PLC Simulator Lucas Nuler

PLC Universal System Simulator Supplementary set of templates
CLC 34
Student Workbook SH5009-6C 2nd edition Author: Toni Fleumer
Lucas-Nlle
Lehr- und Messgerte GmbH Siemensstrae 2 D-50170 Kerpen
PLC Universal System Simulator
Table of contents
A B C D E F
Brief description ............................................................................................................... 1 Technical data ................................................................................................................... 2 Pin assignment .................................................................................................................. 3 Assembly plan.....................................................................................................................4 Template overview ............................................................................................................ 5 Experiment descriptions..................................................................................................... 7 Cleaning system............................................................................................................. 7 Furnace door control .................................................................................................... 11 Bending tool ................................................................................................................. 15 Embossing machine ..................................................................................................... 19 Drilling tool.................................................................................................................... 23 Selective belt switch ..................................................................................................... 27 Pipe bending machine.................................................................................................. 31 Gate control system ..................................................................................................... 35 Pump control 1 ............................................................................................................. 39 Pump control 2 ............................................................................................................. 43 Reaction vessel ............................................................................................................ 47 Automatic tablet filler .................................................................................................... 51
A Brief description
This PLC Universal System Simulator from LUCAS-NLLE LEHRSYSTEME is used to simulate various processes. It allows testing of PLC programs for any particular task regardless of the PLC manufacturer.
Note
The input and output addresses in the PLC programs have been arbitrarily selected irrespective of any particular manufacturers and correspond to the relevant terminal diagrams in the experiment descriptions These addresses will need to be modified in line with the PLC system and wiring. This also applies to the assignment lists. If the simulator is connected via the system terminals, the interface assignment specified in this operating manual (Section C) should be observed.
The various process are implemented simply by employing the corresponding template. The buttons and switches on the system simulator are used to represent sensors, while the visible LEDs represent actuators. The training objective is to create and test PLC programs, especially their basic functions (AND, OR etc.), timing functions and processing of instructions. Programming methods for the event of a break in wiring are conveyed as well.
CLC34 INTRODUCTION
B Technical data
Inputs and outputs
Supply voltage Current consumption Dimensions (HxWxD) Weight
8 Digital inputs, 24V 20 Digital outputs, 24V (maximum of 8 employed) 2 Analog inputs, 0-10V 2 Analog outputs, 0-10V 24V DC 0.3 A 297x456x125 1 kg
Connection to any PLC via:
4-mm safety sockets for each input/output 37-pin connecting plugs, one pin for each of the inputs/outputs SO3715-1A SO3715-1B SO5155-2J SO3715-1C SO5155-2K
Order numbers:
PLC Universal System Simulator Basic set of templates CLC34 experiment descriptions I Supplementary set of templates CLC34 experiment descriptions II
CLC34 INTRODUCTION
C Pin assignment
PLC inputs
E 0.0 E 0.1 E 0.2 E 0.3 E 0.4 E 0.5 E 0.6 E 0.7 E 1.0 E 1.1 E 1.2 E 1.3 E 1.4 E 1.5 E 1.6 E 1.7 E 8.0 E 8.1 E 8.2 E 8.3 E 8.4 E 8.5 EW 320 EW 322 +24V GND A 4.0 A 4.1 A 4.2 A 4.3 A 4.4 A 4.5 A 4.6 A 4.7
Pin 24 Pin 23 Pin 22 Pin 21 Pin 2 Pin 3 Pin 4 Pin 5 Pin 28 Pin 27 Pin 26 Pin 25 Pin 6 Pin 7 Pin 8 Pin 9 Pin 14 Pin 13 Pin 12 Pin 11 Pin 29 Pin 30 Pin 18 Pin 17 Pin 19/37 Pin 1/20 Pin 24 Pin 23 Pin 22 Pin 21 Pin 2 Pin 3 Pin 4 Pin 5-{}Pin 18 Pin 17
37-pin plug
S1 Switch S2 Switch S3 Switch S4 Switch S5 Switch S6 Switch S7 Switch S8 Switch Reserved Reserved S9 Acknowledgement S10 Acknowledgement S11 Acknowledgement S12 Acknowledgement S13 Acknowledgement S14 Acknowledgement S15 Acknowledgement S16 Acknowledgement S17 Acknowledgement S18 Acknowledgement S19 Acknowledgement S20 Acknowledgement Inlet 1 Inlet 2 Supply voltage Supply voltage H1 LED H2 LED H3 LED H4 LED H5 LED H6 LED H7 LED H8 LED
Designation
Designation
PLC outputs
37-pin plug
AW 320 AW 322
0...10 V Actual value Outlet
The addresses stated here apply to Lucas-Nlle's basic PLC unit configured for use as shown in the assembly plan in Section D of this manual. If a different PLC module or card configuration is employed (input/output addresses depend on slot position in the case of many control units), the input and output addresses should be altered accordingly.
CLC34 INTRODUCTION
D Assembly plan
+15V +5V +24V
SM321 SM322 SM321 SM322 SM334
+15V +5V +24V
0,8A tr
+24V
+24VSPS 0V -15V
0 0 0 0
0V
ANALOG I/O, 4/2-CH. SO3713-3E
-15V
With the help of two 37-pin plugs, it is possible to connect appropriate PLC control units without a need for long set-up procedures. Appropriate PLCs include all LUCAS-NLLE devices possessing system connector terminals and 32 digital inputs.
Note
If the system plug connectors (2 x 37-pin) are used with a PLC unit possessing just 16 digital inputs, those assigned S15 to S20 will need to be connected individually if required. This is necessary, for instance, in experiments 3, 5, and 7.
Using 37-wire cables, the system simulator's input and output sections are connected to the PLC's output and input sockets respectively. Discrete 4-mm safety sockets can be used to connect PLC units from any manufacturer.
Caution The simulator is designed to operate with a 24 V DC voltage. No other voltage levels may be applied to its terminals (except in the case of analog signal processing). Ensure correct polarity when establishing connections. Only voltages between 0V and 10V should be applied to the simulator's analog section. Ensure correct polarity when establishing connections.
Caution
CLC34 INTRODUCTION
E Template overview
No. Set Name 1 2 Cleaning system 2 2 Furnace door control 3 2 Bending tool 4 2 Embossing machine 5 2 Drilling tool 6 2 Selective belt switch 7 2 Pipe bending machine 8 2 Gate control system 9 2 Pump control 1 10 2 Pump control 2 11 2 Reaction vessel 12 2 Automatic tablet filler
Overview of templates for the PLC application board
AI AO DI DO - 8 3 - 6 2 8 6 8 6 8 8 8 4 6 7 6 4 7 1 7 2 4 4 6 8
AI: Analog inputs (of the system simulator => PLC outputs) AO: Analog outputs DI: Digital inputs DO: Digital outputs The inputs here refer to inputs to the system simulator (=> PLC outputs).
CLC34 INTRODUCTION
CLC34 INTRODUCTION
F Experiment descriptions
Cleaning system
REINIGUNGSBAD / CLEANING SYSTEM
oben top Korb Position Basket Position
unten botton
Start
Stop
S1
Hand
Y1 H1 S14 H3
S2
Autom.
S3
Takt Frequency
S4 S6
Korb heben
S5
t
Korb senken
Y2 H2 S13
S7
Basket down
Hub Lift
S8
Basket up
Korb Basket
SO3715-1C01
Exercise:
To clean workpieces, a cleaning system's container is to be lifted and lowered pneumatically.
Description of function:
Operating-mode switches S3 and S4 can be used to select manual and automatic modes respectively. If both operating modes are inadvertently selected at the same time, manual mode has priority. In manual mode, the piston is extended with switch S7 and retracted with switch S8. It must be ensured that the immersion period does not exceed 5 seconds. After three immersions, the system turns off; it can be restarted with switch S1. In automatic mode, the system is started with button S1. After three lifting/lowering operations, the basket remains in its up position and the system turns off. The immersion period is 5 seconds in each case. The status of the immersion process is to be indicated by lamp H3. The cleaning system is stopped with switch S2, ending all movements immediately. The program must ensure that function is not impaired in the event of a wire breaking.
Experiment procedure:
a) Place the CLEANING SYSTEM template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.
CLC 34/1 EXPERIMENT DESCRIPTION / CLEANING SYSTEM

Assignment list Inputs Input Component ID
Start button Stop button Manual mode switch Manual mode switch Automatic mode switch Limit switch piston up Limit switch piston down Lower basket button
PLC
Symbol
Assignment
Outputs Output
Solenoid valve extend Solenoid valve retract Cycle display
Component ID
PLC
Symbol
Assignment
Flags, timers, counters Designation PLC

Activation flag Extend piston Retract piston Compare flag Max. immersion time Number of immersions 8 Operating mode flag
Symbol
Assignment

Terminal diagram
d) Draw up a terminal diagram.
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the CLEANING SYSTEM template for the PLC universal system simulator.
10
Furnace door control
OFENSTEUERUNG / FURNACE DOOR CONTROL
auf open Tr Position Door Position
zu close
Offnen
Schliessen
S S14 Ofentr Furnace door
S4 S13
S1
Open Stop Close B1
S2 S4 S6 S8
S3 S5 S7
Y1 H1
Y2 H2
B1
SO3715-1C02
Exercise:
A furnace door is controlled by means of a 5/3-way directional control valve.

In its initial position, the furnace door is closed. Pressing switch S1 triggers solenoid valve Y2 to open the door. Limit switch S14 or stop switch S3 deactivate solenoid valve Y2. If the furnace door has been stopped by limit switch S14 or stop switch S3, the door is closed automatically by solenoid valve Y1 after a delay of 6 seconds. The closing procedure can also be commenced by means of button S2. Stop button S3 can be used to halt the closing of the door. If a total opening time of 30 seconds is exceeded through repeated operation of the stop button, this button is disabled and the furnace door closes automatically. Closing of the door is completed by deactivating solenoid valve Y1 when limit switch S13 is reached. Blocking light barrier B1 stops the closing process which only continues once the light barrier has been unblocked again. The movements of the door must be mutually interlocked. The program must ensure that function is not impaired in the event of a wire breaking.
CLC 34/2 EXPERIMENT DESCRIPTION / FURNACE DOOR CONTROL
11

a) Place the FURNACE DOOR CONTROL template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.
Assignment list Inputs

Open button Close button Stop button Light barrier B1 Limit switch Door open Limit switch Door shut
Input
Component ID
PLC
Symbol
Assignment
Outputs
Solenoid valve Close door Solenoid valve Open door
Output
Component ID
PLC
Symbol
Assignment
Flags, timers, counters

Close door Delay 6 s Delay 30 s
Designation
PLC
Symbol
Assignment
12

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the FURNACE DOOR CONTROL template for the PLC universal system simulator.
13
14
Bending tool
BIEGEWERKZEUG / BENDING TOOL
rechts right Zylinder 3 Position Cylinder 3 Position
links left
oben top Zylinder 2 Position Cylinder 2 Position Zyl.2 Cyl.2
unten botton
oben top Zylinder 1 Position Cylinder 1 Position Zyl.1 Cyl.1
unten botton
Start
S1
Stop
S2
Y3
H3
Y2
H5
S3
S4
S16
S18
S5
S6
S15 S13 S14 Y4 Zyl.3 Cyl.3 H4
S17
Y1
H6
S7
S8
H2
H1
Y5
Y6
SO3715-1C03
Exercise:
A bending tool driven by 3 pneumatic cylinders is used to bend metal sheets.

After the metal sheet has been placed manually on the workbench and start switch S1 pressed, the sheet is fixed by piston 1. Piston 2 then bends the sheet by 90, before piston 3 gives the sheet its final shape. When activated by means of start switch S1, the system automatically moves to its initial position, i.e. the three pistons are retracted by solenoid valves Y1, Y4 and Y6 respectively. Once the system has reached its initial position, cylinder 1 is extended by solenoid valve Y2 and clamps the sheet on the workbench. On reaching limit switch S17, solenoid valve Y2 is deactivated, solenoid valve Y3 activates and the piston of cylinder 2 extends to bend the sheet by 90. Solenoid valve Y3 is deactivated when limit switch S15 is reached. After a delay of 2 seconds, the piston of cylinder 2 is retracted again by means of solenoid valve Y4. On reaching limit switch S16, solenoid valve Y4 is deactivated, dolenoid valve Y5 activates and the piston of cylinder 3 extends to bend the sheet into its final shape. Solenoid valve Y5 is deactivated on when limit switch S14 is reached. After a delay of 2 seconds, the piston of cylinder 3 is retracted again by means of solenoid valve Y6.
CLC 34/3 EXPERIMENT DESCRIPTION / BENDING TOOL
15

On reaching limit switch S13, solenoid valve Y6 is deactivated, and the piston of cylinder 1 retracted again via dolenoid valve Y1 which is deactivated subsequently when limit switch S18 is reached. This process is repeated on pressing the start switch. It should be possible to stop the system by means of stop button S2 whenever required. Any subsequent restart via switch S1 first moves the system to its initial position. The program must ensure that function is not impaired in the event of a wire breaking.
a) Place the BENDING TOOL template on the PLC universal system simulator.
b) Connect up the process to the PLC. c) Create an assignment list.

Start button Stop button Limit switch Piston 1 retracted Limit switch Piston 1 extended Limit switch Piston 2 retracted Limit switch Piston 2 extended Limit switch Piston 3 retracted Limit switch Piston 3 extended
Input
Component ID
PLC
Symbol
Assignment
16

Outputs
Solenoid valve Piston 3 retract Solenoid valve Piston 3 extend Solenoid valve Piston 2 extend Solenoid valve Piston 2 retract Solenoid valve Piston 1 extend Solenoid valve Piston 1 retract
Output
Component ID
PLC
Symbol
Assignment

Activation flag
Designation
PLC
Symbol
Assignment
Step flag Disable start Step flag Initial position Step flag Piston 1 extend Step flag Piston 2 extend Step flag Piston 2 retract Step flag Piston 3 extend Step flag Piston 3 retract Step flag Piston 1 retract Step flag Done Delay
17

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the BENDING TOOL template for the PLC universal system simulator.
18
Embossing machine
PRGEMASCHINE - AUTOMATIK / EMBOSSING MACHINE - AUTOMATIC
Start
Stop
S1 S3
Y2 S9 H2 Y3 H3 S8 S11 Y1 H1 S12 Auswerfen Eject Y4 H4 Korb Basket Prgen Emboss B1 opt. Sensor
S2 S4 S6
opt. Sensor
S5 S7
B1
S8
SO3715-1C04
Exercise:
The machine in this exercise is used to emboss workpieces. A pushing cylinder slides the workpiece underneath the stamping die driven by a separate cylinder. After being embossed, the workpiece is lifted by an ejection cylinder and blown off the workbench by an air stream activated by Y2.
Pressing start switch S1 triggers solenoid valve Y1, whereupon the pushing cylinder extends to slide the workpiece into the stamping well. Magnetic valve Y1 is deactivated on reaching limit switch S9, whereupon the pushing cylinder retracts. When limit switch S9 signals that the pushing cylinder's piston has retracted, a delay of 2 seconds is allowed to elapse, after which solenoid valve Y3 comes on to extend the piston for embossing the workpiece. On reaching limit switch S11, solenoid valve Y3 is turned off and the embossing cylinder's piston retracts. When limit switch S11 signals that the embossing cylinder's piston has retracted, a delay of 2 seconds is allowed to elapse, after which solenoid valve Y4 comes on to extend the ejection piston for lifting the workpiece. At the same time, solenoid valve Y2 is activated, causing an air stream to blow the workpiece off the workbench into a collection basket. On detection of the workpiece by sensor S8, solenoid valves Y2 and Y4 close, and the ejection piston retracts.
CLC 34/4 EXPERIMENT DESCRIPTION / EMBOSSING MACHINE
19

When limit switch S12 signals that the ejection piston has retracted, the whole procedure is repeated. It should be possible to stop the system by means of stop button S2 whenever required. The program must ensure that function is not impaired in the event of a wire breaking.
a) Place the EMBOSSING MACHINE template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.

Start button Stop button Limit switch piece pushed out Limit switch piece lifted Limit switch Stamp down Light barrier B1
Input
Component ID
PLC
Symbol
Assignment
Outputs
Solenoid valve Push Solenoid valve compressed air Solenoid valve Stamp Solenoid valve Eject
Output
Component ID
PLC
Symbol
Assignment
20

Activation flag Pulse flag for B1 Edge flag for B1 Step flag Disable start Step flag Push out Step flag Delay Y3 Step flag Stamp Step flag Delay Y4 Step flag Eject Step flag Done Delay
Designation
PLC
Symbol
Assignment
21

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the EMBOSSING MACHINE template for the PLC universal system simulator.
22
Drilling tool
BOHRVORRICHTUNG / DRILLING TOOL
rechts right Abschieber Position Push Position
links left
oben top Auswerfer Position Eject Position
unten botton
oben top Bohrer Position Drill Position
unten botton
Start
S1
Stop
S2
Y7
H7
Zyl.3 Cyl.3 Bohrer Drift
Y5 S18
H5
S3
S4
S5
S6
S13 Zyl.1 Cyl.1 Abschieben Push
S14
S17 Y6 H6
S7 S8
S16
H2 Y2
H1 Y1
Auswerfen Eject
Zyl.2 Cyl.2
S15 H4 Y4
H3 Y3
SO3715-1C05
Exercise:
A tool is used here to automatically drill holes in workpieces. A cylinder pushes the workpieces out of a magazine and underneath the drill. The hole is then bored by means of a second cylinder. After the drilling procedure, the workpiece is lifted by a third cylinder and blown off the table by means of compressed air.
When activated by means of start switch S1, the system automatically moves to its initial position, i.e. the three pistons are retracted by solenoid valves Y1, Y3 and Y6 respectively. Once the system has attained its initial position, solenoid valve Y2 is activated, the piston of the pushing cylinder extends and clamps the workpiece in the drilling position. When limit switch S14 signals that the piston has extended, Y2 is deactivated, solenoid valve Y5 then activates and the piston of the drilling cylinder extends to drill the workpiece. On reaching limit switch S17, solenoid valve Y5 is deactivated, Y6 is activated and the drilling cylinder returns to its initial position. Limit switch S18 deactivates solenoid valve Y6, whereupon Y1 is activated and the piston of the pushing cylinder releases the workpiece. On reaching limit switch S13, magnetic valve Y1 is deactivated, solenoid valve Y4 is activated and the ejection cylinder lifts the workpiece. Limit switch S16 deactivates solenoid valve Y4, whereupon solenoid valve Y7 is activated and compressed air blows the workpiece off the drilling table. After a delay of 2 seconds, solenoid valve Y7 is deactivated and solenoid valve Y3 simultaneously activates until the piston of the ejection cylinder reaches limit switch S15.
CLC 34/5 EXPERIMENT DESCRIPTION / DRILLING TOOL
23

After that, the process described above is repeated. It should be possible to stop the system by means of stop button S2 whenever required. Any subsequent restart via switch S1 first moves the system to its initial position. The program must ensure that function is not impaired in the event of a wire breaking.
a) Place the DRILLING TOOL template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.

Start button Stop button Limit switch Piston 1 retracted Limit switch Piston 1 extended Limit switch Piston 3 retracted Limit switch Piston 3 extended Limit switch Piston 2 extended Limit switch Piston 2 retracted
Input
Component ID PLC
Symbol
Assignment
24

Outputs Output
Solenoid valve Piston 1 retract Solenoid valve Piston 1 extend Solenoid valve Piston 2 retract Solenoid valve Piston 2 extend Solenoid valve Piston 3 extend Solenoid valve Piston 3 retract Solenoid valve Compressed air
Component ID PLC
Symbol
Assignment

Activation flag Step flag Disable start Step flag Initial position Step flag Piston 1 extend Step flag Piston 3 extend Step flag Piston 3 retract Step flag Piston 1 retract Step flag Piston 2 extend Step flag Compressed air on Step flag Piston 2 retract Step flag Done Delay
Symbol
Assignment
25

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the DRILLING TOOL template of the PLC universal system simulator.
26
Selective belt switch
SELEKTIVE BANDWEICHE / SELECTIVE BELT SWITCH
E S5
E S6
E S7
Start
Stop
S1 A S3
Lichtschr. B1
S2 S4
Lichtschr. B2
S5 S B1 S B2 S9 S B3
Opt.Sens. B1 Lichtschr. B3
S6
Opt.Sens. B2
S7
Opt.Sens. B3
S8
H1 Y1
SO3715-1C06
Exercise:
A selective belt switch differentiates between short and long workpieces, routing them to different production areas.
When the system is activated by means of start switch S1, the belt switch moves to its A setting. If a long part passes the sensor, all three of its light barriers are engaged simultaneously for a brief period, causing the switch to remain on its A setting. If a short part passes the sensor, its three light barriers are engaged separately in succession, causing the switch to move to its B setting and remain there for a maximum of 5 seconds. After this period or on detection of a long part, the switch returns to its A setting. The program must ensure that function is not impaired in the event of a wire breaking.
CLC 34/6 EXPERIMENT DESCRIPTION / SELECTIVE BELT SWITCH
27

a) Place the SELECTIVE BELT SWITCH template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.

Start button Stop button Limit switch piston retracted Light barrier B1 Light barrier B2 Light barrier B3
Input
Component ID
PLC
Symbol
Assignment
Outputs
Belt switch cylinder
Output
Component ID
PLC
Symbol
Assignment

Activation flag Edge flag for B1 Time monitoring position B
Designation
PLC
Symbol
Assignment
28

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the SELECTIVE BELT SWITCH template for the PLC universal system simulator.
29
30
Pipe bending machine

ROHRBIEGEANLAGE / PIPE BENDING MACHINE
innen in Wagen Trolley aussen out zu close Schutzgitter Saftey Guard auf open oben top Werkzeug Tool unten botton
Start
S1
W. beladen
S2 S4 S6 S8
auf up
H3
H5
Y1
S3
T. loaded
ab down
H4
S18
S5 S7
S15 Schutzgitter Saftey Guard S17 H6 Y2
Wagen Trolley S3
S14 S13
H7
S16 W1/H1 W2/H2
SO3715-1C07
Exercise:
A workpiece placed manually on a carriage is formed into a certain shape by a pipe bending machine.
When initiator S3 indicates that a pipe has been placed manually on the carriage, the system can be started with switch S1. Contactor K2 closes to draw the carriage toward the bending unit. On reaching limit switch S14, K2 is deactivated and K4 triggered to close the safety grille. Once the safety grille is closed (S16), contactor K7 switches on the heater. After a heating period of 10 seconds, solenoid valve Y1 is triggered to lower the bending tool. On reaching limit switch S17, heater contactor K7 opens again. After a delay of 10 seconds, the bending tool is raised by solenoid valve Y2. On reaching limit switch S18, contactor K3 opens the safety grille again. Once the safety grille is open (S15), it stops and contactor K1 is triggered to move the carriage away from the bending unit. K1 is deactivated when limit switch S13 is reached. System restart should only be possible after the bent pipe has been removed from the carriage and a new blank has been placed on it. The program must ensure that function is not impaired in the event of a wire breaking.
CLC 34/7 EXPERIMENT DESCRIPTION / PIPE BENDING MACHINE
31

a) Place the PIPE BENDING MACHINE template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.

Start button Limit switch for carriage out Limit switch for carriage loaded Limit switch for carriage in Limit switch for safety grille open Limit switch for safety grille shut Limit switch for piece up Limit switch for piece down
Input
Component ID PLC
Symbol
Assignment
Outputs
Motor contactor Move carriage out Motor contactor Move carriage in Motor contactor Grille open Motor contactor Grille shut Solenoid valve Bending tool down Solenoid valve Bending tool up Heating contactor
Output
Component ID PLC
Symbol
Assignment
32

Activation flag Activation flag Edge flag for S1 Step flag Disable start Step flag Move in Step flag Safety grille shut Step flag Heating on Step flag Tool down Step flag Heating off Step flag Tool up Step flag Safety grille open Step flag move out Step flag Done
Designation
PLC %M 0.0
Symbol AF
%M 0.0 %M 0.1 %M 1.0 M 1.1 M 1.2 M 1.3 M 1.4 M 1.5 M 1.6 M 1.7 M 2.0 M 2.1
AF Edge_S1 SF_0 SF_1 SF_2 SF_3 SF_4 SF_5 SF_6 SF_7 SF_8 SF_9
Assignment Logic 1 -> System on Logic 1 -> System on Logic 1 -> Positive edge Logic 1 -> Step activated Logic 1 -> Step activated Logic 1 -> Step activated Logic 1 -> Step activated Logic 1 -> Step activated Logic 1 -> Step activated Logic 1 -> Step activated Logic 1 -> Step activated Logic 1 -> Step activated Logic 1 -> Step activated
33

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the PIPE BENDING MACHINE template for the PLC universal system simulator.
34
Gate control system

TORSTEUERUNG / GATE CONTROL SYSTEM
auf open Tor Position Door Position zu close
Automatik
Tippen
S1
Automatic Auf Inching Zu
S2 S4
Close
S3
Open Halt
S5
Stop Hindernis
S6 S8
S7 S14 zu close auf open M H3 S13
S7
Obstruction
K1 K2
H1 H2
SO3715-1C08
Exercise:
A factory gate is to be opened and closed automatically or gradually by pressing a button manually. Two power contactors control the gate motor.
If switch A1 is set to automatic operating mode, briefly pressing opening switch S3 triggers power contactor K2 and causes the sliding gate to open until limit switch S14 is reached. Briefly pressing the closing switch S4 in automatic mode triggers power contactor K1 and causes the gate to close until limit switch S13 is reached. Opening and closing of the gate can be halted by switch S5. Movement is also halted if switch S7 signals an obstruction. If switch S2 is set to manual mode, the gate can be opened with switch S3 and closed with switch S4 for as long as either switch remains pressed. Limit switches S13 and S14 retain their original function. Here too, movement is interrupted if switch S7 signals an obstruction. If the automatic and manual modes are selected together inadvertently, manual mode has priority. Measures must be taken to ensure that the two power contactors cannot be activated simultaneously (which would result in a short circuit). The program must ensure that function is not impaired in the event of a wire breaking.
CLC 34/8 EXPERIMENT DESCRIPTION / GATE CONTROL SYSTEM
35

a) Place the GATE CONTROL SYSTEM template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.

Automatic mode selector Manual mode selector Gate open button Gate close button Gate halt button Gate open limit switch Obstruction switch Gate closed limit switch
Input
Component ID
PLC
Symbol
Assignment
Outputs
Gate close motor contactor Gate open motor contactor
Output
Component ID
PLC
Symbol
Assignment

Operating mode flag
Designation
PLC
Symbol
Assignment
36

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the GATE CONTROL SYSTEM template for the PLC universal system simulator.
37
38
Pump control 1
PUMPENSTEUERUNG 1 / PUMP CONTROL 1
Tank 1 max.
Tank 1 min.
S1 Tank 1 S1 max S3 max Tank 2 S5 max Tank 3 S7 max Tank 4

Tank 2 max. Tank 2 min.
S2 S4
Tank 3 min.
S3
Tank 3 max.
S5 S2 min H S4 min H S6 min H S8 min H

Tank 4 max. Tank 4 min.
S6 S8
S7
H5 M1
H6 M2
H7 M3
H8 M4
SO3715-1C09
Exercise:
Four tanks which can be emptied manually are filled from a common reservoir via four pumps, one to each tank. Every tank has a signal sensor for indicating when they are full and empty.
The pumps have the following in-circuit power ratings: Pump 1: 3 kW Pump 2: 2 kW Pump 3: 7 kW Pump 4: 5 kW As soon a tank is notified to be empty, the control system should cause it to fill up again. Total power consumption must not exceed 10 kW. The program must ensure that function is not impaired in the event of a wire breaking.
a) Place the pump control template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.
CLC 34/9 EXPERIMENT DESCRIPTION / PUMP CONTROL 1
39

Tank 1 full Tank 1 empty Tank 2 full Tank 2 empty Tank 3 full Tank 3 empty Tank 4 full Tank 4 empty
Input
Component ID PLC
Symbol
Assignment
Outputs
Pump motor 1 Pump motor 2 Pump motor 3 Pump motor 4
Output
Component ID
PLC
Symbol
Assignment
40

Terminal diagram
+24V
SPS
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the PUMP CONTROL template for the PLC universal system simulator.
41
42
Pump control 2
PUMPENSTEUERUNG 2 / PUMP CONTROL 2
S3 P+S4
Druck Pressure
Start
S1
Stop
S2
gross
Netz Net S3
klein
S4
excessive
S5
low
S6
P1
P2
P3
P4
H1
H2
H3
H4
S7
S8
Saugbehlter
Suction tank
SO3715-1C10
Exercise:
Four pumps feed the contents of a suction container into a network. The pumps are activated and deactivated individually to maintain the network pressure within a certain range.
Activation and deactivation are to be followed by a reaction delay of 3 seconds before the next stage is activated or deactivated. Starting the system via switch S1 activates pump 1. If pressure sensor S4 indicates excess low pressure, pump 2 is activated after a 3-second delay and further pumps are similarly added until all pumps are active or the pressure has reached the required value. If pressure sensor S3 indicates excess high pressure, the most recently activated pump is deactivated. If necessary, further pumps are deactivated after a 3-seconds delay in each case until all pumps are inactive or the pressure has dropped again into the pre-set range. The system can be deactivated by means of stop button S2; this deactivates all currently active pumps. If both sensors S3 and S4 indicate excess high and excess low pressure respectively, a fault is assumed and the system is shut down. The program must ensure that function is not impaired in the event of a wire breaking.
43

a) Place the PUMP CONTROL 2 template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.

Start button Stop button Pressure sensor Pressure too high Pressure sensor Pressure too low
PLC
Symbol
Assignment
Outputs Output
Contactor Pump 1 Contactor Pump 2 Contactor Pump 3 Contactor Pump 4
Component ID
PLC
Symbol
Assignment

Activation flag Timer for pump 2 on Timer for pump 3 on Timer for pump 4 on Timer for pump 4 off Timer for pump 3 off Timer for pump 2 off Timer for pump 1 off
Symbol
Assignment
44

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the PUMP CONTROL 2 template for the PLC universal system simulator.
45
46
Reaction vessel
REAKTIONSGEFSS / REACTION VESSEL
Start
Stop
S1 U Umwlzpumpe Circulating pump Druck Pressure

S2
Inching
Automatic
H3
H4 Y2
S3 Sicherheitsventil Safety valve

P> P>
S4 S6
S5
P S5 P S6
S7
S8
H1 Y1
Khlwasserabfluss Cooling water outlet
S7 S8
Normal Regular
H2
Khlwasserzufluss Cooling water inlet SO3715-1C11 Heizung
Strung Stoppage
H5
H6
Heating
Exercise:
The liquid in a reaction vessel is to be maintained at a constant temperature.

When the system is started with switch S1, circulation pump U commences intermittent operation at 5-second intervals and the heater raises the temperature of the cold liquid to the required level, during which process the pressure in the reaction vessel also rises. Attainment of the required pressure and temperature values is indicated by lamp H6. If the temperature exceeds the required value (S7), circulation pump U switches to continuous operation and solenoid valve Y1 opens a supply of cooling water. Once the temperature has dropped again to the normal level, the pump resumes intermittent operation and the supply of cooling water is shut off. If pressure sensor S5 indicates overpressure, the cooling water supply is opened via Y1, overpressure valve Y2 is opened, the circulation pump switches to continuous operation and a fault notification is output via H2. The fault notification output and safety valve can only be deactivated via stop switch S2. The system can be deactivated at any time by means of stop switch S2. The program must ensure that function is not impaired in the event of a wire breaking.
CLC 34/11 EXPERIMENT DESCRIPTION / REACTION VESSEL
47

a) Place the REACTION VESSEL template on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.

Start button Stop button Pressure sensor Pressure too high Pressure sensor Pressure too low Sensor Temperature too high Sensor Temperature too low
PLC
Symbol
Assignment
Outputs Output
Coolant solenoid valve Fault notification Motor contactor for circulation pump Safety valve Heating contactor Indicator normal
Component ID
PLC
Symbol
Assignment

Activation flag Timer for pump Timer for idle period
Symbol
Assignment
48

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the REACTION VESSEL template for the PLC universal system simulator.
49
50
Automatic tablet filler

TABELETTENABFLLAUTOMAT / AUTOMATIC TABLET FILLER
Start
Stop
S1
B1 B2
S2 S4
2 Tabletten
S3
1 Tablette
S5
Y S3 B1 H2
1 Tablet 3 Tabletten 2 Tablets
S6 S8
E
H3 H5 H7 S4 B2
S
H4 H6 H8
S7
3 Tablets
H1 M1
SO3715-1C12
Exercise:
Tubes are to be filled with a specified number of tablets from a storage reservoir.
Before the system is started via switch S1, the desired quantity of tablets is pre-selected with switches S5, S6 or S7. If 2 pre-selector switches are inadvertently pressed at the same time, the system remains inactive. Motor M drives a conveyor belt until light barrier B2 indicates that a tablet tube has arrived at the filling point. Solenoid valve Z opens the storage reservoir to let tablets drop into the tube. Tablets are counted by light barrier B1. Once the pre-set quantity of tablets has been reached, solenoid valve Y closes again, the belt motor re-starts and the next filling cycle is commenced. The number of tablets currently in a tube is to be indicated by lamps H3, H5 and H7. Further transport of the tablets is to be indicated by lamps H4, H6 and H8. If a different number of tablets is requested by means of the corresponding switch, or stop switch S2 is pressed, the filling process currently in progress is completed with the currently selected tablet quantity. The program must ensure that function is not impaired in the event of a wire breaking.
CLC 34/12 EXPERIMENT DESCRIPTION / AUTOMATIC TABLET FILLER
51

a) Place the template for the AUTOMATIC TABLET FILLER on the PLC universal system simulator. b) Connect up the process to the PLC. c) Create an assignment list.

Start button Stop button Light barrier B1 Light barrier B2 Pre-selector switch n=1 Pre-selector switch n=2 Pre-selector switch n=3
Input
Component ID
PLC
Symbol
Assignment
Outputs
Belt drive motor contactor Fill solenoid valve Tablet indicator 3 Tablet indicator 2 Tablet indicator 1 Tablet indicator 3 Tablet indicator 2 Tablet indicator 1
Output
Component ID PLC
Symbol
Assignment
52

Activation flag Pre-selected tablet count Pre-selected tablet count Pre-selected tablet count Off signal flag Edge flag for motor Edge flag for B2 Aux flag for motor edge Count 1 Count 2 Count 3 Counter for n=1 Counter for n=2 Counter for n=31
Designation
PLC
Symbol
Assignment
53

Terminal diagram
+24V
PLC
0V
e) Write a PLC program in instruction list, ladder diagram or function block diagram mode. f) Program the PLC. g) Test the program with the AUTOMATIC TABLET FILLER template for the PLC universal system simulator.
54
We appreciate your feedback
We welcome suggestions or notification of any errors based on your personal experience and observations. Your feedback is considered important in revising our manuals.
Thank you for your interest and cooperation.
Re: Manual Notes: Date:
Copyright 2006 LUCAS-NLLE GmbH. All rights reserved. This manual is protected by copyright. All rights reserved. This manual may not be photocopied, microfilmed or reproduced using any other technique, nor translated into a machine language - in particular one intended for use by data processing facilities - without the written approval of LUCASNLLE. Expressly excluded here are students' worksheets which may be reproduced in the quantities required for educational purposes within the institution which has procured this manual. Any amendments made without express permission from LUCAS-NLLE will annul the manufacturer's liability and any guarantee claims.
LUCAS-NLLE Training and Measuring Equipment Address: Siemensstrae 2 D-50170 Kerpen (Sindorf) Postal address: Postfach 11 40 D-50140 Kerpen Tel.: +49-2273-5670 Fax: +49-2273-56730 E-mail: vertrieb@lucas-nuelle.com
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Lucas-Nlle Lehr- und Megerte GmbH

Siemensstrae 2 D-50170 Kerpen-Sindorf Telefon +49 2273 567-0 Fax +49 2273 567-30 www.lucas-nuelle.de

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PLC Universal System Simulator Supplementary set of templates

Student Workbook SH5009-6C 2nd edition Author: Toni Fleumer

Lehr- und Messgerte GmbH Siemensstrae 2 D-50170 Kerpen

PLC Universal System Simulator

PLC Universal System Simulator

PLC Universal System Simulator

Inputs and outputs

Supply voltage Current consumption Dimensions (HxWxD) Weight

Connection to any PLC via:

PLC Universal System Simulator

0...10 V Actual value Outlet

PLC Universal System Simulator

SM321 SM322 SM321 SM322 SM334

+15V +5V +24V

PLC Universal System Simulator

Overview of templates for the PLC application board

PLC Universal System Simulator

PLC Universal System Simulator

oben top Korb Position Basket Position

To clean workpieces, a cleaning system's container is to be lifted and lowered pneumatically.

CLC 34/1 EXPERIMENT DESCRIPTION / CLEANING SYSTEM

PLC Universal System Simulator

Solenoid valve extend Solenoid valve retract Cycle display

Flags, timers, counters Designation PLC

CLC 34/1 EXPERIMENT DESCRIPTION / CLEANING SYSTEM

PLC Universal System Simulator

CLC 34/1 EXPERIMENT DESCRIPTION / CLEANING SYSTEM

PLC Universal System Simulator

CLC 34/1 EXPERIMENT DESCRIPTION / CLEANING SYSTEM

PLC Universal System Simulator

Furnace door control

OFENSTEUERUNG / FURNACE DOOR CONTROL

auf open Tr Position Door Position

S S14 Ofentr Furnace door

A furnace door is controlled by means of a 5/3-way directional control valve.

CLC 34/2 EXPERIMENT DESCRIPTION / FURNACE DOOR CONTROL

PLC Universal System Simulator

Assignment list Inputs

Flags, timers, counters

CLC 34/2 EXPERIMENT DESCRIPTION / FURNACE DOOR CONTROL

PLC Universal System Simulator

CLC 34/2 EXPERIMENT DESCRIPTION / FURNACE DOOR CONTROL

PLC Universal System Simulator

CLC 34/2 EXPERIMENT DESCRIPTION / FURNACE DOOR CONTROL

PLC Universal System Simulator

BIEGEWERKZEUG / BENDING TOOL

rechts right Zylinder 3 Position Cylinder 3 Position

oben top Zylinder 2 Position Cylinder 2 Position Zyl.2 Cyl.2

oben top Zylinder 1 Position Cylinder 1 Position Zyl.1 Cyl.1

S15 S13 S14 Y4 Zyl.3 Cyl.3 H4

A bending tool driven by 3 pneumatic cylinders is used to bend metal sheets.

CLC 34/3 EXPERIMENT DESCRIPTION / BENDING TOOL

PLC Universal System Simulator

b) Connect up the process to the PLC. c) Create an assignment list.

CLC 34/3 EXPERIMENT DESCRIPTION / BENDING TOOL

PLC Universal System Simulator

Flags, timers, counters

CLC 34/3 EXPERIMENT DESCRIPTION / BENDING TOOL

PLC Universal System Simulator

CLC 34/3 EXPERIMENT DESCRIPTION / BENDING TOOL

PLC Universal System Simulator

CLC 34/4 EXPERIMENT DESCRIPTION / EMBOSSING MACHINE

PLC Universal System Simulator

Assignment list Inputs