plc training manual_china

Siemens CPU226PLC Trainer

Training Manual (A)

Yalong Science & Technology Group Co., Ltd.

Preface

Programmable controller, in brief PLC, and it is a new industrial automatic controller based on

American traditional sequence controllers, microelectronic technology and computer technology in

1960s.

Presently, in China, PLC is used widely in steel and iron, petroleum, chemical industry, electric

power, construction materials, machinery manufacture, automobile, light industry, transportation and

environmental protection. With the advancement of industrial control technologies, PLC is widely used

in industrial production process and automatic control fields. To satisfy the requirements in the society,

many colleges, secondary technical and vocational schools have set up the related courses and subjects.

The PLC application technology is a highly practical subject, only through actual and practical

operations, can students really learn the knowledge and skills. We developed a whole set of PLC trainers,

including PLC controller and 6 types of training models, as well as related ladders and instructions for

students to learn how to make programming. Students also can design and make ladders and programs

according to teaching models.

The controller is Siemens S7-200 CPU226 PLC, compact and reliable, easy to operate. Now we

developed AC 3-phase motor control, automatic washing machine control, stepper motor control,

traffic lighting control, 4-floor elevator control and electrical plating automatic production line control

and so on. The students, through training, can learn and understand various instructions and functions,

to improve programming skills and PLC application capabilities.

The manual is divided into 3 parts, part 1 is to introduce S7-200 programming software, part 2 is

for programming training, and part 3 is to introduce PLC application training.

Content PART 1. STEP7-MICRO/WIN32 PROGRAMMING SOFTWARE ..................................... 1

1. STEP7-MICRO/WIN32 SOFTWARE .................................................................................. 1

2. STEP7-MICRO/WIN32 BRIEF INTRODUCTION ................................................................. 4

3. PROGRAMMING AND OPERATION ....................................................................................... 8

4. STEPS .............................................................................................................................. 11

5. PRECAUTIONS ................................................................................................................. 11

PART 2. PLC BASIC INSTRUCTION AND TRAINER .................................................... 12

1. YALONG PLC TRAINER .................................................................................................. 12

2. SIEMENS S7-200 PLC ................................................................................................. 12

3. PLC BASIC INSTRUCTION TRAINING ............................................................................... 12

PART 3. PLC TRAINING .................................................................................................... 16

TRAINING 1. AUTOMATIC WASHING MACHINE CONTROL .................................................... 16

TRAINING 2. 3-PHASE MOTOR SEQUENCE CONTROL ........................................................... 20

TRAINING 3. STEPPER MOTOR CONTROL ............................................................................ 23

TRAINING 4. TRAFFIC LIGHTCONTROL ............................................................................... 27

TRAINING 5. 4-FLOOR ELEVATOR CONTROL ....................................................................... 30

TRAINING 6. ELECTRICAL PLATING PRODUCTION CONTROL ............................................... 34

TRAINING 7. WATER TOWER LEVEL AUTOMATIC CONTROL ................................................. 38

TRAINING 8. AUTOMATIC FORMING MACHINE .................................................................... 41

TRAINING 9. AUTOMATIC CHARGING SYSTEM .................................................................... 44

TRAINING 10. MULTI-LIQUID AUTOMATIC BLENDING ......................................................... 47

TRAINING 11. AUTOMATIC STEEL ROLLING MACHINE......................................................... 50

TRAINING 12. MAILS ALLOCATION MACHINE ..................................................................... 54

TRAINING 13. IRON TOWER LIGHTING ................................................................................ 58

1

Part 1. STEP7-Micro/WIN32programming software

1. STEP7-Micro/WIN32 software

1. Brief description

Programming software STEP7-Micro/WIN32 Version 3.1 is suitable for S7-200 series of PLC

system setting (CPU group), for programs development and real-time monitor operation; Updated

Microwin3.1 SPL V3.1 functions; Toolbox provides users instruction and touch screen TP070 group

software, SP1 and Toolbox software. STEP7-Micro/WIN32 software is based on Windows application

software.

2. Programming software installation

Programming software STEP7-Micro/WIN32 can be installed on PC(man and computer) and

SIMATIC programming PG70. Installation methods are lower:

(1) Installation

PC486 or higher, can install Windows 95 and above operating systems, memory: 8MB and above,

hard disc: 50MB and above.

(2) Installation methods

Click Microwin 3.1→Microwin 3.1 SPL→Toolbox→Microwin 3.11, to install.

3. Establish S7-200 CPU communication

S7-200 CPU and PC communication connection is by special PC/PPL cable, or by MPI card and

common cables. Take PC as the main controller, through PC/PPL cable or MPI card and or some PLC

connection, for equipments communication.

(1) PC/PPL communication

PC/PPL supports PC, according to PPL communication protocol setting special cable, with

communication modules, external braud rate setting switches and the two terminals are RS-232 and

RS-485 ports. PC/PPL RS-232 terminal is connected to computer RS-232 communication port COM1

and COM2 ports, PC/PPL terminal (RS-485) is connected to S7-200 CPU communication port.

(2) MPI communication

MPI card provides a RS-485 terminal port, for straight and network connection, when MPI

communication is established, you can make STEP7-Micro/WIN32 connections to many other

equipment networks, each S7-200 can be the main controller and has each own address. Install MPI

card in PC and PCL, then start installation, the setting file is stored in Windows directory, CPU and

PCRS-485 ports are in cable connection. (3) Communication parameters setting

The communication parameters setting include S7-200 CPU address, PC software address and

PORT setting. Shown in Diagram1-1-1 is communication parameters setting dialogue block. drag

monitor menu, click communication (M), to show communication parameters. The system programmer

2

local default address is 0. Remote address is according to actual PC/PPL and PLC address setting, when

other communication parameters modification is needed, double click PC/PPL Cable icon, to modify

setting communication parameters.

Diagram1-1-1 communication parameters setting dialogue block

4. S7-200CPU power supply

The first step is to provide S7-200 CPU power supply, in Diagram1-1-2 is DC power supply and

AC power supply.

Before assembly and disassembly, you shall turn off power supply.

Diagram1-1-2 CPU-200 power supply

5. RS-232/PPL multi-cable connection

(1) Connect RS-232/PPL RS-232 terminal (“PC”) to programming equipment communication port.

(2) Connect RS-232/PPL RS-485 terminal (“PPL”) to S7-200 terminal port O or port I.

(3) Diagram1-1-3 is RS232/PPL multi-cable connection DIP switch.

Double click

3

Diagram1-1-3 RS232/PPL cable connection

6. Download program

(1) You can click download icon, or in command menu, click File>Download to download program.

Refer to Diagram1-1-4.

(2) Click OK to download programs into S7-200.

If S7-200 is working, if you are reminded that the CPU will be in stop mode, click Yes to make

S7-200 in STOP mode.

Diagram1-1-4 download program

S7-200 CPU working mode

S7-200 modes: stop mode and operation mode. CPU panel LED status displays current operation

mode. In stop mode, S7-200 will not run programs, and then you can download programs, data and

CPU system setting. In operation mode, run S7-200 program.

1. S7-200 operation mode

4

If you want to start in STEP7-Micro/WIN software S7-200 mode, S7-200 mode switch setting is

TERM or RUN, when S7-200 is in RUN mode, run program.

1. Click operation icon or select PLC>RUN.

2. Click Yes to switch mode.

When S7-200 is working, the CPU will run program to make Q0.0 LED indicator light ON and

OFF.

Diagram1-1-5 S7-200 jump operation mode

You can select Debug>Program Status to monitor program, STEP7-Micro/WIN to display running

result, if you want to stop running program, you can click STOP icon or select menu command

PLC>STOP to make S7-200 in STOP mode.

2. Power supply budget:

The S7-200 CPU has an internal power supply, to provide 24V DC power supply for CPU

self\extended modules and other equipments. S7-200 provides all 5V DC logic power supplies for all

extended modules in the system, you shall make your system configured with CPU 5V power supply,

for further modules, if your requirements are higher than CPU power supply capacities, then you have

to clear off some modules or select a better power supply. S7-200 CPU also provides 24V DCsensor

power supply, and the 24VDC can be power supply for input points, extended modules, relay coils or

other equipments, if the equipment power consumption exceeds sensor power supply budget, you have

to prepare another external 24VDC power supply power supply for the system.

2. STEP7-Micro/WIN32 brief introduction

Programming software step 7-micro/win32 basic function is to help users to complete PLC

application programs development, in PLC parameters setting, encryption and monitor functions.

STEP7-Micro/WIN32 programming software, in off-line mode, can be used for program input,

edit, and translation functions.

Programming software, in on-line modes (PLC and programming PC are connected), the upload,

download, communication test and real-time monitor functions are available.

STEP7-Micro/WIN32 window group and functions

Click

5

STEP7-Micro/WIN32 window main menu includes file, edit, monitor, PLC, debugging, tools,

windows help, line is tools bar shortcut button, other is window information display, as shown in

Diagram 1-2-1.

Window information display is for program data display, browse bar, instruction tree and output

windows display. When in monitor menus, tools bar, browse bar and instruction tree can be shown in

windows; you can select tools bar output windows, to display output windows block. Under the output

windows, is status bar, to show STEP7-Micro/WIN32 status information.

Diagram1-2-1 STEP7-Micro/WIN32window group

View -- common programming buttons:

View-- program block, icon, table, status diagram, data block, system block, intercross reference and

communication button.

Tools-- instruction guide, TD200 guide, position control guide, EM253 control panel and demodulator

guide button;

Instruction tree-- all project objects in current program editor (LAD, FBD or STL), an instruction tree

window. You can operate on all open projects and objects in the branches of the project.

Status diagram-- allow program input, output or variables input, to monitor its status.

Output window-- output information during program or instruction translation. When lists of program

errors are output, it will display corresponding program networks in the program editor window

6

Inser Network

Sort Descending uploadcompile

Compile All Dowenload Sort Descending

Options

Delete Network

Toggles Network Comment

Toggle Bookmark

Toggles Dou Comments

Program Status

automatically.

Status bar-- in Micro/WIN32 operation, the operation status information.

Program editor--project editor (LAD, FBN or STL), local variables table and program windows. If

needed, you can extend window, overlay local variables table. Click the labels on the bottom of the

program editor window, and can move among main programs, subprograms and interrupt programs.

Local variables table-- definite and assign local variables (variables in subprograms and interrupt

programs).

Menu The common or tools shortcut buttons (as shown in Diagram1-2-2). You can select items in the

tools bar.

Diagram1-2-2 tools bar

Diagram1-2-3 standard tools bar

Diagram1-2-4 common tools bar

Diagram1-2-5 debugging tools bar

Undo

Toggle Bookmark

Run

Stop

Chart Status Singel Read

ForceWrite All Unforce

Unforce All

7

Line Operation

Contact-F4

Coil-F6

Diagram1-2-6 LAD instruction tools bar

Allow you to use mouse or keyboard to run instructions. And you can select “tools” menu, modify

according to your requirements.

1. Main menu and submenu status information

(1) File

Create, open, close, save, save as, import, export, upload, download, page setting, print and

preview.

(2) Edit

Cancel, cut, paste, all select, insert, delete, search, replace, for program modification operation.

(3) View

Monitor menu functions:

① You can select program datadisplay window to display various program editors. Such as

statement table (STL), ladder (LAD), function Diagram (FBD);

② You can make data block, icon table setting;

③ Make setting on system block intersection, communication parameters;

④ Tools bar can be used to select browse bar, instruction tree and output windows;

⑤ Zoom in/out;

⑥ Program block properties setting.

(4) PLC

PLC menu is used to establish PLC on-line communication, such as to use software to change PLC

work mode, to edit users’ programs, to clear PLC programs and reset power supply, display PLC

information and make PLC setting.

(5) Debug

Debugg menu has items such as on-line dynamic debugging, single scan, multiply scans, and

program status. Select “submenu” and monitor menu zoom in/out function.

(6) Tools

Tools menu has a complicate instruction guide (PID, NETR, NETW, HSC instructions) and TD200

setting guide, and TP070 (touch screen) setting.

(7) Windows

Windows menu is used to select window display and display format (ladder, statement table and

various tables).

(8) Help Help menu can provide S7-200 instruction system and programming software information, has

Box-F9

8

on-line help, search, access, download functions.

2. Tools bar

Tools bar is in mouse operation, to transform common STEP7-Micro/WIN32 operation in button

form setting into tools bar form setting. You can use “Tool bars” in “View” menu to display or hide 4

tools bar: Standard, Debug, common and Instruction tools bars.

3. Navigation Bar

Navigation Bar is a programming button to switch window functions quickly. In the bar,

“Navigation Bar” in “View”menu is used to select whther it is open. Navigation Bar incorporates

program block (Program Block), Symbol Table, Status Chart, Data Block, System Block, Cross

Reference, and Communication Icon. Click a button, and then the main window is switched. All

operations in Navigation Bar can be done in “Instruction Tree” window or “View” menu. 4. Instruction tree

Instruction tree is a programming instruction tree table. You can use “(Instruction Tree)” in

“View”menu to select, shortcuts are in programming and PLC instructions.

5. Output window

Output window is used to display program translation results, such as program block and block

sizes, errors and codes etc. In addition, from Navigation Bar, click system block and communication

button, you can set PLC parameters. Such as setting communication braud rate, PLC power supply data,

memory range, setting input filtering parameters setting, passwork setting and so on.

3, Programming and operation

(1) Project creation (users program)

1, Open created project file

Open created project:

(1) Open file menu, to current project, and open file;

(2) From the file name opened, in current project file list, select. Or in Windows source manager,

tofind a proper directory, project file is avaible in extended file name.

2, Create a new project (file)

Create a new project:

(1) Click “create” shortcut button;

(2) click “create” button to create a new file;

(3) Click program block icon, to create a new STEP7-Micro/WIN32 project.

3, Confirm CPU types

Open a project, before writing a program, you can select PLC types. You can confirm CPU types.

①in instruction tree, right click project 1(CPU), in pop up dialogue block, left click types (T)…pop up

PLC typesdialogue block, select PLC type, and confirm;②use PLC menu to select types (T)…, pop up

PLC type dialogue block, then select a correct CPU type.

9

(2) Ladder editor

1, Ladder fundamental

The current can flow through a switch, and the coil represents current charged relay or output;

instruction box represents instruction box functions when current flows.

2, Ladder layout principle

The network shall start from contacts, coil or instruction box..

Attention: in each users program, 1 coil or instruction box only can be used for one time, more

coils in serial connection are not allowed.

(3) Ladder input instruction (programming elements)

1, Enter ladder (LAD) editor

In drag monitor menu, click ladder (L), to enter ladder edit status, and click program edit window

display ladder edit icon.

2, Programming elements inputmethods

Programming elements are coils, contacts, and cables. It is normaly is sequence input, you can put

programming elements in the position of the cursors (input instruction), or you can move cursor to any

position to input programming elements.

Diagram1-3-1ladder instruction

The programming elements input can be done by double click on instruction tree, drag and click

tools bar shortcut keys F4 (contacts), F6(coil), F9(instruction box), or double clilck instruction tree to

select input programming software.

The tools bar has 7 programming keys, the first four are to connect cables, and the latter 3 are

contacts, coil, and instruction box.

The programming elements input is in program edit window, move cursor onto the elements, then

input programming elements. The programming elements input is two methods. ①By mouse and left

key to input programming elements, for example, input contacts elements, move cursor into

programming area, left key click tools bar contacts button, to show a menu, use mouse to click the

programming elements, push return key, input programming elements, then click programming

网络2

网络1 网络题目（单行）Network1 Network Title(Single row)

Network2

10

elements???, input number; ②By function keys (F4, F6, F9), shift key and return key to place

programming elements. For example, to place output contacts, push F6 key, pop up a menu, in the menu,

select programming elements (By shift keys to search for programming elements), push return key, the

programming elements will he highlighted, push return key again, cursor will select elements???, input

number, push return key to confirm, then by shift key, to move cursor to next stage, input a new

program. When input address, icon is out of range or and instruction types are not compatible, a read

curve will be shown on bottom.

3, Ladder function instruction input

By instruction tree and double click, input function instruction.

4, Program edit and parameters setting

Cut, copy, paste, insert and delete, character string replace, search.

5, Program translation, upload and download.

(1) Translation

When users program is edited, in CPU menu or tools bar, click translation shortcut button to

carryout program translation, when translation is finished, in output window, translation results are

display, where errors can be shown, you can modify the programs according to prompts, then restart

translation, till no errors in translation.

(2) Download

When translation is finished, click download shortcut button in standard tools bar or drag filemenu,

select download, pop up download dialogue block, select program block, data block, system block to

download, push confirm button, to download the selected content into PLC memory.

(3) Upload

Upload instruction function is tp send PLC programs or data into editor (PC).

To click upload shortcut keys in the standard tools bar or drag file menu select upload, pop up

upload dialogue block. Select program block, data block, system block to upload, in program display

window upload PLC internal program and data.

(4) Program monitor, operation, debugging

1, Program operation

When PLC working mode is in TERM or RUN status, run STEP7-Micro/WIN32 menu command

or click shortcut button to make software setting in CPU working mode.

2, Program monitor

The program editor can monitor programrun process and all elements status and data during PLC

operation.

Ladder monitor function: drag debugging menu, select program status, close contacts. In RUN

status, it can carry out timing and counting process operation, in each cycle, it can output refreshed

status of each element, and it can dynamically display timing, counter current values, in order to

observe program on-line operation dynamically, shown in Diagram 1-3-2.

11

Diagram1-3-2ladder operationstatus monitor

3, Dynamic debugging

Combined with program monitor operation dynamic display, and analysis on program operation

results, as well as factors effecting program operation, then you can exit program operation and monitor

status, in STOP status, you can carry out program modification, edit, translation, download, monitor

operation, till you obtain the corrent final results.

4, Translation language

SIMATIC instruction and IEC1131-3 instruction select methods, drag tools menu, in pop up

dialogue block, you can select the instruction system.

5, Other functions

STEP7-Micro/WIN32 programming software has PID (close-loop control), HSC (high-speed

counting), NETR, NETW (network communication) and TD200 for guide function.

4, Steps

1. Do electrical circuit wiring.

2. Input STEP7-Micro/WIN32, and translate.

3. Download translated program from PC (STEP7-Micro/WIN32 programming software) to PLC

controller.

4. In PC monitor status, start program debugging.

5. Run program and record.

5, Precautions

1. Turn off power supply before wiring.

2. When circuit is connected, checked by teacher, then you can turn on power supply.

3. All communication cable shall be off.

网络2

网络1 网络题目（单行）Network1

Network2

Network Title(Single row)

12

Part 2. PLC basic instruction and trainer

1. Yalong PLC training Trainer

It is composed of Yalong PLC controller and 13 modules.

1. PLC controller: Siemens S7-200 CPU226CN controller, 12V/1A DC power supply. PLC I/O

ports, and knob switches.

2. 13 modules:

(1) Automatic washing machine control (8) Automatic forming machine

(2) 3-phase AC asynchronous motor control (9) Automatic charging system

(3) Stepper motor control (10) Multi-liquid automatic blending

(4) Traffic lightcontrol (11) Automatic steel rolling machine

(5) Elevator control (12) Mails allocator

(6) Electrical plating production linecontrol (13) Iron tower lighting

(7) Water tower level automaticcontrol

3. Controller has wiring sockets. Use cables to connect S7-200 controller.

2.SIEMENS S7-200 PLC brief introduction

Table 2-2-1 SIEMENS S7-200 PLC brief introduction

Digital input 24 input Digital output 16 output Digital I/O mapping zone 256 (128 input/128 output) Analogy I/O maping zone 64(32 input/32 output) Allowable maximum extended modules 7 modules Allowable maximum enable modules 7 modules single-phase counter 6, 30KHz 2-phase counter 4, 20KHz Pulse output 2 20KHz Timer quantity 256 1ms 4 10ms 16 100ms 236 Counter quantity 256 (super capacitor and batteries standby) Time interrupt 2pcs 1ms resolution Analogy potentiometer 2pcs 8-bit resolution

3. PLC basic instruction training

1. Timer instruction

13

Diagram2-3-1 timer applicationladder

As shown in Diagram 2-3-1, turn on delay timer, timer T37 will start timing, the normaly open

contacts are turned on, drive Q0.0 output; when I0.0 is off, T37 resets, when current value clears, status

bit will be cleared, to recover to initial status. If I0.0 is ON, and is OFF before the time is over, then T37

will reset, and Q0.0 will not output.

2. Counter instruction

Diagram2-3-2counter instruction applicationladder andtime sequenceDiagram

When I0.1 is OFF, substractor C1 is changed from 3 to 0.

1、 Instruction program

Diagram 2-3-3 Bit operation instruction application ladder

NetworklI0.0

T37

Network2

( )

T37 Q0.0

IN TON

PT+10-

I0.1

C1I0.0

Networkl

CD CTD

+3-

CD

PV

23

01

23

I0.

I0.

C

Q0.

网络1

网络2

M0.0

M0.0I0.1I0.0

（）

I0.2 I0.4 Q0.1

（）

0.3

Network1

Network2

14

Ladder logic relation: Network 1 M0.0 = (I0.0+M0.0) I0.1

Network 2 Q0.1 = (I0.2+I0.3) I0.4

Network 1: when input I0.0 is set (I0.0=1), input terminal I0.1 is clear (I0.1= 0→ I0.1 =1 status),

coil M0.0 is on (internal standard M0.0 is 1), normally open contacts will close, to make I0.0 reset voil

(I0.0=0), M0.0 coil is powered. M0.0 coil is normally contact, I0.1 is ON (I0.1=1→ I0.1=0), M0.0

self-lock circuit is open, coil off.

Network 2: when input I0.2 or I0.3 is set, when I0.4 is clear, and output coil Q0.1 on.

2、 Sequence control instruction:

When I0.0 input is on, start S0.0, run program, first step, output Q0.0 is 1(ON red light) Q0.1 is 0

(OFF green light), start timer T37, 2S later, jog jump instruction, S0.1 is 1, S0.0 is 0, program enter the

second step, output Q0.1 is 1 (green light ON), Q0.0 is 0 (red light OFF), in a same time, start timer T38,

2s later, jog instruction, S0.0 is 1, S0.1 is 0, program enter the first step, cycle in this way.

Diagram2-3-4 sequence control instruction applicationladder

S C R

S 0 . 1

网络 16

（）

Q 0 . 0S M 0 . . 0

网络 7

R

S

Q 0 . 1

（）T 3 8

I N T O N

P T+ 2 0 -

T 3 8

（）

0.0

网络 8

网络 9

（）S C R E

S C R T

S

S C R T

S C R E（）

网络 5

网络 4

0.1

（）

T 3 7

+ 2 0 - P T

T O NI N

T 3 7（）

Q 0 . 1

S

S

S C R

0.0

网络 3

S M 0 . . 0 Q 0 . 0

（）

（）

I 0 . 0 0.0

网络 2

网络 1 Network1

Network2

Network3

Network4

Network5

Network9

Network8

Network7

Network16

15

3、 jump instruction

Diagram2-3-5jump instruction applicationladder

In Network 4, JUMP makes the program jump over branches (Network 5-15), to LBL 4. “N” is as same as the “N” in LBL command. In the scanning periods during jump, the program stops, and the status of each out elements in the program never changes, and does not response to any changes in situations.

LBL

4Netork16

Q0.2

（）

Q0.1

Netork5

JMP

Netork4

（）

M10.0 Q0.0

4I0.3

（）

Network 4

//I0.3 is on, jump to LD I0.3

LBL 4, run JMP 4

//Network 5 Network 5

Network 5 jumped LD M10.0

Does not run =Q0.0

AN Q0.2

=Q0.1

//LBL 4, jump program entry Network16

LBL

Network17

16

Part 3. PLC application training

Training 1. Automatic washing machine control

1, Purposes

1, Learn programmer basic operation and programmer input, check and operation.

2, Learn PLC automatic washing machine control fundamental and I/O port connection, PLC

programming and debugging operation.

3, Learn I/O port distribution andI/O port wiringmethods.

4, Learn PLC programming language.

2, components

1, Yalong PLC- controller.

2, Yalong PLC- automatic washing machine control.

3, computer or programmer.

4, Safe cables.

5, PLC serial communication cable.

3, Fundamental

Automatic washing machine working modes:

(1) Push start button, water supply solenoid valve open, water supply indicator light ON.

(2) Push upper limit button, water supply indicator light OFF.

(3) A few seconds later, drain light is ON, drying tank light will be ON and OFF.

(4) Push limit button, drain light OFF, water supply light ON.

(5) Repeat (1) - (4) process

(6) When you push limit button for the third time, buzzer light is ON, 5s later, it is OFF, the whole

process will be fnihsed.

(7) In operation process, push stop button to finish process.

(8) Manual drain button is an independent operation command, push manual drain, and push limit

button.

17

4, I/O Table 3-1-1 automatic washing machine I/O

Input Output I0.0 Start button Q0.0 Water supply indicator light I0.1 Stop button Q0.1 Drain indicator light I0.2 Upper limit button Q0.2 Forward blend indicator light I0.3 Lower limit button Q0.3 Back blend indicator light I0.4 Manual drain button Q0.4 Drying indicator light

Q0.5 Buzzer indicator light

5, I/O circuit

Diagram 3-1-1 automatic washing machine controlI/O circuit

6, Steps 1, Turn off PLC controller power supply, do wiring according to Diagram 3-13-2, do not short

circuit 12V and 24V power supply.

2, Insert power supply cable into PLC controller power supply socket, and insert 220V power

supply socket.

3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer,

download programs into PLC then put PLC in RUN status.

4, Turn on 2.7(2.4, 2.5, 2.6 are off).

5, Training operations are according to working modes operation.

7, Circuit Connect automatic washing machine control circuit according to Diagram 3-1-2.

8, Questions 1, Washing machine rotates forward, back time are 10s, cycle for 5 times.

I0.0Start

Stop

Drain

Lower limit

For ward blendindicator light

Back blend

Drying indicator light

Buzzer indication light

1L

2L

Upper limit

Water supply indicator light

Drsin indication light

12V FU

I0.1

I0.3

I0.2

I0.4

1M

Q0.5

Q0.2

Q0.3

Q0.1

Q0.0

24V

CPU 226 CN

+-+ -

2M

Q0.4

indicator light

19

Diagram 3-1-2 automatic washing machine circuit

YL-PC Automatic Washing machine PLC Panel

Start Stop COM BuzzerBackDrain

Water Forward DryDrainLowerlimitupplimit

I0.1

Q0.01L

+- 12V

I0.0 I0.3I0.2 I0.4

Q0.1 Q0.2 Q0.3 Q0.4 Q0.5

COM

1M

IN OUT2

M L+2MCOM COM

spply

blend

blend

20

Training 2, 3-phase motor sequence control

1, Purposes

1, Learn 3-phase motor sequence control fundamental.

2, Learn ladder programming methods and learn instruction programs.

3, Learn I/O port distribution andI/O port wiringmethods.

4, Understand programmer basic operation and programmer input, modification, check and operation.

2, Cmponents


2, Yalong PLC3-phaseasynchronous motor sequence control.

3, Computer or programmer.

4, Safe cables.


3, Fundamental

3-phase motor sequence control:

(1) Turn on forward switch SB1, then push SB1, motor will Y-△ start, Y operation, 5s later, it starts △

operation.

(2) Turn on stop switch SB3, then push SB3, motor will stops.

(3) Turn on back switch SB2, then push SB2, motor will Y-△ start, Y operation, 5s later, it starts △

operation. When it moves forward, it cannot move back; when it moves back, it cannot move forward. Positive

back switching is only available by stop.

(4) Turn on stop switch SB3, then push SB3, motor stops.

4, I/O

Table 3-2-1 3-phase motor sequence control I/O Input Output

I0.0 Forward start switch Q0.0 KM1

I0.1 Back start switch Q0.1 KM2 I0.2 Stop switch Q0.2 KM△

Q0.3 KMY

21

5, I/O circuit

Diagram 3-2-13-phase motor sequence controlI/O circuit

6, Steps

1, Turn off PLC controller power supply, do wiring according to Diagram 3-13-2, do not short circuit 12V

and 24V power supply.

2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket.

3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download

programs into PLC then put PLC in RUN status.

4, Turn on 2.6 (2.4, 2.5, 2.7 are off).

5, Operation and observe.

7, Circuit

Connect 3-phase motor sequence control circuit shown in Diagram 3-2-2.

8, Questions

1, Rrequirements: forward start operation for 30s, then stop for 2s, start back operation for 30s, then stop for

2s, repeat.

I0.0

I0.1

I0.2

1M

Q0.0

Q0.1

1L

12V FU

KM1

KM2

KM

KMY

SB1

SB2

SB3

2M24VQ0.3

Q0.2

CPU 226 CN

22

Diagram 3-2-23-phase motor sequence control circuit

1L 0.0

I0.0

KM2KM1

KMΔ KMYSB3SB2SB1

PLC PanelYL-PC Motor Control

I0.1 I0.2

Q0.1 Q0.2 Q0.3

COM

COM

IN

OUT

12V- +

COMCOM 2M L+M1M

23

Training 3, Stepper motor control

1, Purposes

1, Learn stepper motor fundamental.

2, Understand how to use stepper ladder instruction programming methods.

3, Understand ladder programming methods and learn instruction programming methods.

4, Learn I/O port distribution and I/O port wiring.

5, Learn programmer basic operation and programmer input, check, modification and operation.

2, Components


2, Yalong PLC- stepper motor demonstration board.


4,Safe cables.


3, Fundamental

1, Stepper motor control requirements are following:

The stepper motor control mode is in 4-phase, 4-step control, each step is 15° rotation, each cycle,

24 steps. When motor is in forward rotation, the power supply time sequence:

When the motor is in back rotation, the power supply time sequence:

2, Stepper motor has some switches, the functions are following:

(1) Start/stop switch--control stepper motor start or stop

(2) Forward /back switch--control stepper motor forward or back

(3) Speed switch--control stepper motor continuous operation and jog operation,

S Stage is jog operation.

N3 Stage is high-speed operation.

N2 Stage is middle-speed operation.

N1 Stage is low-speed operation.

(4) Jog button switch, push jog button 1 time, motor rotates for one step.

4. I/O

DC CB BA AD

AB BC CD DA

24

Table 3-3-1 stepper motor I/O Input Output

I0.0 Forward/back button Q1.0 A phase I0.1 Speed 3 stage Q1.1 B phase I0.2 Speed 2 stage Q1.2 C phase I0.3 Speed 1 stage Q1.3 D phase I0.5 Manual button I0.6 Start/stop button I0.7 Jog button

5. I/O circuit

Diagram 3-3-1 stepper motor I/O circuit

6, Steps

1, Turn off PLC controller power supply, do wiring according to Diagram 3-13-2, do not short



supply socket.



4, Turn on 2.6, 2.7(2.4, 2.5 are off).

5, Training operation:

(1) Make forward /back switch setting is “forward”.

(2) Select speed stage N1, N2 and N3, make start/stop switch is in “start”, observe how the motor

works. Push stop button, to stop the motor.

N3

N2

N1

Manul

Start

S

Forward andBack Rotation

I0.0A

I0.1

1M

B

C

D

Q1.0

Q1.1

Q1.2

Q1.3

2L

I0.2

I0.3

I0.5

I0.6

I0.7

24V

FU12V

CPU 226 CN

-+

+-

2M

3L

25

(3) Make forward /back switchsetting is “back ”, repeat (2) operation .

(4) Select S stage, enter manual jog mode, start/stop switch setting is in “start”, push jog button 1

time, motor will rotate for a step. The start/stop switch setting is in “stop”, make stepper motor to exit

the work status.

7, Circuit

Connect stepper motor control circuit according to diagram 3-3-2.

8, Questions

(1) How to change stepper motor rotation speed.

(2) Make programs to make stepper motor forward 3.5 circles, back 3 circles.

26

Diagram 3-3-2 stepper motor control circuit

12V- +

2L Q1.0

I0.0

N3 N2 N1BA

C D

Forwardand bachrotation

StartManul

PLC PanelYL-PC Stepping Motor

S

COM

I0.1 I0.3I0.2 I0.7I0.6I0.5

Q1.1 Q1.2 Q1.3

COM

OUTIN

3L

1M M L+2MCOM COM

Stop

27

Training 4, traffic lightcontrol

1, Purposes

1, Learn traffic light fundamental and operation methods.

2, Learn PLC control PLC I/O connection methods.

3, Learn ladder programming methods and understand instruction programming methods.

4, Larn programmer basic operation and programmer input, check, modification and operation

operation.

2, Components


2, Yalong PLC-traffic lightcontrol.

3, Programmer or computer.

4, Safe cables.


3, Fundamental

Traffic light control:

(1) The start andstop switch S1, S2, are used to control system “start” and “stop”. S3 is a shielded

traffic light.

(2) Traffic light display.

When east & west red light is ON, south & north green light is ON, when green light ON time is

finished, the green light flashes for 3 times, each 1s, then the yellow light is ON for 2s, when the south

& north yellow light is OFF, east & west green light is ON, south & north red light is ON, when east &

west green light is ON, when the ON time is finished, green light flashes for 3 times, each 1s, then the

yellow light is ON for 2s, when east & west yellow light is OFF, the east & west red light is ON, and

south & north green light is ON……cycle and cycle in this way.

4, I/O

Table 3-4-1traffic lightcontrol I/O

input output I0.0 Start witch Q0.0 east & westred light I0.1 Stop sitch Q0.1 east & westgreen light I0.2 Shielded switch Q0.2 east & westyellow light

Q0.3 south & northred light Q0.4 south & northgreen light

Q0.5 south & northyellow light

5, I/O circuit

28

Diagram 3-4-1traffic lightcontrolI/O circuit

6, Steps




supply socket.



4, Turn on 2.5 (2.4, 2.6, 2.7 are off).

5, Training operation process:

(1) Turn on S1, observe traffic light change.

(2) Turn on shielded switch S3, observe light change, down S3, observe light change.

(3) Turn on stop switch S2, observe light change, down S2, and observe light change.

(4) Compare switch S2 and S3. S2 makes light OFF, S3 makes light temporarily OFF.

7, Circuit

Connect traffic light control circuit according to Diagram 3-4-2.

8, Questions

Requirements: traffic lightcontrol system 7:00~22:00, it works according to training requirements,

22:00~7:00, it changes direction, cycles (in program debugging, time adjustment is 7:00~22:00, 5 min,

22:00~7:00, 2 min). try to modify control program and debug.

I0.2

FU12V

1L

Q0.3

Q0.2

Q0.1

Q0.0

1M

I0.1

I0.0S1

S3

S2

Q0.4

Q0.5

East and west

24V

CPU 226 CN

2M

2L

red light

East and westgreen light

East and westyellow light

South and northred light

green light

yellow light

South and north

South and north

29

Diagram 3-4-2 traffic lightcontrol circuit

12V- +

1L Q0.0

I0.0

S3S2S1

PLC PanelYL-PC Traffic Automatic and Manul coutrol

EastWest

SouthNorth

I0.1 I0.2

Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.5

COM COMIN

OUT

COMCOM 2M L+M1M

green yellow red

green yellow red

30

Training 5, 4-floor elevator control

1, Purposes

1, Learn elevator fundamental. 2, Learn multi-input, multi-output, logic relation complicate program control. 3, Learn ladder programming methods and understand instruction programming methods. 4, Learn programmer basic operation and programmer input, check, modification and operation.

2, Components

1, Yalong PLC- controller. 2, Yalong 4-floor elevator control. 3, Programmer or computer. 4, Safe cables. 5, PLC serial communication cable.

3, Fundamental

1, Elevator input signals and meaning:

(1) Position signals Position signalsare from sensor SQ1~SQ4. Normally are OFF, when elevator arrives, it is ON. (2) Instruction signals The instruction signals are “1 to 4” (K7~K10), composed of 4 instruction buttons. Push a button,

the elevator will move to the corresponding floor. (3) Calling signals There are 6 calling signals, composed of K1~K6 calling buttons. Push the calling button, the

elevator will stop. For example, push K3, the passengers on the second floor want to move upward, push K4, then the passengers want to move downward.

2, Elevator output signals and meanings

(1) Operation direction signals The operation direction signals are composed of arrow indicator lights, to display elevator

movement direction. (2) Instruction register signals Instruction register signals are composed of L11~L14 indicator lights, the corresponding

instruction signals are received (registered). When instruction is run, signals are off. For example, when the elevator is on the second floor, push “3”, L12 is ON, and the signals are received. The elevator will move upward to the third floor and stop, then L12 OFF.

(3) Calling register signals There are 6 calling register signals, composed of L1~L6 indicator lights, similar to the instruction

register signals above. (4) Floor indication signals

31

The signals are the floor positions, composed of 7-segment numberic display, LEDa~LEDg. 3, Analogy elevator operation principle

(1) Receive and register all instruction signals, calling signals, register and output register signals. (2) According to registered signals, judge whether elevator is moving upward or downward. For

example, when the elevator in the second floor, instruction is for first floor, then it will move downward; if instruction is for forth floor, it will move upward.

(3) When the elevator receives signals, then it will decide its direction firstly. For example, when the elevator is in third floor, you can input second floor instruction signal, forth floor instruction signal, first floor instruction signal. Otherwise, when the elevator moves downward to second floor→upward to the forth floor→downward to the first floor; in a same direction, the elevator will move downward to the second floor→downward to the first floor →upward to the forth floor. Obviously, in the second mode, the travel distance is less, so the efficiency is higher.

(4) Same direction stop function. For example, when elevator is in first floor, instruction is floor 4, it moves upward, when floor 3 calling signal comes, if it upward (K5), when elevator arrives floor 3, it stops in floor 3; if calling signal is downward (K4), it cannot stop, and it will return to floor 3 and stop.

4, I/O

Table 3-5-1 4-floor elevator control I/O

input output I0.0 1-floor position

switch SQ1 Q0.0 Upward indication

I0.1 2-floor position switch SQ2

Q0.1 Downward indication


Q0.2 Upward drive


Q0.3 Downward drive

I0.4 1-floor instruction switch K10

Q0.4 1-floor instruction register







I1.0 1-floor upward button K1

Q1.0 1-floor upward calling register





I1.3 2-floor downward button K2

Q1.3 2-floor downward calling register

I1.4 3-floor downward buttonK4


I1.5 4-floor downward buttonK6


Q1.6 Door close Q1.7 Door open

32

5, I/O circuit

Diagram 3-5-1 4-floor elevator control I/O circuit

6, Steps



2, Insert power supply cable into PLC controller power supply socket, and insert the other end to

220V power supply socket.



4,Turn on 2.5,2.7(2.4,2.6 不 turn on ).

5, According to fundamentalworking modes operation, observe results.

Q1.0

Q0.5

Q0.4

Q0.6

Q0.7

Q0.3

Q0.2

Q0.0

Q0.1

Q1.2

Q1.1

Q1.3

Q1.4

Q1.5

Q1.6

I1.4

I1.3

I1.1

I1.2

I0.1

I0.0

I0.2

I0.3

I0.7

I0.6

I0.4

I0.5

I1.0

Q1.7

M

M

1-floor position switch SQ1

1-floor instruction switch K10

1-floor upward button K1

I1.5

3L

2L

1L1M









3-floor downward buttonK4

2-floor downward button K2

4-floor downward buttonK6

Upward indication

Downward indication

Downward drive

Upward drive

1-floor instruction register




1-floor upward calling register


2-floor downward calling register




Door close

Door open

CPU 226 CN

24V 12V FU

SQ1

SQ2

SQ3

SQ4

K10

K9

K8

K7

K1

K3

K5

K2

K4

K6

2M

33

Diagram 3-5-24-floor elevator control circuit

1L

YL-PC 4-Floor Elevator PLC Panel

2LQ0.0

+- 12V

Q1.0

Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7

Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17

Q1.4

COM

Q0.1 Q0.2 Q0.3 Q0.4 Q0.5 Q0.6 Q0.7

Q1.1 Q1.2 Q1.3 3L Q1.5 Q1.6 Q1.7

I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7

I1.0 I1.1 I1.2 I1.3 I1.4 I1.5

0V12V

OUT

X7X6X5X4X3X2X1X0

X15X14X13X12X11X10

1M M L+2MCOM COM

34

Training 6, Electrical plating production line control

1, Purposes

1, Learn electrical plating production linesequence controlprocess.

2, Learn I/O distribution and wiring.

3, Learn ladder programming methods and understand instruction programming methods.


2, Components


2, Yalong electrical plating production line control.


4, Safe cables.


3, Fundamental

1, Process:

Diagram 3-6-1electrical plating production linecontrol work process

On the leftside of the electrical plating production line, insert the workpiece and send automatic

start signal, and it will rise and start automatic movement. Then it stops on the position for a period

required, and drops automatically. Each time when it stops, it will stop for a period, then drops

automatically, to finish each procedure on the production line, then it will return to original position

automatically for workpiece insertion again.

2, Work flow chart is following:

Origin: when it is in the initial status, hook is in lower limit position.

Automatic process:start→hook upward→upper limit travel switch closes→rightward to No. 1→

xk1 travel switch closes→hook drops into No. 1→lower limit travel switch closes→electrical plating

delay→hook upward…….from No. 3, hook moves upward, leftward to right limit position, and hook

drops to lower limit position (origin).

Continuous mode: when hook returns to origin, delay for a period, it will automaticcally move

XK1 XK2 XK3

No.1 No.3 No.2

Left limit

Lower limit

Origin

Upper limit

35

upward, rightward, cycle and cycle. When you push “stop” button, it will stop immediately, and it will

stop when it return.

Single cycle: from origin, push startbutton, it will operate for a cycle, then stop in origin. It is

needed to repeat for a second cycle, you shall push start button. when you push “stop” button, it

immediately stops, push “start” button, it continues.

Jog: push start button, it will jog each time.

4, I/O

Table 3-6-1electrical plating production linecontrol I/O

input output I0.0 Upper limit travel switch Q0.0 Rise I0.1 Lower limit travel switch Q0.1 Drop I0.2 Left limit Q0.3 Rightward I0.3 XK1 travel switch Q0.4 Leftward I0.4 XK2 travel switch Q0.7 Origin I0.5 XK3 travel switch I0.6 Origin switch I0.7 Continuous mode switch I1.0 Start button I1.1 Stop button I1.2 Stepper button I1.3 Single cycle button

5, I/O circuit

Diagram 3-6-1electrical plating production linecontrolI/O circuit

Origin

Leftward

Rightward

Drop

Rise

Q0.7

Q0.4

Lower limittravel switch

Left limit

Upper limit travel switch I0.0

I0.1

1M

Q0.0

Q0.1

Q0.3

1L

I0.2

I0.5

I0.4

I0.3XK1

XK3

XK2

Stepper button

Single cyclebutton

Stop buttonI1.1

I1.2

I1.3

I1.0

I0.7

I0.6Origin switch

Start button

Continuous mode switch

FU12V

CPU 226 CN

24V 2M

2L

36

6, Steps




supply socket.



4, Turn on 2.5, 2.6 (2.7, 2.8 are off).

5, Process:

(1) Push “origin” switch, make it in initial position, then origin indicator light is ON.

(2) Push “continuous work” switch, thenpush “start” button, make it continuously work, observe

equipment work process. Push stop button, observe equipment how to stop .

(3) Push “single cycle”switch, select single cycleworking modes, push “start”button, a cycle later,

it stops in origin, in work process, push “stop” button, observe whether it can stop immediately, then

push “start” button, see whether it continues.

(4) Push “jog” switch, select jog working modes.

(5) In “continuous work”, “single cycle” and “jog”, push “origin” button, it will return to origin.

7, Circuit

Connect electrical plating production line control circuit according to Diagram 3-6-2.

37

Diagram 3-6-2 electrical plating production line control circuit

12V- +

1L Q0.0

I0.0

Continuousmode switch

Single cyclebutton

Stepper button

Left limitUpper limit Lower limit

PLC PanelYL-PCelectrical plating production linecontrol

1 2 3

StopStartOriginswitch

Rise Rightward

OriginLeftwardDrop

I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7

I1.1 I1.2 I1.3

Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.7COM

COM

OUT

IN

I1.0

COM 2M L+M1M

38

Training 7, Water tower level automatic control

1, Purposes

1, Learn water tower level automatic control fundamental.

2, Learn ladder programming methods and instruction programming methods.


2, Components

1, Yalong PLC controller.

2, Yalong PLC water tower level automatic control.


4, Safe cables.


3, Fundamental

Water tower level working modes:

When water tank level is lower than the lower limit level (S4 is ON), the solenoid valve Y opens,

S4 is OFF, and level is higher than lower limit level. When water tank level is higher than the upper

limit level (S3 is ON), the solenoid valve Y closes.

When water tower level is lower than the lower limit level (S2 is ON), pump M works, to supply to

water tower, and S2 is OFF, level is higher than the lower limit level .when water tower level is higher

than the upper limit level (S1 is ON), pump M stops.

When water tower level is lower than lower limit level, and the water tank level is also lower than

lower limit level, pump M will not start.

4, I/O

Table 3-7-1water tower level automatic control I/O

input output

I0.1 water tower upper limit Q0.1 solenoid valve Y

I0.2 water tower lower limit Q0.2 pump M

I0.3 water tank upper limit

I0.4 water tank lower limit

39

5, I/O circuit

Diagram 3-7-1 water tower level automatic control I/O circuit

6, Steps




supply socket.



4, Turn on 2.5, 2.6, 2.7 (2.4 is off).


(1) Turn off limit switch S4, solenoid valve Y is ON, lower limit switch S4 resets.

(2) Turn on limit switch S3, solenoid valve Y is OFF, upper limit switch S3 resets.

(3) Turn off limit switch S2, pump M is ON, lower limit switch S2 resets.

(4) Turn on limit switch S1, pump M is OFF, upper limit switch S1 resets.

7, Circuit

Connect water tower level automatic control circuit according to Diagram 3-7-2.

8, Questions

When the water tank level is lower than the lower limit level (S4 is ON), solenoid valve Y opens to

input water, within 3s, switch S4 does not close, then the solenoid valve Y doeas not open, and faults

occur, then indicator light Y flashes.

I0.1

I0.2

I0.3

I0.4

1M

Q0.1

Q0.2

1L

water tower upper limit S1

water tower lower limit S2

water tank upper limit S3

water tank lower limit S4

pump M

solenoid valve Y

FU12VCPU 226 CN24V 2M

40

Diagram 3-7-2 water tower level automatic control circuit

12V- +

1L Q0.0 Q0.1

I0.1

S1 S2 S3 YM

PLC PanelYL-PCwater tower level automatic control circuit

S4

I0.2 I0.3 I0.4

COM

Q0.2

COMIN OUT

1M M L+2MCOM COM

41

Training 8, Automatic forming machine

1, Purposes

1, Understand automatic forming machine fundamental. 2, Learn programming software usage and program input, check, modification and operation

debugging. 3, Learn I/O port distribution and I/O ports.

2, Components

1, Yalong PLC controller. 2, Yalong PLC automatic forming machine. 3, Computer or programmer. 4, Safe cables. 5, PLC serial communication cable.

3, Fundamental

Automatic forming machine working modes:

(1) Initial status, when materials are put into forming machine, each oil cylinder status is in initial position, the solenoid valve Y1, Y2, Y4 close (OFF), the solenoid valve Y3 works (ON).position switchS1, S3, S5 are off (OFF), position switch S2, S4, S6 closes (ON).

(2) Push start button, solenoid valve Y2=ON upper oil cylinder piston moves downward, position switch S4=OFF. when position switch S3=ON, start left, right oil cylinder (solenoid valve Y3=OFF; solenoid valve Y1=Y4=ON), A piston moves rightward, C piston moves leftward, position switch S2, S6 is OFF.

(3) When oil cylinder piston reach terminal, then position switches S1, S5 are ON. Then each oil cylinder will return to initial position, A, B, C oil cylinder returns (solenoid valve Y1=Y2=Y4=OFF; solenoid valve Y3=ON), position switch S1=S3=S5=OFF.

(4) When A, B, C oil cylinder will return to origin (position switch S2=S4=S6=ON), the system will return to the initial position.

(5) Put materials, push start button to restart.

4, I/O

Table 3-8-1 automatic forming machine I/O

input output I0.0 start Q0.1 solenoid valve 1 I0.1 Position switch S1 Q0.2 solenoid valve 2 I0.2 Position witch S2 Q0.3 solenoid valve 3 I0.3 Position switch S3 Q0.4 solenoid valve 4 I0.4 Position switch S4 I0.5 Position switch S5 I0.6 Position switch S6

42

5, I/O circuit

Diagram 3-8-1 automatic forming machine I/O circuit

6, Steps




supply socket.



4, Turn on 2.4(2.5, 2.6, 2.7 are off).

5, Operation:

(1) Turn S1-S6 in OFF status, turn Y3 ON.

(2) When PLC starts, turn on S2, S4, S6.

(3) Turn on start switch 0.0, Y2, Y3.

(4) Make S4=OFF (down), S3=ON (up), Y1, Y2, Y4 ON.

(5) Make S2=S6=OFF (down); make S1=S5=ON (up), Y3 light ON.

(6) Make S1=S3=S5=OFF, S2=S4=S6=ON, Y3 light ON. S1-S6 indicator lights are ON.

7, Circuit

Connect automatic forming machine circuit according to Diagram 3-8-2.

8, Questions

How to carry out automatic counting control?

I0.1

I0.2

1M

Q0.4

Q0.3

Q0.2

Q0.1

S1

S2

S3

S4

S5

1L

2L

solenoid valve Y1

solenoid valveY2

solenoid valveY4

solenoid valveY3

I0.3

I.04

I0.5

I0.6S6

24V

12V FU

CPU 226 CN

startI0.0

2M

43

Diagram 3-8-2 automatic forming machine circuit

12V- +

1L Q0.0 2L

I0.1

S1 S2 S3 Y2Y1

Y3 Y4S6S5S4

PLC PanelYL-PC Automatic forming machine

I0.2 I0.3 I0.4 I0.5 I0.6

Q0.1 Q0.3Q0.2 Q0.4

COM COM

IN OUT

COM 1M M L+2MCOM

44

Training 9, automatic charging system

1, Purposes

1, Understand automatic charging control system work flow.

2, Learn how to use programming software to make automatic charging control system program.

3, Learn I/Odistribution,I/O connection methods and program operation debugging.

2, Components


2, Yalong PLC automatic charging system.


4, Safe cables.


3, Fundamental

Automatic charging system control: In initial status, red light L2 is OFF, green light L1 is ON, to allowe vehicle for charging. When

K2, motor M1, M2, M3 is OFF. When vehicle comes (S2 switch is on), L2 is ON, and L1 is OFF, M3

works, motor M2 works when M3 works for 2s, motor M1 works when M2 starts for 2s, delay for 2s,

K2 opens. When vehicle is loaded (S2 OFF), K2 closes, motor M1, delay for 2s, then stops, M2 stops

when M1 stops for 2s, M3 stops when M2 stops for 2s. L1 is ON, L2 is OFF, and vehicle can leave.

S1 is the materials detection switch, when it is full, K2 will open, S1 is cut out, when it is not full,

K1 is open, and K2 will not open.

4, I/O

Table 3-9-1 automatic charging system I/O

Input output I0.0 Upper limit level switch S1 Q0.0 Supply switch K1 I0.1 Position detection switch S2 Q0.1 switch K2

Q0.2 motor M1 Q0.3 motor M2 Q0.4 motor M3 Q0.5 green light L1 Q0.6 red light L2

5, I/O circuit

45

Diagram 3-9-1 automatic charging systemI/O circuit

6, Steps




supply socket.



4, Turn on 2.4, 2.5, 2.7 (2.6 is off).


(1) Start, L1 green light is ON, K1 light is ON.

(2) Upper switch S2 (indicator light ON), L1 green light is OFF, L2 red light is ON, motor M3, M2,

M1 are ON.

(3) Upper switch S1 (indicator light ON), K1 is OFF, K2 is ON.

(4) Lower switch S2 (indicator light ON), motor M1, M2, M3 are OFF, L1 is ON, K1 light is ON,

recver to (1).

7, Circuit

Connect automatic charging system circuit according to Diagram 3-9-2.

8, Questions

According to control requirements above, how to make vehicle counting function?

S1

S2

I0.0

I0.1

M

M

M

K1

K2

M1

M2

M3

L1

L2

1M

1L

2L

Q0.0

Q0.1

Q0.2

Q0.3

Q0.4

Q0.5

Q0.62M

12V FU

24V

CPU 226 CN

46

Diagram 3-9-2 automatic charging system circuit

12V- +

1L Q0.0

I0.1I0.0

S1S2

PLC PanelYL-PC Automatic charging system

K1 K2 M1 M2

M3L2L1

COMQ0.1 Q0.3Q0.2 2L Q0.4 Q0.5 Q0.6

COM

OUTIN

1M M L+2MCOM COM

47

Training 10, Multi-liquid automatic blending

1, Purposes

1, Understand multi-liquid automatic blending control system fundamental.

2, Learn ladder programming methods and instruction programming methods.

3, Learn programmer operation and programmer input, check, modification, download, upload and

operation.

2, Components


2, Yalong PLC multi-liquid automatic blending.


4, Safe cables.


3, Fundamental

Multi-liquid automatic blending control requirements:

In initial status, the container is empty, and the solenoid valve Y1, Y2, Y3, Y4 and blender M is

off, level sensor L1, L2, L3 are OFF.

Push start button, solenoid valve Y1, Y2 open, input liquid A and B, level is L2 (L2 and L3 are

ON), stop input (Y1, Y2 is OFF). Open liquid C solenoid valve Y3 (Y3 is ON), input liquid C, when

level rises to L1 (L1 is ON), stop input (Y3 is OFF). Start blender M, blending time is 3s. Then solenoid

valve Y4 starts, drain liquid, when level drops to L3 (L3 is OFF), delay for 5s, Y4 closes. Push start

button to restart.

4, I/O

Table 3-10-1 Multi-liquid automatic control I/O

I/O port Remark I/O port Remark I0.0 Start Q0.1 solenoid valve Y1 I0.1 L1 Q0.2 solenoid valve Y2 I0.2 L2 Q0.3 solenoid valve Y3 I0.3 L3 Q0.4 solenoid valve Y4 I0.4 T Q0.5 Blender M

Q0.6 Furnance H

48

5, I/O circuit

Diagram 3-10-1 Multi-liquid automatic blending I/O circuit

6, Steps




supply socket.



4, Turn on 2.4, 2.5, 2.7 (2.6 is off).


(1) Turn start switch 0.0, solenoid valve Y1, Y2 light ON.

(2) Turn on L3, L2, solenoid valve Y1, Y2 OFF, solenoid valve Y3 ON.

(3) Turn on L1, solenoid valve Y3 OFF, blender M is ON, 5s later, the solenoid valve Y4 is ON.

(4) Turn off L1, L2, L3, delay for 5s, the solenoid valve Y4 is OFF.

7, Circuit

Connect multi-liquid automatic blending circuit according to Diagram 3-10-2.

8, Questions

How to add temperature control function?

I0.1

I0.2

I0.3

I0.4

1M

1L

2L

Q0.1

Q0.2

Q0.3

Q0.4

Q0.5

Q0.6

L1

L2

L3

TM

H

solenoid valve 1

solenoid valve2

solenoid valve3

solenoid valve4

CPU 226 CN

24V

12V FU

Blender M

Furnance H

2M

49

Diagram 3-10-2 Multi-liquid automatic blending machine circuit

12V- +

1L Q0.0

I0.1

L1 L2

Y3Y2Y1

Y4 M HTL3

PLC PanelYL-PC Multi-liquid automatic blending

I0.2 I0.4I0.3

Q0.1 Q0.3Q0.2 2L Q0.4 Q0.5 Q0.6

COM COM

OUT

IN

COMCOM 2M L+M1M

50

Training 11. Automatic steel rolling machine

1, Purposes

1, Learn automatic steel rolling machine system work process.

2, Learn shift register/display circuit fundamental.

3, Learn programmer operation and programmer input, check, modification, download, upload and

operation.

2, Components


2, Yalong PLC automatic steel rolling machine.


4, Safe cables.


3, Fundamental

Automatic steel rolling machinecontrol requirements:

When you push start switch, motor M1, M2 will run. Then motor M3 forward, when steel plate

rolling is finished, S1 signal is OFF, sensor S2 is ON, steel plate arrives, the solenoid valve Y2 works,

motor M3 moves back, S2 is off, S1 is on and the motor M3 will rotate forward. when S1 is off, repeat.

When the third rolling is done, S2 is on, and then it stops. You can restart.

Register/display circuit fundamental is below:

Diagram 3-11-1 register/display circuit fundamental

51

Integrated circuit CD4015 is a 4-bit shift register, function is: 1CP, 2CP is click input terminal,

1CR, 2CR is clear terminal, 1DS, 2DS is serials data input terminal, 1Q0~1Q3, 2Q0~2Q3 is data output

terminal, VDD is positive power supply,VSS is ground.

The circuit input pulse signals are from PLC Y1 port, CD4015 output terminal 1Q0~1Q2,

indicator lights (3 LED). Circuit fundamental is that, when pulse arrives 2CP terminal, 2Q0 is high level.

Then 1Q0 is high level, drive LED (upper) ON. When 2CP receives pulse, 1Q1 is high level, drive LED

is ON, 1Q0 is in high level, if 2CP receives pulse, 1Q2 is high level, drive LED(lower) ON, 1Q0, 1Q1 are

in high level. When 1Q3 is high level, through diode, make 1CPclear, 1Q0~1Q3 is in low level.

4, I/O

Table 3-11-1 automatic steel rolling machine I/O

input output I0.0 Start Q0.1 Y1 I0.1 Sensor S1 Q0.3 Solenoid valve Y2 I0.2 Sensor S2 Q0.4 Motor M1

Q0.5 Motor M2 Q0.6 Motor M3 forward Q0.7 Motor M3back

5,I/O circuit

Diagram 3-12-2 automatic steel rolling machine I/O circuit

Q0.7

Q0.6

Q0.5

Q0.4

Q0.3

Q0.1

2L1L1M

Motor M2

Motor M1

Solenoid valve Y2

Y1

M

M

I0.2

I0.1

S2

S1

M

MMotor M3 forward

Motor M3back

FU12V24V

CPU 226 CN

StartI0.0

2M

52

6, Steps




supply socket.



4, Turn on 2.4, 2.5, 2.7 (2.6 is off).


(1) Turn on Y1, M1, M2 light ON.

(2)Up S1, down S1, Y1, M1, M2 and leftward light is ON (M3 forward).

(3)Up S2, down S2, Y1 lights, Y2 and rightward arrow light is ON(M3 back).

(4)Up S1, down S1, Y1 lights, M1, M2 and leftward arrow light is ON (M3 forward).

(5)Up S2, down S2, Y13 lights, Y2 and rightward arrow light is ON (M3 back).

(6)Up S1, down S1, M1, M2, Y13 lights and leftward arrow light is ON (M3 forward).

(7)Up S2, down S2, whole process is finished.

7, Circuit

Connect automatic steel rolling machine circuit according to Diagram 3-11-3.

8, Questions

According to technical process above, how to add workpiece counting function ?

53

Diagram 3-11-3 automatic steel rolling machine circuit

12V- +

1L Q0.1

S1 Y1M3ForwardM1

M2 M3Back Y2S2

PLC PanelYL-PC automatic steel rolling machine

I0.1 I0.2

Q0.3 Q0.4 Q0.52L Q0.6 Q0.7

COM

0V

12V

IN OUT

COMCOM 2M L+M1M

54

Training 12, mails allocator

1, Purposes

1, Learn mails allocator fundamental and demonstration fundamental.

2, Learn programmer operation and programmer download, upload, check and operation.

2, Components


2, Yalong PLC mails allocator.

3, Programmer (or computer).

4, Safe cables.


3, Fundamental

1, Mails allocator fundamental:

When started, green light L2 is ON, red light L1 is OFF, motor M5 runs, for mails allocation. The

switch S2 is ON, toggle switches are mails number (1.0~1.3 is toggle switch for 1, 2, 4, 8), from toggle

switch, you can read constant 1, 2, 3, 4, 5. If other than the 5 numbers, red light L1 will flash to alarm,

motor M5 stops. Restart, if it is normal, then red light is ON, green light is OFF, motor M5 runs, PLC

samples motor optical encoder S1 pulses (from mails code reader to corresponding box), when mails

arrives allocation box and enter mails box. Then red light is OFF, green light is ON, you can continue

allocation.

2, Fundamental

L1, L2 are red, green indicator lights, S2 switch is code reader, M1-M4 are impellers, and the

indicator light is waiting. The circuit fundamental is shown in Diagram 3-12-1, when switch is OFF,

LED (upper) is ON, LED (lower) OFF, when switch closes, LED (upper) is OFF, LED (lower) is ON.

M5 is the motor, S1 is optical encoder, the pulse circuit is shown below, when a terminal is

connected to the power supply, NE555 starts, pulse signals, through S1 terminal, are for PLC input

terminal to sample.

55

Diagram 3-12-1 mails allocation control system demonstration fundamental diagram

4, I/O

Table 3-12-1 mails allocation control system I/O

Input output

I0.0 Analogy optical encoder S1 Q0.1 Analogy impeller M1

I0.1 Start Q0.2 Analogy impeller M2

I0.2 Analogy code reader S2 Q0.3 Analogy impeller M3

Q0.4 Analogy impeller M4 Q0.5 Drive motor M5 Q0.6 Red light L1 Q0.7 Green light L2

5, I/O circuit

Diagram 3-12-2 mails allocation control systemI/O circuit

Red light L1

Drive motor M5M

S1

启动

I0.0

I0.1

M

M

Analogy impeller M1

1M

1L

2L

Q0.1

Q0.2

Q0.3

Q0.4

Q0.5

Q0.6

Q0.7Green light L2

Analogy impeller M2

Analogy impeller M4

Analogy impeller M3

M

M

S2I0.2

FU12V

CPU 226 CN24V2M

56

6, Steps




supply socket.



4, Turn on 2.4, 2.5 (2.6, 2.7 is off).


(1) 1.0-1.3, the binary number shall be within 1-5 (1.0, 1.1, 1.2, 1.3 is 1, 2, 4, 8).

(2) Push 0.1, L2, M5 is ON.

(3) L1 is ON, L2 is OFF, when it recovers, L2, L5 are ON.

(4) Then you can recheck mails.

7, Circuit

Connect mails allocation control system circuit according to Diagram 3-12-3.

8, Questions

How to add vehicle counting function according to control requirements above?

57

Diagram 3-12-3 mails allocatorcircuit

12V- +

Q0.0 Q0.1 Q0.2 2L

I0.2I0.0

S1 M4M3M2

L1 L2S2

PLC PanelYL-PC mails allocator

M5M1 1L Q0.3 Q0.4 Q0.5 Q0.6 Q0.7

0V12V

OUTIN

1M M L+2MCOM COM

58

Training 13. Iron tower lighting

1, Purposes

1, Learn hwo to use function instructions.

2, Understand 7-segment decoder fundamental.

3, Learn I/O distribution and connection methods.

4, Learn programmer operation and programmerdownload, upload, check and operation.

2, Components


2, Yalong iron tower lighting module.


4, Safe cables.


3, Fundamental

Iron tower lighting control requirements:

Automatic lighting, a light each time in sequence, and students can design various patterns.

4, I/O

Table 3-13-1 iron tower lighting I/O

Output output Q0.0 Color light L1 Q1.1 7-segment decoder A Q0.1 Color light L2 Q1.2 7-segment decoder B Q0.2 Color light L3 Q.13 7-segment decoder C Q0.3 Color light L4 Q1.4 7-segment decoder D Q0.4 Color light L5 Q1.5 7-segment decoder E Q0.5 Color light L6 Q1.6 7-segment decoder F Q0.6 Color light L7 Q1.7 7-segment decoder G Q0.7 Color light L8 Q1.0 Color light L9

59

5, I/O circuit

Diagram 3-13-1 iron tower lightingI/O circuit

6, Steps




supply socket.



4, Turn on 2.4, 2.5, 2.7 (2.6 is off).

5, Start automatic lighting, one light each time; from botton to top, then from top to bottom.

7, Circuit

Connect iron tower lighting circuit according to Diagram 3-13-2.

8, Questions

1, How to change lighting time interval?

2, How to make a same lighting color ON and OFF in a same time?

Color light L1

1L

3L

Q0.1

Q0.0

2L

Q0.2

Q0.3

Q0.7

Q0.6

Q0.4

Q0.5

Q1.0

Q1.6

Q1.5

Q1.7

Q1.4

Q1.3

Q1.1

Q1.2

7-segment decoderA

Color light L2

Color light L4

Color light L3

Color light L6

Color light L5

Color light L7

Color light L8

Color light L9

7-segment decoderB

7-segment decoderD

7-segment decoderC

7-segment decoderE

7-segment decoderF

7-segment decoderG

12V FUCPU 226 CN

60

Diagram 3-13-2 iron tower lighting circuit

12V- +

1L Q0.0

Q1.4

PLC PanelYL-PC iron tower

3L

A L1

L2

L3

L4

L5

L6

L7

L8

L9

B

C

E

F

G

HD

Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.5

Q0.6 Q0.7 Q1.0 Q1.1 Q1.3Q1.2

Q1.5 Q1.7Q1.6

COM

IN OUT

M L+2MCOM

plc training manual_china

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