Io List

Manual for Laboratory, PLC Connection.
Dublin Institute of Technology

Kevin Street
Dublin 8
Manual for Laboratory

PLC, HMI and SCADA
Version 2.0
Revision:
Version 2:
Chapter 6, Get started at some programming samples, insertion of

Module 9 Counters and incrementing the other Modules as a result,
January 2003.
Chapter 12, Analogue to Digital was added to cover A/D conversion
is based on the Mitsubishi manual FX2N 4AD.
Chapter 12, Conveyor Rig I/O list and photograph.
Lecturer: Dr. John McGrory

School of Control Systems and Electrical Engineering,
Dublin Institute of Technology, Room 10, Kevin Street, Dublin 8.
Phone:
+353-(0)1-402-2848
E-Mail:
john.mcgrory@dit.ie
Web Site: http://eleceng.dit.ie/jmcgrory/
Dr. J.McGrory, DIT Kevin Street. Version 2.0, File: plc_manual_laboratory V02
Page 1 of 122
Table of Contents
TABLE OF CONTENTS .................................................................................................................2
CHAPTER 1, HOW TO GET STARTED..........................................................................................5
STEP 1: HOW TO START THE PROGRAMMING TOOL ON THE PC ...........................................................5
STEP 2: HOW TO START A NEW PROJECT .........................................................................................6
STEP 3: HOW START PROGRAMMING ...............................................................................................8
STEP 4: CONVERT THE PROGRAM ...................................................................................................8
STEP 5: STOP THE PLC.................................................................................................................9
STEP 6: UP LOADING THE PROGRAM TO THE PLC........................................................................... 10
STEP 7: SWITCH THE PLC TO RUN MODE ..................................................................................... 12
STEP 8: MONITOR THE PLC ......................................................................................................... 12
CHAPTER 2, STAGES IN DEVELOPING A PLC SYSTEM .......................................................... 13
CHAPTER 3, SOME OF THE MAIN SECTIONS OF THE PLC DEVELOPER SCREEN................ 14
LADDER FUNCTION KEYS: ............................................................................................................ 14
TOGGLE BETWEEN LADDER LOGIC AND LIST OF INSTRUCTIONS ........................................................ 15
READ AND WRITE MODE ............................................................................................................... 16
MONITORING .............................................................................................................................. 16
PROJECT DATA LIST .................................................................................................................... 17
DOCUMENTATION, COMMENTS, STATEMENTS AND NOTES ............................................................... 18
PLC STATUS DIAGNOSTIC ........................................................................................................... 20
CHAPTER 4, DOWN LOAD FROM THE PLC............................................................................... 21
CHAPTER 5, GX DEVELOPER SUB SCREENS .......................................................................... 22
PROJECT SUBMENU .................................................................................................................... 22
EDIT SUBMENU ........................................................................................................................... 23
FIND/REPLACE SUBMENU ............................................................................................................ 23
CONVERT SUBMENU .................................................................................................................... 24
VIEW SUBMENU .......................................................................................................................... 24
ONLINE SUBMENU ....................................................................................................................... 24
DIAGNOSTICS SUBMENU .............................................................................................................. 25
TOOLS SUBMENU ........................................................................................................................ 25
CHAPTER 6, GET STARTED AT SOME PROGRAMMING SAMPLES ....................................... 26
DONT FORGET THE FOLLOWING.................................................................................................... 26
MODULE 1, ON/OFF INPUT AND OUTPUT ....................................................................................... 27
MODULE 2, IN SERIES INPUT AND OUTPUT (AND) .......................................................................... 28
MODULE 3, IN PARALLEL INPUT AND OUTPUT (OR)......................................................................... 28
MODULE 4, UNIVERSAL STARTING HANDLE .................................................................................... 30
MODULE 5, INTERLOCKS .............................................................................................................. 31
MODULE 6, INTERNAL FLAGS ........................................................................................................ 32
MODULE 7, SET/RESET AND PULSE.......................................................................................... 33
MODULE 8, TIMERS ..................................................................................................................... 34
Operation of delay ON timer .................................................................................................. 35
Operation of delay OFF timer ................................................................................................ 35
MODULE 9, COUNTERS ................................................................................................................ 36
MODULE 10, INTERLOCKS II THE EXCLUSIVE OR ......................................................................... 37
MODULE 11, MULTIPLE BRANCH OUTPUTS ..................................................................................... 38
MODULE 12, SPECIAL RELAYS...................................................................................................... 39
M8013, 1 second clock pulse................................................................................................. 39
M8014, 1 minute clock pulse ................................................................................................. 39
Page 2 of 122

MODULE 13, DANGER, FORCE ON/OFF ......................................................................................... 40
MODULE 14, MASTER CONTROL AND MASTER CONTROL RESET ...................................................... 41
CHAPTER 7, QUESTIONS TO GIVE YOU EXPERIENCE ........................................................... 42
EXERCISE 1, DOOR BELL ............................................................................................................. 42
EXERCISE 2, MOTOR START/STOP................................................................................................ 43
EXERCISE 3, OPERATOR HAND PADS ............................................................................................ 44
EXERCISE 4, OPERATOR HAND PADS, EMERGENCY STOP AND GUARD ............................................. 45
EXERCISE 5, PUMPING TANK ........................................................................................................ 46
EXERCISE 6, LABEL STAMPING ..................................................................................................... 47
EXERCISE 7, MOTOR JOGGING ..................................................................................................... 48
EXERCISE 8, ALARM SENSOR ....................................................................................................... 49
EXERCISE 9, CONVEYOR DELAY ................................................................................................... 50
EXERCISE 10, W ASHING MACHINE ................................................................................................ 51
EXERCISE 11, TRAFFIC LIGHTS I ................................................................................................... 52
EXERCISE 12, TRAFFIC LIGHTS II .................................................................................................. 53
EXERCISE 13, CONVEYOR BOTTLE COUNTER ................................................................................. 54
EXERCISE 14, 24 HOUR CLOCK USING COUNTERS AND SPECIAL RELAYS .......................................... 55
EXERCISE 15, CONVEYOR TIMER .................................................................................................. 56
EXERCISE 16, ORANGE CONCENTRATE PLANT ............................................................................... 57
CHAPTER 8, HOW THE PLC IS WIRED UP TO THE OUTSIDE WORLD.................................... 58
CHAPTER 9, HMI, MMI AND OMI................................................................................................ 59
STEP 2: START A NEW PROJECT ................................................................................................... 63
STEP 3: GETTING STARTED.......................................................................................................... 64
STEP 4: MORE INVOLVED HMI, DISPLAY ANALOGUE DATA .............................................................. 69
STEP 5: BAR CHARTS .................................................................................................................. 70
STEP 6: FORCE OUTPUTS ............................................................................................................ 73
CHAPTER 10, OPC SERVER ...................................................................................................... 78
STEP 1:
STEP 2:
STEP 3:
STEP 4:
STEP 5:
STEP 6:
STEP 7:
LOAD UP THE SOFTWARE ............................................................................................... 78

ADD A CHANNEL ........................................................................................................... 79
ADD A DEVICE .............................................................................................................. 80
ADD A GROUP .............................................................................................................. 83
ADD A TAG ................................................................................................................... 84
RUN OPC CLIENT ......................................................................................................... 86
GENESIS ...................................................................................................................... 87
CHAPTER 11, SCADA ................................................................................................................ 90

W HAT DOES A SCADA PACKAGE DO? ........................................................................................... 90
STEP1: GETTING STARTED .......................................................................................................... 90
STEP2: GRAPHICAL REPRESENTATION........................................................................................... 91
STEP3: DYNAMICS ...................................................................................................................... 93
STEP4: STANDARD GAUGES ........................................................................................................ 97
STEP5: CHECK BOXES ................................................................................................................ 98
STEP6: GRAPHICAL REPRESENTATION........................................................................................... 99
STEP7: DIGITAL DISPLAY ........................................................................................................... 100
STEP8: DATE AND TIME DISPLAY................................................................................................. 101
STEP9: BUTTONS ...................................................................................................................... 102
STEP10: SYMBOL LIBRARY ........................................................................................................ 103
STEP12: MULTI FUNCTION ......................................................................................................... 105
STEP13: ARITHMETIC ................................................................................................................ 106
GOOD W ORKING PRACTICE ....................................................................................................... 110
Consistency ........................................................................................................................ 110
Storyboard .......................................................................................................................... 111
Page 3 of 122

EXERCISE LABORATORY 1 ......................................................................................................... 112
CHAPTER 12, ANALOGUE TO DIGITAL PLC MODULES ........................................................ 116
CHAPTER 13, LABORATORY CONVEYOR RIG ...................................................................... 122
Page 4 of 122
Chapter 1, How to get started

Step 1: How to start the programming tool on the PC
Direct the mouse screen pointer to the Start icon at the bottom of the screen in
the windows menu bar. Press the Start icon once with the left mouse key as
shown in the diagram below.
A pop up menu should have been displayed as shown above. Now select the
program icon from the popped up menu.
Page 5 of 122
Direct the mouse pointer down to the MELSOFT Application icon, continuing on to
the GX Developer, where you click the mouse left button while hovering over the
GX Developer icon. A screen similar to the diagram below will be loaded.
Step 2: How to start a new project

At the top left of the screen close to the blue bar, select the Project text button and
the menu below will be displayed. Select a New Project.
Page 6 of 122
When the New Project Icon is selected you will be asked to select the PLC to
which the software is connected. The room K044 the PC is connected to the
FXO(S) PLC so this option should be chosen. Make sure Ladder is chosen under
the program type area.
Then click OK and the following screen will be displayed.
Page 7 of 122
Step 3: How start programming

The operator of the system can then construct the ladder logic they wish to be
loaded on to the PLC. See the end of this document for more information.
Ladder Logic
Step 4: Convert the program
Once the ladder logic is constructed it needs to be converted. When the code is
converted the ladder rung numbers appear automatically. If there are any ladder
construction faults in the code the software will give a warning at this time. Note
however that the ladder logic may be wrong but its construction may be correct
and thus no errors appear. If the converting is not completed when changing from
this screen the last converted ladder logic will be reloaded and all new changes will
be lost.
Convert
Page 8 of 122
Step 5: Stop the PLC

On the PLC where the programming lead is attached there is a Run/Stop switch.
The when ever you are going to change the program you need to switch the PLC
into Stop mode and the green run light will be turned off.
Input Terminals
Input LED
Indicators
The Switch
for Run/Stop
Power, Run/Stop and

CPU LEDs
Output LED
Indicators
Output Terminals
Page 9 of 122
Step 6: Up Loading the program to the PLC

The converted program can now be transferred to the PLC by clicking on the
Online option on the main bar at the top and click on to Write to PLC.
When the Write to PLC is clicked you should see the dialogue box as shown
below.
Page 10 of 122
Before you click Execute make sure all the boxes are checked (or use Select All).
As you become expert and aware of the software limitations you can select only
the items you wish to change.
Make sure to click all the boxes

When Execute is pressed your program will then be written to the PLC.
Page 11 of 122
Step 7: Switch the PLC to RUN mode

See step 5 above and return the switch to the Run position.
Step 8: Monitor the PLC
It is standard practice to make sure the newly uploaded program is working
correctly before leaving the PLC. By selecting Online and then Monitor the
operator is able to start the monitoring of the PLC. The operator will see the ladder
logic and at the contacts and coils a blue bar will be in place if the status is on and
blank if the status is off. Remember to turn off the monitoring if you wish to alter the
code.
Page 12 of 122
Chapter 2, Stages in Developing a PLC System

All projects will follow the same seven steps so it is worth your while noting them in
your head.
1.
List the Inputs and Outputs and include a descriptive text of what they are.
2.
Construct the ladder logic of the system using the developer software.
3.
Convert the ladder logic.
4.
Switch the PLC into Stop Mode.
5.
Up load the program to the PLC
6.
Switch the PLC into Run Mode.
7.
Set the development software to monitor and make sure program is working
before leaving it.
Page 13 of 122
Chapter 3, Some of the main sections of the PLC developer screen.

Ladder Function Keys:
These buttons allow the

ladder logic to be constructed
The buttons highlighted in the diagram above allow for the logic block used in the
ladder logic to be constructed.
From left to right we have
1.
Normally Open Contact
2.
Branched (parallel) Normally Open Contact
3.
Normally Closed Contact
4.
Branched (parallel) Normally Closed Contact
5.
Action (Output)
6.
Instruction such as timer, counter etc
7.
Insert vertical line
8.
Insert horizontal line
9.
Remove vertical line
10.
Remove horizontal line
Page 14 of 122
Toggle between Ladder Logic and List of Instructions

If the operator wishes to view the list of instruction used to construct the current
logic then the button shown can be used to toggle between them.
Toggle between Ladder Logic

and List of instructions
The diagram below shows the instruction list for ladder logic.
List of instructions
and not Ladder Logic
Page 15 of 122
Read and write mode

If the operator wishes to put some of the ladder logic routine into read mode it will
prevent the code from being changed accidentally. The code can be put back into
the run mode if desired for changes to be made.
Read and write modes can be

selected using these buttons
Monitoring
The development software can be used for monitoring the operation of the PLC.
The operator can connect on to the PLC and monitor the PLCs logic. For technical
reasons the operator cannot make changes to the logic while the system is in run
mode and/or being monitored.
Monitor of the PLC current status

can be selected using these buttons
Page 16 of 122
Project Data List

The project data list can be used for toggling between a wider logic screen and the
project data list. This list contains key components in relation to the project:
Project Data List

1.
2.
Program
This is where the ladder logic stored. The main program to run is usually
called main and any other subroutines would be given relevant names.
Device Comment
At the beginning of the projects design it is usual practice to complete a list
of the inputs and outputs that
are going to be required on the
project. The operator can then
type in at this location at the
start and avoid having to insert
them directly into the ladder
logic which can be time
consuming.
Page 17 of 122
Documentation, Comments, Statements and Notes

A good system is one that works and a great system is one that works and is well
documented. The documentation of your code should be short, sweet and
understandable. When using the PLC developer software the operator can view
the device name and comments associated with them. The operator can also add
Statements and Notes associated with the ladder logic they are designing so any
person viewing the program can see what they have done and why!
Page 18 of 122
In the screen shot below the green text in the ladder logic is the statement entered
so an understanding of why the code was constructed and some of its dangers or
benefits could also be included.
Statement for the ladder run below it
Page 19 of 122
PLC Status Diagnostic

If the operator wishes to view current status of the PLC without having to look at it
(perhaps it is in a control panel) the PLC diagnostic screen can be utilised. By
selecting Diagnostic from the top menu you will see the screen as detailed below.
Page 20 of 122
Chapter 4, Down Load from the PLC

In some cases the ladder logic code may not be available on the computer system
the GX Developer is located. (Although we recommend backups of all work are
saved onto floppy drives or better regularly). In these extreme cases it is possible
for the ladder logic to be read from the PLC.
At this stage it is important to note that all the comments and text will not be
retrieved as they were never uploaded to the PLC in the first place to save space
and improve speed.
By switching the PLC to Stop and the using the Online and Read from PLC we
can then ask the existing code on the PLC to be downloaded to the development
software. Remember only the Address, Data and ladder rungs are available.
Page 21 of 122
Chapter 5, GX Developer Sub Screens

Project Submenu
Page 22 of 122
Edit Submenu
Find/Replace Submenu
Page 23 of 122
Convert Submenu
View Submenu
Online Submenu
Page 24 of 122
Diagnostics Submenu
Tools Submenu
Page 25 of 122
Chapter 6, Get started at some programming samples

Dont forget the following
When the ladder logic is completed remember to complete the following:
1.
Convert the program, (Choose Convert from the top menu bar and drill
down)
2.
Switch the PLC to STOP mode (Actually on the PLC itself)
3.
Write the program to the PLC (Choose Online from the top menu bar and
drill down to Write to PLC)
4.
If you wish to monitor the PLC (Choose Online from the top menu bar and
drill down to Monitor then drill across to Start Monitor)
Page 26 of 122
Module 1, On/Off Input and Output

The first PLC program is stated below with a ladder logic and electrical equivalent.
It is one input switch X001 and one output switch Y001.
X007
Y001
Switch
1
Ground
Page 27 of 122
Module 2, In Series Input and Output (AND)

The second PLC program is stated below with a ladder logic and electrical
equivalent. This has three input switches X001, X002 and X003 wired in series and
one output switch Y001. Note all three switches need to be closed if the system is
to work.
X001 X002 X003
Y001
Switch Switch Switch

1
2
3
Ground
Module 3, In Parallel Input and Output (OR)
Page 28 of 122
The first PLC program is stated below with a ladder logic and electrical equivalent.
This has three input switches X001, X002 and X003 wired in parallel and one
output switch Y001. Note only one of the three switches needs to be closed if the
system is to work.
X001
Y001
X002
X003
Switch 1
Switch 2
Ground
Switch 3
Page 29 of 122
Module 4, Universal Starting handle

The fourth PLC program is stated below with a ladder logic and electrical
equivalent. The circuit is set up so when X001 is closed electricity goes through
X002 and on to power the light. At this stage the relay is activated closing the
Normally Open contact as Y001. Note that Y001 is both input and an output.
With contact Y001 now closed the circuit stays lit until the Normally closed contact
X002 is opened.
This would be the same as pressing in a start button allowing the system to start
and then stopping the system by pressing a stop switch.
X001
Y001
X002
Y001
Switch
1
Switch
2
Ground
Relay
Relay
Page 30 of 122
Module 5, Interlocks
On some occasions it is necessary to provide a link between two processes in
order that they are related in some say, this is call Interlock. In the example below
you can see the first rung of the ladder. X001 closes and assuming activity Y002 is
not activated then the contact Y002 stays normally closed and Y001 is activated.
When this happens the normally closed contact Y001 in the second rung of the
ladder opens ensuring Y002 does not start at the same time. (Remember a rung
on a ladder diagram moves from the left vertical rail to the right vertical rail and not
the branches that dont make it fully across)
The same can be said for the second ladder rung. X002 closes and assuming
activity Y001 is not activated then the contact Y001 stays normally closed and
Y002 is activated. When this happens the normally closed contact Y002 in the first
rung of the ladder opens ensuring Y001 does not start at the same time.
X001
Y002
Y001
Y001
Y002
Y001
X002
Y002
Switch1
Relay 2
Ground
Relay 1
Relay 1
Switch 2
Relay 1
Ground
Relay 2
Relay 2
Page 31 of 122
Module 6, Internal Flags

As well as inputs and outputs, the PLC will need to hold internal signals for data
such as "ready to run" or "system healthy" and so on. It would be wasteful to
allocate real outputs for these signals, so the PLC is provided with areas of internal
data storage for this purpose. Depending on the manufacturer and the background
of the user, these areas for holding data are known, by names which are
associated with hard-wired relays e.g. auxiliary coils and internal relays, or with
microprocessors e.g. working areas, internal operation flags or just simply flags.
Internal flags are used in exactly the same way as inputs and output. Just as
inputs are identified by an X reference and outputs by a Y,
INTERNAL FLAGS are identified by an M.
In the example below; When X001 is closed M1 is activated which closes the
normally open contact M1 and activates Y001.
X001
M1
M1
Y001
Page 32 of 122
Module 7, SET/RESET and PULSE

The SET and RESET commands allows you to Latch and Delatch any ladder
rung. The PULSE facility enables a short pulse to be generated within the PLC
which is often used to carry out the RESET command. A control procedure
requires that an output Y5 is Latched and delatched. Input X1 is used to set
Latch-on output Y5.
Input X2 when activated makes the PLC send a pulse to an internal flag M1.
The internal flag M1 is then used to RESET output Y0
X001
SET Y005
X002
PLS M1
M1
RST Y005
Page 33 of 122
Module 8, Timers
A PLC must be able to control systems which have a time component in their
operation. For example a traffic light system or even a duty/stand-by cycle
changer. Time is a major aspect of control systems and the following text should
be covered.
The FX0(S) has 56 timers which have the identification code of T0 to T55. All the
timers function with 100msec clock pulses, but timers T32 to T55 can also be set
to 10msec pulses. The longest period which can be pre-set to is:
K32767 X100Msec =3276.7 seconds = 54 minutes, 36 seconds.
The timer number Txx where xx is the timers no. and the timer duration Kxx where
xx is the number of pulses.
X001
T1 K120
In the example above Timer No.1 has a pre set value of K120. One clock pulse K
is equal to 100msec so 120 x 100msec is equal to 12000msec which is equal to 12
seconds.
A timer falls in to two categories.
1.
Delay ON timer
2.
Delay OFF timer
Page 34 of 122
Operation of delay ON timer

The timer set up below starts counting when X001 is on and after 12 seconds have
elapsed the normally open contact of T1 closes activating Y1. Note that the time is
a non-retentive timer. If X001 is released before the 12 seconds is completed then
the timer resets its self.
X001
T1 K120
T1
Y1
Operation of delay OFF timer

The timer set up below starts counting when X001 is on and after 12 seconds have
elapsed the normally closed contact of T1 opens deactivating Y1. Note that the
time is a non-retentive timer. If X001 is released before the 12 seconds is
completed then the timer resets its self.
X001
T1 K120
T1
Y1
Page 35 of 122
Module 9, Counters
A powerful feature of PLCs is there ability to count. In simple terms it is a pulse
counter.
The construction of the counter system has a similar format to that of the timers,
however, the K value is not multiplied by anything (i.e. the K for timers means
multiply by 10ms or 100ms depending on the system being used).
The Counter Identifier identifies the counter chosen. This can be assigned to
device comment in the same way as the inputs, timers, outputs and internal flags.
In this example C12 is used. The second number is the quantity of pulses before
the C12 counter activates. In this case K7 is shown meaning that after 7 pluses the
counter C12 will be activated.
The memory storage of the value in the counter is retentive (i.e. it retains the value
until reset or the PLC is switched into the stop mode.
Counter Identifier
C12 K7
Quantity before activation
In the ladder logic shown below the button X006 is used to pulse the C12 timer.
After 7 pulses the C12 timer will switch to the activate state. The only way to
deactivate this timer is to reset the C12 timer using the RST C12 instruction. You
can see that this reset instruction is connected to the X007 switch. An important
note to keep in mind is that if during counting the X007 is pressed it will reset the
C12 counter erasing what number was being stored at the time.
X007
RST C12
X006
C12 K7
C12
Y3
Page 36 of 122
Module 10, Interlocks II the Exclusive OR

In some cases the OR gate needs to be refined to give a more definitive output.
Assume that you have two outputs and you have two inputs and you have been
asked to design a system to let one or the other operate but not both at the same
time.
In the example given below if the normally open X007 contact on the top is closed
the second normally closed X007 will open stopping the lower rung being activated
thus stopping Y001 from starting. Thus Y000 is the only one to start.
Alternatively, if the normally open X004 contact on the top is closed the second
normally closed X004 will open stopping the lower rung being activated thus
stopping Y000 from starting. Thus Y001 is the only one to start.
X007
X004
Y000
X004
X007
Y001
Page 37 of 122
Module 11, Multiple branch outputs

On occasion it is necessary to have multiple outputs from a single input. To
achieve this a layout similar to the ladder logic shown below should be used.
In this example X007 would switch Y000, Y001, Y002 and Y003 at the same time.
X007
Y000
Y001
Y002
Y003
Page 38 of 122
Module 12, Special Relays

As we have seen the FX0(s) has flags (auxiliary relays) available for the
programmer to use. These flags can hold the status of part of a programme without
using up a scarce output. There are also special flags which can be equally as
useful especially when used with counters or outputs that need to pulse. They are
the M8013 and M8014 devices
M8013, 1 second clock pulse
This contact will close in 1 second cycles, therefore any output controlled by
M8013 will pulse on for 0.5 seconds and off for 0.5 seconds.
M8013
Y000
1
0
0s
0.5s
1.0s
1.5s
2.0s
Time->
M8014, 1 minute clock pulse

This contact will close in 60 second (1 minute) cycles, therefore any output
controlled by M8014 will pulse on for 30 seconds and off for 30 seconds.
M8014
Y000
1
0
0s
30s
60s
90s
120s
Time->
Page 39 of 122
Module 13, Danger, Force On/Off

In the PLC there is a facility to force a coil on or off.
This forces the Output to the on or off status without a need for the complete logic
protection sequence it in the ladder logic being used. The PLC can be in Run or
Stop mode which makes this facility a potential hazard. By entering Online then
down to Debug and then on to Device Test you enter the lower screen below. It
now allows you enter a coil and force it on or off.
Page 40 of 122
Module 14, Master Control and Master Control Reset

The master control and master control reset is used to switch on and odd levels of
instruction within an sequential programme. The levels used in the MC instruction
start from 0 and can go up to 8. In our following example programme there is only
level of master control so n = 0. If there was another level of master control the
same programme we would use n=1 for it and so on.
The symbol for Master Control is
Page 41 of 122
Chapter 7, Questions to give you experience

Exercise 1, Door Bell
Design a small direct circuit used in a door bell application. The doorbell is only to
rung when the push button is pressed. Use an I/O list, sketch the ladder logic and
written description.
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Page 42 of 122
Exercise 2, Motor Start/Stop

Design a small PLC circuit to start a motor using a start button and keep the motor
running until the stop button is pressed. Use an I/O list, sketch the ladder logic and
written description.
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Page 43 of 122
Exercise 3, Operator Hand Pads

On some machines the operator could be duped into placing their hands in danger
during the operation of the equipment.
You have been asked to develop a specification for Operator Hand Pads that allow
the operator of a 100-ton press close the die tool only when both his hands are
free from the tool. Use an I/O list, sketch the ladder logic and written description.
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Page 44 of 122
Exercise 4, Operator Hand Pads, Emergency Stop and Guard

As in question 3 above some machines the operator could be duped into placing
their hands in danger during the operation of the equipment.
You have been asked to develop a specification for Operator Hand Pads that allow
the operator of a 100-ton press close the die tool only when both his hands are
free from the tool. The press on your instructions is now fitted with an emergency
stop and safety guard which need to be taken into consideration. Use an I/O list,
sketch the ladder logic and written description. (Should the emergency stop be
hardwired or soft wired?)
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Page 45 of 122
Exercise 5, Pumping Tank

In the diagram below you can see pump system feeding a tank.
You have been asked to develop a specification to allow the pump start when a
low level probe X001 is activated and stop the pump when the high level probe
X002 is activated. You can assume that the pump is on/off and a stop/start
arrangement is required
Use an I/O list, sketch the ladder logic and written description.
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Page 46 of 122
Exercise 6, Label Stamping

In the diagram below you can see a product running on a conveyor. The conveyor
drive motor, Optical sensors and label stamping cylinder can be assumed on/off
control.
You have been asked to develop a specification to allow the conveyor start and
stop with two buttons and only label the product when it presents its self at the
position correct sensor and up right sensor together. Assume Optical sensor No2
is the correct position sensor and Optical sensor No1 is the up right sensor.
Label Stamping
cylinder
Product
Optical Sensor No 1
Optical Sensor No 2
Conveyor
Conveyor
Drive Motor
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Page 47 of 122
Exercise 7, Motor Jogging

During a factory maintenance shut-down conveyor motors which locate
components are checked for correct position. Design a specification to jog the
motor forward and reverse. Assume that the motor has a forward controller and
reverse controller. Place interlocks in the programme which will prevent the motor
from being jogged in two directions at the same time. Use an I/O list, sketch the
ladder logic and written description.
Conveyor
Conveyor
Drive Motor
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Page 48 of 122
Exercise 8, Alarm Sensor

A movement sensor is to be used to switch on a security light. The light will stay on
for 20 seconds and then go off. The sensor is to be connected to input X1, it will
only give a momentary pulse as it detects movement. The security light is
connected to Y2 and is controlled by T1 which is programmed as a delay off timer.
Design a system using the PLC to control the above circuit.
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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Exercise 9, Conveyor Delay

A process has been developed which requires the conveyor to stop for 7 seconds
when the container hits the LED proximity sensor (i.e. the first sensor on the rig).
Using the conveyor rig design and implement you system. Use an I/O list, sketch
the ladder logic and written description.
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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Exercise 10, Washing Machine

A customer has asked your company to renovate an old machine and replace the
spin cycle timers and relays with a PLC control. It is your task to create a
programme which will carry out the specified time sequenced operation and to test
it out using your laboratory rig.
Specification
Pressing a push button starts the spin cycle. The motor will spin the drum slowly
for 15 seconds sat the end of this period the drum will spin quickly for 30 seconds,
then decelerate and turn slowly for 10 seconds before coming to a halt.
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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Exercise 11, Traffic Lights I

You have been asked to develop and implement a traffic lights sequence using the
following outputs.
Red Light is
Yellow Light is
Green Light is
Y003
Y004
Y005
Specification
Red is on for 10 seconds, Amber is on for 5 seconds and Green is on for 15
seconds and then the cycle starts again.
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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Exercise 12, Traffic Lights II

You have been asked to develop and implement a traffic lights sequence using the
following outputs.
Red Light is
Yellow Light is
Green Light is
Y003
Y004
Y005
Specification
Red is on for 10 seconds, Amber on for 5 seconds and Green is on for 15 seconds
and then the cycle starts again.
When a push button is pressed the sequence changes to Blue on for 12 seconds,
Amber and Green is on for 15 seconds and then the cycle starts again and after
one cycle the lights revert back to the original operation.
FX PLC
Relay
From
Y1
Relay
From
Y2
Relay
From
Y3
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Exercise 13, Conveyor Bottle counter

You have been asked to develop a system to package bottles to the following
specification.
Steel trays travel down the conveyor. When the tray is sensed by the first proximity
sensor the conveyor should stop and the red light should be switched on
(highlighting a danger and the same signal is use to initiate a pick and place
machine). The separate pick and place machine then loads the bottles into the tray
one by one. As each bottle is loaded the signal X007 (green push button) emulates
a bottle detect and counter (Say push the button six times to fill the tray). When the
tray is full the red light should be turned off and the conveyor started moving the
tray away and delivering another tray to the loading system.
McGrory
McGrory
Conveyor
Conveyor
Drive Motor
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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Exercise 14, 24 Hour Clock using Counters and special relays

specification.
A twenty 24 hour clock is to be designed using M8013 and M8014 special relays.
Construct the ladder logic so when viewed in monitor mode the counter registers
show the hours, minutes and seconds that have elapsed.
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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Exercise 15, Conveyor Timer

specification.
Steel trays travel down the conveyor. When the tray is sensed by the first proximity
sensor the conveyor should stop and the red light should be switched on. A
process unknown to you will be performed on the tray for 12 seconds. After this
time red light should be turned off and the conveyor started moving the tray away
and delivering another tray to the loading system.
--------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
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Exercise 16, Orange Concentrate Plant

You have been asked to develop a system to manufacture orange juice from
concentrate. Tank 1 contains water and Tank 2 contains concentrated orange
juice. Both tanks have low level probes which should stop the respective pumps
when the tank is empty (indicated by the loss of signal of the low level probe)
Both pumps are to be automated so they can only work together (at the same time)
and never alone or the resultant product would be too strong or weak. Tank 3
contains the diluted orange juice and has a low level probe and a high level probe.
When the high level is actuated both pumps feeding Tank 3 should stop. The
conveyor should be connected to a stop/start switch arrangement. When a
container is present the conveyor should stop and Pump 3 should operate for 10
seconds then stop and allow the conveyor move the container on.
Low Level Probe
Tank 1
Low Level Probe
Pump 1
Tank 2
Pump 2
Low Level Probe

High Level Probe
Tank 3
Pump 3
Product
Conveyor
Conveyor
Drive Motor
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Chapter 8, How the PLC is wired up to the outside world

The PLC has particular wiring arrangements. The diagram below highlights how
the system is wired up. As you can see the inputs are driven from a 24V supply
directly into the contact terminals. This could be in some cases 12V, 110V or 220V
on other similar product manufactures equipment.
It is important to isolate the inputs using a fuse or better to avoid the PLC getting
damaged. However the Outputs are only Volt Free Contacts so a relay is needed
to complete the control action and in this case up to 220V can be wired in but
usually for safety 24V should be used.
X001
X000
Mains
Address Data
X000 0
X001
Y000
Y000
24V
Switch wired
in from a 24V
supply
Relay
Outputs must be isolated from

the PLC using a relay to protect
the PLC
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Chapter 9, HMI, MMI and OMI

As you have seen from the laboratory session so far the PLC is a very powerful
piece of equipment. The PLC itself however has a downfall. It displays very little
information on the operation its controlling. Without the monitoring software
running on a PC or Laptop we would have to depend on the Input and Output
LEDs which tell us only if the signal is on or off (analogue values are non existent)
but nothing specific about the process itself.
Input LEDs
Output LEDs
One way of overcoming this is by using the operator panel usually called any of the
three titles below.
HMI Human Machine Interface
MMI Man Machine Interface
OMI Operator Machine Interface
A digital image of the E200 HMI as used in the Laboratory is shown below.
Dont worry about all the different names as they all in essence mean the same
thing. The HMI is a component to assist the processing automation system that
allows the operator view the process and interact with it.
Some of the standard features of the HMI is as follows;
Viewing and changing of I/O

Displaying of analogue values
Alarms
Bar Graphs
Information text
Full graphical screens (similar to monitors) are being used in industry.
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To design a good system its always a good idea to construct a storyboard from
which the system will be developed.
It is important to note at this point that the HMI and the PLC are both connected to
the one port at the back of the computer. It is therefore impossible to have the PLC
in monitoring mode and upload the E-Designer files at the same time. You will see
an error appear stating that the port is being used by another package.
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It would be advisable to set up a simple ladder logic code running on the PLC
before running the E-Designer Software.
In this case X007 the green button starts the conveyor Y001. X006 the red button
stops the conveyor. Of course the universal starting switch will keep the conveyor
running for us.
X004 will be used for the Counter C1. Every time the X004 button is pressed it will
increment the C1 counter by one. If you wish to put in a reset for the counter that is
up to you but not needed for this example.
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Step 1: How to load the E-Designer Programme

From the main desktop screen press the Start button using the mouse pointer
and progress up to Program then across to E-Designer and finally to the EDesigner icon.
From there the following screen should be loaded on to the computer screen
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Step 2: Start a new project

From the file menu on the top bar choose New and click on the text.
The following screen will be displayed and you will be able to choose the model of
the HMI unit installed in the Laboratory
Remember the Terminal is a E200 6.0x and the Controller system is a FX0(S)CPU.
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When the above is completed you will then be shown the screen below:
Step 3: Getting Started

Instead of jumping in and programming loads of screens lets take a little time to
explore the functions available to us using the HMI
If you double click on the Main block in the middle of the screen the following
screen will appear.
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The screen displays an emulation of what the user will see when their code is
uploaded to the HMI.
Start by clicking the large white area and type in Main

Conveyor. If the program was now uploaded the text Main
Conveyor would be displayed. But lets add a little to system
before we do that. Click on the Main Conveyor and move the
cursor to the end of the r and press return. Type in something
like Conveyor followed by a space and using the small O/I box
in the Icon selection set as shown to the right and the following
screen appears.
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Enter in something like Y1 (Which we know is the conveyor running signal, on the
PLCs provided) and when it is at off we want the Stopped word to appear and
when it is on we want the Running words to appear. Then press Apply and OK.
You can then see the software would have placed in a piece of text as shown
below.
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Transfer the code to the HMI unit by choosing Transfer from the top menu and
Project from the sub menu.
The following screen will appear and allow you send your programme up to the
HMI
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When Send is pressed the you will be asked to confirm if you want to upload and
when yes is pressed the code is then transferred across to the HMI
At the same time you will see the HMI screen change indicating that the code is
changing.
When this is completed you will see.
Main Conveyor
Conveyor Off
If you now start the conveyor by pressing the green button the following text is
displayed:
Main Conveyor
Conveyor On
This simple program shows us two important things about HMIs.
1.
We can add descriptive text about processes for the operator to see.
2.
We can have a dynamic changing of text linked to a changing process.
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Step 4: More involved HMI, Display Analogue Data

It is not only possible to have a descriptive text and dynamic changing of text in
two states, but we can also display data contained within registers such as the
Timer or Counter.
If we return to the Main screen on the E-Developer and continue to a new line we
can add a little more text. Type in Counter and after that press the 0.3 Icon from
the right menu and the following will be displayed
Type in C1 (at the beginning of this section I asked you to upload a simple ladder
logic program to the PLC, C1 was the counter, a number between 1 and 20 linked
to X004) and leave the rest the same as shown.
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Now your system will operate as before and you will see.
Main Conveyor
Conveyor Off
Counter 0
As you start the system you will then be able to have the conveyor change from Off
to On using X007 and X006 and increment the counter by pressing X004.
Step 5: Bar Charts
If you wish to place a bar chart it can also be completed using the HMI. This would
be used where a number is just not enough. Consider the following example. A
tank of liquid ranges between 0 and 10 meters in height. By just stating that the
height is 2 to an unfamiliar operator would mean nothing but when the graph
shows 2 out of 10 it would mean more.
Return to the E-Designer Main screen and at the end of the counter number
information press return. Then click on the --# icon.
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When the dialogue box appears put C1 in the Analogue Signal section and click on
Calc.. to fill in the upper and lower values for this case choose lower 0 and upper
20 as that is what we have put in the PLC ladder logic. Of course this could be
changed showing a scale if that is necessary.
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You will see a #------------------------- appears on the HMI. As shown below.
Main Conveyor
Conveyor Off
Counter 10
XXXXXXXXXXXXXXX
As you start the system you will then be able to have the conveyor change from Off
to On using X007 and X006 and increment the counter by pressing X004. As you
get closer to the 10 the more panels will be darkened.
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As a way of reminding you, this simple program shows us three important things
about HMIs.
1.
2.
3.
We can have Graphical features.
Step 6: Force Outputs
The particular screen used in the laboratory has five Text spaces, Five LEDS and
Five Buttons. If we want to edit any of these Items all we have to do is double click
on the element needed. If it is the Text then you can fill in what you want the
operator to see. If you wish to use the LEDS for something then you can assign
them.
The five buttons below the screen can be used to force Outputs.
If you double click on any of the buttons a dialogue box appears asking you do you
want this to be a local or global key. A Global Key would be something that will
appear on every screen designed and using a Local Key would mean it is only for
this screen. For our case choose Local Key.
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The screen dialogue box can be filled in as shown below.

Button 1 is Unused
Button 2 is The same as pressing X7
Button 1 is The same as pressing X4
Button 1 is The same as Forcing On Y1
Button 1 is Unused
IMPORTANT: I cannot stress enough the danger of using Button 4 to Force

On/Off the Y1 coil to drive the conveyor as the system has now no protection
in place.
Main Conveyor
Conveyor Off
Counter 10
XXXXXXXXXXXXXXX
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Reminding you again, this simple program shows us four important things about
HMIs.
1.
2.
3.
We can have Graphical features
4.
We have a way of providing output control.
Step 7: Now connecting this together, Storyboard
As you have experienced the above features of a HMI allow for interaction of the
operator and the previous inaccessible PLC. But to use this tool effectively some
planning is needed.
I would suggest making a storyboard of how you feel the system should be
designed and them implement and test it. In this way the operator can drill through
relevant screens, making the best of the limited space (screen size, buttons and
LEDs) on the HMI.
Firstly identify the locations on the HMI you wish to use. For this illustration I
assume the following:
Screen Title
Main
Screen
No.1
No.2
No.3
No.4
No.5
Text:
Text:
Text:
Text:
Text:
LED:
LED:
LED:
LED:
LED:
Button: Button: Button: Button: Button:
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The detail of the screens can now be written in typed text as shown in the sample
below. You fill in the detail you wish to enter into the HMI. Using this method it is
possible to develop a system that flows, allowing the operator access the
information in a meaning full way (a fully documented way as well) and avoid any
possible pitfalls or delays when coding. The testing of this is following the story
board and seeing if it works
Block 1
Block 2
Screen Title:
Main Screen
Screen Title:
Main Screen
Main Screen:
Conveyor System
Main Screen:
Conveyor System
No.1
No.1
Text:
Return to Main Menu
Text:
Return to Main Menu
LED:
N/A
LED:
N/A
Button:
Link to Main Screen Block 1
Button:
Link to Main Screen Block 1
No.2
No.2
Text:
Alarms
Text:
HVAC 1
LED:
N/A
LED:
N/A
Button:
Link to Alarms Block 2
Button:
Link to HVAC 1 Block 6
No.3
No.3
Text:
Trends
Text:
HVAC 2
LED:
N/A
LED:
N/A
Button:
Links to Trends Block 3
Button:
Links to HVAC 2 Block 8
No.4
No.4
Text:
N/A
Text:
HVAC 3
LED:
N/A
LED:
N/A
Button:
N/A
Button:
No.5
No.5
Text:
N/A
Text:
HVAC 4
LED:
N/A
LED:
N/A
Button:
N/A
Button:
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When each screen is developed it can be arranged using the Block Manager which
allows the flow from one block to another using arrows. The following screen
shows what a fully implemented system would look like before it is up loaded to the
HMI
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Chapter 10, OPC Server

For the data from the PLC to be accessed by the SCADA system it is necessary to
employ the features of an OPC Server. OPC stands for OLE for Process control
and OLE stands for Object Linking and Embedding. In simple terms the address
and data table in the PLC is copied.
How to set up the OPC server
Step 1:
Load up the software
In a similar fashion to the MELSOFT and the E-Designer we also load up the OPC
server by clicking on Start Programs Kepware and then on the Kepware
serverEX text. The screen shown below will appear.
You can see that every event is date and time stamped so the operator is kept full
aware of what is happening at all times.
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Step 2:
Add a Channel
The channel refers to the communication link from the PC to the PLC.
You will need to enter in all the details about the serial port, baud rate and so on.
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The channel name will appear in the dialogue box on the left of the screen showing
that it is available.
Step 3:
Add a Device
Then you will be asked to confirm the type of device running on the Channel (in our
case it is a Mitsubishi FX, other units available by using the scroll down menu).
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You will be asked to call it a name so you could identify it over the network. For
example this could be PLC_MMC1_Building_1.
As the FX PLC we use has a number of different models FX0S, FX1N etc. you
need to confirm the exact Device model.
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The timeouts and number of fails in the communications should also be entered so
the SCADA system can be alerted of any error when they happen.
If finishes up with a device summary and finish ends this part.
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Step 4:
Add a Group
You can see as we perform changes to the program it lists the date and time of
each event with a brief summary of it.
Now if we choose a Tag Group to keep respective tags together. An example of

this would be Air Handling Unit 1 controls should be kept together and so should
Air Handling Unit 2 and Air Handling Unit 3.
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For us we will enter a group called K044 which is of course the laboratory you are
in at the moment.
Step 5:
Add a Tag
The tag group is similar to a folder but we need now to select tags on the PLC. We
type in a Name we wish to use, the PLC address and a brief description of what it
does. Remember when we up loaded a program to the PLC and read it back from
the PLC it lost all its statements and notes. All that came back was the Address
and the ladder logic nothing else. The same happens here. So this tag entry is
where we fill in this detail again.
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Once entered the following line appears on the OPC server giving the Tag Name,
Address, Data type, DDE Scan cycle, Scaling if any and lastly the description.
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Step 6:
Run OPC Client
Now the hard work is done and we can start the OPC client running by choosing
the Hammer from the Icon menu.
A new screen appear which shows the KEPware Server on the left and all the
channel and device and group items. Click on the DeviceK044 and you will then
see the I/O entered into it
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You can now see the data stored at the address which in this case is a 0 or a 1.
Step 7:
Genesis
This information can now be accessed through the SCADA package Genesis using
the OPC Universal Tag and Browser.
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Chapter 11, SCADA

The lecture notes need to be viewed in relation to the following.
What does a SCADA package do?
Most SCADA packages have the following:
Graphical representation of the process to be controlled
Trend data against itself or time or another data source
Alarm if a condition has been achieved.
Data logging
Historical information
Step1: Getting Started
Click on Start, Programs, ICONICS Genesis32 and Graphwor32
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Step2: Graphical representation

The following screen appears. This screen is the configuration screen for the
graphical side to this package.
Lets start with a simple screen to let the as shown below. It looks complex but its
only make up of a number of components connected together.
Batch Display
CompA
CompB
Batch Start/Stop ?
Tank Level
????????
Discharge Pump
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In the sketch below you can see some of the components used to construct the
screen. The elbow is drawn once and copied and rotated. The same is for the pipe
and switches and valve. In fact these objects can be imported from the symbol
library in the package and if you develop a great drawing you could save it to the
library as well. The graphical display is only limited by your imagination.
Batch Display
CompA
CompB
Batch Start/Stop ?
Batch Start/Stop ?
Tank Level
????????
Discharge Pump
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Step3: Dynamics
You can uses the dynamics feature of the SCADA package to make objects move,
flash change color, rotate and change size etc.
If you take the sample of the mixer shown in the sample batch it is simply made
up of four separate images which are displayed in an animated sequence.
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Toggle between the two displays
Slide 1
Slide 2
Slide 3
Slide 4
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Any image or component in the process can be made dynamic. By choosing the
Dynamics menu from the top bar and choosing Action you have a choice of
different aspects that can be used.
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Lets take a simple example. If you draw the following components and select all
you will be automatically shown the following icons
Selector, Analogue and Animator

By clicking on each one you will be given a number of screens which can be used
to put dynamics on to the screen.
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Step4: Standard Gauges

Within the Genesis SCADA package there are standard gauges that you can use.
These gauges are features that only need the I/O data tag and give you various
options on how the gauge will look. Because they are standard modules the code
to display them was only written once and each instance of the gauge is a clone of
the original thus saving space compared to a personalized gauge designed by the
programmer.
Selection of options
Vertical
Circular
Horizontal
I/O Tag
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Step5: Check Boxes

Instead of having a button you may wish to use the check box function. It could be
printing out reports or ticking that an alarm has been accepted.
Actions that will happen

Check Box
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Step6: Graphical representation

Graphical Features
The highlighted section below is used to align selected items.
Features to help line up selected items

If you wish to change the order in which items appear you can use the highlighted
section below.
Select the order in which items appear

Front, Back. Layered
If you wish to rotate items you can using the highlighted section below.
Rotate
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Step7: Digital Display

By choosing the icon as shown below you can place a Digital display on the
screen. The Property Inspector on the right asks for the colors, fonts and title of the
digital display. The Property Inspector on the left is involved with the OPC tag (i.e.
its reference to the OPC server data). Note both screens cannot be seen at the
same time, although shown below but are accessed via the toggle taps at the top
of the box.
Digital Display
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Step8: Date and Time display

If the designer wishes to display the date and time on a graphical screen all they
need to do is press the clock icon as shown and the dialogue boxes appear
allowing most variation of the date and time to be displayed.
Digital Display
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Step9: Buttons
Buttons in a good SCADA system can be used for many things. In this package the
list of what can be done is displayed when you choose the down scroll arrow on
the action.
As you choose a certain aspect the dialogue box changes to allow
Digital Display
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Step10: Symbol Library

The Genesis SCADA package has a symbol library where you can store standard
images of pumps, pipes etc and use them when ever you want. You can also use
the existing images for your own screens.
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Step11: Trending
Toggle between the ten displays

Trending Chart
Choice of Chart
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Step12: Multi function

On occasion it is necessary to have a number of different things happen an
element in the SCADA package. In the example given below we started with a
rectangle, then added a size change, then flash on/off and finally pick. All of these
were added to the rectangle and could be added to almost any item developed on
the SCADA system.
Started as a Rectangle Then Size changes was added

Then Flash on/off was added
Then Pick was added
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Step13: Arithmetic
If your are able to get the height in a tank and wish to display the volume, it is
possible by using the arithmetic feature.
Height
Volume would
be height x area
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Joining the screens together

As explained in the buttons section above it is possible to link to another screen by
pressing on a button and loading up another screen. This is a very powerful tool as
it allows the system to be much more than one screen to having many screens.
Remember all the Genesis files have a .gdf extension.
The screen displayed below is VBATanks.gdf. The Bean Factory button on the top
right is linked to the VBABeanRoaster.gdf which is shown on the next page
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Another very good example of using the buttons or other diagrams is the
Notebook1.gdf example. The folder tabs are used to load up the screens from No1,
2, 3, 4, 5 and also back to No.1 if available.
No 1
No 2
No 3
No 4
No 5
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Good Working Practice

Consistency
It would be a good idea to set up a template at the beginning of the systems
development so consistency of the end product is evident. On the example screen
below you can see a line and under the line you have the date, the DIT logo and
buttons to take you to the common screens. Windows applications have been
consistent from product to product and once you have been trained or familiar with
one you can then use all of them.
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Storyboard
Another good design tool when using SCADA systems is the use of storyboards
showing where one screen would be linking on to another. Using the folder
example you can see how it works. It identifies what is going to be displayed on
each screen and how it links from one to the other.
No 1
No 2
No 3
No 4
No 5
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Exercise Laboratory 1
Batch Display
CompA
CompB
Batch Start/Stop ?
Tank Level
????????
Discharge Pump
Construct a graphical user interface as shown above.
Aim:
Procedure:
1
2.
3.
4.
5.
6.
7.
8.
9.
10.
Start the Genesis GraphWorks module. Move the mouse arrow to the
windows start button and press with the left button. Go into programs,
Iconics Genesis 32, Graphworks and finally Graphworks32.
Press OK on the Licence and note the time on when the package expires.
Set the background to white.
Using the symbol library given, start constructing the screen as shown
above. Remember to save the screen as you go along.
Make sure you use the zoom-in and zoom-out command to ensure that all
the images are joined together.
The button, switches and level indicators and be put into the mimic using
the bottom icon bar of the Graph works package.
The text can also be put on to the mimic using the icon bar provided.
When the graphics are in place and completed you may begin to add
animation. Use the top tool menu and choose Dynamics and then Actions.
Ensure that the Dynamic actions are linked to the OPC Server as
demonstrated by the instructor.
Use the tools, Runtime menu to start the system mimic and use the
configure to return to the GraphWorks editor.
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Batch Display
Batch Display
CompA
CompA
CompB
CompB
Batch1
BUTTON
Batch Start/Stop ?
Batch Start/Stop ?
Tank Level
Tank Level
????????
????????
Discharge Pump
Discharge Pump
Demonstrate the ability to convert from one graphical user interface

to another as shown above and introduce the standard gauges.
Aim:
Procedure:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Start the Genesis GraphWorks module. Move the mouse arrow to the
windows start button and press with the left button. Go into programs,
Iconics Genesis 32, Graphworks and finally Graphworks32.
Begin a new file using, FILE NEW .
Change the background to white.
Load up the batch file as before.
Add in a button and call it Batch 2.
Now make changes to the file and save the file as Batch 1.
Make more changes to the Batch file and call it Batch 2.
Enter Batch 1 again and ensure the button when clicked loads up batch 2.
Save Batch 1 again.
Enter Batch 2 again and ensure the button when clicked loads up batch 1.
Runtime should interchange between the files.
Check out the features of GENESIS like Dials and gauges and switches.
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Produce a dynamic animated image.
Aim:
Slide 1
Slide 2
Slide 3
Slide 4
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Aim:
Calculate the volume in a tank knowing the height.
Height
Volume would
be height x area
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Chapter 12, Analogue to Digital PLC Modules

The following pages are copies of the FX2N 4-AD manual from Mitsubishi.
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Chapter 13, Laboratory Conveyor Rig

The Input/Output List for the Laboratory Conveyor Rig is given below:
Input/Output List
Address
Description
X0
Box Detect Sensor
X1
Long Box Detect Sensor
X2
Box at Kicker Sensor
X3
Option Switch at bottom of Operator Control Station
X4
Black Push Button on Operator Control Station
X5
Option Switch at top of Operator Control Station
X6
Red Push Button on Operator Control Station (Normally Closed)
X7
Green Button on Operator Control Station (Normally Closed)
Y0
Y1
Y2
Y3
Y4
Y5
Kicker
Conveyor Belt
Blue Lamp
Red Lamp
Yellow Lamp
Green Lamp
Y1 Conveyor
X2 Box at Kicker Sensor

Y0 Kicker
Y4 Yellow
Y3 Red
Y5 Green
X1 LONG Box Detect Sensor

Y2 Blue
X0 Box Detect Sensor

X5 Option Switch
X4 Black P.B.
PLC
X6 Red P.B.
X7 Green P.B.
HMI, OMI
or MMI
Operator
Control
Station
X3 Option Switch
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Manual for Laboratory, PLC Connection.

Dublin Institute of Technology

Manual for Laboratory

Chapter 6, Get started at some programming samples, insertion of

Lecturer: Dr. John McGrory

Manual for Laboratory, PLC Connection.

Manual for Laboratory, PLC Connection.

LOAD UP THE SOFTWARE ............................................................................................... 78

CHAPTER 11, SCADA ................................................................................................................ 90

Manual for Laboratory, PLC Connection.

Manual for Laboratory, PLC Connection.

Chapter 1, How to get started

Manual for Laboratory, PLC Connection.

Step 2: How to start a new project

Manual for Laboratory, PLC Connection.

Then click OK and the following screen will be displayed.

Manual for Laboratory, PLC Connection.

Step 3: How start programming

Manual for Laboratory, PLC Connection.

Step 5: Stop the PLC

Power, Run/Stop and

Manual for Laboratory, PLC Connection.

Step 6: Up Loading the program to the PLC

Manual for Laboratory, PLC Connection.

Make sure to click all the boxes

Manual for Laboratory, PLC Connection.

Step 7: Switch the PLC to RUN mode

Manual for Laboratory, PLC Connection.

Chapter 2, Stages in Developing a PLC System

Manual for Laboratory, PLC Connection.

Chapter 3, Some of the main sections of the PLC developer screen.

These buttons allow the

Manual for Laboratory, PLC Connection.

Toggle between Ladder Logic and List of Instructions

Toggle between Ladder Logic

Manual for Laboratory, PLC Connection.

Read and write mode

Read and write modes can be

Monitor of the PLC current status

Manual for Laboratory, PLC Connection.

Project Data List

Project Data List

Manual for Laboratory, PLC Connection.

Documentation, Comments, Statements and Notes

Manual for Laboratory, PLC Connection.

Statement for the ladder run below it

Manual for Laboratory, PLC Connection.

PLC Status Diagnostic

Manual for Laboratory, PLC Connection.

Chapter 4, Down Load from the PLC

Manual for Laboratory, PLC Connection.

Chapter 5, GX Developer Sub Screens

Manual for Laboratory, PLC Connection.

Manual for Laboratory, PLC Connection.

Manual for Laboratory, PLC Connection.

Manual for Laboratory, PLC Connection.

Chapter 6, Get started at some programming samples

Manual for Laboratory, PLC Connection.

Module 1, On/Off Input and Output

Manual for Laboratory, PLC Connection.

Module 2, In Series Input and Output (AND)

Switch Switch Switch

Module 3, In Parallel Input and Output (OR)