EET 319

PLC Fundamentals

LABORATORY MANUAL

Lab # 4

Event Sequencing

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Objective 1: Introduction to event sequencing

Most automatic machines perform a number of actions in order to accomplish the task for
which they have been designed. The specific order in which these actions is performed is
called a sequence and each action is called a sequence step or event.
One method that can be used to create the sequence of steps is an event-driven sequence.
This method uses an input device of some type to sense that one step has been completed and
signal the next step to begin. Logic is then used in the PLC to cause each step to occur by
turning output devices either ON or OFF, as shown in Figure 4-1-1.
Each step of the sequence follows this same pattern:

* An input is activated.
* The program logic decides what actions to take.
* The action for that step is performed.

Figure 4-1-1. Control Process of a Step in a Sequence

Operation of the reciprocating actuator PLC program

A basic example of a PLC program that performs an event-driven sequence is reciprocating

cylinder program. This is a 3-step sequence, as shown in Figure 4-1-1 (next page).
When the operator pushes a start button, a cylinder will extend until it actuates limit switch
2LS. After actuating the limit switch, the cylinder retracts. This graphical diagram can be
summarized by the following table:

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 Figure 4-1-1. Graphical Logic Process of Reciprocating Cylinder Sequence

Activity 1: Operation of Single-Cycle Actuator Reciprocation Program

Procedure Overview
In this procedure, you will enter and run the program just described that performs
a single-cycle cylinder reciprocation sequence. To do this, you will set up and use
the 17200 Electro-pneumatic Application Panel.

1. Perform the following sub-steps to prepare the PLC trainer for use.
1.1 Make sure that all power to the PLC and its components is OFF at this time.
1.2 Mount the 17200 Electro-pneumatic Application Panel on the top of the PLC
Console and Connect the 17203 Interface Cable Assembly.
1.3 Turn ON switch 2 of the I/O Simulator Panel. All other switches should be OFF
at this time. Switch 2 will simulate a N.C. stop pushbutton.

2. Power up your PLC trainer.

3. Start up the PLC programming software.

4. Create a new PLC project.

5. Configure the I/O for your PLC project

6. Rename the program file LAD2 MAINPROG.

7. Enter and then verify the ladder logic of program file MAINPROG so that it appears as
shown in Figure 4-1-2 (next page).

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 Figure 4-1-2. Single-Cycle Single Cylinder Reciprocating Program

NOTE
Switch 1 and switch 2 are I/O simulator switches that will take the place of PB1 and
PB2
in this program. To test this program, you will use the I/O Simulator Panel and
the Electro-pneumatic Application Panel.

8. Save your PLC project to diskette as file name and processor name ACT51.

9. Download your PLC project to the processor and go online.

10. Place the PLC program into the REMOTE RUN mode.

11. Perform the following sub steps to test your new PLC program.

11.1 Examine the PLC program on the computer monitor. You should observe that XIC
instructions O:2/0 and I:1/0 are false and all other instructions are true.
These causes output O:2/0 to be OFF.
11.2 Turn I/O simulator switch 1 ON/OFF (this simulates a momentary pushbutton)
to start the sequence. Output O:2/0 should turn ON and cylinder 1 should begin
to extend. Also, notice that seal-in instruction O:2/0 is now closed.
As the cylinder leaves 1LS, input I:1/2 should turn OFF.
When the cylinder reaches 2LS, input I:1/3 should turn ON and output O:2/0
should turn OFF. The cylinder should begin to retract.

12. Repeat step 11 several times to become more familiar with the operation of the program.
During one of the cycles, try turning switch 2 OFF/ON (this simulates a momentary
stop pushbutton). You should observe that the cylinder immediately retracts and stops.

13. Place the PLC in REMOTE PROGram mode and go offline.

14. Print out a copy of your PLC program and place it in your portfolio.

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Skill 1: Design a reciprocating actuator sequence PLC program.

Procedure Overview:
In this procedure, you will design a PLC program that uses a double-solenoid DCV to
control a cylinder. This is a variation of the program you used in Activity 1.

1. Examine the following information.

Scenario: You work as a PLC program designer in a factory that makes appliances from
sheet metal. Your task is to develop a program that will cause a punch press to stamp
parts on an assembly line. The machine will start when a button is pushed and complete
one cycle of a pressing operation.

The general sequence, I/O diagram and power diagram (Figure 4-1-3) are as follows:
General Sequence:
* When switch 1 is turned ON/OFF, the cylinder will extend.
* When the cylinder is fully extended, actuating 5LS, it will retract.
* A double-solenoid valve was selected for the application so that the punch will
immediately stop if the valve loses its electrical control signal.
* When the cylinder is fully retracted, it will stop.
* Turning switch 2 off at any time will cause the cylinder to immediately retract
and then stop.

Figure 4-1-3. I/O Diagram

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2. Use the information from step 1 to develop your PLC program.
Hint: This program is similar to the single solenoid program you just tested except that
you will need to turn on Sol 2B as well as turn OFF Sol 2A to retract the cylinder.

3. Perform the following sub steps to prepare the PLC trainer for use.

3.1 Make sure that all power to the PLC is OFF.

3.2 Make sure the air supply is connected and adjusted to 50 psi.
3.3 Prepare the 17200 panel by making sure that cylinder 2 is in the retracted position
and is holding 3LS closed. You may need to press the manual override with a pencil
in order to retract the cylinder.
3.4 Turn ON switch 2 of I/O Simulator Panel. All other switches should be OFF at
this time.

4. Power up your PLC trainer.

5. Start up the PLC programming software.

6. Create a new PLC project

.
7. Configure the I/O for your PLC project.

8. Rename the program file LAD2 MAINPROG.

9. Enter the PLC program that you developed in step 2 into program file 2 (MAINPROG).

10. Verify your PLC project to check for errors. If any errors exist, correct them.

11. Save your PLC project to your diskette as file name and processor name AP51
.
12. Download your PLC project to the processor and go online.

13. Use the PLC programming software to place the PLC into the REMOTE RUN mode.

14. Turn switch I ON/OFF to test the operation of your program.

Cylinder 2 should extend completely and then retract.

15. Repeat step 14 several times to become more familiar with the operation of the program.
During one of the cycles, try turning switch 2 OFF/ON. You should observe that
the cylinder immediately retracts and stops.

16. Use the PLC programming software to place the PLC in REMOTE PROGram
mode and go offline from the processor.

17. Print out a copy of your ladder diagram and place this in your portfolio. It will be

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 used in your assessment.

SELF REVIEW
1. Each action in a sequence is called a __________ or __________ .

2. An event-driven sequence uses _________ to determine when each step has been
completed.

3. A basic example of a PLC event-driven sequence program is a _______________ .

4. The logic in a single-cycle actuator program uses a _________ (XIO/XIC) instruction

to de-energize the extend solenoid.

5. The 17200 Electro-pneumatic Application Panel has a __________ solenoid valve

and a ____________ solenoid.

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Objective 2: Continues Cycle Logic

Activity 1. Operation of Continuous Cycle Actuator Reciprocating Program

Procedure Overview:
Function of an internal output instruction:
Internal output instructions look and operate just like the OTE instructions that you have
already been using. They can control XIC and XIO instructions with the same address.
They do not, however, directly control the outputs of a PLC. Instead, internal output
instructions are used to provide additional control logic to the PLC program.
Two applications of internal output instructions include:
* Program Memory Logic
* Program Interlocks
The addressing of the internal output instruction starts with a B, as shown in the example
of Figure 4-2-1.

Figure 4-2-1. Internal Output Instruction

For the A-B SLC 500, the available addresses for internal output instructions (default setup)
are B3:0/0-B3:255/15. This means that there are 4096 internal bits available for you to use.

The parts of this address are explained as follows:

* The B of this address defines the file type of the instruction, a bit in this case.
* The 3: defines the file number of the instruction. You may recall that 3 is the PLC data
table's default bit file.
* The 0 defines the element number of bit file 3. The Bit file has 256 elements (0-255).
If no element is specified, 0 is assumed.
* The /0 identifies the bit number. Bit numbers can range from 0-15.
When the internal output instruction is energized, all instructions with the same address
switch to the energized state, as shown in Figure 4-2-2 (next page) . No outputs, however,

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are directly turned on by the instruction.

Figure 4-2-2. Internal Output Instruction

In the procedure, you will enter and run the PLC program just described that continuously
cycles a single actuator.

1. Turn ON switch 2 on the Simulator Panel. All other switches should be OFF at this time.

2. Power up your PLC trainer.

3. Start up the PLC programming software.

Figure 4-2-3. Continuous-Cycle Actuator Reciprocating Program

4. Create a new PLC project.

5. Configure the I/O for your PLC project.

6. Rename the program file LAD 2 MAINPROC3.

7. Enter the ladder logic of program file MAINPROG so that is appears as shown in
Figure 4-2-3.

8. Verify your PLC project to check for errors. If any errors exist, correct them

9. Save your PLC project to diskette as file name and processor name ACT52.

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10. Download your PLC project to the processor and go online.

11. Use the PLC programming software to place the PLC in the REMOTE RUN mode.

12. Perform the following sub steps to test your new PLC program.

12.1 Take a moment to look at the condition of the program on the computer monitor.
Only XIC instructions I:1/1 and I:1/2, should be true (highlighted).
12.2 Turn switch 1 ON and then OFF again. The cylinder should extend and retract
continuously.
12.3 Turn switch 2 OFF and then ON again. The cylinder should retract completely
and then stop.

13. Repeat step 12 several times to become familiar with the operation of a PLC continuous
cycle program.

14. Use the PLC programming software to place the PLC into REMOTE PROGram mode
and go offline from the processor.

15. Print out a copy of the ladder program and place this in your portfolio.

SELF REVIEW

1. A continuous cycle sequence program ______________________the program until

the stop pushbutton is pressed.

2. A continuous cycle sequence program uses a _______________ to make the program start
another cycle.

3. A _____________________________ rung is used to indirectly control the operation

of a continuous cycle sequence program.

4. A single-cycle sequence program uses ________________ ____________ to directly

control the stop/start logic in a program.

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Objective 3: Multiple Actuator Event Sequencing.

The program technique, which controls a single actuator event-driven sequence, can also be
applied to machines with multiple actuators. A common example is the clamp and drill
application, shown in Figure 4-3-1. In this application, a clamp cylinder holds the part in
place while the drill cylinder extends to drill the part.

Figure 4-3-1. Clamp and Drill Operation

Activity 1. Operation of a Clamp and Drill Sequence.

Procedure Overview
In this procedure, you will enter and run the PLC program just described that performs
the clamp and drill operation sequence.

1. Make sure that all of the I/O Simulator Switches are OFF at this time.

2. Power up the PLC trainer if it is not already done.

3. Start up the PLC programming software.

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4. Create a new PLC project.

5. Configure the I/O for your PLC project.

6. Rename the program file LAD 2 MAINPROG.

7. Enter the ladder logic of program file MAINPROG so that it appears as shown in
Figure 4-3-2.

Figure 4-3-2. Clamp and Drill Program

8. Verify your PLC project to check for errors. If any errors exist, correct them.

9. Save your PLC project to diskette as file name and processor name ACT53.

10. Download your PLC project to the processor and go online.

11. Use the PLC programming software to place the PLC in REMOTE RUN mode.

12. Perform the following sub steps to test your new PLC program.

12.1 Look at the condition of the program on the computer monitor. Only input I:1/2
should be ON.
12.2 Turn switch 1 ON and then OFF again to start the sequence.
Observe the operation of the program. It should perform the following sequence:

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13. Repeat step 12 several times to become familiar with the operation of a clamp and drill
program.
14. Use the PLC software to place the PLC into REMOTE PROGram mode and go offline
from the processor.
15. Print out a copy of the ladder program and place this in your portfolio.

Skill 1: Design a continuous cycle clamp and drill sequence PLC program.

Procedure Overview:
In this procedure, you will modify the PLC clamp and drill program used in Activity 1
to make the sequence cycle continuously after pressing the start pushbutton.

1. Examine the following information.

Scenario: You work as a manufacturing engineer in a company.
Your task is to develop a program that will cause a machine to clamp and drill pans on an
assembly line. The machine will start when a pushbutton is pressed and continue to
clamp and drill parts until a stop button is pushed.

The general sequence (Figure 4-3-3) and I/O diagram (Figure 4-3-4) are as follows:

Figure 4-3-3. General sequence

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 Figure 4-3-4. I/O Diagram

2. Use the information from step 1 to develop your PLC program.

3. Turn ON switch 2 on the Simulator Panel. All other switches should be OFF at this lime.

4. Power up the PLC trainer.

5. Start up the PLC programming software.

6. Create a new PLC project.

7. Configure the I/O for your PLC project.

8. Rename the program file LAD2 MAIINPROG.

9. Enter the PLC program that you developed in step 2 into program file 2 (MAINPROG).

10. Verify your PLC project to check for errors. If any errors exist, correct them.

11. Save your PLC project to your diskette as file name and processor name AP52.

12. Download your PLC project to the processor and go online.

13. Use the PLC programming software to place the PLC into the REMOTE RUN mode.

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14. Perform the following sub steps to test the operation of your program.

14.1 Turn switch 1 ON and then OFF . The system should perform the clamp and drill
operation, except that it should repeat continuously.
14.2 Turn switch 2 OFF and then ON again. The sequence should stop after it has
completed its current cycle.
15. Use the PLC programming software to place the PLC in the REMOTE PROGram mode
and go offline from the processor.

16. Print out a copy of your ladder diagram and place this in your portfolio. It will be used in
your assessment.

17. Exit the PLC programming software and shutdown Windows.

18. Turn off the PLC trainer, computer, and monitor.

SELF REVIEW

1. A ________ _________ _________ program is a common example of a multiple actuator

sequence program.

2. A clamp cylinder's DCV is normally selected as a _____________________ position

3. design for safety.

3. The __________ diagram shows how the machine will react if control power is lost.

4. The drill cylinder is retracted by turning _____________ (ON/OFF) the solenoid valve
using a _____________ instruction.

5. Each rung in a sequence program controls a specific _____________ in the sequence.

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