plc lab write up

FINAL

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Sean Forbes & Cody BougieInstructor: Ron Chartrand

4/19/20152015

PLC Control Systems – Final ReportELR223

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Table of ContentsTable of Contents...........................................................................................................................1

Table of Figures..............................................................................................................................4

Table of Tables...............................................................................................................................6

Lab 8A............................................................................................................................................8

Introduction...............................................................................................................................9

Ladder Logic............................................................................................................................. 10

I/O Listing.................................................................................................................................11

Hardware AutoCAD Drawing....................................................................................................12

Summary.................................................................................................................................. 13

Lab 8B.......................................................................................................................................... 14

Introduction............................................................................................................................. 15

Ladder Logic............................................................................................................................. 16

I/O Listing.................................................................................................................................17


Summary.................................................................................................................................. 19

Lab 9A.......................................................................................................................................... 20

Introduction............................................................................................................................. 21

Ladder Logic............................................................................................................................. 22

I/O Listing.................................................................................................................................23


Summary.................................................................................................................................. 25

Lab 9B.......................................................................................................................................... 26

Introduction............................................................................................................................. 27

Ladder Logic............................................................................................................................. 28

I/O Listing.................................................................................................................................29


Summary.................................................................................................................................. 31

Lab 10.......................................................................................................................................... 32

Introduction............................................................................................................................. 33

Ladder Logic............................................................................................................................. 34

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I/O Listing.................................................................................................................................35


Summary.................................................................................................................................. 37

Lab 11A........................................................................................................................................ 38

Introduction............................................................................................................................. 39

Ladder Logic............................................................................................................................. 40

I/O Listing.................................................................................................................................41


Summary.................................................................................................................................. 43

Lab 11B........................................................................................................................................ 44

Introduction............................................................................................................................. 45

Ladder Logic............................................................................................................................. 46

I/O Listing.................................................................................................................................47


Summary.................................................................................................................................. 49

Lab 12A........................................................................................................................................ 50

Introduction............................................................................................................................. 51

Ladder Logic............................................................................................................................. 52

I/O Listing.................................................................................................................................54


Summary.................................................................................................................................. 56

Lab 12B........................................................................................................................................ 57

Introduction............................................................................................................................. 58

Ladder Logic............................................................................................................................. 59

I/O Listing.................................................................................................................................62

Hardware AutoCAD Listing.......................................................................................................63

Summary.................................................................................................................................. 64

Lab 12C........................................................................................................................................ 65

Introduction............................................................................................................................. 66

Ladder Logic............................................................................................................................. 67

I/O Listing.................................................................................................................................70


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Summary.................................................................................................................................. 72

Lab 12D........................................................................................................................................ 73

Introduction............................................................................................................................. 74

Ladder Logic............................................................................................................................. 76

I/O Listing.................................................................................................................................79


Summary.................................................................................................................................. 81

Lab 13A........................................................................................................................................ 82

Introduction............................................................................................................................. 83

Ladder Logic............................................................................................................................. 85

I/O Listing.................................................................................................................................87


Summary.................................................................................................................................. 89

Lab 13B........................................................................................................................................ 90

Introduction............................................................................................................................. 91

Sequencer Setup...................................................................................................................93

Ladder Logic............................................................................................................................. 94

I/O Listing.................................................................................................................................95


Summary.................................................................................................................................. 97

Lab 14A........................................................................................................................................ 98

Introduction............................................................................................................................. 99

Ladder Logic........................................................................................................................... 101

I/O Listing...............................................................................................................................103

Hardware AutoCAD Drawing..................................................................................................104

Summary................................................................................................................................105

Lab 14B...................................................................................................................................... 106

Introduction........................................................................................................................... 107

Ladder Logic........................................................................................................................... 109

I/O Listing...............................................................................................................................111


Summary................................................................................................................................113

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Lab 14C...................................................................................................................................... 114

Introduction........................................................................................................................... 115

Sequencer Setup.................................................................................................................116

Ladder Logic........................................................................................................................... 117

I/O Listing...............................................................................................................................118


Summary................................................................................................................................120

Lab 15A...................................................................................................................................... 121

Introduction........................................................................................................................... 122

Ladder Logic........................................................................................................................... 123

I/O Listing...............................................................................................................................124


Summary................................................................................................................................126

Lab 15B...................................................................................................................................... 127

Introduction........................................................................................................................... 128

Ladder Logic........................................................................................................................... 129

I/O Listing...............................................................................................................................130


Summary................................................................................................................................132

Lab 15C...................................................................................................................................... 133

Introduction........................................................................................................................... 134

Ladder Logic........................................................................................................................... 135

I/O Listing...............................................................................................................................136


Summary................................................................................................................................138

Appendix....................................................................................................................................139

Timer Instruction....................................................................................................................139

Up Counter Instruction...........................................................................................................141

Sequencer Output Instruction................................................................................................143

References................................................................................................................................. 146

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Table of FiguresFigure 1 Lab 8A Ladder Logic.......................................................................................................9Figure 2 Hardware Layout of Lab 8A..........................................................................................11Figure 3 Lab 8B Ladder Logic......................................................................................................15Figure 4 Hardware Layout for Lab 8B.......................................................................................17Figure 5 Lab 9A Ladder Logic.....................................................................................................21Figure 6 Hardware Layout for Lab 9A........................................................................................23Figure 7 Lab 9B Ladder Logic.....................................................................................................27Figure 8 Hardware Layout for Lab 9B........................................................................................29Figure 9 Lab 10 Ladder Logic.....................................................................................................33Figure 10 Hardware Layout for Lab 10......................................................................................35Figure 11 Lab 11A Ladder Logic.................................................................................................39Figure 12 Hardware Layout for Lab 11A....................................................................................41Figure 13 Lab 11B Ladder Logic.................................................................................................45Figure 14 Hardware Layout for Lab 11B....................................................................................47Figure 15 Lab 12A Ladder Logic (1)...........................................................................................51Figure 16 Lab 12A Ladder Logic (2)...........................................................................................52Figure 17 Hardware Layout for Lab 12A....................................................................................54Figure 18 Lab 12B Ladder Logic (1)............................................................................................58Figure 19 Lab 12B Ladder Logic (2)............................................................................................59Figure 20 Lab 12B Ladder Logic (3)............................................................................................60Figure 21 Hardware Layout for Lab 12B....................................................................................62Figure 22 Lab 12C Ladder Logic (1)............................................................................................66Figure 23 Lab 12C Ladder Logic (2)............................................................................................67Figure 24 Lab 12C Ladder Logic (3)............................................................................................68Figure 25 Hardware Layout for Lab 12C....................................................................................70Figure 26 Lab 12D Ladder Logic (1)...........................................................................................75Figure 27 Lab 12D Ladder Logic (2)...........................................................................................76Figure 28 Lab 12D Ladder Logic (3)...........................................................................................77Figure 29 Hardware Layout for Lab 12D....................................................................................79Figure 30 Lab 13A Ladder Logic (1)...........................................................................................84Figure 31 Lab 13A Ladder Logic (2)...........................................................................................85Figure 32 Hardware Layout for Lab 13A....................................................................................87Figure 33 Array for Sequencer Control......................................................................................92Figure 34 Lab 13B Ladder Logic.................................................................................................93Figure 35 Hardware Layout for Lab 13B....................................................................................95

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Figure 36 Lab 14A Ladder Logic (1).........................................................................................100Figure 37 Lab 14A Ladder Logic (2).........................................................................................101Figure 38 Hardware Layout for Lab 14A..................................................................................103Figure 39 Lab 14B Ladder Logic (1)..........................................................................................108Figure 40 Lab 14B Ladder Logic (2)..........................................................................................109Figure 41 Hardware Layout for Lab 14B..................................................................................111Figure 42 Array for Sequencer Control....................................................................................115Figure 43 Lab 14C Ladder Logic...............................................................................................116Figure 44 Hardware Layout for Lab 14C..................................................................................118Figure 45 Examples of RSView 32 Software Menus................................................................121Figure 46 Lab 15A Ladder Logic...............................................................................................122Figure 47 Example of A Motor Running (Green) and of A Motor Not Running (Red)..............122Figure 48 Example of RSView 32 Window; Where Tags Are Created and Matched With Their Corresponding ‘Tag’ In The RSlogix 5000 Program (One Motor)...............................................123Figure 49 Hardware Layout for Lab 15A..................................................................................124Figure 50 Lab 15B Ladder Logic...............................................................................................128Figure 51 Example of Three Motors Running (Green) and Three Motors Not Running (Red).128Figure 52 Example of RSView 32 Window; Where Tags Are Created and Matched With Their Corresponding ‘Tag’ In The RSLogix 5000 Program (Three Motors)..........................................129Figure 53 Hardware Layout for Lab 15B..................................................................................130Figure 54 Example of Trending Window in RSLogix 5000.......................................................133Figure 55 Lab 15C Ladder Logic...............................................................................................134Figure 56 Hardware Layout for Lab 15C..................................................................................136

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Table of TablesTable 1 I/O Table for Lab 8A.......................................................................................................11Table 2 I/O Table for Lab 8B.......................................................................................................17Table 3 I/O Table for Lab 9A.......................................................................................................23Table 4 I/O Table for Lab 9B.......................................................................................................29Table 5 I/O Table for Lab 10.......................................................................................................35Table 6 I/O Table for Lab 11A.....................................................................................................41Table 7 I/O Table for Lab 11B.....................................................................................................47Table 8 I/O Table for Lab 12A.....................................................................................................54Table 9 I/O Table for Lab 12B.....................................................................................................62Table 10 I/O Table for Lab 12C..................................................................................................70Table 11 I/O Table for Lab 12D..................................................................................................79Table 12 I/O Table for Lab 13A..................................................................................................87Table 13 I/O Table for Lab 13B..................................................................................................95Table 14 I/O Table for Lab 14A................................................................................................103Table 15 I/O Table for Lab 14B................................................................................................111Table 16 I/O Table for Lab 14C................................................................................................118Table 17 I/O Table for Lab 15A................................................................................................124Table 18 I/O Table for Lab 15B................................................................................................130Table 19 I/O Table for Lab 15C................................................................................................136

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Lab 8A

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Three Motor Start


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Introduction

The objective of lab 8A was to design a program on the PLC programming software that would

be able to turn on three motors once the corresponding start button was pressed. The program

will allow any of the three motors to be turned on and turned off in any order that the user

chooses. In addition the program must contain a master stop button that will be able to stop all

the motors at the same time when pressed. Given the demands of the program we decided it

would be best if each motor was placed on its own rung since each motor required its own start

and stop button. Firstly we started by creating a “master stop” on each rung aliased to the same

button, thus enabling the user to shut down all the motors at once in the event of an emergency.

There is a total of three master stop buttons in the finished program, but only one physical master

stop button, each master button was programmed as a normally open (Examine On) contact;

However the master stop button was wired as a normally closed (Examine Off) contact. Another

stop button was added to each rung so the user could turn off each motor separately without

affecting any of the other motors running. Each of these stop buttons were programmed as a

normally closed contact and were aliased to separate inputs. All three start buttons have a contact

that is in parallel with the button, this contact energizes once the start button is pressed and

allows the whole rung to remain energized. The three start buttons were programmed as

normally open (Examine On) contacts were aliased to separate inputs. The motors (outputs) are

located at the end of the rung so when the contact energizes the motor will also energize. Each

motor was also aliased to separate outputs. In this lab the outputs were connected to three

separate lights that represent the motors. With the above programmed properly, this program

allows the user to run and stop any of the three motors at any time.

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Ladder Logic

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Figure 1 Lab 8A Ladder Logic

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I/O ListingInputs Outputs

Local:3:I.Data.1 (Master_Stop) Local:4:O.Data.1 (Motor1_Run)

Local:3:I.Data.2 (Motor1_Stop) Local:4:O.Data.2 (Motor2_Run)

Local:3:I.Data.3 (Motor1_Start) Local:4:O.Data.3 (Motor3_Run)

Local:3:I.Data.4 (Motor2_Stop)

Local:3:I.Data.5 (Motor2_Start)



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Table 1 I/O Table for Lab 8A

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Hardware AutoCAD Drawing

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Figure 2 Hardware Layout of Lab 8A

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Summary

This lab was a good introduction to basic ladder logic PLC programming. By starting with a lab

that required us to create a program that would allow us to start and stop three motors separately

we were able to quickly learn how each instruction can affect the outcome and operation of a

program. Lab 8A required us to create a program that will start and stop three motors separately,

while using an emergency stop to stop all motors in case of an emergency. By placing the motors

on separate rungs we were able to accomplish the task of starting and stopping each motor

separately.

During the course of this lab, we learned that even though the program shows the stops as

Normally Open contacts; that they have to be wired as Normally Closed contacts to allow the

program to operate as intended. Having the stops wired as Normally Closed (Examine Off)

contacts we are ensuring that when the emergency stop or stops are pressed they cut all power

off that is flowing into the system/ motor. When the emergency stop or stops are pressed, the

contacts open; sending a logic zero into the system. This is safety feature due to the fact we are

not energizing the stops to have them turn off equipment.

In conclusion, this lab allowed us to learn basic instructions in ladder logic that can be used to

accomplish simple tasks like starting and stopping three motors.

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Lab 8B

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Three Interlock Motor Start

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Introduction

The objective of Lab 8B was to design a program on the PLC programming software that would

allow the user to turn on three motors only if the previous motor is energized. Therefore this

program will allow motor one to be turned on at any time the user choses by pressing the start

button for motor one. However motor two and three cannot be turned on at any time. Motor two

will not be able to energize unless motor one is running and motor three will not be able to turn

on unless both motor one, and two are energized. We found that this program can be designed by

simply adding and aliasing a few contacts to the lab 8A program. The first rung was left alone

because no changes needed to be made to energize motor one. To prevent motor two from being

able to start at any time and only after motor one was running we added just one normally open

(Examine On) contact before the start button of motor two. This contact was then aliased to the

energizing contact of the motor one start button thus we can now see that if that contact is not

energized, motor one will not be running and motor two will not be able to run. This same idea

was implemented to rung two. Two contacts were added so motor three would not be able to be

turned on unless motor two and motor one were running. One contact was aliased to the

energizing contact of the motor one start button and the other contact was aliased to the

energizing contact of the motor two start button. With the above programmed properly, this

program will only allow the user to start each motor in numerical order and the stopping of one

motor will also cause any sub sequential motors to also stop.

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Ladder Logic

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Figure 3 Lab 8B Ladder Logic

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Local:3:I.Data.1 (Master_Stop) Local:4:O.Data.1 (Motor1_Run)







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Table 2 I/O Table for Lab 8B

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Figure 4 Hardware Layout for Lab 8B

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Summary

This lab required us to start three motors like lab 8A, but motor two and three couldn’t start

without motor one being already energized. This allowed us to learn how to disable motors we

did not want to start without another motor already running. We were able to accomplish this

requirement by implementing a contact from motor one, on the same rung as motor two. This

would only allow motor two to start once motor one is already energized. We accomplished the

same task for motor three by adding two contacts on the same rung as motor three. One contact

from motor one and the other from motor two. This would only allow motor three to start once

motor one and two were both energized and running.

We soon realized that this was easier said than done with our minimum experience at the time.

After some thinking we realized we had to add Normally Open contacts (aliased to a previous

motor) on the rung of a motor we did not want to start until the previous motor was energized

and running. This proved to be hard to follow at first, but eventually made sense once we had the

program operating as it was intended to.

In conclusion, this lab allowed us to apply our knowledge we gained from lab 8A by having to

start three motors; only this time motor one had to be energized before motor two could start, and

motor one and two had to be energized before motor three could start.

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Lab 9A

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Forward & Reversing Motor


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Introduction

The objective of Lab 9A was to design a program on the PLC programming software that would

allow the user to run a single motor in the forward direction and in the reverse direction. The

program will not allow for instantaneous forward and reverse switching and the stop push button

must be pushed in order to run the motor in the opposite direction. Given the requirements for

the program we saw that we needed to interlock a total of four contacts and only two rungs

would need to be utilized. The first rung we set up for the forward operation of the motor such

that when the normally open start button was pressed, and the energizing contact located in

parallel with the start button would energize and the motor would energize and run in the

forward direction. The reverse operation was set up almost identically. By adding a normally

closed contact on both rungs and interlocking them with the energizing contacts on the opposite

rungs such as the energizing contact on rung one was aliased with a normally closed contact on

rung one and the energizing contact on rung one was aliased with a normally closed contact on

rung 0 we can prevent both rungs being energized at the same time (which would burn out the

contacts) and only allow the motor to run in one direction unless the rung was de-energized first.

For example when the start push button is pushed and the energizing contact energizes, the

normally closed contact on the opposite rung will open disabling that rung until the energizing

contact is de-energized. With the above programmed properly, this program will allow the user

to run a motor in the forward direction or reverse direction but will not allow the user to switch

directions instantaneously.

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Ladder Logic

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Local:3:I.Data.0 (Master_Stop) Local:4:O.Data.0 (Motor_Run_FWD)

Local:3:I.Data.1 (Motor_FWD) Local:4:O.Data.1 (Motor_Run_REV)

Local:3:I.Data.2 (Motor_REV)

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Figure 6 Hardware Layout for Lab 9A

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Summary

This lab required us to start one motor in either the forward direction or reverse direction. Once

the motor was operating in one direction, the motor was not able to instantaneously switch

directions. This was accomplished by having a normally closed contact aliased to the sealing

contacts of the opposite directions on each rung (Rung 0 was aliased to the reverse direction,

Rung 1 was aliased to the forward direction). Upon completion of this lab, we were able to learn

and gain experience in the importance of interlocking motors.

As we started to progress through the lab, we soon hit a road block. This problem came about

when we realized that we cannot have the same output on two different rungs. Once we realized

we had to use to two different outputs to simulate the forward direction and reverse direction we

soon had another problem. This problem was created when we could start the ‘motor’ in both the

forward and reverse directions at the same time! Although this is an easily spotted error, we still

had to figure out how we were going to utilize instructions to interlock the two directions so the

stop button must be pressed before we are able to switch directions. After playing around with a

few different ideas we soon realized we must alias a normally closed contact (on the forward

rung) to the sealing contact of the reverse direction start button. The same thing was

accomplished on the reverse rung, where we had a normally closed contact aliased to the sealing

contact of the forward direction.

In conclusion, this lab was a great learning experience due to the fact we had to do some

troubleshooting to allow the program to operate as we were required.

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Lab 9B

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Instant Forward & Reversing a Motor


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Introduction

The objective of Lab 9B was to design a program on the PLC programming software that wold

allow the user to run a single motor in the forward direction and in the reverse direction with

instantaneous switching. Warning: switching the direction of a motor instantaneously may be

hazardous and could damage the motor and process. Allowing the motor to switch directions

instantaneously, two changes can be made to the configuration of Lab 9A. Given the

requirements for the program we saw that by interlocking the push buttons and the normally

closed contacts (instead of the energizing contacts) on the opposite rungs we could switch the

direction of the motor in a push of a button. If the motor is running in the forward direction and

the user wished to run the motor in the reverse direction, the user would simply press the reverse

start button. By pushing the reverse start push button, the interlocked normally closed contact on

the forward operation rung will open, momentarily breaking the circuit, de-energizing the

energizing contact.

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Ladder Logic

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Local:3:I.Data.0 (Master_Stop) Local:4:O.Data.0 (Motor_Run_FWD)

Local:3:I.Data.1 (Motor_FWD) Local:4:O.Data.1 (Motor_Run_REV)

Local:3:I.Data.2 (Motor_REV)

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Summary

This lab required us to go one step further with the knowledge we gained from lab 9A by

requiring us to be able to switch directions instantaneously. This was accomplished by having a

normally closed contact aliased to the opposing start button. Rung 0 had a contact that was

aliased to the reverse start button, while rung 1 had a contact aliased to the forward start button.

Upon completion of this lab, we would realize that this method of changing directions is not very

practical due to the harm it can do to a motor or system.

As we began to setup the program we quickly realized it was very similar to lab 9A, but a new

problem had arisen. We got to the point where we could start the ‘motor’ in both directions at the

same time (again)! Although we had this error occur in the previous lab, we still had to figure out

a way to use instructions to interlock the two directions. Using our knowledge we had gained

from lab 9A, we quickly thought of a method that should allow us to disable the reverse rung

when we press the forward start button, and vice versa. Once we seen this method working

(normally closed contacts aliased to the opposing stat button), we started to become curious as to

why this method is harmful to motors and other equipment. With some research and guidance,

we learn that this method is bad due to the fact that during the time of switching directions, the

CEMF is combined with the now reversed power supply. This allows for more voltage, which

means more current, which means the motor has to deal with nearly 20 times the rated current

rating of the motor. This could ultimately break the motor and/or other components in the

system.

In conclusion, this lab was a great learning experience due to the fact we learned another way of

interlocking, and how some methods are better than others.

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Lab 10

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Push On / Push Off


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Introduction

The objective of this lab was to design a program on the PLC programming software that would allow

the user to start a simple flasher program. This means that as soon as the start push button has been

pressed that output of the program will flash on and off. As seen in the ladder logic this lab requires that

the program must have a one-shot (ONS). The one-shot is located on rung 1 and it has the sole purpose

of keeping the “Flip/Flop Trigger” output ON for only one scan. Therefore once the one-shot sends a

pulse to the “Digital Memory” sealing contact on rung 1, a “Digital Memory” contact on rung 2 will

energize and close and turn on the Light (Digital Output). Since there is a normally closed light contact

aliased to the output, when the light energizes the normally closed contact will open causing the light to

turn off. At this point in time the parallel branch on rung 2 will energize; the “Digital Memory” normally

closed contact will re-close and the normally open contact also aliased to the light will energize when

the light is ON. Therefore, when the normally closed “Digital Output” contact opens, the normally open

contact closes causing the light to flash ON. This process will repeat every time the one-shot on rung one

pulse the “Digital Memory” output. With all of the above programmed properly this program will allow

the user to start a simple flasher circuit.

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Ladder Logic

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Figure 9 Lab 10 Ladder Logic

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I/O ListingInputs Outputs Internal Inputs

Local:3:I.Data.0 (Digital_Input) Local:4:O.Data.1 (Digital_Memory) One_Shot

Local:4:O.Data.2 (Digital_Output)

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Table 5 I/O Table for Lab 10

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Figure 10 Hardware Layout for Lab 10

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Summary

This lab required us to create a program that will allow us to turn and output on/off every time

the digital input is pressed. This was accomplished by utilizing a one-shot instruction. The one-

shot instruction allows us simulate a pulse every time the digital input is pressed. These pulses

cause changes to the digital memory output, which then toggle the digital output when the rung

is energized. Upon completion of this lab, we were curious to see how this circuit would operate

on its own (Lab 11B).

As the lab progressed, we realized we didn’t fully understand how the circuit was actually

accomplishing the task of switching the output on and off. After reading the description in the

text book and doing some research on the one-shot instruction we quickly realized what we were

missing in the operation of the circuit. The one-shot instruction remembers the value of the input

that was used, and sends it on to the output. When a normally open contact is momentarily

closed, a high (1) is sent to the one-shot, which then turns on the output on that rung. If a

normally open contact is momentarily closed again, the one-shot receives a low (0), which then

turns the output off.

In conclusion, this lab was a great learning experience by introducing us to a new programming

instruction, which allows us to broaden our knowledge on PLC programming.

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Lab 11A

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Motor Time Start


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Introduction


allow the user to start a single motor three seconds after the start push button was pressed. In

order to successfully program this type of operation we decided that utilizing two rungs would be

the easiest way. Rung 0 contains a master stop that was programmed as a normally open but

physically wired as a normally closed button, a start button with an energizing contact, and the

timer is located at the end of the rung. The preset value of the timer was set to “3000” indicating

3000 milliseconds, or 3 seconds. The normally open contact that is aliased to the timers done bit

(DN) is locate on rung 1 with the motor, therefore when the start button is pressed, the

energizing contact will energize, and energize the timer, this will cause the timer to start

counting. Once the timer’s accumulated value equals 3000, the done bit will be activated, closing

the contact on rung 1, energizing the motor. In order for this program to work successfully all the

contacts must be aliased properly. In this case the master stop was aliased to the input card (input

0) and the start button was also aliased to the input card (slot 1). It is crucial that the contact on

rung 1 (Timer_Done) is aliased to the done bit (DN) of the timer, or the rung will never become

energized and the motor will never turn on. The motor must also be aliased to the output card

(output 0) or the light will never turn on. With all of the above programmed properly this

program will allow the user to start a motor three seconds after the start button is pressed.

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Ladder Logic

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Local:3:I.Data.0 (Master_Stop) Local:4:O.Data.0 (Motor) Timer.DN (Timer)

Local:3:I.Data.1 (Motor_Start)

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Summary

This lab required us to create a program that will allow us to start a motor three seconds after the

start button has been pressed. This was accomplished by using a timer on instruction. This

allowed us to delay the starting of the motor by three seconds, once the start button was pressed.

Every time the accumulated value of the timer was equal to the preset value of the timer, he

motor would energize due to the timer contact on the same rung. Upon completion of this lab, we

were able to thoroughly understand the operation of how a timer works.

As we began to set-up the program we realized we had no way of keeping the timer energized

after the start button was pressed momentarily. After looking through our previous labs, we

noticed we needed a sealing contact that would be in parallel with the start button, which would

‘seal’ (close) once energized. As seen in Figure 11, we aliased this contact to the enable bit of the

timer. This was unnecessary since the enable bit of the timer is energized as long as the timer is

counting, so as long as the sealing contact remains energized, the timer enable bit would remain

energized. Once our small issue was resolved the program worked as specified, allowing the

motor to energize three seconds after the start button was pressed.

In conclusion, this lab was a great learning experience by introducing us to a new programming

instruction, which allows us to broaden our knowledge on PLC programming. This new

instruction (the timer) opened our minds as to what was to come next in our future labs.

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Lab 11B

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Push On/ Push Off (Half-Second Flasher)


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Introduction

The objective of lab 11B was to design a program on the PLC programming software that would

allow the user to start a half-second flasher program as soon as power is applied to the program.

The program required the use of a single timer set to a half of a second. With that being said, as

soon as power is applied to the circuit, the timer would begin its count right away. The timer is

configured to reset itself every time the done bit energizes. Once the timer completes its count

the done bit will energize and a normally open contact on rung 1 will energize. When this contact

energizes and closes, the light will become true and turn on. The light will remain energized

through the parallel branch on rung 1. Once the timer has completed its count for a second time,

the normally closed contact in the parallel branch will open causing the light to de-energize. The

light will become energized once again when the timer completes its count for a third time. With

all of the above programmed properly, this program will allow the user to start a half-second

flasher program as soon as they apply power.

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Ladder Logic

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N/A Local:4:O.Data.0 (Flash) Timer1.DN (Timer1)

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Summary

This lab required us to create a program that will allow us to turn an output on & off every ½ a

second automatically. This was accomplished by utilizing the timer instruction. With this timer

set to 500 milliseconds (0.5 seconds), we are able to control the time at which the output turns on

& off. This program begins to work as soon as it is downloaded to the PLC. Using a normally

closed contact aliased to the timer done bit, we are allowing the timer to reset itself ever time the

accumulated value equals the preset value. Upon completion of this lab, we were able to

understand how to use a timer done bit to reset a timer.

As the lab progressed, we encountered the problem of how we were going to be able to reset the

timer automatically without any outside interference. Using our knowledge from the previous

lab, we thought of a way to utilize the done bit of the timer, on the same rung as the timer. We

understood that every time the timer accumulated value equals the preset value, that the timer

done bit would be energized. This would cause normally closed contacts to open, and normally

open contacts to close, if aliased to the done bit. Therefore, we realized that maybe if we place a

normally closed contact on the same rung as the timer; that when energized will reset the timer

back to zero and start its timing sequence again.

In conclusion, this lab was a great learning experience by allowing us to learn how to create a

program that will operate on its own without any outside interference, once started.

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Lab 12A

50

Six Motor Time Start Using Timer Instruction


FINAL

Introduction

The objective of this lab was design a program on the PLC software that would start six motors

one after the other. The first motor would turn on as soon as the start button was pressed and the

remaining motors would start 3 seconds after the previous motor has started. This lab only

required one start push button and one master stop button to de-energize the whole process when

pressed. Rung 0 was programmed to energize a series of contacts to energize and turn on the

motor on rung 1. In this case the master stop button was only needed on the first rung because

de-energizing the first rung would ultimately de-energize motor one and everything subsequent

to that motor. This program was programmed so everything would energize in sequence, three

seconds after one another. For example once the start push button has been pressed, the first

motor will energize and turn on. The sealing contact on rung 2 (Timer1) will also energize when

the sealing contact on rung 1 energizes, allowing the timer on rung 2 to start counting. Once the

timer reaches the accumulated value of 3000, a contact on rung 3 will energize that is aliased to

the done bit (DN) of the timer, this will enable another timer to start its three second count. The

done bit of Timer1 is also aliased to a contact on rung 7, this rung contains the second motor,

therefore when the contact energizes the motor will energize and turn on. This operation was

duplicated several more times to successfully turn on all the motors according to the

requirements of the lab. With the above programmed properly, this program will allow the user

to start a total of six motors in a timed sequence of three seconds after the first motor is

energized.

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Ladder Logic

52

Figure 15 Lab 12A Ladder Logic (1)

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53


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Local:3:I.Data.0 (Master_Stop) Local:4:O.Data.1 (Motor1) Seal

Local:3:I.Data.1 (Motor_Start) Local:4:O.Data.2 (Motor2) Timer1.DN (Timer1)

Local:4:O.Data.3 (Motor3) Timer2.DN (Timer2)


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55

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Summary

This lab required us to create a program that will allow us to turn on six motors at different

times. This was accomplished by utilizing five timers. By using these timers, we were able to

start the motors in a timed sequence (three seconds after each other). A preliminary requirement

of starting motor one immediately, once the start button has been pressed. Each motor after

motor one is separated by a three second timer, which allows the subsequent motors to start in

order. Upon completion of this lab, we were able to utilize timers to start numerous motors in a

desired order.

As we began to set up the program we realized we needed a way to separate motors once the

start push button was pressed. This created a problem because each motor had to start three

seconds after the motor before it had started. Therefore, by using some previous knowledge we

had gained from early labs, we knew we had to use the timer done bits to accomplish this task.

Once we had created a program that would start motor one once the start button was pressed, we

used a timer on a separate rung and another output after the timer on another rung. This allowed

us to test our theory. After proving that we needed to use a normally open contact aliased to the

timer done bit in series with the motor, we used the same idea to start the other motors as seen in

Figures 15 & 16.

In conclusion, this lab was a great learning experience by proving that timers can be used to start

different motors or equipment in an organized sequence.

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FINAL

Lab 12B

58

Six Motor Time Start and Timed Shutdown


FINAL

Introduction


allow the user to start six motors in a timed sequence of three seconds after the push button is

pressed and motor one is energized. In addition, the program will have a timed shutdown

sequence of four seconds starting with motor six; Therefore the shutdown sequence will be,

motor 6, motor 5, motor 4, motor 3, motor 2, and motor 1. Given the requirements for this lab, a

total of one master stop button and one start button will be used. Once the start button is pressed,

the first motor will energize and the first timer will begin its three second count. Once the

accumulated value of the timer reaches 3000, the second motor will become energized and the

second timer will also begin another 3 second count. This same sequence of operations will

continue for all the remaining motors, so that all six motors eventually turn on. This program

should be identical to the program in lab 12A. However in addition, the Timer5 done bit is also

aliased to a contact on rung 7, once this contact is energized, Timer1_off will begin its four

second count. Once the accumulated value has reached 4000, a normally closed (Examine OFF)

contact will open on rung 17. Since motor six is on rung 17, the motor will de-energize and turn

off. The Timer1_off done bit is also aliased to a normally open contact on rung 8 which allow

Timer2_off to begin its four second count. Once the timers’ accumulated value reaches 4000,

motor 5 will de-energize and turn off, and Timer3_off will begin counting. This sequence will

continue until all motors are turned off. With the above programmed properly, this program will

allow the user to start a total of six motors in a timed sequence of three seconds, which will

automatically turn off in a timed sequence of four seconds starting with the sixth motor.

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Ladder Logic

60

Figure 18 Lab 12B Ladder Logic (1)

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61


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Timer1_off.DN (Timer1_off)






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Hardware AutoCAD Listing

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Summary

This lab required us to create a program that will allow us to turn on & off six motors at different

times. This was again accomplished using timers, as seen in lab 12A, but this time we are using

11 timers. The first five timers are used exactly the same way as in the previous lab, except the

done bit of timer five is used to start the timing of the sixth timer (Timer1_Off). The sixth timer

is used to turn off motor six by opening a normally closed contact that is aliased to its done bit.

The same process is used for timers seven (Timer2_Off), eight (Timer3_Off), nine

(Timer4_Off), ten (Timer5_Off), and eleven (Timer6_Off); which turn off motors five, four,

three, two, and one respectively. Upon completion of this lab, we were able to utilize timers to

stop numerous motors in a desired order.

As the lab progressed, we encounter an issue while trying to turn off the motors, once they were

all on. The problem started when we were trying to decide how we were going to keep the

motors energized until we wanted to turn them off. After playing around with some different

ideas, we came to the conclusion that we must use normally closed contacts on all of the motor

rungs. These contacts were to be aliased to the desired four second timer to decide their shut

down sequence. This allowed each motor to turn on when the rung become energized. Once the

desired Timer(#)_Off done bit was energized, we were able to see that the normally closed

contact would then open, ultimately de-energizing the rung and turning off the motor.

In conclusion, this lab was a great learning experience by proving that timers can be used to turn

off different motors or equipment in an organized sequence in addition to turning them on.

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Lab 12C

66

Six Motor Time Start and Timed Shutdown with Automatic Recycled Start-up


FINAL

Introduction

The objective of lab 12C was to design a program on the PLC programming software that would

allow the user to start six motors in a timed sequence of three seconds, and then turn the motors

off in reverse order in a timed sequence of four seconds starting with motor six. In addition, the

program will automatically start the turn on sequence once all motors have been de-energized.

Therefore the program will continuously turn on all the motors and turn them off until the master

stop button is pressed. This program should only contain a total of one master stop button and

one start button. The turn on sequence will be identical to that of lab 12A and lab 12B, where as

soon as the start button is pressed motor one will energize and a three second timer will begin to

count. When the timer’s accumulated value reaches the preset value of 3000, the done bit will

become energized along with a contact aliased to the timers done bit, therefore this contact will

close and the next motor will become energized and another timer will begin counting to start the

next motor in sequence. The turn off sequence is also very similar to that of lab 12B. When the

last on timer (Timer5) counts to three seconds, the sixth motor will become energized and the

first off timer will also begin counting. Once the first off timer (Timer1_off) counts to four

seconds, a total of two contacts will energize, both of which are aliased to the done bit of the

timer. One normally closed contact on the same rung as Motor 6 will open causing Motor 6 to

de-energize, and another normally open contact will close to allow the second off timer to begin

its four second count. This operation will proceed until all motors are off. Once the final off timer

has completed its count of four seconds, the done bit of that timer will energize causing Motor 1

to de-energize. A normally open contact will also energize on rung 13 causing the Reset timer to

begin its count of one second. Once the Reset timer has completed its count a normally closed

contact on rung 2 will open momentarily causing the accumulated values of all the timers to

return to 0. Therefore the contact will re-close and Timer1 will restart counting since the seal

contact is still energized.

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Ladder Logic

68Figure 22 Lab 12C Ladder Logic (1)

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69

Figure 23 Lab 12C Ladder Logic (2)

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70

Figure 24 Lab 12C Ladder Logic (3)

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71

Table 10 I/O Table for Lab 12C

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Reset.DN (Reset)

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73

Figure 25 Hardware Layout for Lab 12C

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Summary

This lab required us to create a program that will allow us to automatically restart the turning on

& off of six motors at different times. This was accomplished by adding one more timer to the

previous labs requirements. This timer is used to reset the whole program, by opening the

normally closed contact on the same rung as Timer1. This causes all of the timers’ accumulated

values to reset to zero. Upon completion of this lab, we were able to utilize a timer to reset other

times to allow for our program to restart.

As we began to set-up the program we realized we had to come up with a way to reset all of the

timers’ accumulated values to zero. We solved this issue by adding another timer, which we

would call Reset, to remind us the use of this timer. By adding a normally closed contact (aliased

to the Reset done bit) in series with Timer1, we were able to de-energize Timer1. This caused all

subsequent rungs with timers and outputs to become de-energized, due to the various contacts

that opened (See Figures 22, 23, & 24). By de-energizing Timer1 and the other timers, we were

able to reset the accumulated value back to zero. This allowed the sequence to start over, once

the reset timer had been de-energized.

In conclusion, this lab was a great learning experience by proving that we can reset a program by

just using a timer.

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Lab 12D

75

Six Motor Time Start and Timed Shutdown with Automatic Recycled Start-up Four Times Only


FINAL

Introduction

The objective of lab 12D was to design a program on the PLC programming software that would

allow the user to start six motors in a timed sequence of three seconds, then turn the motors off in

reverse order in a timed sequence of four seconds starting with motor six and automatically

restarting this process. In addition, the program will include a counter, therefore limiting the

amount of repeats to a desired value. This lab requires that counter to count to four repeats and

then de-energize the circuit. The turn on sequence will be identical to that of lab 12A, 12B and

lab 12C, where as soon as the start button is pressed motor one will energize and a 3 second

timer will begin to count. When the timer’s accumulated value reaches the preset value of 3000,

the done bit will become energized along with a contact aliased to the timers done bit, therefore

this contact will close and the next motor will become energized and another timer will begin

counting to start the next motor in sequence. The turn off sequence is also very similar to that of

lab 12B and 12C. When the last on timer (Timer5) counts to three seconds, the sixth motor will

become energized and the first off timer will also begin counting. Once the first off timer

(Timer1_off) counts to four seconds, a total of two contacts will energize, both of which are

aliased to the done bit of the timer. One normally closed contact on the same rung as Motor 6

will open causing Motor 6 to de-energize, and another normally open contact will close to allow

the second off timer to begin its four second count. This operation will proceed until all motors

are off. Once the final off timer has completed its count of four seconds, the done bit of that will

energize, causing Motor 1 to de-energize. A normally open contact will also energize on rung 13

causing the Reset timer to begin its count of one second. Once the Reset timer has completed its

count, a normally closed contact on rung 2 will open momentarily causing the accumulated

values of all the timers to return to 0. The Reset timer will also close a normally open contact on

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rung 15, which will energize the counter momentarily until all timers are reset. This will cause

the counters accumulated value to increment by 1. Once the counters accumulated value reaches

the preset value the done bit will become energized. This will cause a normally closed contact on

rung 0 to energize and open, thus de-energizing the entire circuit. When the sealing contacts de-

energize, the counter reset will become energize therefore resetting the counter accumulated

value back to 0. The program will now be ready for the user to hit the start button again to begin

the process. With the above programmed properly, this program will allow the user to start a

total of six motors in a timed sequence of three seconds, which will automatically turn off in a

timed sequence of four seconds starting with the sixth motor and repeat a total of four times.

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Ladder Logic

78

Figure 26 Lab 12D Ladder Logic (1)

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79


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Local:3:I.Data.1 (Motor_Start) Local:4:O.Data.2 (Motor2) Timer1_On.DN (Timer1_On)

Local:4:O.Data.3 (Motor3) Timer2_On.DN (Timer2_On)










Reset.DN (Reset)

Counter1.DN (Counter1)

81

Table 11 I/O Table for Lab 12D

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82

Figure 29 Hardware Layout for Lab 12D

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Summary


& off of six motors at different times, a total of four times. This was accomplished by utilizing

the up counter instruction. The up counter, allows us to stop the program from repeating more

than four times. By using a normally closed contact (Aliased to the counter done it) on rung 0,

we are able to de-energize the sealing contact, which de-energizes the whole program. Upon

completion of this lab, we were able to utilize a counter to record how many times the process

has repeated its cycle.

As the lab progressed, we encountered an issue when we wanted to utilize the up counter to stop

the program after it had repeated four times. While using the counter, we quickly learned that the

program would keep repeating even though the accumulated value had reached the preset value.

Therefore, we inquired the assistance of the RSLogix help feature to assist us in the operation of

the counter. We then realized that the counter had a done bit just like the timer. This allowed us

to utilize a normally closed contact (Aliased to the counter done bit) in series with the sealing

contact; which would open once the accumulated value of the counter was equal to the preset

value of the counter. This caused the seal to de-energize, which ultimately de-energized motor 1,

which caused all subsequent rungs to de-energize.

In conclusion, this lab was a great learning experience by introducing us to the up counter

instruction and allowing us to experiment with its capabilities.

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Lab 13A

84

Six Motor Time Start and Timed Shutdown with Automatic Recycled Start-up Four Times Only Using Limit Test


FINAL

Introduction


allow the user to start six motors in a timed sequence of three seconds, then turn the motors off in

reverse order in a timed sequence of four seconds starting with motor six. The program will also

automatically start the turn on sequence once all motors have been de-energized; the process will

be limited to four repeats. The program must be programmed only with the Limit test operation.

Therefore each motor will be turned on using a Limit test. In the program a total of two timers

were used, one timer (Timer) is used to establish the test value for each Limit instruction. The

timer has a preset value of 40000 (40 seconds) which is the total time for the process to complete

one cycle of operation. Each limit instructions “Test” value is aliased to the Timer.ACC,

therefore when the timer’s accumulative value reaches 1 the first limit instruction will become

true and energize the first motor. Each Limit was programmed identically with only the lower

and upper limits changing according to when the specific motor needed to be turned on. The

motors will stay energized as long as the timer’s accumulated value is within the lower limits and

high limits. This program was programmed to meet the requirements of the lab, therefore each

motor will turn on three seconds after the previous motor has energized, and each motor will turn

off in a timed sequence of four seconds in reverse order starting with Motor 6. Since the first

Limit has a high limit of 38000, all motors will be turned off when the accumulated value of the

timer reaches 40000. When “Timer” finishes its count the done bit will energize, also energizing

a normally closed contact on rung 11, thus causing the counter to increment by one in its

accumulative value. Once the counter accumulated value reaches the preset value, the counters

done bit will become energized, which will cause a normally closed contact on rung 0 to open

and de-energize the process. To restart the process the user must push the start button again. To

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allow for the user to simply push the start button to start the process again, an extra reset

instruction was programmed to reset the counter. When the counters accumulated value is equal

to the preset value the counter will de-energize rung 0 as explained before, the sealing contacts

will also de-energize. The normally closed contact on the same rung is open during the normal

operation period of the process, but when the counter causes rung 0 to de-energize, the sealing

contact on rung 4 closes therefore resetting the accumulated value of the counter back to 0. Since

the accumulated value of the timer is no longer equal to the preset value, the normally closed

contact on rung 0 closes therefore enabling the rung to become energized once again as soon as

the start button is pressed. With the above programmed properly, this program will allow the

user to start a total of six motors in a timed sequence of three seconds, which will automatically

turn off in a timed sequence of four seconds starting with the sixth motor and repeat the process

four times.

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Ladder Logic

87


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88


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Local:3:I.Data.1 (Motor_Start) Local:4:O.Data.2 (Motor2) Timer.DN (Timer)

Local:4:O.Data.3 (Motor3) Timer_Reset.DN (Timer_Reset)

Local:4:O.Data.4 (Motor4) Limit Tests x 6

Local:4:O.Data.5 (Motor5) Counter.DN (Counter)

Local:4:O.Data.6 (Motor6)

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Summary



the limit instruction. The limit instruction allows us to control when the rung will be true, by

watching the accumulated value of a timer. As long as the accumulated value of the timer is

between the range that is specified by the limit instruction, the rung will be true. Once the

accumulated value is outside of the specified range, the rung will be false. Upon completion of

this lab, we were able to utilize the limit instruction to control when we wanted each motor to

turn on and off.

As we began to set-up the program we realized that we had to tell the limit instructions which

values to test so they would operate when we wanted them to. This again led us to the RSLogix

help feature, where we quickly learned that the limit instruction required an alias or value of

some sort in order to operate. Therefore, after some more critical thinking, we realized we had to

use a timer that would have a preset value greater than the duration of the sequence of the motors

turning on & off. Once we had the timer set up, we aliased the limit instructions test value to the

Timer.ACC. This allowed the limit instruction to ‘test’ all the values that would be provided by

the accumulated value of the timer.

In conclusion, this lab was a great learning experience by introducing us to the limit instruction

and allowing us to learn how we can utilize this instruction to control the operation of outputs.

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Lab 13B

92

Six Motor Time Start and Timed Shutdown with Automatic Recycled Start-up Four Times Only; Using Sequencer Output


FINAL

Introduction


allow the user to start six motors in a timed sequence of three seconds, and then turn the motors

off in reverse order in a timed sequence of four seconds starting with motor six. The program

will also automatically start the turn on sequence once all motors have been de-energized; the

process will be limited to four repeats. The program must be programmed only with the

sequencer output. A total of one master stop button and one start button is needed to start the

process. Once the start push button is pressed the sealing contact energizes, therefore the

normally closed sealing contact on rung 1 will open enabling the counter to count. A sealing

contact on rung 2 is also energized enabling the timer to start counting. Once the accumulated

value of the timer reaches the preset value, a normally open contact aliased to the timers done bit

is energized on rung 3 with the sequencer. The timer also resets itself with the normally closed

contact aliased to the timers done bit; every time the timer’s accumulated value equals the preset

value the contact opens momentarily then re-closes since the accumulated value will not be equal

to the preset value. Therefore every time the timer counts to one second (or the desired

programmed time) the sequencer will move to its next programmed position. The programmed

positions are shown below in Figure 33. The mask of the sequencer is also programmed so only

six outputs can be changed. Once the sequencer has completed the “length” of 40 moves the

done bit will become energized, this done bit is aliased with a normally open contact on rung six

with the counter. Therefore every time the sequencer finishes 40 moves (including the motors

turning on and turning off), the counter will increment the accumulated value by one. When the

counters accumulated value equals the preset value, the normally closed contact on rung 0 will

momentarily open and de-energize the circuit. This will cause the sealing contact on rung 7 to

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open, shifting a 0 into the move instruction. The move instruction will then move the 0 (low) into

the sequencer causing all the outputs to de-energize and the process to stop. If the MOV

instruction is not used the sequencer will stop in the position it was stopped in meaning outputs

may be left on. Referring back to when the counter de-energizes the circuit; this happens only for

a brief second because the normally closed contact on rung 1 will re-close, energizing the

counter reset instruction. Therefore the process may be started again by simply pressing the start

push button. With the above programmed properly, this program will allow the user to start a

total of six motors in a timed sequence of three seconds, which will automatically turn off in a

timed sequence of four seconds starting with the sixth motor and repeat the process four times.

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Sequencer Setup

95

Figure 33 Array for Sequencer Control

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Ladder Logic

96Figure 34 Lab 13B Ladder Logic

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Local:3:I.Data.1 (Motor_Start) Local:4:O.Data.1 (Motor2) Timer.DN (Timer)

Local:4:O.Data.2 (Motor3) Timer_Reset.DN (Timer_Reset)

Local:4:O.Data.3 (Motor4) Sequencer Output (Control)

Local:4:O.Data.4 (Motor5) Counter.DN (Counter)

Local:4:O.Data.5 (Motor6) MOV (Move)

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Summary



the sequencer output instruction. The sequencer output instruction allows us to control when

each output is to be turned on or off by changing position according to an array. This array

allows for various combinations of outputs to be controlled and read by the sequencer. Also, by

creating a mask we are able to tell the sequencer which outputs we want it to control and those

we do not want it to control. Upon completion of this lab, we were able to utilize the sequence

output instruction to control when we wanted each motor to turn on and off.

As the lab progressed, we encountered a problem when we wanted the outputs to de-energize and

the sequencer to reset its position to zero. We noticed this was an issue when we tried stopping

the program while it was in the middle of its operation. By inquiring the assistance of our

instructor and the help feature on RSLogix, we were able to see that we had to utilize a MOV

(Move) instruction to ‘move’ a zero into the position of the sequencer, once the stop button was

pressed. Once we had set-up the MOV instruction, we still had an issue. The MOV instruction

was turning our outputs off, but our sequencer was still at the position it was stopped at (it did

not reset to zero). Therefore we had to use a reset instruction aliased to the control portion of the

sequencer. This allowed us to reset the sequencer position to zero when the stop button was

pressed, ultimately allowing us to start the sequence from the beginning.

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In conclusion, this lab was a great learning experience by introducing us to the sequencer output

instruction and allowing us to use it to control different outputs by controlling there state

(On/Off).

Lab 14A

100

Traffic Lights with Delayed Red Lights (Timers Inst.)

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Introduction


allow the user to start a traffic light with a total of 12 lights. The program was designed for a

basic traffic light with, two reds, two greens, and two yellows (North-South, East-West). The

lights will be energized for a fixed length of time such as; the red lights will be on for five

seconds, the green lights will be on for four seconds, and the yellow lights will be on for three

seconds. The program will begin as soon as the start push button is pressed. When the start

button is pressed, all seal contacts will become energized and all four red lights will turn on. As

seen in Figure 36 below, all red lights are located on rung 7 in a parallel branch. There are a total

of six timers used in the program and each are very necessary with respect to the operation of the

program. The first timer tagged “Till_Green1” will energize once the sealing contact is

energized. Once this timer has completed its five second count (meaning all the red lights have

been on for five seconds) a contact on rung 2 will energize to start the “Till_Yellow1” timer and

a normally closed contact will energize and open on rung 7, therefore the North and South red

lights will turn off. A normally open contact on rung 8 will also energize turning on the North

and South green lights. Once the timer “Till_Yellow1” has completed its four second count, the

normally closed contact on rung 8 will energize and open, therefore turning off the green lights

and a normally closed contact on rung 9 will energize, turning on the North and South yellow

lights. In addition, the “Till_Yellow1” timer’s done bit will energize a normally open contact on

rung 3, allowing the timer “Till_Red1” to begin its three second count. After the timer

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“Till_Red1” has completed its count, the North and South lights will return to their red state.

This process is then repeated with different timers that correspond to the East and West sides.

Once the East and West lights have turned have turned yellow the “Reset” timer will begin its

three second count. This will allow the East and West lights to remain on for three seconds. Once

the Reset timer has completed its count, the done bit will energize and couple of contacts will

energize. A normally closed contact will open on rung 11 causing the East and West yellow

lights to de-energize and turn off. A normally closed contact will energize and open on rung 1

causing the accumulated values of all the timers to return to 0, therefore the “Reset” timer will

reset and the normally closed contact (Reset.DN) will de-energize and close, thus allowing the

timer “Till_Green1” to begin counting again. The process will repeat until the master stop push

button is pressed and de-energizes all the sealing contacts. With all of the above programmed

properly, this program will allow the user to start a timed sequence of lights that can be

configured as a traffic light.

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Ladder Logic

103Figure 36 Lab 14A Ladder Logic (1)

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Local:3:I.Data.0 (Master_Stop) Local:4:O.Data.1 (North_Red) Seal

Local:3:I.Data.1 (Start) Local:4:O.Data.2 (East_Red) Reset.DN (Reset)

Local:4:O.Data.3 (South_Red) Till_Green1.DN (Till_Green1)

Local:4:O.Data.4 (West_Red) Till_Yellow1.DN (Till_Yellow1)

Local:4:O.Data.5 (North_Green) Till_Red1.DN (Till_Red1)

Local:4:O.Data.6 (East_Green) Till_Green2.DN (Till_Green2)

Local:4:O.Data.7 (South_Green) Till_Yellow2.DN (Till_Yellow2)

Local:4:O.Data.8 (West_Green)

Local:4:O.Data.9 (North_Yellow)

Local:4:O.Data.10 (East_Yellow)

Local:4:O.Data.11 (South_Yellow)

Local:4:O.Data.12 (West_Yellow)

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Summary

This lab required us to create a program that will allow us to control traffic lights with the use of

timers. This was accomplished by strategically placing outputs and timers. By keeping all of the

timers in order, we were able to configure different rungs to energize at desired times. Also by

keeping the outputs (Red, Green, & Yellow lights) organized, we were able to quickly set up a

program to control the lights. Upon completion of this lab, we were able to utilize timers to

control the length of time each pair of lights were on.

As we began to set-up the program we realized we needed a way to keep at least two red lights

on while the other directions where changing (Green and Yellow). After a while of playing with

some different ideas, we came up with the idea to throw both pairs of red lights in parallel. This

allowed us to separately control their states with different timers (See Rung 7 in Figure 36). This

also gave us the ability to turn on the one set of red lights again by placing another contact in

parallel to an already existing one. By doing this we can switch the direction of which lights are

red at a given time, allowing us to ensure at least two directions have red lights active at all

times.

In conclusion, this lab was a great learning experience by allowing us to control traffic lights

with timers, making us think of ways to utilize these previously learned instructions to meet the

requirements of this lab.

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Lab 14B

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Traffic Lights with Delayed Red Lights (Limit Inst.)


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Introduction


allow the user to start a traffic light with a total of 12 lights. In addition the program must be

programmed with the Limit Test Instruction along with any other necessary instructions. The

program was designed for a basic traffic light with, two reds, two greens, and two yellows

(North-South, East-West). The lights will be energized for a fixed length of time such as; the red

lights will be on for five seconds, the green lights will be on for four seconds, and the yellow

lights will be on for three seconds. The program will begin its sequence as soon as the start push

button is pressed. There are a total of seven limit test instructions that were used in the designing

of this program, each of which will be testing the accumulated value of one timer and the lights

will energize with respect to the low and high limits of the limit test instruction on the same

branch as the specific lights. With that being said, once the start button is pressed all sealing

contacts are energized and the main timer begins to start its count. The timer is located on rung 1

and has a preset value of 24000, this is the total time it takes for the traffic light to complete one

full sequence with respect to the time specifications of each light. All of the red lights will be

energized and turn on when the accumulated value of the timer equals 1. Once the timer reaches

an accumulated value of 5000, the North and South red lights will de-energize, and the North and

South green lights will turn on until the accumulated value of the timer reaches 9000. Once the

accumulated value of the timer reaches 9000, the green lights will de-energize and the North and

South yellow lights will energize until the accumulated value of the timer reaches 12000. When

the timer reaches 12000, the North and South yellow lights de-energize and the North and South

lights re-energize due to the two parallel limit test instructions on rung 2. The North and South

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red lights will remain on until the East and West side lights complete their full sequence. The

cycle will end when the accumulated value of the timer reaches 24000, at this point in time the

timers done bit will energize and the normally closed contact on rung 1 will energize therefore

resetting the accumulated value of the timer back to 0. The “Reset.DN” contact then re-closes

and the timer begins its count again and the light sequence repeats. With all of the above

programmed properly, this program will allow the user to start a timed sequence of lights that

can be configured as a traffic light.

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Ladder Logic

111Figure 39 Lab 14B Ladder Logic (1)

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Local:3:I.Data.1 (Start) Local:4:O.Data.2 (South_Red) Timer.DN (Timer)

Local:4:O.Data.3 (North_Green) Limit Instruction x 7

Local:4:O.Data.4 (South_Green)



Local:4:O.Data.7 (East_Red)

Local:4:O.Data.8 (West_Red)

Local:4:O.Data.9 (East_Green)




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Summary

This lab required us to design a program that would run a basic traffic light with a total of twelve

lights using the Limit Test instruction. After having used the Limit test instruction in a previous

lab the programming of this lab went fairly smoothly. Just as in lab 13A, one timer was used for

the Limit instructions. A different limit instruction was programmed with different low limits

and high limits in order for the lights to turn on in the proper sequence.

This is where we encountered our first and only problem. In the beginning we could not figure

out how to turn the North and South Red lights back on, and stay on for the duration of the East

and West cycle. Since the North and South Red lights had to be turned on at the half way point

of the program (which was twelve seconds in), we came to the conclusion that a limit test

instruction had to be placed in parallel of the one currently on rung 2. Thus by making the low

limit twelve seconds and the high limit twenty-four seconds we were able to turn the North and

South Red lights back on for the duration of the East and West light cycle.

In conclusion, this lab had us apply our knowledge gained from the previous lab using the Limit

Test instruction to a challenging yet practical lab of controlling a traffic light.

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Lab 14C

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Traffic Lights with Delayed Red Light (Sequencer O/P Inst.)


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Introduction

The objective of lab 14C was to design a program on the PLC programming software that would

allow the user to start a traffic light with a total of 12 lights. In addition the program must be

programmed with the Sequencer Instruction along with any other necessary instructions. The

program was designed for a basic traffic light with, two reds, two greens, and two yellows

(North-South, East-West). The lights will be energized for a fixed length of time such as; the red

lights will be on for five seconds, the green lights will be on for four seconds, and the yellow

lights will be on for three seconds. The program will begin its sequence as soon as the start push

button is pressed. Once the start push button is pressed all sealing contacts are energized and the

timer begins its count. The timer was configured to have a preset value of 1000 and when the

done bit energizes the timer will reset its accumulated value back to 0, therefore continuously

counting to 1000 until the sealing contact is de-energized. The timer must be configured like this

in order to keep shifting the position of the sequencer. With that being said the array of the

sequencer must also be edited accordingly. The configuration of the array that was used with our

sequencer can be observed in Figure 42. When the timer’s accumulated value reaches 1000 the

done bit of the timer energizes and a normally open contact on rung 2 will energize, thus

changing the sequencers position to the next position in the array. Each “1” in the array represent

a high output therefore the number of 1’s in the position represents how many lights are on. With

that being said the sequencers destination must be the output card to physically turn on the lights.

Each position in the array represents a different state, for example “1111 1111 1111” represents

all the red lights energized. Each set of 1’s is highlighted above to further indicate which set of

1’s affect what colour of lights. The MOV instruction must be used if the user wished to stop the

program. Once the stop button is pressed, the sealing contact will de-energize and close therefore

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moving a 0 to all of the outputs. The reset command must also be used, once the sealing contact

de-energizes and closes, the sequencer is reset back to position 0. Therefore all the outputs are

shut off and the sequencer is ready to start from the first position when the start button is pushed

again. With all of the above programmed properly, this program will allow the user to start a

timed sequence of lights that can be configured as a traffic light.

Sequencer Setup

Figure 42 Array for Sequencer Control

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Ladder Logic

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Figure 43 Lab 14C Ladder Logic

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Local:3:I.Data.1 (Start) Local:4:O.Data.1 (South_Red) Timer.DN (Timer)

Local:4:O.Data.2 (North_Green) Sequencer Output (Control)

Local:4:O.Data.3 (South_Green) MOV (Move)

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Local:4:O.Data.6 (East_Red)

Local:4:O.Data.7 (West_Red)

Local:4:O.Data.8 (East_Green)




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Summary

This lab required us to design a program that would run a basic traffic light with a total of twelve

lights using the sequencer output instruction. Since the sequencer output instruction was used in

a previous lab we already had some experience setting it up. From our experience we knew that a

timer must be programmed along with the sequencer, to change the sequencer position to the

next position configured in the array. Therefore the program was designed such that; when the

start button is pressed all sealing contact will become energize and the timer would being its

count of one second, each timer the timer completed its count, the done bit would energize and

the sequencer would change to the next position. The MOV instruction must also be configured

to shift a zero into the sequencers current position in order to stop the process.

Since this lab required us to set up the sequencer with a larger array we encountered some small

difficulties. The organization of the lights was the most difficult task that we encountered during

this lab. The problem extended outside of the program to how the outputs were wired. The

outputs needed to be wired a specific way so we could see if the outputs were acting like a traffic

light (changing in pairs such as North, South and East, West). Once the outputs were wired

correctly with respect to the operation of a normal traffic light, the program operated perfectly.

In conclusion, this lab provided us with a challenge as well as with a practical application for our

program using a sequencer output instruction.

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Lab 15A

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HMI for 1 Motor Start/Stop


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Introduction

The objective of this lab was to design a program on the PLC programming software and a

program on the Rockwell Software that would allow the user to start and stop a single motor from

the computer using buttons programmed in the Rockwell Software. The PLC program was

designed with a basic stop button, a start button with a sealing contact, and a motor as an output.

In addition to this basic set-up two extra buttons were programmed in, HMI_Stop and

HMI_Start. These buttons are used by the Rockwell Software to start and stop your program. In

the Rockwell Software, each button and motor was given an address that corresponded to the

PLC program. Once the two buttons and motor were configured from the software’s library, the

software was then able to start and stop the motor. When the motor is started, the motor image on

the software turned green, indicating it was on. When the stop button was pressed the image of

the motor would turn red indicating it was off. With both of these programs programmed

properly the user is able to start and stop a motor from a computer.

Even though the main objective of this lab was to design a simple program that would start and

stop a motor, we were encouraged to play with the software and learn more about it. We found

that the human-machine interface (HMI) was very user friendly and it required little effort to

start and stop a motor. By examining the HMI software’s available library, we noticed that the

HMI can be used for a large variety of process control applications.

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Figure 45 Examples of RSView 32 Software Menus

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Ladder Logic

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Figure 47 Example of A Motor Running (Green) and of A Motor Not Running (Red)

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Local:3:I.Data.2 (Start) Local:4:O.Data.1 (Motor) HMI_Stop

Local:3:I.Data.3 (Master_Stop) HMI_Start

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Figure 48 Example of RSView 32 Window; Where Tags Are Created and Matched With Their Corresponding ‘Tag’ In The RSlogix 5000 Program (One Motor)


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Summary

This lab required us to design a simple program that would be able to start and stop a motor. We

then had set up our own network using RSLinx and set up an HMI in the RSView 32 program.

This lab presented us with a lot of new software that we were required to work with. The first

thing that must be done is the network you plan to connect to the PLC must be configured. After

the network was configured we had to design the PLC program that would allow us to start and

stop one motor. The next step was to download the program to the PLC using the network we

configured. We then proceeded to learn our way through the RSView 32 software and configure

our HMI so the process can be controlled through the buttons configured in the software.

The first part of the lab went smoothly as there was nothing to difficult. It wasn’t till we started

trying to set up the HMI software that we experienced our first problems. We tried to follow the

steps provided precisely but some important factors were unclear or left out. At first we found

the configuration of the tags difficult because we did not know if they had be to named the same

as in our PLC program, so we just named them the same anyway. The next problem we ran into

was setting up the OPC server to use. We quickly discovered that the correct OPC server said “In

Process” under the “Type” heading. This lab took about 6 hours to complete because each time,

we had to re-configure our own network, so we also decided to start fresh with the HMI

program. By the third time of going through the lab, the instructions were barely used since we

were more familiar with the program. In the end we successfully set up the HMI program to

work with our PLC program, and the benefits of using the HMI became clear to us.

In conclusion, this lab gave us the opportunity to the learn how to use the HMI in the RSView 32

program and configure our own network to communicate with the PLC.

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Lab 15B

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HMI for 3 Motor Start/Stop


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Introduction

The objective of this lab was to design a program on the PLC programming software and a

program on the Rockwell Software that would allow the user to start and stop three motors from

the computer using buttons programmed in the Rockwell Software. The PLC program was

designed with a three basic stop and start buttons with a sealing contact for each, and three

motors as outputs. In addition to this basic set-up two extra buttons were programmed in for each

motor a, HMI_Stop and a HMI_Start. These buttons are used by the Rockwell Software to start

and stop your program. In the Rockwell Software, each button and motor was given an address

that corresponded to the PLC program. Once the six buttons and three motors were configured

from the software’s library, the software was then able to start and stop the motors. When the

motor is started, the corresponding motor image on the software turned green, indicating it was

on. When the stop button was pressed the image of the motor would turn red indicating it was

off. With both of these programs programmed properly the user is able to start and stop three

motors from a computer.

This lab allowed us to further experiment with the operation of the HMI software. By completing

the lab we noticed that there was very little difficulty in starting and stopping three motors

compared to the last lab where only one motor had to be programmed. In this lab the visual

effects and capabilities of the HMI became more prominent as we were dealing with more

motors. The HMI gave us the ability to visually see what motor was energized and what motor

was not energized. This capability can be very useful for large operations like in a factory, where

the motors controlling your process may be scattered or further away.

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Ladder Logic

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Figure 51 Example of Three Motors Running (Green) and Three Motors Not Running (Red)

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Local:3:I.Data.1 (Stop_1) Local:4:O.Data.1 (Motor_1) HMI_Master_Stop

Local:3:I.Data.2 (Start_1) Local:4:O.Data.2 (Motor_2) HMI_Stop_1

Local:3:I.Data.3 (Stop_2) Local:4:O.Data.3 (Motor_3) HMI_Start_1

Local:3:I.Data.4 (Start_2) HMI_Stop_2

Local:3:I.Data.5 (Stop_3) HMI_Start_2

Local:3:I.Data.6 (Start_3) HMI_Stop_3

HMI_Start_3

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Summary

This lab required us to design a simple program that would be able to start and stop a three

motors. We then had to set up an HMI in the RSView 32 program to control our PLC program.

Although we were fairly familiar with the RS View 32 program and setting up the HMI, this lab

had us apply our knowledge to set up more motors. The first thing we had to design was the

PLC program that would allow us to start and stop three motors. The next step was to download

the program to the PLC using the network we configured. We then proceeded by configuring the

HMI making sure we covered every step for each of the buttons to avoid any problems.

The setting up of the lab went fairly smoothly, but it wouldn’t be a learning experience if we

didn’t encounter at least one problem. As we programmed the HMI, we tagged each motor as a

“Memory” instruction. When we went to run our program we noticed that all the motors would

not turn green when the start button was pressed. This problem was eventually solved by

examining each tag we configured and narrowing down what was different from the last lab.

This is when we discovered that the motors had to be tagged as a “Device”. After this was done

the operation went smoothly.

In conclusion, this lab allowed us to apply the knowledge we gained from the previous lab and

apply it to a larger process containing three motors instead of one motor.

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Lab 15C

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Creating and Running a Trend


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Introduction

The objective of lab 15C was to investigate the trending capabilities that are available on the

RSLogix 5000. A program was designed on the PLC programming software to start a three

second timer that resets itself and starts over timing again for three seconds until the stop push

button was pressed. In order for the user to view a trend for the timer, the scope and tag must be

selected. For this lab “Main Program” was selected as the scope and “Timer.ACC” was selected

as the tag to view the accumulated value of the timer as it counts to three and resets to zero.

Although the trending feature of the RSLogix 5000 was only used to monitor the counting of a

timer, we recognized the importance this would have in other processes such as controlling the

temperature and pressure in a tank or controlling the water level in a tank. By using the trending

feature, the user will have the ability to visually monitor their process from a distance away and

record data.

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Figure 54 Example of Trending Window in RSLogix 5000

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Ladder Logic

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Figure 55 Lab 15C Ladder Logic

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Local:3:I.Data.1 (Stop) N/A Seal

Local:3:I.Data.2 (Start) Timer.DN (Timer)

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Summary

This lab required us to monitor the accumulated value of a timer through the trend feature of the

RSLogix 5000. The first step was very familiar to us at this point in with the amount of

experience we have gained throughout the year. We first designed a simple program that would

energize a timer once a start button was pressed and the timer would reset itself each time its

accumulated value reached its preset value. No output was need for this lab. This task was

accomplished within minutes and no problems arisen while programming the operation. The next

part of the lab was to access the trending feature of the RSLogix 5000. This was very new to us,

but luckily we were provided with instructions that walked us through the lab.

Although this lab appeared simpler and the instructions were given to guide us through the lab,

we managed to skip a small detail, but this was very easily fixed. When selecting the tag name

“Time.ACC” we accidently skipped the step that said “Click the Add button” so the tag will be

added to the “Tags to Trend List” and just pressed finished; therefore the program was not told to

trend anything. We quickly read the steps again and solved our small problem in a matter of

seconds.

In conclusion, this lab allowed us to explore a new feature that the RSLogix 5000 had to offer

and taught us how to apply the trending feature towards an application.

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Appendix

Timer Instruction

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Up Counter Instruction

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Sequencer Output Instruction

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References

Back EMF, Eddy Currents, and Magnetic Damping - Boundless Open Textbook. (n.d.). Retrieved April 17, 2015, from https://www.boundless.com/physics/textbooks/boundless-physics-textbook/induction-ac-circuits-and-electrical-technologies-22/magnetic-flux-induction-and-faraday-s-law-161/back-emf-eddy-currents-and-magnetic-damping-571-8079/

DC Motor Protection. (n.d.). Retrieved April 18, 2015, from http://www.ohioelectricmotors.com/dc-motor-protection-804

HMI | Human Machine Interfaces. (n.d.). Retrieved April 18, 2015, from http://www.anaheimautomation.com/manuals/forms/hmi-guide.php#sthash.L7SdbQdR.dpbs

RSLogix 5000 “Help” Feature

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http://www.anaheimautomation.com/manuals/forms/hmi-guide.php#sthash.L7SdbQdR.dpbs

http://www.ohioelectricmotors.com/dc-motor-protection-804

http://www.ohioelectricmotors.com/dc-motor-protection-804

https://www.boundless.com/physics/textbooks/boundless-physics-textbook/induction-ac-circuits-and-electrical-technologies-22/magnetic-flux-induction-and-faraday-s-law-161/back-emf-eddy-currents-and-magnetic-damping-571-8079/



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