PRACTICAL EXERCISES MANUAL

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TABLE OF CONTENTS
7 PRACTICES MANUAL ............................................................................................................. 2
7.1 EQUIPMENT DESCRIPTION .................................................................................................... 2
7.1.1 Introduction ................................................................................................................................................ 2
7.1.2 Description ................................................................................................................................................. 3
7.2 PRACTICES .................................................................................................................................. 7
7.2.1 Practice 1: Temporization ........................................................................................................................... 7
7.2.2 Practice 2: Counting ................................................................................................................................... 9
7.2.3 Practice 3: Sequential Control .................................................................................................................. 11
7.3 REAL APPLICATION................................................................................................................ 15
7.3.1 Introduction .............................................................................................................................................. 15
7.3.2 Necessary elements .................................................................................................................................. 15
7.3.3 Application carrying-out........................................................................................................................... 15
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7 PRACTICES MANUAL

7.1 EQUIPMENT DESCRIPTION

7.1.1 Introduction

Many applications are nowadays controlled by programmable logic

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

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

The N-PLCE-CLA is a washing machine training module. It is designed to

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

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

provided with switches, push buttons and LEDs to simulate the commonly elements
in an automatic washing machine. These elements simulate condition such as door
open, drum empty, motor on, etc. These conditions are evaluated by the PLCE in
order to perform the required action.

Figure 1: N-PLCE-CLA

The N-PLCE-CLA is a model of an automatic washing machine. It includes

the most common elements in this device such as a program selector, a motor, a
pump, an agitator, a thermostat, etc. Some of these elements are simulated by using
switches or push buttons and they are connected to PLC inputs.
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INPUT ELEMENT
X0 THERMOSTAT1
X1 THERMOSTAT2
X2 PROGRAM_SELECTOR3
X3 PROGRAM_SELECTOR2
X4 PROGRAM_SELECTOR1
X5 TEMPERATURE1
X6 TEMPERATURE2
X7 START_BUTTON
X8 LID_SWITCH
X9 EMPTY_WATER
XA FULL_WATER
XB
XC
XD
XE
XF

Table 1: Inputs N-PLCE-CLA

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

- THERMOSTAT1: input to detect if the temperature of the water selected has

been reached to temperature1.

- THERMOSTAT2: input to detect if the temperature of the water selected has

been reached to temperature2.

- PROGRAM SELECTOR 3, 2 and 1: inputs to select the program . These

inputs will be used as initial conditions. The user can set up to eight initial
conditions. Depending on these initial conditions, for instance, the user could
control how long some stages of the cleaning process will take.

- TEMPERATURE1, TEMPERATURE2: inputs to select the temperature of the

water. The user can select between two values. These values determine how
long the heating element will be on.

- START_BUTTON: input to start the program selected using the selector

switches.
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- LID_SWITCH: input to indicate the status of the door (open/closed).

- EMPTY_WATER, FULL_WATER: input to indicate whether the water level

of the drum is full or empty.

The training module also contains other elements such as valves, motors
and other more elements that are controlled by the PLCE to perform the required
functionality of the washing machine. These elements are directly connected to the
PLCE outputs.

OUTPUT ELEMENT
Y0 PROGRAM_STATUS3
Y1 PROGRAM_STATUS2
Y2 PROGRAM_STATUS1
Y3 WATER_INLET_VALVE
Y4 WATER_OUTLET_VALVE
Y5 HEATING_ELEMENT
Y6 MOTOR_FORWARD
Y7 MOTOR_REVERSE
Y8 PUMP
Y9
YA
YB
YC
YD
YE

Table 2: Outputs N-PLCE-CLA

The outputs are described as:

- PROGRAM_STATUS1, PROGRAM_STATUS2 and

PROGRAM_STATUS3: output that could be used to indicate the current
stage of the process. For example, it could be used as it is described on the
next table.
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STATUS

PS1 WASHING

PS2 RINSING

PS3 SPINNING

Table 3: Program Status Indicator

- WATER_INLET_VALVE: output that is used to fill the drum.

- WATER_OUTLET_VALVE: output that is used to empty the drum.

- HEATING_ELEMENT: output that controls the switching of the heating

element. This element is used to heat the water.

- MOTOR_FORWARD and MOTOR_REVERSE: these two signals are

used to control the running of the agitator.

- PUMP: output to control the pump to take away the water.

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7.2 PRACTICES

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

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

7.2.1 Practice 1: Temporization

7.2.1.1 Objective

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

In this practice we will develop a program that could be used to control the
agitation process. Let’s assume that the process starts when the drum is full of water.
During the agitation the motor is running back and reverse alternately during 5s.

7.2.1.2 Necessary elements

 PLCE

 N-PLCE-CLA

 PLCE connection cable

7.2.1.3 Practice carrying-out

The sequence of events necessary to control two types of drilling is

represented in the picture below, using a flowchart.
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Figure 2: Flowchart of practice 1

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7.2.2 Practice 2: Counting

7.2.2.1 Objective

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

In this practical exercise we will develop a program that counts how many
times the washing machine is used. This program will be helpful, for instance, to
determine the useful life of the washing machine.

7.2.2.2 Necessary elements

 PLCE

 N-PLCE-CLA

 PLCE connection cable

7.2.2.3 Practice carrying-out

The sequence of events necessary is represented in the picture below, using

a flowchart.

 The process starts setting the counters equal to 0.

 After that, the counter increases its value when the start button is pressed.

 The program will finish when the counter is equal to 1000.

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Figure 3: Flowchart of practice 3

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7.2.3 Practice 3: Sequential Control

7.2.3.1 Objective

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

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

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

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

1. The program status has to show that the current state is washing. After the
start, the program opens the inlet valve so water enters the machine and fills up
the drum until the water level detector indicates full water (START_BUTTON,
FULL_WATER, WATER_INLET_VALVE, PROGRAM_STATUS1).

2. The program switches on the heating element and the water is heated. The
heating keeps on until the thermostat (THERMOSTAT2) indicates that the
temperature selected has been reached (HEATING_ELEMENT,
THERMOSTAT2).

3. The motor and the agitator start running. Firstly, the motor runs forward during
10s and then it runs reverse during 10s (MOTOR_FORWARD,
MOTOR_REVERSE).

4. After the agitation the program opens the outlet valve. Then it switches on the
pump to help empty the water away from the drum
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(WATER_OUTLET_VALVE, PUMP).

7.2.3.2 Necessary elements

 PLCE

 N-PLCE-CLA

 PLCE connection cable

7.2.3.3 Practice carrying-out

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

flowchart.
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Figure 4: Flowchart of practice 4

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7.3 REAL APPLICATION

7.3.1 Introduction

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

7.3.2 Necessary elements

 PLCE

 N-PLCE-CLA

 PLCE connection

7.3.3 Application carrying-out

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

1. The clothes and the detergent are put in the machine and the door lid switch is
closed (LID_SWITCH).

2. The program is selected using the program selector and then the start button is
pressed. This selector works as the programmer, and depending on the program
selected some elements or others will be activated or not. There is a program
status display that shows the current stage of the cleaning process
(START_BUTTON, TEMPERATURE1, TEMPERATURE2).
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Rembember that the user can choose as many programs as desired. For this
practical exercise, let’s consider that we have memorized only two programs.

PROGRAM DURATION

PROGRAM1 WASHING 20 min

(Large RINSING 2 cycles

Program)
SPINNING 20 min

PROGRAM2 WASHING 10 min

(Short RINSING 1 cycle

Program)
SPINNING 0 cycles

Table 4: Example of selectable programs

For this practical exercise, the user will select the PROGRAM1. That
means that the washing stage will take 20 min, the filling-emptying process will be
repeated twice during the rinsing process and the spinning will take 20 min
(PROGRAM_SELECTOR1, PROGRAM_SELECTOR2,
PROGRAM_SELECTOR3).

3. The program status has to show that the current state is washing
(PROGRAM_STATUS1). The program opens the inlet valve so water enters the
machine and fills up the drum until the water level detector indicates full water
(EMPTY_WATER, FULL_WATER, WATER_INLET_VALVE).
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4. The program switches on the heating element and the water is heated
(HEATING_ELEMENT). The heating keeps on until the thermostat indicates that
the temperature selected has been reached (THERMOSTAT1, THERMOSTAT2).

5. The motor and the agitator start running. The motor is alternating running forward
and reverse for 10s (MOTOR_FORWARD, MOTOR_REVERSE).

6. After agitation for the time specified (see table 4) for the current program, the
programmer opens the outlet valve. Then, it switches on the pump to help
emptying the water away from the drum (WATER_OUTLET_VALVE, PUMP).

7. The programmer opens the water inlet valve again so clean water enters the drum.
The program status has to change from washing to rinsing
(WATER_INLET_VALVE, PROGRAM_STATUS2).

8. The programmer makes the drum rotate back and forth so the clean water rinses
the clothes. It empties the drum and repeats this process twice to get rid of all the
detergent (see table 4) (WATER_OUTLET_VALVE, WATER_INLET_VALVE,
PUMP, MOTOR_FORWARD, MOTOR_REVERSE).

9. When the clothes are rinsed, the programmer makes the drum rotate at higher
speed to spin for the time specified for the program (see table 4). This is how
spinning gets the clothes dry. The program status has to change from rinsing to
spinning. The pump removes any remaining water until the sensor level detects
there is no water left (EMPTY_WATER, FULL_WATER,
WATER_OUTLET_VALVE, PUMP, PROGRAM_STATUS3,
MOTOR_FORWARD, MOTOR_REVERSE).