Exercise 8

Controlling a Batch Mixing Process

EXERCISE OBJECTIVE

To create a ladder program for controlling a batch mixing process.

To test program operation through the completion of verification steps.

DISCUSSION

Today's PLC's are used in many branches of modern industry, such as rubber and
plastic, chemical and petrochemical, power, metals, pulp and paper, materials
handling, machining and manufacturing. Automation of industrial processes through
the PLC capabilities has brought a substantial improvement in production. Safer and
more comfortable working conditions, increased production, efficiency, minimal
downtime, higher quality products, are only a few examples of the innumerable
system benefits provided by PLC installations. In most applications, PLC installations
provided investment payback and additional savings.

A good example of industrial process where the PLC can be very beneficial is
chemical batch mixing. The PLC controls the ratio of two or more chemicals,
determines the mixing time, and monitors the heating temperature, as well as the low
and high tank limit levels. This PLC application provides faster batching and
consistent formulations from batch to batch.

PROCEDURE SUMMARY

In the first part of this exercise, you will connect the Lab-Volt PLC Trainer to the
computer used to run the P-SIM and RSLogix softwares. You will run P-SIM and
select the Batch Simulator, which simulates an automated system controlling
chemical batch mixing. You will then create a ladder program in order to control the
batch mixing process. You will test program operation through the completion of
verification steps.

Notice that the Batch Simulator can be controlled in a same manner using ladder
programs that are quite different. The student is encouraged to improve the ladder
program wherever possible, keeping in mind that fewer programming steps are
advisable.

EQUIPMENT REQUIRED

Refer to the Equipment Utilization Chart, in Appendix A of this manual, to obtain the
list of equipment required to perform this exercise.

8-1
Controlling a Batch Mixing Process

PROCEDURE

Setup

G 1. Connect the PLC Trainer, Model 3240-2, to the computer used to run
RSLogix 500 and P-SIM through the P-SIM to PLC Interface, Model 3243.
Then, connect the computer to the PLC communications port, through a
1761-CBL cable.

Note: If you are using the former PLC Trainer Model 3240-1,
connect the PLC Trainer to the computer used to run RSLogix
and P-SIM, through the Voltage Converter/Isolator, Model 3242,
and the P-SIM to PLC Interface, Model 3243. Then, connect the
computer to the communication port of the PLC on the
PLC Trainer, through the PC Interface, Model 3246-1. (Refer to
Figure E-2 of the manual for the detail of the connections to
make).

G 2. On the PLC Trainer, Model 3240-2, make sure the V1 and V2 toggle
switches of the PLC output jacks are set to 24 VDC (togle switches upward).

Note: If you are using the PLC Trainer Model 3240-1, make sure
to connect both PLC output groups to the trainer 24-V DC source,
not to the 120 (240)-V AC source, which could damage the
interface modules, Models 3243 and 3242.

G 3. Turn on the computer. Do not start RSLogix 500 for now.

G 4. On the computer, start the P-SIM Simulator program

In the entry window of P-SIM, select the Serial Port command of the main
menu, then select the serial port (COM 1, 2, 3 or 4) that corresponds to the
computer serial port to which the P-SIM to PLC Interface module,
Model 3243, is connected.

G 5. Turn on the PLC Trainer. In the entry window of P-SIM, select the Initialize
IO Board command of the main menu, which will bring up a window asking
you if you want to reset the IO board now. Click OK to close the box and
reset the board.

In the entry window of P-SIM, select the Batch Simulator option of P-SIM.
This will bring up the Batch Mixing Simulation window (see Figure 8-1).

8-2
Controlling a Batch Mixing Process

Figure 8-1. The P-SIM Batch Mixing Simulation window.

Controlling a Batch Mixing Process

G 6. The P-SIM Batch Mixing Simulation window allows control of an industrial

batch mixing process. The purpose of this process is to combine two
reactants (A and B) to produce a third product (C). Reactants A and B are
first charged into the tank in proportions of two to one. The reactants are
then mixed and the temperature is raised to a certain value (temperature
setpoint). Then the mixing operation continues for 30 seconds. The
temperature is automatically kept at setpoint during this period. The reaction
product (C) is then withdrawn from the tank.

Observe that the addresses of the input devices in the Batch Mixing
Simulation window correspond to the PLC input bit addresses listed in
Table 8-1.

8-3
Controlling a Batch Mixing Process

BATCH MIXING INPUT DEVICES CORRESPONDING PLC

INPUT BIT ADDRESS

Momentary-action, normally-closed pushbutton I:0/0

switch S1: I:1/0

Momentary-action, normally-open pushbutton I:0/1

switch S2: I:1/1

Temperature switch: I:1/2 I:0/2

Low-level switch: I:1/3 I:0/3

High-level switch: I:1/4 I:0/4

Flowmeter FL1: I:1/5 I:0/5

Flowmeter FL2: I:1/6 I:0/6

Flowmeter FL3: I:1/7 I:0/7

Table 8-1. Addresses of the Batch Mixing devices and their corresponding PLC input bit address.

G 7. Now, observe that the addresses of the output devices in the Batch Mixing
Simulation window correspond to the PLC output bit addresses listed in
Table 8-2.

BATCH MIXING OUTPUT DEVICES CORRESPONDING PLC

OUTPUT BIT ADDRESS

Mixer: O:1/0 O:0/0

Pump P1: O:1/1 O:0/1

Pump P2: O:1/2 O:0/2

Pump P3: O:1/3 O:0/3

Heater: O:1/4 O:0/4

RUN lamp: O:1/5 O:0/5

STANDBY lamp: O:1/6 O:0/6

FULL lamp: O:1/7 O:0/7

Table 8-2. Addresses of the Batch Mixing devices and their corresponding PLC output bit address.

G 8. On the computer, start RSLogix 500 (leave the P-SIM Batch Mixing
Simulation window open). In RSLogix, create a new project having the
following processor name: ECS8.

8-4
Controlling a Batch Mixing Process

G 9. Based on Tables 8-1 and 8-2, write a ladder program for the P-SIM Batch
Simulator which will control the following sequence of operations:

Upon power up, the STANDBY lamp in the control panel of the batch
mixer is lit. The pumps, the mixer, and the heater are off. The RUN and
FULL lamps in the batch-mixer control panel are also off.

Pressing the START pushbutton (momentary-action, normally-open

switch S2, I:1/1), by clicking it using the mouse, starts pump P1, turns
the RUN lamp on, and turns the STANDBY lamp off. This causes
reactant A to be pumped into the tank.

Once flowmeter FL1 has generated 10 pulses, pump P1 is stopped and

pump P2 is started. This causes reactant B to be pumped into the tank.

Once flowmeter FL2 has generated 10 pulses, pump P2 is stopped, the

FULL lamp turns on, the mixer is started, and the heater is turned on.
Both reactants are then mixed and heated up to the temperature
setpoint.

Once the temperature of the reactants reaches the setpoint value, the
contacts of temperature switch I:1/2 close. The mixing operation then
continues for 30 seconds. During this time interval, the reactant
temperature is automatically kept very close to the setpoint value (by
switching the heater on and off).

After the 30-second mixing interval, pump P3 is started to withdraw the

product from the tank, the mixer is stopped, the heater is turned off, and
the FULL lamp turns off.

Once the level of product in the tank has decreased below the
minimum-level limit, the contacts of the LO-LEVEL switch (I:1/3) open.
This causes pump P3 to stop and the batch mixing process to repeat
(through the starting of pump P1 and so on).

Pressing the STOP pushbutton (momentary-action, normally-closed

switch S1, I:1/0) stops the system at any sequential step of the mixing
process, turns the RUN lamp off, and turns the STANDBY lamp on. At
this point, pressing the START pushbutton causes the mixing process
to resume from the step reached up to when the system was stopped,
the RUN lamp to turn on, and the STANDBY lamp to turn off.

The LO-LEVEL switch prevents the mixer and heater from being turned
on as long as the level of reactants in the tank is lower that the
minimum-level limit. In fact, this switch contacts remain open as long as
the level of reactants is lower than the minimum-level limit.

When the level of reactants exceeds the maximum-level limit, the

contacts of the HI-LEVEL switch (I:1/4) close. This causes pumps P1
and P2 to stop, the RUN lamp to turn off, and the FULL lamp to turn on,

8-5
Controlling a Batch Mixing Process

while the STANDBY lamp remains off. This situation remains until the
START pushbutton is pressed and kept pressed, thereby starting
pump P3 (to withdraw the product from the tank) and turning the RUN
lamp on. When the FULL lamp turns off, the START pushbutton can be
released without causing pump P3 to stop. Once the level of the product
in the tank has decreased below the minimum-level limit, the contacts
of the LO-LEVEL switch open. This causes pump P3 to stop and the
batch mixing process to repeat (through the starting of pump P1 and so
on).

Write your ladder program on paper. Note that pulse generation from
flowmeters FL1 through FL3 is automatically controlled by the software
during the animated process, as well as the opening and closing of the
HI- and LO-LEVEL switch contacts.

G 10. Enter your ladder program in program file LAD 2 of project ECS8. Verify
each rung, then save the project in a project file having the same name as
the processor name. Download the project to the PLC. Go online and set
the PLC in the Run mode.

Testing the Ladder Program with the P-SIM Batch Simulator

G 11. Test program operation by completing the verification steps below. If the
program fails to function, do not proceed to the next step. Go offline to
modify the program as required, then go back online to complete the
verification steps.

a. Upon power up, the STANDBY lamp in the control panel of the batch
mixer should be ON. The pumps, the mixer, and the heater, should be
off. The RUN and FULL lamps in the batch-mixer control panel should
also be off.

b. Press the START pushbutton S2. Pump P1 should start, the RUN lamp
should turn on, and the STANDBY lamp should turn off. This causes
reactant A to be pumped into the tank.

c. Once flowmeter FL1 has generated 10 pulses, pump P1 should stop

and pump 2 should start. This causes reactant B to be pumped into the
tank.

d. Once flowmeter FL2 has generated 10 pulses, pump P2 should stop,

the FULL lamp should turn on, the mixer should start, and the heater
should turn on. This causes the reactants to be mixed and heated up to
the temperature setpoint.

e. Once the temperature of the reactants reaches the setpoint value, the
mixing operation should continue for 30 seconds. During this time
interval, the heater should turn on and off to keep the reactant
temperature very close to the setpoint value.

8-6
Controlling a Batch Mixing Process

f. After the 30-second mixing interval, pump P3 should start to withdraw

the product from the tank, the mixer should stop, the heater should turn
off, and the FULL lamp should turn off.

g. Once the level of product in the tank has decreased below the
minimum-level limit, pump P3 should stop and the batch mixing process
should repeat (through the starting of pump 1 and so on). Observe
circuit operation through a few cycles to verify that proper control is
performed by the PLC.

h. Press the STOP pushbutton S1 while reactant A is being pumped into

the tank. Pump P1 should stop immediately, the RUN lamp should turn
off, and the STANDBY lamp should turn on.

i. Press the START pushbutton. Pump P1 should restart, the RUN lamp
should turn on, and the STANDBY lamp should turn off.

j. Press the STOP pushbutton while reactant B is being pumped into the
tank. Pump P2 should stop immediately, the RUN lamp should turn off,
and the STANDBY lamp should turn on.

k. Press the START pushbutton. Pump P2 should restart, the RUN lamp
should turn on, and the STANDBY lamp should turn off.

l. Press the STOP pushbutton while the reactants are being mixed and
heated. The mixer should stop, the heater should turn off immediately,
the RUN lamp should turn off, and the STANDBY lamp should turn on.

m. Press the START pushbutton. The mixer should restart, the heater
should turn on, the RUN lamp should turn on, and the STANDBY lamp
should turn off.

n. Press the STOP pushbutton while the reaction product is being

withdrawn from the tank. Pump P3 should stop, the RUN lamp should
turn off, and the STANDBY lamp should turn on.

o. Press the START pushbutton. Pump P3 should restart, the RUN lamp
should turn on, and the STANDBY lamp should turn off.

p. Stop system operation while reactant A is being pumped into the tank.
Force PLC input bit I:0/3 off to simulate a low level of reactant in the
tank. Press the Start pushbutton to restart the batch mixing process.
Once the required quantity of reactants A and B has been pumped into
the tank and the FULL lamp has turned on, the mixer should not start
and the heater should remain off because the sensed (detected) level
of reactant in the tank is below the low-level limit. Remove the force
installed on PLC input bit I:0/3. System operation should resume.

q. Stop system operation while reactant B is being pumped into the tank.
Force PLC input bit I:0/6 off to simulate a failure of flowmeter FL2. Press
the Start pushbutton to restart the batch mixing process. When the level
of reactant reaches the high-level limit, pump P2 should stop

8-7
Controlling a Batch Mixing Process

immediately, the RUN lamp should turn off, and the FULL lamp should
turn on. The STANDBY lamp should remain off.

r. Press and hold the START pushbutton (by pressing and holding the
mouse left button). Pump P3 should start immediately to withdraw the
reactants from the tank and the RUN lamp should turn on. When the
FULL lamp turns off, release the START pushbutton. Pump P3 should
remain on until the reactants have been completely withdrawn from the
tank, and the batch mixing process should restart automatically.

s. Stop system operation while reactant A is being pumped into the tank.
Remove the force installed on PLC input bit I:0/6. Press the START
pushbutton. The batch mixing process should resume.

G 12. Have your instructor verify the operation of the program.

G 13. When you have finished, set the PLC in Program mode, and clear the PLC
memory.

G 14. Close RSLogix 500, then close P-SIM.

G 15. Turn off the computer.

G 16. On the PLC Trainer, make sure that all PLC inputs are deactivated. Turn off
the PLC Trainer. Remove all connection leads, if any, and return all the
equipment.

CONCLUSION

In this exercise, you created a ladder program for controlling a batch mixing process.
You tested program operation through the completion of verification steps. Industrial
processes being composed of dynamic and static elements, PLC programmation can
be difficult since the combined effects of these elements are hard to visualize.
However, a good understanding of the system requirements, coupled to a
systematic, step-by-step system approach, minimize the programmation errors and
the time required to troubleshoot and tune the system.

8-8