43 SKILL 10 DESIGN A PLC PROGRAM THAT USES AN ANALOG OUTPUT TO CONTROL AN SCR POWER CONTROLLER Procedure Overview In this procedure, you will design a PLC program that controls an SCR Power Controller with an analog output signal. In this application, the BCD/LED Station will provide a BCD value that is used by the PLC program to output an analog signal. Do This 1. Design a PLC program given the following information: Scenario: You work for a company that manufactures industrial electrical ovens. The ovens have an SCR power controller that regulates the amount of electric power to the electrical heaters of the ovens. The customer wants to use BCD thumbwheels to control the analog output signal to the SCR power controller. The input signal to the SCR power controllers will range from 0 to 5 milliamps. The BCD values will range from 0 to 7999. BCD THUMBWHEELS DISCRETE INPUT MODULE ANALOG COMBINATION MODULE 0500 PLC REMIIN O ALLEN BRADLEY SCR POWER CONTROLLER TO OVEN OUTPUT SIGNAL 0 TO 5 mA OUTPUT CHANNEL 0 AND WORD ADDRESS O:6.0 -TEMPERATURE RANGE - 0 TO 7999°C OVEN Write the PLC program to use the BCD thumbwheels to control the signal from the analog output module. The general sequence, I/O diagram and pictorial are provided. General Sequence · The BCD value is converted into an integer value. · The integer value is used to control the output of an analog module. · The milliamp output (0 to 5 milliamps) of the analog module controls the power output of the SCR power controller (simulated on the analog display). · Turn the SCR power controller fully on with any output exceeding 5 mA. 1:1/0 1:1/1 1:1/2 ANALOG CHANNEL 1:1/3 0 OUTPUT O:6.0 I:1/4 1:1/5 1:1/6 4:1/7 1:1/8 1:1/9 I:1/10 1:1/11 I:1/12 1:1/13 I:1/14 I:1/15 Figure 64. PLC I/O Diagram 2. Make sure that all power to the PLC trainer and its components are off. 3. Mount the 89-BCD/LED Station to the left-hand side of the PLC trainer's Field Device Unit. 4. Mount the 89-AS-B Analog Station to the right-hand side of the PLC trainer's Field Device Unit. 5. Verify that the 1746-NIO4I analog module's dip switches are set for voltage input signal. If not, make it so. 40630-AB LAP 14 ANALOG OUTPUT MODULES Copyright @ 2012 Amatrol, Inc. 77

DELIVERABLES: List all inputs and outputs for this industrial automation process. Use CADe software to create the schematic diagram for this process. Use LOGO! Softcomfort to create a ladder diagram that controls the overall process. 1. 2. 3. 4. Explore the potential implications of sensor failures within the system and propose effective measures to mitigate these failures. Additionally, address how redundancy or monitoring could be implemented to ensure continued operational reliability. 5. How does the system distinguish between a momentary fluctuation in water levels and a sustained rise that requires shutter activation? 6. What are the maintenance and calibration requirements for the water level sensors, and how frequently should they be inspected or serviced?/nTASK OVERVIEW: Dam Shutter Control System dam shutters control using Programmable Logic Controllers (PLC), the main objective is to efficiently control water levels in a dam. The system manages three threshold values, two motors for opening shutters to release excess water, and includes light indicators for status feedback. Additionally, an emergency stop button ensures safety and reliability in the industrial automation process. Inside the dam, water accumulates, and the system operates as follows: when the water level reaches the first sensor and the second sensor remains uncovered, a green indicator light illuminates, signifying that the water level is within safe limits. If the water rises to cover the second sensor, it signals the controller to activate a three-phase motor, which, in turn, opens the first dam shutter, enabling controlled water release. As the water level exceeds the acceptable range, the green light turns off. If the water level is between the first and second sensors, a yellow indicator light comes on to indicate that the water level falls within this intermediate range. When the water level surpasses the second sensor, a red indicator light activates, drawing attention to the elevated water level. In addition to these features, a time-sensitive mechanism has been integrated. If the water level transitions from the first sensor to the second sensor within a span of 10 minutes, both shutters will automatically open to expedite the water release process, ensuring effective dam management. If the water continues to rise and covers the third sensor, a second three-phase motor initiates the opening of another shutter, triggering an alarm system. The alarm only ceases when the water level falls below the third sensor. Both motors operate in reverse to close the shutters when the water level returns to the acceptable range, between the first and second sensors.

P3-3. Draw a ladder diagram that will cause the output, pneumatic solenoid PS6124, to be ON when both push button switches PB6121 and PB6122 are closed (pushed), and either limit switch LS6123 is open or limit switch LS6125 is closed. Do this problem for the ControlLogix, MicroLogix, SLC-500, S7,Modicon Unity and/or GE PLCs. For the GE PLC, use (1) I/O Variable and/or (ii) CPU Memory addressing. Show only the I/O address with the ladder contacts/coils. a) For a ControlLogix processor, the input/output devices are wired to: PS6124: Output module, chassis 'REM_2', slot 5, channel 12 PB6121: Input module, local chassis, slot 0, channel 7 PB6122: Input module, local chassis, slot 0, channel 8 LS6123: Input module, chassis 'REM_2', slot 4, channel 5 LS6125: Input module, chassis 'REM_3', slot 7, channel 0

4. (15 points) Based on the PLC input/output diagrams shown below, draw PLC ladder logic diagrams. Input A Input B Output Y Input A Input B High Low- High Low. High Low- Output Y High Low High Low High Low

P5-14. Develop a ladder logic program to handle a low bunker alarm for a coal-fired power plant coal bunker. The devices are shown in Figure P5.14. Normal sequence of events: Coal bunker 2 becomes low for 3 seconds (BUNK2_LLEV turns off for 3 sec.) which causes • BUNK2_LLMP starts flashing (1 sec. on, I sec. off) • ALARM HORN sounds (turns on).

Introduction Learning Outcomes - EAT240 - Automation for Manufacturing Coursework Assignment Control System for Mixing Tanks This coursework exercise will provide you with the opportunity to demonstrate the skills you will develop throughout the module. Specifically, the following learning outcomes will be assessed: LO2 - Design integrated automated systems using controllers, sensors, and actuators. LO4 - Design and implement an automated system to solve a range of problems including the control of common actuators. LO5 - Design and test typical programming solutions for use with automation systems. Practical Design Exercise The assessment is a practical design exercise worth 50% of the module mark. You will be required to work individually to develop a control system for an industrial application. Scenario, Scenario - A manufacturing company has recently installed a new paint line. The paint line (see figure 1) can mix different colours of specialist paint to a set temperature. After the mixing process has been completed the tank will empty to fill a batch of tins. The completed batch will then be transferred to a labelling process before final transfer to a warehouse, ready to be shipped to the customer. Task - Your company has been contacted to tender for the control system for the paint mixing and packaging line. The project manager has decided to utilise your skillset and you have been tasked with individually designing a PLC program for the machine that as a minimum meets the basic system requirements. As part of the tender process, you must submit the appropriate documentation to an industrial standard, including sequential flow charts, machine drawings and PLC programs. Note: Please note all work should be completed on an individual basis and you will need to carry out a face-to-face demonstration of your finished programme in order to complete the assessment. Task 1 - System Control, The system shown in figure 1 is to be controlled by the PLC. The PLC will perform the following functions using the sequences and basic requirements listed below, Sequence 1 – (Paint A) is heated to a temperature of 30 degrees and mixed for a 2-minute cycle. Sequence 2 – (Paint B) is heated to a temperature of 60 degrees and mixed for a 5-minute cycle time. A) - Basic System Program Requirements (to be used as guidance), Step 1 - Upon activation of the system ready push Button, the system will be made ready to use - only if the conveyor, heating elements and mixing tanks are switched off. This will also be indicated by a red "System ready" light. The system must have an emergency stop to shut down the full system. Note: Emergency stop should stop the full system from working until reset. Step 2 - When the "system ready" light is on, the process will start after a 10 second delay when selected by the machine operator and the conveyor will then move the empty tins to the appropriate filling station. Step 3 - Once the batch of tins is present at the filling stations and the low-level sensor is activated, the fill pumps are energised to allow the filling of tank A or B until the high-level sensor is activated. Step 4 - When the tanks are full, the mixing and heating cycle will start. After the mixing cycle is complete, there will be a delay for 5 seconds to allow the paint to settle and then the tank will empty until low level sensor is activated and the batch is complete. Note - You must ensure that if there is a loss of power the mixing cycle does not exceed the paint cycle time. Step 5- Once the batch has been completed, energise conveyor motor and transfer to the warehouse process. Note: The number of batches must be counted in and out of the warehouse location and once 50 batches have been made, the program will prevent the operator from making any more, until the system has been reset. EAT240 PLC Design Notes (20 Marks) The customer has asked for a comprehensive a set of design notes for the PLC program based on the required functionality described above. This may include: ● Flowchart or Sequential Function Chart 1/0 list Variable list Comments on the purpose of each rung Pneumatic/Hydraulic Drawings PLC/HMI Program (20 Marks) You will create your PLC program individually using your design notes. You can refer to the to the following documentation which is available through the CCW software and on Rockwell Automation website (details in the lab guides): ● CCW programming manual Micro820 hardware manual CCW quick start guide Actuator/Sensor Evaluation and Selection (10 Marks) Based on your experience of developing the PLC Program consider how the machine could be improved, you may wish to consider performance, efficiency, reliability, or maintainability as part of your assessment. You should refer to the actuators and sensors which are used and choose at least 2 actuators and sensors that could be used to improve the system, providing a description and evaluation of each type. You will present a brief (max 4 pages) report which summarises the evaluation, supported by appropriate references to your earlier work and any relevant technical documentation. Engagement with Lab Sessions While there are a number of elements to this assessment much of the work is based on the activities that you will carry out online and during the laboratory sessions. Therefore, if you engage with these activities you will greatly enhance your chances of achieving a good mark. After each session you should try to think about how the material covered could contribute to the assignment and make a note of this to support the design exercise. The laboratory sessions will involve the use of the Rockwell Micro 820 PLC. Any submission for alternative devices e.g. Arduino will not be accepted. Importance of Design One of the most important themes in this module is the importance of design. It is important, therefore, that you allow adequate time to design your program. If you fail to do so you will not only jeopardise the design elements of the coursework, but you will also make it extremely difficult to score well for the coding activities. Avoiding Accusations of Plagiarism Any code you write must be entirely your own. You may bring listings into the coding sessions but if these have been sourced from another source e.g. a text book or the internet, then this must be fully acknowledged using comments which clearly and unambiguously identify the extent of the code involved (e.g. by labelling the start and end of the section in question) and the source. You should also ensure that all work in the written submissions is your own and correctly referenced. Where you draw on references you should ensure that you clearly explain their relevance to your own work. If you are unsure on the correct way to reference any material, please ask or refer to the guidance available via the University Library Website: http://library.sunderland.ac.uk/find-resources/referencing/ Presentation of Work Presentation of work is of critical importance. The elements being submitted electronically should be typed and clearly formatted making appropriate use of headings and subheadings. Your design notes for the PLC program may be handwritten or typed but MUST be clear and legible.

Introduction Learning Outcomes - EAT240 - Automation for Manufacturing Coursework Assignment Control System for Mixing Tanks This coursework exercise will provide you with the opportunity to demonstrate the skills you will develop throughout the module. Specifically, the following learning outcomes will be assessed: LO2 - Design integrated automated systems using controllers, sensors, and actuators. LO4 - Design and implement an automated system to solve a range of problems including the control of common actuators. LO5 - Design and test typical programming solutions for use with automation systems. Practical Design Exercise The assessment is a practical design exercise worth 50% of the module mark. You will be required to work individually to develop a control system for an industrial application. Scenario, Scenario - A manufacturing company has recently installed a new paint line. The paint line (see figure 1) can mix different colours of specialist paint to a set temperature. After the mixing process has been completed the tank will empty to fill a batch of tins. The completed batch will then be transferred to a labelling process before final transfer to a warehouse, ready to be shipped to the customer. Task - Your company has been contacted to tender for the control system for the paint mixing and packaging line. The project manager has decided to utilise your skillset and you have been tasked with individually designing a PLC program for the machine that as a minimum meets the basic system requirements. As part of the tender process, you must submit the appropriate documentation to an industrial standard, including sequential flow charts, machine drawings and PLC programs. Note: Please note all work should be completed on an individual basis and you will need to carry out a face-to-face demonstration of your finished programme in order to complete the assessment. Task 1 - System Control, The system shown in figure 1 is to be controlled by the PLC. The PLC will perform the following functions using the sequences and basic requirements listed below, Sequence 1 – (Paint A) is heated to a temperature of 30 degrees and mixed for a 2-minute cycle. Sequence 2 – (Paint B) is heated to a temperature of 60 degrees and mixed for a 5-minute cycle time. A) - Basic System Program Requirements (to be used as guidance), Step 1 - Upon activation of the system ready push Button, the system will be made ready to use - only if the conveyor, heating elements and mixing tanks are switched off. This will also be indicated by a red "System ready" light. The system must have an emergency stop to shut down the full system. Note: Emergency stop should stop the full system from working until reset. Step 2 - When the "system ready" light is on, the process will start after a 10 second delay when selected by the machine operator and the conveyor will then move the empty tins to the appropriate filling station. Step 3 - Once the batch of tins is present at the filling stations and the low-level sensor is activated, the fill pumps are energised to allow the filling of tank A or B until the high-level sensor is activated. Step 4 - When the tanks are full, the mixing and heating cycle will start. After the mixing cycle is complete, there will be a delay for 5 seconds to allow the paint to settle and then the tank will empty until low level sensor is activated and the batch is complete. Note - You must ensure that if there is a loss of power the mixing cycle does not exceed the paint cycle time. Step 5- Once the batch has been completed, energise conveyor motor and transfer to the warehouse process. Note: The number of batches must be counted in and out of the warehouse location and once 50 batches have been made, the program will prevent the operator from making any more, until the system has been reset. EAT240 PLC Design Notes (20 Marks) The customer has asked for a comprehensive a set of design notes for the PLC program based on the required functionality described above. This may include: ● Flowchart or Sequential Function Chart 1/0 list Variable list Comments on the purpose of each rung Pneumatic/Hydraulic Drawings PLC/HMI Program (20 Marks) You will create your PLC program individually using your design notes. You can refer to the to the following documentation which is available through the CCW software and on Rockwell Automation website (details in the lab guides): ● CCW programming manual Micro820 hardware manual CCW quick start guide Actuator/Sensor Evaluation and Selection (10 Marks) Based on your experience of developing the PLC Program consider how the machine could be improved, you may wish to consider performance, efficiency, reliability, or maintainability as part of your assessment. You should refer to the actuators and sensors which are used and choose at least 2 actuators and sensors that could be used to improve the system, providing a description and evaluation of each type. You will present a brief (max 4 pages) report which summarises the evaluation, supported by appropriate references to your earlier work and any relevant technical documentation. Engagement with Lab Sessions While there are a number of elements to this assessment much of the work is based on the activities that you will carry out online and during the laboratory sessions. Therefore, if you engage with these activities you will greatly enhance your chances of achieving a good mark. After each session you should try to think about how the material covered could contribute to the assignment and make a note of this to support the design exercise. The laboratory sessions will involve the use of the Rockwell Micro 820 PLC. Any submission for alternative devices e.g. Arduino will not be accepted. Importance of Design One of the most important themes in this module is the importance of design. It is important, therefore, that you allow adequate time to design your program. If you fail to do so you will not only jeopardise the design elements of the coursework, but you will also make it extremely difficult to score well for the coding activities. Avoiding Accusations of Plagiarism Any code you write must be entirely your own. You may bring listings into the coding sessions but if these have been sourced from another source e.g. a text book or the internet, then this must be fully acknowledged using comments which clearly and unambiguously identify the extent of the code involved (e.g. by labelling the start and end of the section in question) and the source. You should also ensure that all work in the written submissions is your own and correctly referenced. Where you draw on references you should ensure that you clearly explain their relevance to your own work. If you are unsure on the correct way to reference any material, please ask or refer to the guidance available via the University Library Website: http://library.sunderland.ac.uk/find-resources/referencing/ Presentation of Work Presentation of work is of critical importance. The elements being submitted electronically should be typed and clearly formatted making appropriate use of headings and subheadings. Your design notes for the PLC program may be handwritten or typed but MUST be clear and legible.