PRACTICAL EXERCISES MANUAL

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TABLE OF CONTENTS
7 PRACTICES MANUAL ............................................................................................................. 2
7.1 EQUIPMENT DESCRIPTION .................................................................................................... 2
7.1.1 Introduction ................................................................................................................................................ 2
7.1.2 Description ................................................................................................................................................. 3
7.2 PRACTICES .................................................................................................................................. 7
7.2.1 Practice 1: Temporization ........................................................................................................................... 7
7.2.2 Practice 2: Counting ................................................................................................................................... 9
7.2.3 Practice 3: Sequential Control .................................................................................................................. 11
7.3 REAL APPLICATION................................................................................................................ 14
7.3.1 Introduction .............................................................................................................................................. 14
7.3.2 Necessary elements .................................................................................................................................. 14
7.3.3 Application carrying-out........................................................................................................................... 14
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7 PRACTICES MANUAL

7.1 EQUIPMENT DESCRIPTION

7.1.1 Introduction

Many applications are nowadays controlled by programmable logic

controllers (PLCs). The PLC may be considered as a special purpose computer. The
reliance on these PLCs is due to their high reliability and efficiency. The PLC has
many advantages over other control systems. It is well known for its flexibility, lower
cost, operational speed, reliability and easy of programming.

The PLCE is the PLC training module designed by EDIBON. The PLCE is a
modularized PLC that depending on the requirements it can include digital and
analog inputs and outputs, switches, push buttons, potentiometers, etc. The PLCE can
also be used to work with some training modules together. These modules have been
specially developed to study the PLCE working in real applications.

The N-PLCE-CME is a training module of a mixer control system. It is

designed to demonstrate the PLCE. This module allows controlling an event
sequence. The user can develop some different programs using the PLCE software to
request the events generated by the training module.
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7.1.2 Description

The N-PLCE-CME is a training module to work with PLCE. The system is

provided with switches, push buttons and leds to simulate the commonly elements in
an automatic mixer control system. These elements simulate conditions such as
different materials, different levels of mixing, etc. These conditions are evaluated by
the PLCE in order to perform the required action.

Figure 1: N-PLCE-CME

The N-PLCE-CME is a model of an automatic mixer control system. It

includes the most common elements in this device such as an agitator, exit valves,
leds inputs and outputs, etc. Some of these elements are simulated by using switches
or push buttons and they are connected to PLC inputs.
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INPUT ELEMENT
X0 START
X1 STOP
X2 MODE
X3 LEVEL_SENSOR_1
X4 LEVEL_SENSOR_2
X5 LEVEL_SENSOR_3
X6
X7
X8
X9
XA
XB
XC
XD
XE
XF

Table 1: Inputs N-PLCE-CME

In the following lines there is a description of each input.

- START: input to begin the process.

- STOP: input to stop the process.

- MODE: input to select the mode (mode 1 or mode 2).

- LEVEL_SENSOR_1: input to indicate when the level of the mixture has

reached the level 1.

- LEVEL_SENSOR_2: input to indicate when the level of the mixture has

reached the level 2.

- LEVEL_SENSOR_3: input to indicate when the level of the mixture has

reached the level 3.
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The training module also contains other elements such as valves, conveyors
and other more elements that are controlled by the PLCE to perform the required
function of the mixer control system. These elements are directly connected to the
PLCE outputs.

OUTPUT ELEMENT
Y0 CONVEYOR_BELT_1
Y1 CONVEYOR_BELT_2
Y2 CONVEYOR_BELT_3
Y3 VALVE_1
Y4 VALVE_2
Y5 VALVE_3
Y6 AGITATOR
Y7
Y8
Y9
YA
YB
YC
YD
YE

Table 2: Outputs N-PLCE-CME

- CONVEYOR_BELT_1: output that is used to move the material 1 from the

hopper 1 to the mixing hopper.

- CONVEYOR_BELT_2: output that is used to move the material 2 from the

hopper 2 to the mixing hopper.

- CONVEYOR_BELT_3: output that is used to transport the mixture to its

destiny.

- VALVE_1: output that is used to add material 1 to the mixing hopper.

- VALVE_2: output that is used to add material 2 to the mixing hopper.

- VALVE_3: output that is used to empty the mixing hopper.

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- AGITATOR: output that is used to control the hopper agitator.

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7.2 PRACTICES

We really recommend to you to read the practices included in the PLCE

manual in order to get familiar with some basics concepts needed for the
developing of the next practices.

7.2.1 Practice 1: Temporization

7.2.1.1 Objective

The objective of this practice is to get familiar with timers. A timer is a very
useful element featured in industrial PLCs. To do this, a PLC program will be
developed to control the time during a simple process.

In this practice we will develop a program that could be used to control the
agitation process.

7.2.1.2 Necessary elements

 PLCE

 N-PLCE-CME

 PLCE connection cable

7.2.1.3 Practice carrying-out

The sequence of events necessary to control the agitator is represented in

the picture below, using a flowchart.

 The process starts turning on the agitator.

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 After that, the program verifies if the agitator has been turned on for 360
seconds.

 When this condition is met, the agitator is turned off and the program finishes.

Figure 2: Flowchart of practice 2

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7.2.2 Practice 2: Counting

7.2.2.1 Objective

The objective of this practice is to get familiar with counters. To do this, a PLC
program will be developed.

In this practice we will develop a program that counts how many times the
button “Stop” is activated. It can be useful to know how many times the system has
some error.

7.2.2.2 Necessary elements

 PLCE

 N-PLCE-CME

 PLCE connection cable

7.2.2.3 Practice carrying-out

The sequence of events necessary to count how many times the stop button
has been activated is represented in the picture below, using a flowchart.

 The process starts setting the counter equal to 0.

 After that, the program verifies if the stop button has been activated.

 If the stop button has been activated, the counter sums 1 to the previous
value.

 If not, the program waits until the stop button is activated.

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 The program finishes when the counter is equal to 50.

Figure 3: Flowchart of practice 3

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7.2.3 Practice 3: Sequential Control

7.2.3.1 Objective

The objective of this practice is to get familiar with sequential control.

Sequential control is ideal for processes that the operation mode is based on steps.
The steps will be executed in a simple order that may change as the result of some
simple decisions. To do this, a PLC program will be developed that executes a
sequence of operations to manage a call request.

In this practice we will control a simple sequence of events. This sequence is

described in the following lines. Note the hardware signals to be considered on each
step.

1. The process begins when the start button is pressed.

2. At this moment, the hopper with the solid material is opened (valve 1) and the
conveyor belt 1 is turned on.

3. When the level 2 is reached, the valve 1 is closed and the conveyor belt 1 is
turned off.

4. Then, the hopper with the liquid material is opened (valve 2) and the conveyor
belt 2 is turned on.

5. When the level 1 is reached, the valve 2 is closed, the conveyor belt 2 is turned off
and the hopper agitator is turned on.

6. A few minutes after, the first mixture is ready and the program turns off the
hopper agitator.
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7.2.3.2 Necessary elements

 PLCE

 N-PLCE-CME

 PLCE connection cable

7.2.3.3 Practice carrying-out

This sequence of events is represented in the picture below, using a

flowchart.
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Figure 4: Flowchart of practice 4

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7.3 REAL APPLICATION

7.3.1 Introduction

With the practical exercises carried out before the students have learnt the
basics about PLC programming. This chapter is designed for advanced users who
have the necessary knowledge to develop very complex programs. The development
of this application is beyond the scope of this manual. We really recommend to
advanced users to try to develop a program that controls a real application.

7.3.2 Necessary elements

 PLCE

 N-PLCE-CME

 PLCE connection

7.3.3 Application carrying-out

The program should consider the following points. Check the hardware signals
to be considered on each requirement.

1. The process begins when the start button is pressed.

2. At this moment, the hopper with the solid material is opened (valve 1) and the
conveyor belt 1 is turned on.

3. When the level 3 is reached, the valve 1 is closed and the conveyor belt 1 is
turned off.

4. Then, the hopper with the liquid material is opened (valve 2) and the conveyor
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belt 2 is turned on.

5. When the level 2 is reached, the valve 2 is closed, the conveyor belt 2 is turned off
and the hopper agitator is turned on.

6. A few minutes after, the first mixture is ready and the program turns off the
hopper agitator.

7. The hopper with the solid material is opened again (valve 1) and the conveyor belt
1 is turned on until the level 1 are reached.

8. At this moment, the hopper agitator is activated a few minutes more. Making the
mixture in two parts, the mixing will be easier.

9. When the mixture is ready, the valve 3 is opened and the conveyor belt 3 is turned
on until the mix level is down the level 3.

10.The program waits a few second more to the hopper is empty and closes the valve
3 and turns off the conveyor belt 3. At this moment, the process begins again.