).

© Festo Didactic 85253-30 33

Job Sheet 3 – Batch Process

9. Download your ladder program to the PLC. Test and comment your ladder
program. Correct the program if it does not behave as expected.

10. Demonstrate the operation of the Level-Process Training System to your

instructor.

Batch process ladder program (with alarm, part 1).

34 © Festo Didactic 85253-30

Job Sheet 3 – Batch Process

Batch process ladder program (with alarm, part 2).

© Festo Didactic 85253-30 35

Job Sheet 3 – Batch Process

Batch process ladder program (with alarm, part 3).

36 © Festo Didactic 85253-30

Job Sheet 3 – Batch Process

Batch process ladder program (with alarm, part 4).

11. Save and print your ladder.

12. Close RSLogix Micro and turn off the PLC.

Name: ______________________________ Date: ____________________

Instructor's approval: ______________________________________________

© Festo Didactic 85253-30 37