PLC Training Manual_china
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Description
Siemens CPU226PLC Trainer
Training Manual (A)
Yalong Science & Technology Group Co., Ltd.
Preface Programmable controller, in brief PLC, and it is a new industrial automatic controller based on American traditional sequence controllers, microelectronic technology and computer technology in 1960s. Presently, in China, PLC is used widely in steel and iron, petroleum, chemical industry, electric power, construction materials, machinery manufacture, automobile, light industry, transportation and environmental protection. With the advancement of industrial control technologies, PLC is widely used in industrial production process and automatic control fields. To satisfy the requirements in the society, many colleges, secondary technical and vocational schools have set up the related courses and subjects. The PLC application technology is a highly practical subject, only through actual and practical operations, can students really learn the knowledge and skills. We developed a whole set of PLC trainers, including PLC controller and 6 types of training models, as well as related ladders and instructions for students to learn how to make programming. Students also can design and make ladders and programs according to teaching models. The controller is Siemens S7-200 CPU226 PLC, compact and reliable, easy to operate. Now we developed AC 3-phase motor control, automatic washing machine control, stepper motor control, traffic lighting control, 4-floor elevator control and electrical plating automatic production line control and so on. The students, through training, can learn and understand various instructions and functions, to improve programming skills and PLC application capabilities. The manual is divided into 3 parts, part 1 is to introduce S7-200 programming software, part 2 is for programming training, and part 3 is to introduce PLC application training.
Content PART 1. STEP7-MICRO/WIN32 PROGRAMMING SOFTWARE ..................................... 1 1. STEP7-MICRO/WIN32 SOFTWARE .................................................................................. 1 2. STEP7-MICRO/WIN32 BRIEF INTRODUCTION ................................................................. 4 3. PROGRAMMING AND OPERATION ....................................................................................... 8 4. STEPS .............................................................................................................................. 11 5. PRECAUTIONS ................................................................................................................. 11 PART 2. PLC BASIC INSTRUCTION AND TRAINER .................................................... 12 1. YALONG PLC TRAINER .................................................................................................. 12 2. SIEMENS S7-200 PLC ................................................................................................. 12 3. PLC BASIC INSTRUCTION TRAINING ............................................................................... 12 PART 3. PLC TRAINING .................................................................................................... 16 TRAINING 1. AUTOMATIC WASHING MACHINE CONTROL .................................................... 16 TRAINING 2. 3-PHASE MOTOR SEQUENCE CONTROL........................................................... 20 TRAINING 3. STEPPER MOTOR CONTROL ............................................................................ 23 TRAINING 4. TRAFFIC LIGHTCONTROL ............................................................................... 27 TRAINING 5. 4-FLOOR ELEVATOR CONTROL ....................................................................... 30 TRAINING 6. ELECTRICAL PLATING PRODUCTION CONTROL ............................................... 34 TRAINING 7. WATER TOWER LEVEL AUTOMATIC CONTROL ................................................. 38 TRAINING 8. AUTOMATIC FORMING MACHINE .................................................................... 41 TRAINING 9. AUTOMATIC CHARGING SYSTEM .................................................................... 44 TRAINING 10. MULTI-LIQUID AUTOMATIC BLENDING ......................................................... 47 TRAINING 11. AUTOMATIC STEEL ROLLING MACHINE......................................................... 50 TRAINING 12. MAILS ALLOCATION MACHINE ..................................................................... 54 TRAINING 13. IRON TOWER LIGHTING................................................................................ 58
Part 1. STEP7-Micro/WIN32programming software 1. STEP7-Micro/WIN32 software 1. Brief description Programming software STEP7-Micro/WIN32 Version 3.1 is suitable for S7-200 series of PLC system setting (CPU group), for programs development and real-time monitor operation; Updated Microwin3.1 SPL V3.1 functions; Toolbox provides users instruction and touch screen TP070 group software, SP1 and Toolbox software. STEP7-Micro/WIN32 software is based on Windows application software. 2. Programming software installation Programming software STEP7-Micro/WIN32 can be installed on PC(man and computer) and SIMATIC programming PG70. Installation methods are lower: (1) Installation PC486 or higher, can install Windows 95 and above operating systems, memory: 8MB and above, hard disc: 50MB and above. (2) Installation methods Click Microwin 3.1→Microwin 3.1 SPL→Toolbox→Microwin 3.11, to install. 3. Establish S7-200 CPU communication S7-200 CPU and PC communication connection is by special PC/PPL cable, or by MPI card and common cables. Take PC as the main controller, through PC/PPL cable or MPI card and or some PLC connection, for equipments communication. (1) PC/PPL communication PC/PPL supports PC, according to PPL communication protocol setting special cable, with communication modules, external braud rate setting switches and the two terminals are RS-232 and RS-485 ports. PC/PPL RS-232 terminal is connected to computer RS-232 communication port COM1 and COM2 ports, PC/PPL terminal (RS-485) is connected to S7-200 CPU communication port. (2) MPI communication MPI card provides a RS-485 terminal port, for straight and network connection, when MPI communication is established, you can make STEP7-Micro/WIN32 connections to many other equipment networks, each S7-200 can be the main controller and has each own address. Install MPI card in PC and PCL, then start installation, the setting file is stored in Windows directory, CPU and PCRS-485 ports are in cable connection. (3) Communication parameters setting The communication parameters setting include S7-200 CPU address, PC software address and PORT setting. Shown in Diagram1-1-1 is communication parameters setting dialogue block. drag monitor menu, click communication (M), to show communication parameters. The system programmer 1
local default address is 0. Remote address is according to actual PC/PPL and PLC address setting, when other communication parameters modification is needed, double click PC/PPL Cable icon, to modify setting communication parameters.
Double click
Diagram1-1-1 communication parameters setting dialogue block
4. S7-200CPU power supply The first step is to provide S7-200 CPU power supply, in Diagram1-1-2 is DC power supply and AC power supply. Before assembly and disassembly, you shall turn off power supply.
Diagram1-1-2 CPU-200 power supply
5. RS-232/PPL multi-cable connection (1) Connect RS-232/PPL RS-232 terminal (“PC”) to programming equipment communication port. (2) Connect RS-232/PPL RS-485 terminal (“PPL”) to S7-200 terminal port O or port I. (3) Diagram1-1-3 is RS232/PPL multi-cable connection DIP switch. 2
Diagram1-1-3 RS232/PPL cable connection
6. Download program (1) You can click download icon, or in command menu, click File>Download to download program. Refer to Diagram1-1-4. (2) Click OK to download programs into S7-200. If S7-200 is working, if you are reminded that the CPU will be in stop mode, click Yes to make S7-200 in STOP mode.
Diagram1-1-4 download program
S7-200 CPU working mode S7-200 modes: stop mode and operation mode. CPU panel LED status displays current operation mode. In stop mode, S7-200 will not run programs, and then you can download programs, data and CPU system setting. In operation mode, run S7-200 program. 1. S7-200 operation mode 3
If you want to start in STEP7-Micro/WIN software S7-200 mode, S7-200 mode switch setting is TERM or RUN, when S7-200 is in RUN mode, run program. 1. Click operation icon or select PLC>RUN. 2. Click Yes to switch mode. When S7-200 is working, the CPU will run program to make Q0.0 LED indicator light ON and OFF.
Click Diagram1-1-5 S7-200 jump operation mode
You can select Debug>Program Status to monitor program, STEP7-Micro/WIN to display running result, if you want to stop running program, you can click STOP icon or select menu command PLC>STOP to make S7-200 in STOP mode. 2. Power supply budget: The S7-200 CPU has an internal power supply, to provide 24V DC power supply for CPU self\extended modules and other equipments. S7-200 provides all 5V DC logic power supplies for all extended modules in the system, you shall make your system configured with CPU 5V power supply, for further modules, if your requirements are higher than CPU power supply capacities, then you have to clear off some modules or select a better power supply. S7-200 CPU also provides 24V DCsensor power supply, and the 24VDC can be power supply for input points, extended modules, relay coils or other equipments, if the equipment power consumption exceeds sensor power supply budget, you have to prepare another external 24VDC power supply power supply for the system.
2. STEP7-Micro/WIN32 brief introduction Programming software step 7-micro/win32 basic function is to help users to complete PLC application programs development, in PLC parameters setting, encryption and monitor functions. STEP7-Micro/WIN32 programming software, in off-line mode, can be used for program input, edit, and translation functions. Programming software, in on-line modes (PLC and programming PC are connected), the upload, download, communication test and real-time monitor functions are available.
STEP7-Micro/WIN32 window group and functions 4
STEP7-Micro/WIN32 window main menu includes file, edit, monitor, PLC, debugging, tools, windows help, line is tools bar shortcut button, other is window information display, as shown in Diagram 1-2-1. Window information display is for program data display, browse bar, instruction tree and output windows display. When in monitor menus, tools bar, browse bar and instruction tree can be shown in windows; you can select tools bar output windows, to display output windows block. Under the output windows, is status bar, to show STEP7-Micro/WIN32 status information.
Diagram1-2-1 STEP7-Micro/WIN32window group
View -- common programming buttons: View-- program block, icon, table, status diagram, data block, system block, intercross reference and communication button. Tools-- instruction guide, TD200 guide, position control guide, EM253 control panel and demodulator guide button; Instruction tree-- all project objects in current program editor (LAD, FBD or STL), an instruction tree window. You can operate on all open projects and objects in the branches of the project. Status diagram-- allow program input, output or variables input, to monitor its status. Output window-- output information during program or instruction translation. When lists of program errors are output, it will display corresponding program networks in the program editor window 5
automatically. Status bar-- in Micro/WIN32 operation, the operation status information. Program editor--project editor (LAD, FBN or STL), local variables table and program windows. If needed, you can extend window, overlay local variables table. Click the labels on the bottom of the program editor window, and can move among main programs, subprograms and interrupt programs. Local variables table-- definite and assign local variables (variables in subprograms and interrupt programs).
Menu The common or tools shortcut buttons (as shown in Diagram1-2-2). You can select items in the tools bar.
Diagram1-2-2 tools bar compile
upload
Sort Descending
Options Undo
Compile All
Dowenload Sort Descending
Diagram1-2-3 standard tools bar Toggles Network Comment Toggle Bookmark Delete Network
Inser Network Toggles Dou Comments
Toggle Bookmark Diagram1-2-4 common tools bar
Chart Status
Singel Read Unforce All
Stop
Run Program Status
Unforce
Write All Force Diagram1-2-5 debugging tools bar
6
Contact-F4
Line Operation
Box-F9
Coil-F6
Diagram1-2-6 LAD instruction tools bar
Allow you to use mouse or keyboard to run instructions. And you can select “tools” menu, modify according to your requirements. 1. Main menu and submenu status information (1) File Create, open, close, save, save as, import, export, upload, download, page setting, print and preview. (2) Edit Cancel, cut, paste, all select, insert, delete, search, replace, for program modification operation. (3) View Monitor menu functions: ① You can select program datadisplay window to display various program editors. Such as statement table (STL), ladder (LAD), function Diagram (FBD); ② You can make data block, icon table setting; ③ Make setting on system block intersection, communication parameters; ④ Tools bar can be used to select browse bar, instruction tree and output windows; ⑤ Zoom in/out; ⑥ Program block properties setting. (4) PLC PLC menu is used to establish PLC on-line communication, such as to use software to change PLC work mode, to edit users’ programs, to clear PLC programs and reset power supply, display PLC information and make PLC setting. (5) Debug Debugg menu has items such as on-line dynamic debugging, single scan, multiply scans, and program status. Select “submenu” and monitor menu zoom in/out function. (6) Tools Tools menu has a complicate instruction guide (PID, NETR, NETW, HSC instructions) and TD200 setting guide, and TP070 (touch screen) setting. (7) Windows Windows menu is used to select window display and display format (ladder, statement table and various tables). (8) Help Help menu can provide S7-200 instruction system and programming software information, has 7
on-line help, search, access, download functions. 2. Tools bar Tools bar is in mouse operation, to transform common STEP7-Micro/WIN32 operation in button form setting into tools bar form setting. You can use “Tool bars” in “View” menu to display or hide 4 tools bar: Standard, Debug, common and Instruction tools bars. 3. Navigation Bar Navigation Bar is a programming button to switch window functions quickly. In the bar, “Navigation Bar” in “View”menu is used to select whther it is open. Navigation Bar incorporates program block (Program Block), Symbol Table, Status Chart, Data Block, System Block, Cross Reference, and Communication Icon. Click a button, and then the main window is switched. All operations in Navigation Bar can be done in “Instruction Tree” window or “View” menu. 4. Instruction tree Instruction tree is a programming instruction tree table. You can use “(Instruction Tree)” in “View”menu to select, shortcuts are in programming and PLC instructions. 5. Output window Output window is used to display program translation results, such as program block and block sizes, errors and codes etc. In addition, from Navigation Bar, click system block and communication button, you can set PLC parameters. Such as setting communication braud rate, PLC power supply data, memory range, setting input filtering parameters setting, passwork setting and so on.
3, Programming and operation (1) Project creation (users program) 1, Open created project file Open created project: (1) Open file menu, to current project, and open file; (2) From the file name opened, in current project file list, select. Or in Windows source manager, tofind a proper directory, project file is avaible in extended file name. 2, Create a new project (file) Create a new project: (1) Click “create” shortcut button; (2) click “create” button to create a new file; (3) Click program block icon, to create a new STEP7-Micro/WIN32 project. 3, Confirm CPU types Open a project, before writing a program, you can select PLC types. You can confirm CPU types. ①in instruction tree, right click project 1(CPU), in pop up dialogue block, left click types (T)…pop up PLC typesdialogue block, select PLC type, and confirm;②use PLC menu to select types (T)…, pop up PLC type dialogue block, then select a correct CPU type. 8
(2) Ladder editor 1, Ladder fundamental The current can flow through a switch, and the coil represents current charged relay or output; instruction box represents instruction box functions when current flows. 2, Ladder layout principle The network shall start from contacts, coil or instruction box.. Attention: in each users program, 1 coil or instruction box only can be used for one time, more coils in serial connection are not allowed.
(3) Ladder input instruction (programming elements) 1, Enter ladder (LAD) editor In drag monitor menu, click ladder (L), to enter ladder edit status, and click program edit window display ladder edit icon. 2, Programming elements inputmethods Programming elements are coils, contacts, and cables. It is normaly is sequence input, you can put programming elements in the position of the cursors (input instruction), or you can move cursor to any position to input programming elements.
网络1 Network Title(Single row) Network1网络题目（单行）
Network2 网络2
Diagram1-3-1ladder instruction
The programming elements input can be done by double click on instruction tree, drag and click tools bar shortcut keys F4 (contacts), F6(coil), F9(instruction box), or double clilck instruction tree to select input programming software. The tools bar has 7 programming keys, the first four are to connect cables, and the latter 3 are contacts, coil, and instruction box. The programming elements input is in program edit window, move cursor onto the elements, then input programming elements. The programming elements input is two methods. ①By mouse and left key to input programming elements, for example, input contacts elements, move cursor into programming area, left key click tools bar contacts button, to show a menu, use mouse to click the programming elements, push return key, input programming elements, then click programming 9
elements???, input number; ②By function keys (F4, F6, F9), shift key and return key to place programming elements. For example, to place output contacts, push F6 key, pop up a menu, in the menu, select programming elements (By shift keys to search for programming elements), push return key, the programming elements will he highlighted, push return key again, cursor will select elements???, input number, push return key to confirm, then by shift key, to move cursor to next stage, input a new program. When input address, icon is out of range or and instruction types are not compatible, a read curve will be shown on bottom. 3, Ladder function instruction input By instruction tree and double click, input function instruction. 4, Program edit and parameters setting Cut, copy, paste, insert and delete, character string replace, search. 5, Program translation, upload and download. (1) Translation When users program is edited, in CPU menu or tools bar, click translation shortcut button to carryout program translation, when translation is finished, in output window, translation results are display, where errors can be shown, you can modify the programs according to prompts, then restart translation, till no errors in translation. (2) Download When translation is finished, click download shortcut button in standard tools bar or drag filemenu, select download, pop up download dialogue block, select program block, data block, system block to download, push confirm button, to download the selected content into PLC memory. (3) Upload Upload instruction function is tp send PLC programs or data into editor (PC). To click upload shortcut keys in the standard tools bar or drag file menu select upload, pop up upload dialogue block. Select program block, data block, system block to upload, in program display window upload PLC internal program and data.
(4) Program monitor, operation, debugging 1, Program operation When PLC working mode is in TERM or RUN status, run STEP7-Micro/WIN32 menu command or click shortcut button to make software setting in CPU working mode. 2, Program monitor The program editor can monitor programrun process and all elements status and data during PLC operation. Ladder monitor function: drag debugging menu, select program status, close contacts. In RUN status, it can carry out timing and counting process operation, in each cycle, it can output refreshed status of each element, and it can dynamically display timing, counter current values, in order to observe program on-line operation dynamically, shown in Diagram 1-3-2.
10
Network Title(Single row) Network1 网络1 网络题目（单行）
网络2 Network2
Diagram1-3-2ladder operationstatus monitor
3, Dynamic debugging Combined with program monitor operation dynamic display, and analysis on program operation results, as well as factors effecting program operation, then you can exit program operation and monitor status, in STOP status, you can carry out program modification, edit, translation, download, monitor operation, till you obtain the corrent final results. 4, Translation language SIMATIC instruction and IEC1131-3 instruction select methods, drag tools menu, in pop up dialogue block, you can select the instruction system. 5, Other functions STEP7-Micro/WIN32 programming software has PID (close-loop control), HSC (high-speed counting), NETR, NETW (network communication) and TD200 for guide function.
4, Steps 1. Do electrical circuit wiring. 2. Input STEP7-Micro/WIN32, and translate. 3. Download translated program from PC (STEP7-Micro/WIN32 programming software) to PLC controller. 4. In PC monitor status, start program debugging. 5. Run program and record.
5, Precautions 1. Turn off power supply before wiring. 2. When circuit is connected, checked by teacher, then you can turn on power supply. 3. All communication cable shall be off. 11
Part 2. PLC basic instruction and trainer 1. Yalong PLC training Trainer It is composed of Yalong PLC controller and 13 modules. 1. PLC controller: Siemens S7-200 CPU226CN controller, 12V/1A DC power supply. PLC I/O ports, and knob switches. 2. 13 modules: (1) Automatic washing machine control
(8) Automatic forming machine
(2) 3-phase AC asynchronous motor control
(9) Automatic charging system
(3) Stepper motor control
(10) Multi-liquid automatic blending
(4) Traffic lightcontrol
(11) Automatic steel rolling machine
(5) Elevator control
(12) Mails allocator
(6) Electrical plating production linecontrol
(13) Iron tower lighting
(7) Water tower level automaticcontrol 3. Controller has wiring sockets. Use cables to connect S7-200 controller.
2.SIEMENS S7-200 PLC brief introduction Table 2-2-1 SIEMENS S7-200 PLC brief introduction Digital input
24 input
Digital output Digital I/O mapping zone Analogy I/O maping zone Allowable maximum extended modules Allowable maximum enable modules single-phase counter 2-phase counter Pulse output Timer quantity 1ms 10ms 100ms Counter quantity Time interrupt Analogy potentiometer
16 output 256 (128 input/128 output) 64(32 input/32 output) 7 modules 7 modules 6, 30KHz 4, 20KHz 2 20KHz 256 4 16 236 256 (super capacitor and batteries standby) 2pcs 1ms resolution 2pcs 8-bit resolution
3. PLC basic instruction training 1. Timer instruction
12
Networkl I0.0
T37 IN
TON
+10- PT
Network2 T37
Q0.0
(
)
Diagram2-3-1 timer applicationladder
As shown in Diagram 2-3-1, turn on delay timer, timer T37 will start timing, the normaly open contacts are turned on, drive Q0.0 output; when I0.0 is off, T37 resets, when current value clears, status bit will be cleared, to recover to initial status. If I0.0 is ON, and is OFF before the time is over, then T37 will reset, and Q0.0 will not output. 2. Counter instruction Networkl
C1
I0.0 CD
CTD
I0. I0.
I0.1
3
3 2
2 1
CD
0
C
+3- PV
Q0.
Diagram2-3-2counter instruction applicationladder andtime sequenceDiagram
When I0.1 is OFF, substractor C1 is changed from 3 to 0. 1、
Instruction program 网络1 Network1 I0.0
I0.1
M0.0 （
）
M0.0
Network2 网络2 I0.2
I0.4
Q0.1 （
）
0.3
Diagram 2-3-3 Bit operation instruction application ladder
13
Ladder logic relation: Network 1 M0.0 = (I0.0+M0.0) I0.1 Network 2 Q0.1 = (I0.2+I0.3) I0.4 Network 1: when input I0.0 is set (I0.0=1), input terminal I0.1 is clear (I0.1= 0→ I0.1 =1 status), coil M0.0 is on (internal standard M0.0 is 1), normally open contacts will close, to make I0.0 reset voil (I0.0=0), M0.0 coil is powered. M0.0 coil is normally contact, I0.1 is ON (I0.1=1→ I0.1 =0), M0.0 self-lock circuit is open, coil off. Network 2: when input I0.2 or I0.3 is set, when I0.4 is clear, and output coil Q0.1 on. 2、 Sequence control instruction: When I0.0 input is on, start S0.0, run program, first step, output Q0.0 is 1(ON red light) Q0.1 is 0 (OFF green light), start timer T37, 2S later, jog jump instruction, S0.1 is 1, S0.0 is 0, program enter the second step, output Q0.1 is 1 (green light ON), Q0.0 is 0 (red light OFF), in a same time, start timer T38, 2s later, jog instruction, S0.0 is 1, S0.1 is 0, program enter the first step, cycle in this way. 网 络 16 Network16
网络1
0 . 0
Network1 I0.0 （
S0.1 SCR
）
0 . 0
网Network2 络2
S
网Network7 络7
SCR
SM0..0
Q0.0
网Network3 络3 SM0..0
Q0.0 S ） Q0.1
（
S ） T37 TON
IN 网Network8 络8 T38
+20- PT T37
（ SCRT） 网Network9 络9
1 . 0
网Network4 络4
+20- PT 0 . 0
IN
（
（ SCRE）
（ SCRT） 网 络5 Network5 （ SCRE）
Diagram2-3-4 sequence control instruction applicationladder
14
（
R ） Q0.1
（
S ） T38 TON
3、
jump instruction
Netork4 4 （JMP）
I0.3
Network 4 //I0.3 is on, jump to LBL 4, run
Netork5
//Network 5
M10.0
Q0.0 （ ） Q0.2
Network 5 jumped
Q0.1
LD
I0.3
JMP
4
Network 5 LD M10.0
Does not run
=Q0.0 AN Q0.2
（ ）
=Q0.1
Netork16
4
//LBL 4, jump program entry
Network16 LBL
LBL
Network17
Diagram2-3-5jump instruction applicationladder
In Network 4, JUMP makes the program jump over branches (Network 5-15), to LBL 4. “N” is as same as the “N” in LBL command. In the scanning periods during jump, the program stops, and the status of each out elements in the program never changes, and does not response to any changes in situations.
15
Part 3. PLC application training Training 1. Automatic washing machine control 1, Purposes 1, Learn programmer basic operation and programmer input, check and operation. 2, Learn PLC automatic washing machine control fundamental and I/O port connection, PLC programming and debugging operation. 3, Learn I/O port distribution andI/O port wiringmethods. 4, Learn PLC programming language.
2, components 1, Yalong PLC- controller. 2, Yalong PLC- automatic washing machine control. 3, computer or programmer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental Automatic washing machine working modes: (1) Push start button, water supply solenoid valve open, water supply indicator light ON. (2) Push upper limit button, water supply indicator light OFF. (3) A few seconds later, drain light is ON, drying tank light will be ON and OFF. (4) Push limit button, drain light OFF, water supply light ON. (5) Repeat (1) - (4) process (6) When you push limit button for the third time, buzzer light is ON, 5s later, it is OFF, the whole process will be fnihsed. (7) In operation process, push stop button to finish process. (8) Manual drain button is an independent operation command, push manual drain, and push limit button.
16
4, I/O Input
Table 3-1-1 automatic washing machine I/O Output
I0.0
Start button
Q0.0
Water supply indicator light
I0.1
Stop button
Q0.1
Drain indicator light
I0.2
Upper limit button
Q0.2
Forward blend indicator light
I0.3
Lower limit button
Q0.3
Back blend indicator light
I0.4
Manual drain button
Q0.4
Drying indicator light
Q0.5
Buzzer indicator light
5, I/O circuit Water supply indicator light
Start
I0.0
Q0.0 Drsin indication light
Stop
I0.1
Q0.1 For ward blend indicator light
Q0.2
Upper limit
I0.2
Back blend indicator light
Q0.3
Lower limit
Drying indicator light
I0.3
Q0.4 Buzzer indication light
Drain
I0.4 - + 24V
1M 2M
Q0.5
1L
+ -
2L
CPU 226 CN
12V
FU
Diagram 3-1-1 automatic washing machine controlI/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-13-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.7(2.4, 2.5, 2.6 are off). 5, Training operations are according to working modes operation.
7, Circuit Connect automatic washing machine control circuit according to Diagram 3-1-2.
8, Questions 1, Washing machine rotates forward, back time are 10s, cycle for 5 times.
17
PLC Panel
YL-PC Automatic Washing machine
Drain
OUT
Water spply
Forward blend
Dry
Drain
Back blend
Buzzer
1L
2
IN upplimit Lowerlimit
Q0.0
Q0.1
Q0.2
Q0.3
Q0.4
COM
Start
Stop
COM
- 12V + COM
I0.0
1M
COM
I0.1
Diagram 3-1-2 automatic washing machine circuit
19
I0.2
2M
I0.3
M
L+
I0.4
Q0.5
Training 2, 3-phase motor sequence control 1, Purposes 1, Learn 3-phase motor sequence control fundamental. 2, Learn ladder programming methods and learn instruction programs. 3, Learn I/O port distribution andI/O port wiringmethods. 4, Understand programmer basic operation and programmer input, modification, check and operation.
2, Cmponents 1, Yalong PLC- controller. 2, Yalong PLC3-phaseasynchronous motor sequence control. 3, Computer or programmer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental 3-phase motor sequence control: (1) Turn on forward switch SB1, then push SB1, motor will Y-△ start, Y operation, 5s later, it starts △ operation. (2) Turn on stop switch SB3, then push SB3, motor will stops. (3) Turn on back switch SB2, then push SB2, motor will Y-△ start, Y operation, 5s later, it starts △ operation. When it moves forward, it cannot move back; when it moves back, it cannot move forward. Positive back switching is only available by stop. (4) Turn on stop switch SB3, then push SB3, motor stops.
4, I/O Table 3-2-1 Input
3-phase motor sequence control I/O Output
I0.0
Forward start switch
Q0.0
KM1
I0.1
Back start switch
Q0.1
KM2
I0.2
Stop switch
Q0.2
KM△
Q0.3
KMY
20
5, I/O circuit
SB1
SB2
SB3
KM1 I0.0
Q0.0
I0.1
Q0.1
KM2
KM Q0.2
I0.2 1M
24V
Q0.3
2M
KMY
CPU 226 CN 1L
12V
FU
Diagram 3-2-13-phase motor sequence controlI/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-13-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.6 (2.4, 2.5, 2.7 are off). 5, Operation and observe.
7, Circuit Connect 3-phase motor sequence control circuit shown in Diagram 3-2-2.
8, Questions 1, Rrequirements: forward start operation for 30s, then stop for 2s, start back operation for 30s, then stop for 2s, repeat.
21
PLC Panel
YL-PC Motor Control KM2
KMΔ
KMY
0 . 0
OUT KM1
Q0.1
1L
Q0.2
Q0.3
COM IN SB1 SB2 SB3
COM
- 12V + COM
1M
I0.0
Diagram 3-2-23-phase motor sequence control circuit
22
COM
I0.1
2M
I0.2
M
L+
Training 3, Stepper motor control 1, Purposes 1, Learn stepper motor fundamental. 2, Understand how to use stepper ladder instruction programming methods. 3, Understand ladder programming methods and learn instruction programming methods. 4, Learn I/O port distribution and I/O port wiring. 5, Learn programmer basic operation and programmer input, check, modification and operation.
2, Components 1, Yalong PLC- controller. 2, Yalong PLC- stepper motor demonstration board. 3, Computer or programmer. 4,Safe cables. 5, PLC serial communication cable.
3, Fundamental 1, Stepper motor control requirements are following: The stepper motor control mode is in 4-phase, 4-step control, each step is 15° rotation, each cycle, 24 steps. When motor is in forward rotation, the power supply time sequence: DC
CB
BA
AD
When the motor is in back rotation, the power supply time sequence: CD AB DA BC
2, Stepper motor has some switches, the functions are following: (1) Start/stop switch--control stepper motor start or stop (2) Forward /back switch--control stepper motor forward or back (3) Speed switch--control stepper motor continuous operation and jog operation, S Stage is jog operation. N3 Stage is high-speed operation. N2 Stage is middle-speed operation. N1 Stage is low-speed operation. (4) Jog button switch, push jog button 1 time, motor rotates for one step.
4. I/O
23
I0.0 I0.1 I0.2 I0.3 I0.5 I0.6 I0.7
Table 3-3-1 stepper motor I/O Input Output Forward/back button Q1.0 Speed 3 stage Q1.1 Speed 2 stage Q1.2 Speed 1 stage Q1.3 Manual button Start/stop button Jog button
A phase B phase C phase D phase
5. I/O circuit Forward and Back Rotation
A I0.0
N3
Q1.0 B
I0.1
N2
Q1.1 C
I0.2
N1
Q1.2 D
I0.3 Q1.3
Manul Start
I0.5 2L
I0.6
3L
S
+
-
12V
FU
I0.7
- + 24V
CPU 226 CN 1M 2M
Diagram 3-3-1 stepper motor I/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-13-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.6, 2.7(2.4, 2.5 are off). 5, Training operation: (1) Make forward /back switch setting is “forward”. (2) Select speed stage N1, N2 and N3, make start/stop switch is in “start”, observe how the motor works. Push stop button, to stop the motor.
24
(3) Make forward /back switchsetting is “back ”, repeat (2) operation . (4) Select S stage, enter manual jog mode, start/stop switch setting is in “start”, push jog button 1 time, motor will rotate for a step. The start/stop switch setting is in “stop”, make stepper motor to exit the work status.
7, Circuit Connect stepper motor control circuit according to diagram 3-3-2.
8, Questions (1) How to change stepper motor rotation speed. (2) Make programs to make stepper motor forward 3.5 circles, back 3 circles.
25
PLC Panel
YL-PC Stepping Motor
N3
IN N2 N1
S
Forward Start Manul Stop and bach COM rotation
OUT A
B
C
D
Q1.0
2L
Q1.1
Q1.2
Q1.3
3L
COM
COM
I0.0
Diagram 3-3-2
1M
COM
I0.1
stepper motor control circuit
26
I0.2
2M
M
I0.3
L+
I0.5
-
I0.6
12V +
I0.7
Training 4, traffic lightcontrol 1, Purposes 1, Learn traffic light fundamental and operation methods. 2, Learn PLC control PLC I/O connection methods. 3, Learn ladder programming methods and understand instruction programming methods. 4, Larn programmer basic operation and programmer input, check, modification and operation operation.
2, Components 1, Yalong PLC- controller. 2, Yalong PLC-traffic lightcontrol. 3, Programmer or computer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental Traffic light control: (1) The start andstop switch S1, S2, are used to control system “start” and “stop”. S3 is a shielded traffic light. (2) Traffic light display. When east & west red light is ON, south & north green light is ON, when green light ON time is finished, the green light flashes for 3 times, each 1s, then the yellow light is ON for 2s, when the south & north yellow light is OFF, east & west green light is ON, south & north red light is ON, when east & west green light is ON, when the ON time is finished, green light flashes for 3 times, each 1s, then the yellow light is ON for 2s, when east & west yellow light is OFF, the east & west red light is ON, and south & north green light is ON……cycle and cycle in this way.
4, I/O Table 3-4-1traffic lightcontrol I/O input I0.0 I0.1 I0.2
Start witch Stop sitch Shielded switch
Q0.0 Q0.1 Q0.2 Q0.3 Q0.4 Q0.5
5, I/O circuit 27
output east & westred light east & westgreen light east & westyellow light south & northred light south & northgreen light south & northyellow light
East and west red light
S1
I0.0
S2
I0.1
S3
I0.2
Q0.0 East and west green light Q0.1 East and west yellow light Q0.2 South and north red light Q0.3 South and north green light
1M 2M
24V
Q0.4 South and north yellow light Q0.5 L L 2 1 12V
FU
CPU 226 CN Diagram 3-4-1traffic lightcontrolI/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-4-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.5 (2.4, 2.6, 2.7 are off). 5, Training operation process: (1) Turn on S1, observe traffic light change. (2) Turn on shielded switch S3, observe light change, down S3, observe light change. (3) Turn on stop switch S2, observe light change, down S2, and observe light change. (4) Compare switch S2 and S3. S2 makes light OFF, S3 makes light temporarily OFF.
7, Circuit Connect traffic light control circuit according to Diagram 3-4-2.
8, Questions Requirements: traffic lightcontrol system 7:00~22:00, it works according to training requirements, 22:00~7:00, it changes direction, cycles (in program debugging, time adjustment is 7:00~22:00, 5 min, 22:00~7:00, 2 min). try to modify control program and debug.
28
PLC Panel
YL-PC Traffic Automatic and Manul coutrol OUT
S1
IN S2 S3
green yellow East West
1L
red
COM
Q0.0
Q0.1
Q0.2
2L
Q0.3
Q0.4
Q0.5
COM green yellow South North
red
COM
1M I0.0
Diagram 3-4-2 traffic lightcontrol circuit
29
COM I0.1
2M I0.2
M
L+
- 12V +
Training 5, 4-floor elevator control 1, Purposes 1, Learn elevator fundamental. 2, Learn multi-input, multi-output, logic relation complicate program control. 3, Learn ladder programming methods and understand instruction programming methods. 4, Learn programmer basic operation and programmer input, check, modification and operation.
2, Components 1, Yalong PLC- controller. 2, Yalong 4-floor elevator control. 3, Programmer or computer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental 1, Elevator input signals and meaning: (1) Position signals Position signalsare from sensor SQ1~SQ4. Normally are OFF, when elevator arrives, it is ON. (2) Instruction signals The instruction signals are “1 to 4” (K7~K10), composed of 4 instruction buttons. Push a button, the elevator will move to the corresponding floor. (3) Calling signals There are 6 calling signals, composed of K1~K6 calling buttons. Push the calling button, the elevator will stop. For example, push K3, the passengers on the second floor want to move upward, push K4, then the passengers want to move downward. 2, Elevator output signals and meanings (1) Operation direction signals The operation direction signals are composed of arrow indicator lights, to display elevator movement direction. (2) Instruction register signals Instruction register signals are composed of L11~L14 indicator lights, the corresponding instruction signals are received (registered). When instruction is run, signals are off. For example, when the elevator is on the second floor, push “3”, L12 is ON, and the signals are received. The elevator will move upward to the third floor and stop, then L12 OFF. (3) Calling register signals There are 6 calling register signals, composed of L1~L6 indicator lights, similar to the instruction register signals above. (4) Floor indication signals 30
The signals are the floor positions, composed of 7-segment numberic display, LEDa~LEDg. 3, Analogy elevator operation principle (1) Receive and register all instruction signals, calling signals, register and output register signals. (2) According to registered signals, judge whether elevator is moving upward or downward. For example, when the elevator in the second floor, instruction is for first floor, then it will move downward; if instruction is for forth floor, it will move upward. (3) When the elevator receives signals, then it will decide its direction firstly. For example, when the elevator is in third floor, you can input second floor instruction signal, forth floor instruction signal, first floor instruction signal. Otherwise, when the elevator moves downward to second floor→upward to the forth floor→downward to the first floor; in a same direction, the elevator will move downward to the second floor→downward to the first floor →upward to the forth floor. Obviously, in the second mode, the travel distance is less, so the efficiency is higher. (4) Same direction stop function. For example, when elevator is in first floor, instruction is floor 4, it moves upward, when floor 3 calling signal comes, if it upward (K5), when elevator arrives floor 3, it stops in floor 3; if calling signal is downward (K4), it cannot stop, and it will return to floor 3 and stop.
4, I/O Table 3-5-1 4-floor elevator control I/O input I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7 I1.0 I1.1 I1.2 I1.3 I1.4 I1.5
output 1-floor position switch SQ1 2-floor position switch SQ2 3-floor position switch SQ3 4-floor position switch SQ4 1-floor instruction switch K10 2-floor instruction switch K9 3-floor instruction switch K8 4-floor instruction switch K7 1-floor upward button K1 2-floor upward button K3 3-floor upward button K5 2-floor downward button K2 3-floor downward buttonK4 4-floor downward buttonK6
31
Q0.0
Upward indication
Q0.1
Downward indication
Q0.2
Upward drive
Q0.3
Downward drive
Q0.4
1-floor instruction register
Q0.5
2-floor instruction register
Q0.6
3-floor instruction register
Q0.7
4-floor instruction register
Q1.0
1-floor upward calling register
Q1.1
2-floor upward calling register
Q1.2
3-floor upward calling register
Q1.3
2-floor downward calling register
Q1.4
3-floor downward calling register
Q1.5
4-floor downward calling register
Q1.6 Q1.7
Door close Door open
5, I/O circuit
1-floor position switch SQ1 2-floor position switch SQ2 3-floor position switch SQ3 4-floor position switch SQ4
1-floor instruction switch K10 2-floor instruction switch K9
SQ1 SQ2
I0.2 SQ4 I0.3 K10
4-floor instruction switch K7
K7
3-floor upward button K5 2-floor downward button K2 3-floor downward buttonK4 4-floor downward buttonK6
I0.4
K9 K8
2-floor upward button K3
I0.1
SQ3
3-floor instruction switch K8
1-floor upward button K1
I0.0
I0.5 I0.6 I0.7
K1
I1.0
K3
I1.1
K5
I1.2
K2
I1.3
K4
Q0.0
Upward indication
Q0.1
Downward indication
Q0.2
M
Upward drive
Q0.3
M
Downward drive
Q0.4
1-floor instruction register
Q0.5
2-floor instruction register
Q0.6
3-floor instruction register
Q0.7
4-floor instruction register
Q1.0
1-floor upward calling register
Q1.1
2-floor upward calling register
Q1.2
3-floor upward calling register
Q1.3
2-floor downward calling register
Q1.4
3-floor downward calling register
Q1.5
4-floor downward calling register
Q1.6
Door close
Q1.7
Door open
I1.4 K6 I1.5
1L
1M 2M
24V
2L CPU 226 CN
12V
FU
3L
Diagram 3-5-1 4-floor elevator control I/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-5-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert the other end to 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4,Turn on 2.5,2.7(2.4,2.6 不 turn on ). 5, According to fundamentalworking modes operation, observe results.
32
YL-PC 4-Floor Elevator
PLC Panel
OUT Y0
Y1
Y2
Y3
Y4
Y5
1L Y6
Y7
Y16
Y17
12V Y10 Y11 Y12 Y13 Y14 Y15
0V
Q0.0
Q0.1
Q0.2
Q0.3
2L
Q0.4
Q0.5
Q0.6
Q0.7
Q1.0
Q1.1
Q1.2
Q1.3
Q1.4
3L
Q1.5
Q1.6
Q1.7
-
COM
X0
X1
X2
X3
X4
X5
X6
X10
X11
X12
X13
X14
X15
COM
X7
1M
COM
M
I0.0
I0.1
I0.2
I0.3
I0.4
I0.5
I1.0
I1.1
I1.2
I1.3
I1.4
I1.5
Diagram 3-5-24-floor elevator control circuit
33
2M
12V +
L+
I0.6
I0.7
Training 6, Electrical plating production line control 1, Purposes 1, Learn electrical plating production linesequence controlprocess. 2, Learn I/O distribution and wiring. 3, Learn ladder programming methods and understand instruction programming methods. 4, Learn programmer basic operation and programmer input, check, modification and operation.
2, Components 1, Yalong PLC- controller. 2, Yalong electrical plating production line control. 3, Programmer or computer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental 1, Process: Upper limit
XK1
XK2
XK3
No.1
No.2
No.3
Left limit
Lower limit Origin
Diagram 3-6-1electrical plating production linecontrol work process
On the leftside of the electrical plating production line, insert the workpiece and send automatic start signal, and it will rise and start automatic movement. Then it stops on the position for a period required, and drops automatically. Each time when it stops, it will stop for a period, then drops automatically, to finish each procedure on the production line, then it will return to original position automatically for workpiece insertion again. 2,
Work flow chart is following:
Origin: when it is in the initial status, hook is in lower limit position. Automatic process:start→hook upward→upper limit travel switch closes→rightward to No. 1→ xk1 travel switch closes→hook drops into No. 1→lower limit travel switch closes→electrical plating delay→hook upward…….from No. 3, hook moves upward, leftward to right limit position, and hook drops to lower limit position (origin). Continuous mode: when hook returns to origin, delay for a period, it will automaticcally move 34
upward, rightward, cycle and cycle. When you push “stop” button, it will stop immediately, and it will stop when it return. Single cycle: from origin, push startbutton, it will operate for a cycle, then stop in origin. It is needed to repeat for a second cycle, you shall push start button. when you push “stop” button, it immediately stops, push “start” button, it continues. Jog: push start button, it will jog each time.
4, I/O Table 3-6-1electrical plating production linecontrol I/O I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7 I1.0 I1.1 I1.2 I1.3
input Upper limit travel switch Lower limit travel switch Left limit XK1 travel switch XK2 travel switch XK3 travel switch Origin switch Continuous mode switch Start button Stop button Stepper button Single cycle button
output Q0.0 Q0.1 Q0.3 Q0.4 Q0.7
Rise Drop Rightward Leftward Origin
5, I/O circuit Upper limit travel switch Lower limit travel switch Left limit
I0.0 I0.1 I0.2
XK1
Rise
Q0.0
Drop
Q0.1
I0.3
XK2
Rightward
Q0.3
I0.4
XK3
Leftward
I0.5
Origin switch Continuous mode switch
Q0.4
I0.6
Origin
Q0.7
I0.7
Start button
I1.0 Stop button
Stepper button Single cycle button
24V
1L 2L
I1.1 I1.2
12V
FU
I1.3 1M 2M
CPU 226 CN
Diagram 3-6-1electrical plating production linecontrolI/O circuit
35
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-6-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.5, 2.6 (2.7, 2.8 are off). 5, Process: (1) Push “origin” switch, make it in initial position, then origin indicator light is ON. (2) Push “continuous work” switch, thenpush “start” button, make it continuously work, observe equipment work process. Push stop button, observe equipment how to stop . (3) Push “single cycle”switch, select single cycleworking modes, push “start”button, a cycle later, it stops in origin, in work process, push “stop” button, observe whether it can stop immediately, then push “start” button, see whether it continues. (4) Push “jog” switch, select jog working modes. (5) In “continuous work”, “single cycle” and “jog”, push “origin” button, it will return to origin.
7, Circuit Connect electrical plating production line control circuit according to Diagram 3-6-2.
36
PLC Panel
YL-PCelectrical plating production linecontrol OUT COM
IN
1L
Rise Rightward
Q0.0
Q0.1
Q0.2
Q0.3 2L
Q0.4
L+
- 12V +
Q0.7
Drop Leftward Origin
Continuous Single cycle Stepper mode switch button button
Origin switch
Start
Stop
Upper limit Lower limit Left limit
1
2
3
COM
I0.0
I1.0
1M
2M
I0.1
I0.2
I0.3
I1.1
I1.2
I1.3
Diagram 3-6-2 electrical plating production line control circuit
37
COM
M
I0.4
I0.5
I0.6
I0.7
Training 7, Water tower level automatic control 1, Purposes 1, Learn water tower level automatic control fundamental. 2, Learn ladder programming methods and instruction programming methods. 3, Learn programmer basic operation and programmer input, check, modification and operation.
2, Components 1, Yalong PLC controller. 2, Yalong PLC water tower level automatic control. 3, Computer or programmer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental Water tower level working modes: When water tank level is lower than the lower limit level (S4 is ON), the solenoid valve Y opens, S4 is OFF, and level is higher than lower limit level. When water tank level is higher than the upper limit level (S3 is ON), the solenoid valve Y closes. When water tower level is lower than the lower limit level (S2 is ON), pump M works, to supply to water tower, and S2 is OFF, level is higher than the lower limit level .when water tower level is higher than the upper limit level (S1 is ON), pump M stops. When water tower level is lower than lower limit level, and the water tank level is also lower than lower limit level, pump M will not start.
4, I/O Table 3-7-1water tower level automatic control I/O input
output
I0.1
water tower upper limit
Q0.1
solenoid valve Y
I0.2
water tower lower limit
Q0.2
pump M
I0.3
water tank upper limit
I0.4
water tank lower limit
38
5, I/O circuit water tower upper limit S1
solenoid valve Y
Q0.1
I0.1
pump M
water tower lower limit S2
I0.2
Q0.2
water tank upper limit S3
I0.3 water tank lower limit S4
I0.4
24V
1L 1M 2M CPU 226 CN
12V
FU
Diagram 3-7-1 water tower level automatic control I/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-7-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.5, 2.6, 2.7 (2.4 is off). 5, Training operation: (1) Turn off limit switch S4, solenoid valve Y is ON, lower limit switch S4 resets. (2) Turn on limit switch S3, solenoid valve Y is OFF, upper limit switch S3 resets. (3) Turn off limit switch S2, pump M is ON, lower limit switch S2 resets. (4) Turn on limit switch S1, pump M is OFF, upper limit switch S1 resets.
7, Circuit Connect water tower level automatic control circuit according to Diagram 3-7-2.
8, Questions When the water tank level is lower than the lower limit level (S4 is ON), solenoid valve Y opens to input water, within 3s, switch S4 does not close, then the solenoid valve Y doeas not open, and faults occur, then indicator light Y flashes. 39
PLC Panel
YL-PCwater tower level automatic control circuit
S1
S2
IN S3
S4
COM
M
1L
OUT Y COM
COM 1M
I0.1
Q0.0
COM
I0.2
Diagram 3-7-2 water tower level automatic control circuit
40
Q0.1
2M
I0.3
M
Q0.2
L+
I0.4
- 12V +
Training 8, Automatic forming machine 1, Purposes 1, Understand automatic forming machine fundamental. 2, Learn programming software usage and program input, check, modification and operation debugging. 3, Learn I/O port distribution and I/O ports.
2, Components 1, Yalong PLC controller. 2, Yalong PLC automatic forming machine. 3, Computer or programmer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental Automatic forming machine working modes: (1) Initial status, when materials are put into forming machine, each oil cylinder status is in initial position, the solenoid valve Y1, Y2, Y4 close (OFF), the solenoid valve Y3 works (ON).position switchS1, S3, S5 are off (OFF), position switch S2, S4, S6 closes (ON). (2) Push start button, solenoid valve Y2=ON upper oil cylinder piston moves downward, position switch S4=OFF. when position switch S3=ON, start left, right oil cylinder (solenoid valve Y3=OFF; solenoid valve Y1=Y4=ON), A piston moves rightward, C piston moves leftward, position switch S2, S6 is OFF. (3) When oil cylinder piston reach terminal, then position switches S1, S5 are ON. Then each oil cylinder will return to initial position, A, B, C oil cylinder returns (solenoid valve Y1=Y2=Y4=OFF; solenoid valve Y3=ON), position switch S1=S3=S5=OFF. (4) When A, B, C oil cylinder will return to origin (position switch S2=S4=S6=ON), the system will return to the initial position. (5) Put materials, push start button to restart.
4, I/O Table 3-8-1 automatic forming machine I/O input I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6
start Position switch S1 Position witch S2 Position switch S3 Position switch S4 Position switch S5 Position switch S6
Q0.1 Q0.2 Q0.3 Q0.4
41
output solenoid valve 1 solenoid valve 2 solenoid valve 3 solenoid valve 4
5, I/O circuit start
S1 S2 S3 S4 S5 S6
24V
solenoid valve Y1
I0.0
Q0.1 solenoid valve Y2
I0.1
Q0.2
I0.2
solenoid valve Y3
Q0.3 I0.3
solenoid valve Y4
Q0.4 I.04 I0.5 I0.6
1L
1M
2L
2M
12V
FU
CPU 226 CN
Diagram 3-8-1 automatic forming machine I/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-8-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.4(2.5, 2.6, 2.7 are off). 5, Operation: (1) Turn S1-S6 in OFF status, turn Y3 ON. (2) When PLC starts, turn on S2, S4, S6. (3) Turn on start switch 0.0, Y2, Y3. (4) Make S4=OFF (down), S3=ON (up), Y1, Y2, Y4 ON. (5) Make S2=S6=OFF (down); make S1=S5=ON (up), Y3 light ON. (6) Make S1=S3=S5=OFF, S2=S4=S6=ON, Y3 light ON. S1-S6 indicator lights are ON.
7, Circuit Connect automatic forming machine circuit according to Diagram 3-8-2.
8, Questions How to carry out automatic counting control? 42
PLC Panel
YL-PC Automatic forming machine
S1
IN S2
S3
COM
OUT Y1
Y2
Y3
Y4
1L
Q0.0
Q0.1
Q0.2
1M
COM
2M
I0.1
I0.2
Q0.3
2L
Q0.4
COM S4
S5
S6
COM
Diagram 3-8-2 automatic forming machine circuit
43
I0.3
M
- 12V +
L+
I0.4
I0.5
I0.6
Training 9, automatic charging system 1, Purposes 1, Understand automatic charging control system work flow. 2, Learn how to use programming software to make automatic charging control system program. 3, Learn I/Odistribution,I/O connection methods and program operation debugging.
2, Components 1, Yalong PLC controller. 2, Yalong PLC automatic charging system. 3, Computer or programmer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental Automatic charging system control: In initial status, red light L2 is OFF, green light L1 is ON, to allowe vehicle for charging. When K2, motor M1, M2, M3 is OFF. When vehicle comes (S2 switch is on), L2 is ON, and L1 is OFF, M3 works, motor M2 works when M3 works for 2s, motor M1 works when M2 starts for 2s, delay for 2s, K2 opens. When vehicle is loaded (S2 OFF), K2 closes, motor M1, delay for 2s, then stops, M2 stops when M1 stops for 2s, M3 stops when M2 stops for 2s. L1 is ON, L2 is OFF, and vehicle can leave. S1 is the materials detection switch, when it is full, K2 will open, S1 is cut out, when it is not full, K1 is open, and K2 will not open.
4, I/O Table 3-9-1 automatic charging system I/O I0.0 I0.1
Input Upper limit level switch S1 Position detection switch S2
Q0.0 Q0.1 Q0.2 Q0.3 Q0.4 Q0.5 Q0.6
5, I/O circuit
44
output Supply switch K1 switch K2 motor M1 motor M2 motor M3 green light L1 red light L2
S1
K1
S2
24V
I0.0
Q0.0
I0.1
Q0.1
1M 2M
K2
M1
Q0.2
M
Q0.3
M
M2
Q0.4
M
M3 L1
Q0.5
L2
Q0.6 CPU 226 CN
1L 2L 12V
FU
Diagram 3-9-1 automatic charging systemI/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-9-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.4, 2.5, 2.7 (2.6 is off). 5, Training operation: (1) Start, L1 green light is ON, K1 light is ON. (2) Upper switch S2 (indicator light ON), L1 green light is OFF, L2 red light is ON, motor M3, M2, M1 are ON. (3) Upper switch S1 (indicator light ON), K1 is OFF, K2 is ON. (4) Lower switch S2 (indicator light ON), motor M1, M2, M3 are OFF, L1 is ON, K1 light is ON, recver to (1).
7, Circuit Connect automatic charging system circuit according to Diagram 3-9-2.
8, Questions According to control requirements above, how to make vehicle counting function?
45
PLC Panel
YL-PC Automatic charging system OUT IN
K1
K2
M1
M2
L1
L2
M3
COM
1L
Q0.0
Q0.1
Q0.2
Q0.3
2L
Q0.4
COM
S2
S1
COM
1M
I0.0
COM
I0.1
Diagram 3-9-2 automatic charging system circuit
46
2M
M
L+
- 12V +
Q0.5
Q0.6
Training 10, Multi-liquid automatic blending 1, Purposes 1, Understand multi-liquid automatic blending control system fundamental. 2, Learn ladder programming methods and instruction programming methods. 3, Learn programmer operation and programmer input, check, modification, download, upload and operation.
2, Components 1, Yalong PLC controller. 2, Yalong PLC multi-liquid automatic blending. 3, Computer or programmer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental Multi-liquid automatic blending control requirements: In initial status, the container is empty, and the solenoid valve Y1, Y2, Y3, Y4 and blender M is off, level sensor L1, L2, L3 are OFF. Push start button, solenoid valve Y1, Y2 open, input liquid A and B, level is L2 (L2 and L3 are ON), stop input (Y1, Y2 is OFF). Open liquid C solenoid valve Y3 (Y3 is ON), input liquid C, when level rises to L1 (L1 is ON), stop input (Y3 is OFF). Start blender M, blending time is 3s. Then solenoid valve Y4 starts, drain liquid, when level drops to L3 (L3 is OFF), delay for 5s, Y4 closes. Push start button to restart.
4, I/O Table 3-10-1 Multi-liquid automatic control I/O I/O port I0.0 I0.1 I0.2 I0.3 I0.4
Remark Start L1 L2 L3 T
I/O port Q0.1 Q0.2 Q0.3 Q0.4 Q0.5 Q0.6
47
Remark solenoid valve Y1 solenoid valve Y2 solenoid valve Y3 solenoid valve Y4 Blender M Furnance H
5, I/O circuit solenoid valve 1 Q0.1
solenoid valve2
L1
Q0.2
I0.1
solenoid valve3
L2
Q0.3
I0.2
solenoid valve4
L3
Q0.4
I0.3
Blender M
T
Q0.5
I0.4
M Furnance H
24V
1M
Q0.6
2M
1L 2L
CPU 226 CN
H 12V
FU
Diagram 3-10-1 Multi-liquid automatic blending I/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-10-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.4, 2.5, 2.7 (2.6 is off). 5, Training operation: (1) Turn start switch 0.0, solenoid valve Y1, Y2 light ON. (2) Turn on L3, L2, solenoid valve Y1, Y2 OFF, solenoid valve Y3 ON. (3) Turn on L1, solenoid valve Y3 OFF, blender M is ON, 5s later, the solenoid valve Y4 is ON. (4) Turn off L1, L2, L3, delay for 5s, the solenoid valve Y4 is OFF.
7, Circuit Connect multi-liquid automatic blending circuit according to Diagram 3-10-2.
8, Questions How to add temperature control function? 48
PLC Panel
YL-PC Multi-liquid automatic blending IN L1
Y1
OUT Y2
Y4
M
Y3
Q0.0
1L
Q0.1
Q0.2
Q0.3
2L
Q0.4
L2
COM
COM L3
T
H
COM
COM
1M
I0.1
I0.2
2M
M
I0.3
Diagram 3-10-2 Multi-liquid automatic blending machine circuit
49
L+
I0.4
- 12V +
Q0.5
Q0.6
Training 11. Automatic steel rolling machine 1, Purposes 1, Learn automatic steel rolling machine system work process. 2, Learn shift register/display circuit fundamental. 3, Learn programmer operation and programmer input, check, modification, download, upload and operation.
2, Components 1, Yalong PLC controller. 2, Yalong PLC automatic steel rolling machine. 3, Computer or programmer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental Automatic steel rolling machinecontrol requirements: When you push start switch, motor M1, M2 will run. Then motor M3 forward, when steel plate rolling is finished, S1 signal is OFF, sensor S2 is ON, steel plate arrives, the solenoid valve Y2 works, motor M3 moves back, S2 is off, S1 is on and the motor M3 will rotate forward. when S1 is off, repeat. When the third rolling is done, S2 is on, and then it stops. You can restart. Register/display circuit fundamental is below:
Diagram 3-11-1 register/display circuit fundamental
50
Integrated circuit CD4015 is a 4-bit shift register, function is: 1CP, 2CP is click input terminal, 1CR, 2CR is clear terminal, 1DS, 2DS is serials data input terminal, 1Q0~1Q3, 2Q0~2Q3 is data output terminal, VDD is positive power supply,VSS is ground. The circuit input pulse signals are from PLC Y1 port, CD4015 output terminal 1Q0~1Q2, indicator lights (3 LED). Circuit fundamental is that, when pulse arrives 2CP terminal, 2Q0 is high level. Then 1Q0 is high level, drive LED (upper) ON. When 2CP receives pulse, 1Q1 is high level, drive LED is ON, 1Q0 is in high level, if 2CP receives pulse, 1Q2 is high level, drive LED(lower) ON, 1Q0, 1Q1 are in high level. When 1Q3 is high level, through diode, make 1CPclear, 1Q0~1Q3 is in low level.
4, I/O Table 3-11-1 automatic steel rolling machine I/O input I0.0 I0.1 I0.2
output Start Sensor S1 Sensor S2
Q0.1 Q0.3 Q0.4 Q0.5 Q0.6
Y1 Solenoid valve Y2 Motor M1 Motor M2 Motor M3 forward
Q0.7
Motor M3back
5,I/O circuit
Start
Y1
I0.0
Q0.1
I0.1
Q0.3
I0.2
Q0.4
M
Q0.5
M
Q0.6
M
S1
Solenoid valve Y2
S2
Q0.7
24V
CPU 226 CN 1L 1M 2L 2M
M
Motor M1
Motor M2
Motor M3 forward
Motor M3back
12V
FU
Diagram 3-12-2 automatic steel rolling machine I/O circuit
51
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-11-3, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.4, 2.5, 2.7 (2.6 is off). 5, Training operation: (1) Turn on Y1, M1, M2 light ON. (2)Up S1, down S1, Y1, M1, M2 and leftward light is ON (M3 forward). (3)Up S2, down S2, Y1 lights, Y2 and rightward arrow light is ON(M3 back). (4)Up S1, down S1, Y1 lights, M1, M2 and leftward arrow light is ON (M3 forward). (5)Up S2, down S2, Y13 lights, Y2 and rightward arrow light is ON (M3 back). (6)Up S1, down S1, M1, M2, Y13 lights and leftward arrow light is ON (M3 forward). (7)Up S2, down S2, whole process is finished.
7, Circuit Connect automatic steel rolling machine circuit according to Diagram 3-11-3.
8, Questions According to technical process above, how to add workpiece counting function ?
52
PLC Panel
YL-PC automatic steel rolling machine 1L
OUT
IN S1
0V
S2
12V
Q0.1
Q0.3
2L
Q0.4
Q0.5
Q0.6
M1 M3Forward Y1
COM M2
M3Back
Y2
COM
COM
1M
I0.1
2M
I0.2
Diagram 3-11-3 automatic steel rolling machine circuit
53
M
L+
- 12V +
Q0.7
Training 12, mails allocator 1, Purposes 1, Learn mails allocator fundamental and demonstration fundamental. 2, Learn programmer operation and programmer download, upload, check and operation.
2, Components 1, Yalong PLC controller. 2, Yalong PLC mails allocator. 3, Programmer (or computer). 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental 1, Mails allocator fundamental: When started, green light L2 is ON, red light L1 is OFF, motor M5 runs, for mails allocation. The switch S2 is ON, toggle switches are mails number (1.0~1.3 is toggle switch for 1, 2, 4, 8), from toggle switch, you can read constant 1, 2, 3, 4, 5. If other than the 5 numbers, red light L1 will flash to alarm, motor M5 stops. Restart, if it is normal, then red light is ON, green light is OFF, motor M5 runs, PLC samples motor optical encoder S1 pulses (from mails code reader to corresponding box), when mails arrives allocation box and enter mails box. Then red light is OFF, green light is ON, you can continue allocation. 2, Fundamental L1, L2 are red, green indicator lights, S2 switch is code reader, M1-M4 are impellers, and the indicator light is waiting. The circuit fundamental is shown in Diagram 3-12-1, when switch is OFF, LED (upper) is ON, LED (lower) OFF, when switch closes, LED (upper) is OFF, LED (lower) is ON. M5 is the motor, S1 is optical encoder, the pulse circuit is shown below, when a terminal is connected to the power supply, NE555 starts, pulse signals, through S1 terminal, are for PLC input terminal to sample.
54
Diagram 3-12-1 mails allocation control system demonstration fundamental diagram
4, I/O Table 3-12-1 mails allocation control system I/O
I0.0 I0.1 I0.2
Input Analogy optical encoder S1 Start Analogy code reader S2
output Q0.1
Analogy impeller M1
Q0.2
Analogy impeller M2
Q0.3
Analogy impeller M3
Q0.4 Q0.5 Q0.6 Q0.7
Analogy impeller M4 Drive motor M5 Red light L1 Green light L2
5, I/O circuit Analogy impeller M1
S1
Q0.1 I0.0
启动
I0.1
M Analogy impeller M2
Q0.2
M
Q0.3
M
Q0.4
M
Q0.5
M
Analogy impeller M3
S2
I0.2
Analogy impeller M4
Red light L1
Q0.6
Green light L2
Q0.7
24V
1L 2L 1M 2M CPU 226 CN
Drive motor M5
12V
FU
Diagram 3-12-2 mails allocation control systemI/O circuit
55
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-12-3, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.4, 2.5 (2.6, 2.7 is off). 5, Training operation: (1) 1.0-1.3, the binary number shall be within 1-5 (1.0, 1.1, 1.2, 1.3 is 1, 2, 4, 8). (2) Push 0.1, L2, M5 is ON. (3) L1 is ON, L2 is OFF, when it recovers, L2, L5 are ON. (4) Then you can recheck mails.
7, Circuit Connect mails allocation control system circuit according to Diagram 3-12-3.
8, Questions How to add vehicle counting function according to control requirements above?
56
PLC Panel
YL-PC mails allocator IN S1
M1
M2
S2
12V
0V
OUT M3
M4
M5
L1
L2
1L
Q0.0
COM I0.0
Q0.1
1M I0.2
Diagram 3-12-3 mails allocatorcircuit
57
Q0.2
COM
Q0.3
2L
2M
M
Q0.4
L+
Q0.5
Q0.6
- 12V +
Q0.7
Training 13. Iron tower lighting 1, Purposes 1, Learn hwo to use function instructions. 2, Understand 7-segment decoder fundamental. 3, Learn I/O distribution and connection methods. 4, Learn programmer operation and programmerdownload, upload, check and operation.
2, Components 1, Yalong PLC- controller. 2, Yalong iron tower lighting module. 3, Programmer or computer. 4, Safe cables. 5, PLC serial communication cable.
3, Fundamental Iron tower lighting control requirements: Automatic lighting, a light each time in sequence, and students can design various patterns.
4, I/O Table 3-13-1 iron tower lighting I/O Output Q0.0 Q0.1 Q0.2 Q0.3 Q0.4 Q0.5 Q0.6 Q0.7 Q1.0
Color light L1 Color light L2 Color light L3 Color light L4 Color light L5 Color light L6 Color light L7 Color light L8 Color light L9
Q1.1 Q1.2 Q.13 Q1.4 Q1.5 Q1.6 Q1.7
58
output 7-segment decoder A 7-segment decoder B 7-segment decoder C 7-segment decoder D 7-segment decoder E 7-segment decoder F 7-segment decoder G
5, I/O circuit
7-segment decoderA 7-segment decoderB
Color light L1
Q1.1
Q0.0
Q1.2
Q0.1
Q1.3
Q0.2
Q1.4
Q0.3
Q1.5
Q0.4
Q1.6
Q0.5
Q1.7
Q0.6
Color light L2
7-segment decoderC 7-segment decoderD
Color light L3
7-segment decoderE
Color light L4 Color light L5
7-segment decoderF 7-segment decoderG
Color light L6 Color light L7
Q0.7 Q1.0
1L 2L CPU 226 CN 3L
Color light L8 Color light L9
12V
FU
Diagram 3-13-1 iron tower lightingI/O circuit
6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-13-2, do not short circuit 12V and 24V power supply. 2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket. 3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download programs into PLC then put PLC in RUN status. 4, Turn on 2.4, 2.5, 2.7 (2.6 is off). 5, Start automatic lighting, one light each time; from botton to top, then from top to bottom.
7, Circuit Connect iron tower lighting circuit according to Diagram 3-13-2.
8, Questions 1, How to change lighting time interval? 2, How to make a same lighting color ON and OFF in a same time?
59
YL-PC iron tower
IN
PLC Panel 1L
Q0.0
Q0.1
Q0.2
Q0.3
2L
Q0.4
Q0.6
Q0.7
3L
Q1.0
Q1.1
Q1.2
Q1.3
Q1.4
Q1.5
Q1.6
Q1.7
OUT
A
E
L6
L1
B
F
L7
L2
C
G
L8
L3
D
H
L9
L4
COM
L5
COM
2M
Diagram 3-13-2 iron tower lighting circuit
60
M
L+
- 12V +
Q0.5
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