Department of Engineering and Design- Room T405 PLC Application Exercises

Supervisors: Mr.K.Rotter/ Mr.S.Mondal Authors: Mr.M.Zahir / Mr.P.Adams

Application Exercise 6. Washing Machine Simulator
This Module is a Washing machine simulator.
The module has all the necessary programming
buttons/switches(9 inputs) to simulate the
operation of a domestic washing machine. The
aim of this exercise is to program the simulator
in ladder logic to carry out a washing cycle set
by the inputs and activate the corresponding
LEDs to indicate that the washing cycle is active.
The students are advised to work out and write
down the operation of machine in plain English
first before attempting to develop a ladder logic
program. This exercise requires the use of
internal Relays(for Start, Tub Full, Tub Half Full)
and a sequencer to carry out the washing cycle.
The Vibration sensor Button and/or the Door
Lock switch can be used to terminate the cycle
or simulate the Vibration that may occur if a machine is over-loaded.
The table below shows the connection of the Inputs and Outputs to the module. You
are advised to use the same names given below for Inputs and outputs and insert
them in the I/O table.


Function Output LEDs PLC Output Function Switch/Button PLC Input
Start 1 StartBTN 1
HotTemp 2 HalfLoadSW 2
TepidTemp 3 SpinSW 3
ColdTemp 4 CoolWashSW 4
SlowFwd 5 HotWashSW 5
SlowRev 6 TubFullBTN 6
FastFwdSpin 7 TubHalfFullBTN 7
PumpON 8 DoorClosedSW 8
TubFilling 9 VibrationBTN 9
TubFull 10

TubHalfFull 11


Locked 12


ColdWater 13

HotWater 14



Where SW, Stands for Switch and BTN, stands for Button in the Input Table.

Department of Engineering and Design- Room T405 PLC Application Exercises
Supervisors: Mr.K.Rotter/ Mr.S.Mondal Authors: Mr.M.Zahir / Mr.P.Adams


Washing Cycle Programming
An example Hot Wash Cycle requires the activation of Hot Wash Input. The Tub
Should be filled by pressing the Tub Full Button to latch the condition. Once the Door
is Locked, and the Start button is pressed the Cycle should start by:
Door Locked indicator ON
Start Light ON
Indicate Hot Water Valve ON
Tub Filling ON
After some delay set by the Tub Full Button, Tub Full Indicator ON, Tub Filling
OFF.
HOT Temperature Indicator ON
The Machine Indicates the Slow Reverse/Forward lights Turning ON/OFF in
sequence separated by reasonable delays.
After the Cycle is finished the Machine empties the Tub, i.e Pump ON and
goes into Fast Spin if the Spin button is pressed.
All indicators are then switched OFF.
At any time if the Door Lock or the Vibration sensor inputs are activated the
machine should stop.
The machine should indicate the sequence with reasonable delays so that the
cycle is not too long and also not too short so that the sequence can be observed
easily.
Similarly, by pressing or latching the various switches and buttons a different
washing cycle should be performed.
Note: The entire ladder logic should be Simulated first before transferring
the program to the PLC.









Department of Engineering and Design- Room T405 PLC Application Exercises
Supervisors: Mr.K.Rotter/ Mr.S.Mondal Authors: Mr.M.Zahir / Mr.P.Adams


How to transfer programs to the PLC
This section describes the step by step procedure for transferring programs to the
PLC. It is essential that you carry out the steps given below exactly.
Ensure the PLC is connected to the power supply and switched ON
Ensure the power supply of any other Rig connected to the PLC is also
switched ON.
Ensure that RS232 Serial cable is connected to the PLCs COM port
Run the TLserver Software if it not already loaded. You will see the following
window appear.


Now click on the Serial Port Setup button above. The following window appears:



Department of Engineering and Design- Room T405 PLC Application Exercises
Supervisors: Mr.K.Rotter/ Mr.S.Mondal Authors: Mr.M.Zahir / Mr.P.Adams


Ensure the message COM1 opened at 38400bps is displayed in the Response
window. If not please call the Technician in charge to assist you. If the message
confirms that the port is opened as shown above then, proceed to the next page.

Click on Controller and select Program transfer to PLC. The following window is
opened:

Now type in 01 in the Detect ID box and click on Memorize Username &
Password to clear the Tick sign. This means the PLC should not be set with a
username and password.
Note: you must not set a Password for any other subsequent experiment or
project. Username can be ignored and left alone as samples.
Therefore the window should appear as shown below before you proceed to the next
step.
Department of Engineering and Design- Room T405 PLC Application Exercises
Supervisors: Mr.K.Rotter/ Mr.S.Mondal Authors: Mr.M.Zahir / Mr.P.Adams


Now click OK.

Click Yes to Overwrite PLCs program.

The i-Trilogi software will now compile the Ladder logic to machine code. If the code
contains errors, then the PLC will display an error message that the compilation is
not successful. You must then go back to editing and correcting your errors.
If the compilation is successful, you will see the message Success! In the
Compilation window shown above.

Department of Engineering and Design- Room T405 PLC Application Exercises
Supervisors: Mr.K.Rotter/ Mr.S.Mondal Authors: Mr.M.Zahir / Mr.P.Adams


Now click on Start Transfer, the following window is displayed:

Click on Yes to Reset PLC?
The program in the PLC will Execute and read data from input ports or output data to
the devices you have programmed. The status of the PLC can be monitored by the
following:

Click on Controller and select On-Line Monitoring. The following example window
appears:

Department of Engineering and Design- Room T405 PLC Application Exercises
Supervisors: Mr.K.Rotter/ Mr.S.Mondal Authors: Mr.M.Zahir / Mr.P.Adams


The status of all devices can be monitored from this window. If A/D converters are
used then the Raw Data from the converters can be seen at the top of the window in
ADC1-8 boxes.
This concludes a successful PLC Program transfer. The same procedure is
used to transfer any program to the PLC.
Virtual LCD Display
You may view the Virtual LCD Display to see other status data by clicking on the
View button. Click View now. You will see the Virtual LCD display window:

This window is used to output up to 4 lines of text to display messages or values of
Global variables. It also displays, the state of the A/D converters 1 to 8 ,PWM
outputs 1 to 8 and the data that is output the D/A channels.