BC 2016 Skills Competition Trade 19 Automation and Control

Rev B Page 1 April 2016

2016 Sample Competition (Based on 2012 PEI Competition)

Trade 19 Automation and Controls

Competitor Name

Station

BC 2016 Skills Competition Trade 19 Automation and Control

Rev B Page 2 April 2016

1.1 - SCENARIO ............................................................. ERROR! BOOKMARK NOT DEFINED.

1.1.1 - GENERAL ...................................................................................................................... 3

1.1.2 – STEP A: WIRING AN AUTOMATED PROCESS WITHIN A PANEL ............................................ 3

1.1.3 – STEP B: PROGRAMMING THE AUTOMATED PROCESS ....................................................... 3

1.1.4 – STEP C: TROUBLESHOOTING ......................................................................................... 3

2.1 – CONDUCTORS ................................................................................................................ 4

2.1.1 – SIZE AND USE................................................................................................................ 4

2.1.2 – COLOUR CODE ............................................................................................................. 4

3.0 - PROCESS DIAGRAM ....................................................................................................... 5

3.1– GENERAL DESCRIPTION ................................................................................................ 6

3.2 - Automatic Mode ........................................................................................................ 6

3.3 - Manual Mode ............................................................................................................. 8

3.4 - Emergency mode ...................................................................................................... 9

4.0 INPUT AND OUTPUT TECHNICAL DETAILS …………………………………………………10

4.1 - INPUT TABLE……………………………………………………………………………….10

4.2 - OUTPUT TABLE……………………………………………………………………………..11

5.0 – TECHNICAL DIAGRAMS……………………………………………………………………….12

5.1 - POWER CIRCUIT WIRING……………………………………………………..………….12

5.2 - INPUT MODULE WIRING………………………………………………………………….13

5.3 - OUTPUT MODULE WIRING……………………………………………………………….13

5.4 - SUGGESTED BACK-PLAIN LAYOUT…………………………………………………...14

5.5 - DOOR LAYOUT ……………….……………………………………………………………14

BC 2016 Skills Competition Trade 19 Automation and Control

Rev B Page 3 April 2016

1.1.1 - General With this challenge, we will assess your: a) Ability to analyze technical data. b) Quality of wiring. c) Capacity to implement an automatic process. d) Troubleshooting techniques.

e) Abilities for error detection.

1.1.2 – Step A: Wiring an automated process within a panel

As a technician, you should have the ability to completely wire a system and make the necessary modifications. We will assess the quality of your manual work, and the precision with which you will reference the drawings provided.

1.1.3 – Step B: Programming the automated process

Allen Bradley will provide the programmable controller used in this challenge. You are provided with a function, and you must program the automated process. The system must be functional, and adhere to the instructions.

1.1.4 – Step C: Troubleshooting

Your ability to detect and solve problems will be assessed.

BC 2016 Skills Competition Trade 19 Automation and Control

Rev B Page 4 April 2016

2.1 – Conductors

2.1.1 – Size and use

1. Power connections must be 14 AWG gauge.

2. Control conductors must be 16 AWG gauge.

3. Any exceptions to paragraphs 1 & 2 will be specifically mentioned on

the drawings.

4. Ground connections must be used for grounding purposes only.

2.1.2 – Colour Code

The following colour code must be used to distinguish circuits:

1. Single phase Identified Conductor Line

white black

2.

Three phase

Identified Conductor

white Line red, black, blue

3.

DC Control

blue

4.

AC Control

Identified Conductor Line

white red

5.

Grounding

green

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Pre-schredded

Raw Material

Bulk Storage

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LS 1

Vacuum Pump

Motor K1

Silo

LS_3

LS_2

Extruder Feeder

Solenoid - S1

Motor K2 Weigh Scale Feeder

Solenoid - 52

Weigh Scale

Barrel Full

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Rev B Page 6 April 2016

3.1 – General Description

The current theme of going green and sustainability, Holland College is aiming to include plastic recycling on our campus.

To reduce our impact on the environment, Holland College has acquired equipment for a plastic recycling process, and the electrical department was made responsible for preparing the automation project. You are assigned to execute the project developed by the engineers at HCPlastics. Below is the

necessary information for the implementation of the work.

The initial stages of the plastic recycling process is the pre-selection and grinding on a mill of appropriate PET (polyethylene terephthalate) type plastic. The outcome of the ground material is kept in a raw material bulk storage tank where a vacuum pump sends it to a silo above an extruder. The silo is equipped with maximum and minimum level sensors that are important to the process. The valve below the silo discharges the material into the extruder according to the project. The extruded plastic then goes to a clipper (dicer) that cuts the long spaghetti like extruded plastic into three different sizes depending on the desired purpose of the finished PET pellet product.

The pellets will then serve as raw material for new plastic products.

Motors MTR_1 (pump) and MTR_2 (extruder) are started by direct on line starters K1 and K2, and motor MTR_3 (Cutting Clipper Motor that will shape the pellets in different sizes) is started by a frequency inverter K3-K4.

For the purposes of this project three different indicator lights will be used to represent the three digital outputs signals from the PLC that would be sent to the Digital inputs of the frequency inverter for 3 different required speed selections. Separate signals are sent to the inverter for forward (K3) and reverse (K4) control of the Clipper Motor.

3.2 Automatic Mode

Automatic/Manual selector switch must be set to Automatic (SS_1_1).

General Operation

Lamp L1 Process Stop, should be on (steady) at power up to indicate that there is power to the system, but it is not in run mode.

For the process to start, there must be sufficient raw material in the bulk storage tank as indicated by the lower level limit LS_1. Also the weigh scale needs to indicate that a barrel with sufficient room (not full) is present via the selector switch SS_2, a preset pellet size (Small, Medium or Large) must be selected before the process can start. The process will not start until all three conditions are true.

Once all three conditions are met, then the process can start by pressing the Process Start button (PB5), and lamp L2 process run will come on continuously.

Rev B Page 7 April 2016

Next the Vacuum Pump motor (K1) will fill the feeder silo until the upper limit (LS_3) indicates that it is full. The silo lower limit (LS_2), and upper limit will then maintain the required amount of feed material for the process via the vacuum pump.

Contacts 13 and 14 on K1 will be used to turn on indicating lamp L3 to show the vacuum pump is active.

During operation, the Extruder Feeder Solenoid (S1) will open and close at alternating ½ second intervals to supply the extruder with raw material. Solenoid S1 is a Normally Closed valve (NC), and opens upon power applied. Lamp 8 (L8) will indicate when solenoid S1 is active/open.

The extrusion process itself requires heat to liquefy the product and separate out impurities, a pump to force the liquid plastic through an extrusion die, and a cooling tank to solidify the extruded plastic. For the purpose of this project the entire extruder is considered one machine powered by contactor K2. Contacts 13 and 14 of K2 will activate Lamp L4 that will indicate when the extruder is active.

The clipper motor is meant to be controlled by a frequency inverter with three digital input preset speeds. These speeds determine the size of the finished PET pellets. By selecting the appropriate size Small (PB2), Medium (PB3) or large (PB4), a digital signal will be sent to an Inverter (not used on this project). Indicator lamps on the output of the PLC will show which size is selected Small (L10), Medium (L11) and large (L12). This selection must be chosen before the process is started. Once the process is running a different size cannot be selected without either pressing the process stop (PB6), and the scale has indicated a full barrel, and new one has been replaced. (See operational specifics for barrel replacement).

Once the product has been extruded and cooled, the long spaghetti like plastic must be cut into pellets by a clipper/dicer blade. As mentioned this clipper will be controlled by a frequency inverter with 3 preset forward speeds. Contactor K3 will allow the contactor to go forward, with contacts 13-14 of K3 indicating the forward motion on the front panel via Lamp 5 (L5). Reverse is only available in Manual mode.

A normally open (NO) solenoid valve (S2) then allows the pellets to be discharged to a storage barrel located on a weigh scale. Lamp 9 (L9) will indicate when the valve is active/closed.

The weigh scale set point tells the system that the barrel is full. Selector switch 2 (SS2) indicates if the barrel is full or not.

Operational Specifics:

When the weigh scale (SS2) indicates that the barrel is full, both solenoids need to close, the extruder (K2) and clipper (K3) will stop until a new barrel is replaced. The vacuum pump will still operate via the silo upper and lower limits as usual to allow the silo to maintain its level.

Lamp 7 (L7), will flash on and off at ½ sec intervals to alert operators that the barrel is full and needs to be replaced with an empty one.

The system knows that a new barrel has been replaced only when the weigh scale (SS2) has been reset, and the same size select button as before is pushed again, at which point the process will continue as before the barrel was full.

Rev B Page 8 April 2016

A different size pellet can only be selected if the stop process button has been pushed, at which point the entire start process can begin new from the top.

If during normal operation, the low level is tripped in the main raw bulk storage tank (LS_1), the vacuum pump (MTR_1) can no longer operate, but the rest of the process will continue until the low level of the silo limit (LS_2) is tripped. Once the silo low limit (LL) has been tripped, solenoid S1 will operate for 10 seconds, the extruder and clipper will allowed to run for 20 seconds, and then solenoid S2 will close at 30 seconds after LL silo has been tripped. These delays allow the system to clear out of product.

After these time delays the system will go into a stop condition, and wait for operator intervention to restart the process anew.

On power up/stop or raw storage empty shut-down, all settings/values should be cleared, ready to start the Automatic process from the beginning.

3.3 Manual Mode

Automatic/Manual selector switch must be set to Manual (SS_1_2).

Once the manual mode has been selected, all three of the size indicating lamps (L10, L11 and L12), will flash in unison at ½ second on/off intervals to indicated manual has been selected.

A jog cycle select button (PB1) is to be programed so that each time the button is pressed, a different part of the process can be manually jogged.

Following the Jog Cycle Sequence in Figure 1, each item will flash for their specified number of flash cycles.

For example: Press the Jog select button once (PB1), the run/jog lamp (L2) will flash on for ½ second and off for 2 seconds (repeating) indicating the vacuum pump can be jogged. Pressing the process start/Jog button (PB5) will now allow the operator to Jog the vacuum pump.

Press the Jog select button a second time, the run /jog lamp will flash on/off alternating for ½ second interval twice, then off for two seconds and then repeat indicating the extruder can now be jogged by pressing the start/jog button.

This cycle repeats for all seven selectable items in the process. ½ second flashes on and off, separated by 2 second gap and then repeat ½ sec flashes to indicate item to be jogged.

If the Jog select button is pressed an eighth time, the cycle resets to jog sequence 1 – Vacuum pump.

Rev B Page 9 April 2016

Figure 2- Jog Cycle Sequence

Note: Reverse for the clipper motor (MTR_3 REV) can only be accessed from manual mode.

Selecting between Manual, and Automatic modes does not require that any of the last state/selection/Values be maintained.

3.4 Emergency mode

The emergency stop button is mounted in the front of the control panel and has 2 sets of NC contacts, it must be connected on the first PLC input as well as control the MCR to kill power to the outputs except L1.

L1 is to flash on and off to indicate that the ESTOP has been pushed. None of the other outputs should operate, and none of the inputs should have any effect as long as the ESTOP is pressed.

The automatic process is not reinitialized after an emergency stop; machine operator intervention is necessary to manually reset the system by selecting Manual Mode (SS_1_2) and then return to Automatic Mode on the selector switch (SS_1_1) and then pressing Process Start/Jog (PB5). Only then can the process resume operation with the normal starting process for Automatic mode.

Rev B Page 10 April 2016

4 - Input and outputs –technical details

4.1 Inputs

The following tables are a recommended assignment of the inputs and outputs for your programmable control. As controllers vary in how they are connected and function, you must check your particular PLC to see if these assignments are suitable.

Inputs detail Symbol Contact

Type

PLC inputs

Assignment

Information supplied at

state «1»

Emergency stop ES (PB7)

NC In0 Emergency stop button not operated

Stop Process Stop (PB6)

NC In1 Button not pressed

Start Process/Jog (Manual) Start/Jog (PB5)

NO In2 Button pressed, start process

Small Pellet Size Select Sm (PB2)

NO In3 Button pressed, small selected

Medium Pellet Size Select Med (PB3)

NO In4 Button pressed, medium selected

Large Pellet Size Select LG (PB4)

NO In5 Button pressed, large selected

Low Level Main Bulk Storage Tank

LS_1 NO In6 Storage tank level ok

Low Level Silo LS_2 NO In7 Silo tank low level ok

Upper Level Silo LS_3 NO In8 Silo tank upper level reached

Weigh Scale Barrel Full Full (SS2)

NO In9 Selector Switch on

Manual mode SS_Man (SS_1_1)

NO In10 Manual mode selected

Automatic Mode SS_Auto (SS_1_2)

NO In 11 Auto mode selected

Jog Cycle Select Jog Sel (PB1)

NO In 12 Button pressed, cycle jog control

Rev B Page 11 April 2016

4.2 Outputs

Outputs detail Symbol PLC outputs

Assignments

Action at state «1»

Red, Lamp 1 ES (L1)

Out0 -½ second flash when E-Stop Pressed -Solid Red when Process Stop Pressed

Green Lamp 2 Run/Jog (L2)

Out1 -Solid when process is running -Flashes to indicate which Manual jog cycle is selected

Amber Lamp 10 Small (L10)

Out2 Small Pellet Size Selected

Amber Lamp 11 Medium (L11)

Out3 Medium Pellet Size Selected

Amber Lamp 12 Large (L12)

Out4 Large Pellet Size Selected

Vacuum Pump K1 K1+ L3 Out5 -Vacuum Pump contactor energized -Lamp L3 energized

Extruder Motor K2 K2 + L4 Out 6 -Extruder Motor contactor energized -Lamp L4 energized

Clipper FWD K3 K3 + L5 Out 7 -Clipper FWD Motor contactor energized -Lamp L5 energized

Clipper REV K4 K4 + L6 Out 8 -Clipper REV Motor contactor energized -Lamp L6 energized

Green Lamp 8 L8 Out 9 Solenoid S1 open

Green Lamp 9 L9 Out 10 Solenoid S2 closed

White Lamp 7 L7 Out 11 Barrel weigh scale set point active

Rev B Page 12 April 2016

5.0 Technical Diagrams

5.1 Power Circuit Wiring

Rev B Page 13 April 2016

BC 2016 Skills Competition Trade 19 Automation and Control

5.2 Input Module Wiring

5.3 Output Module Wiring

Rev B Page 14 April 2016

BC 2016 Skills Competition Trade 19 Automation and Control

5.4 Suggested Backplain Lay-out

Contactor K1 – Telemecanique LC1 D09 Contactor K2 - Omron Contactor K3F/K4R Omron

5.5 Exterior Door Lay-out