1_NanoPLC Demo Unit User's Guide.doc 3/6/2009 Page 1 of 7

NanoPLC (PLR) Demo Unit User’s Guide

Where to Find an Electronic Copy of this User’s Guide...................................................1 Introduction.....................................................................................................................1 Overview.........................................................................................................................2 Test Program...................................................................................................................5

Test Program Operation...............................................................................................5 User I/O Connections ......................................................................................................6

Where to Find an Electronic Copy of this User’s Gui de An electronic copy of this User’s Guide may be found at www.letu.edu/engineeringtips.

Introduction Caution: Hazardous voltages exist in and around this demo unit. Care should be exercised when working with this machine. The NanoPLC (PLR) Demo Unit shown in Figure 1 was designed and built to demonstrate the key features of the Taco SG2-12HR-D Programmable Logic Relay, or PLR, which is also called a NanoPLC. This PLR has the following features, among others: • 6 digital inputs, • 2 analog inputs, • 4 relay outputs capable of handling 8 amps each, • 15 timers, • 15 counters, • and free programming software that supports both ladder logic and function block

diagram. Detailed specifications for this device may be found at the following link:

http://www.bb-elec.com/product_multi_family.asp?MultiFamilyId=39&Trail=32&TrailType=Top or in manual SG2PLR_UserManual_0707m.pdf

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Overview Refer to Figures 1 & 2 to identify components. All PLR analog and digital I/O connects to devices as listed in Table 1. Hand-sketched wiring diagrams are included in Appendix A of this document. Table 1: PLR I/O Connections

PLR I/O Simulator Hardware Digital Input I1 S1 (magnetic door switch) Digital Input I2 S2 (pushbutton) Digital Input I3 S3 (pushbutton) Digital Input I4 S4 (pushbutton) Digital Input I5 S5 (pushbutton) Digital Input I6 S6 (red-guarded toggle switch) Analog Input A1 Potentiometer R2 Analog Input A2 Potentiometer R4 Digital Output Relay Q1 Relay K1, motor M1, lamp NE1A, duplex outlets J1 Digital Output Relay Q2 Relay K2, motor M2, lamp NE2A, duplex outlets J2 Digital Output Relay Q3 Relay K3, lamp socket “yel” (original issue: yellow

lamp), lamp NE3A, 120 VAC duplex outlets J3 Digital Output Relay Q4 Relay K4, lamp socket “red” (original issue: red lamp),

lamp NE4A, 120 VAC duplex outlets J4

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Figure 1: PLR Demo Board

MAIN POWER SWITCH (NOT

VISIBLE)

TB1 (NOT VISIBLE) S2-S6

M1

M2

SOL1

TB2 (NOT VISIBLE)

S8

J1 J2

J3

J4

S1

PLR

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Figure 2: PLR Demo Board, Potentiometer & Relay Detail

R4

R2

K1 K2

K3 K4

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Test Program At the time of this writing, a test program was loaded into the PLR demo unit to demonstrate some of the control capabilities of the PLR. This program is listed is listed in Appendix B and should be available in electronic copy at www.letu.edu/engineeringtips. The original program or any new program(s) may be easily loaded into the PLR by following the instructions in manual SG2PLR_UserManual_0707m.pdf. Therefore, those instructions have not been repeated here.

Test Program Operation The original test program may be tested by following this procedure:

1. Plug NanoPLC demo unit power cord into 120 VAC outlet. 2. Turn on main power switch. 3. Observe that the PLR display lights up. 4. Swing open the small plastic door near the PLR, thus opening switch S1. Note

that the yellow lamp should flash and the PLR display should display a warning message.

5. While observing the blinking yellow light, rotate potentiometer R2 from fully clockwise to fully counter-clockwise and back again. Blink rate should change.

6. Close the plastic door again. 7. While pressing and holding pushbutton S5, watch the PLR display. Next, slowly

rotate potentiometers R2 and R4 from one direction to the other and observe the PLR display.

8. Release S5. 9. Press & release S2 and observe the response at M1 and the PLR display. Note

that M1 stops running after an 11-second timeout period. 10. Press & release S2 again, but before the PLR display shows timeout, press S5.

This button is programmed as the master reset and should stop M1. 11. Press & release S3 and observe M2. 12. Swing open the red cover from toggle switch S6 and flip the switch to the ON

position. Yellow light should flash and PLR display should flash a warning message.

13. While keeping all body parts clear of the PVC pipe connected to solenoid SOL1, press & release S4. Solenoid should activate, red light should illuminate, and PLR display should show solenoid time remaining. Caution: If writing a custom program, SOL1 duty cycle should be limited to 50% or less. To do otherwise will risk causing a fire.

14. Press & release S4 again. Nothing should happen. Note that S4 will only fire the solenoid again after S5 has been pressed or S6 has been cycled.

15. Close S6 red cover again, turning off S6. 16. Turn off main power switch.

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User I/O Connections Users may connect to this demo unit as outlined in Table 2, but should NOT rewire it. External connections are provided for users at TB1 and J1-J4. Refer to Figure 3 for TB1 terminal identification. Table 2: User I/O Connections

Demo Unit Connection Connection Detail TB1 terminals 1, 3, 5, 7, 9, and 11 +24 VDC out from unit TB1 terminal 2 PLR Digital Input I1 (+24 VDC into this

terminal activates input) TB1 terminal 4 PLR Digital Input I2 (+24 VDC into this

terminal activates input) TB1 terminal 6 PLR Digital Input I3 (+24 VDC into this

terminal activates input) TB1 terminal 8 PLR Digital Input I4 (+24 VDC into this

terminal activates input) TB1 terminal 10 PLR Digital Input I5 (+24 VDC into this

terminal activates input) TB1 terminal 12 PLR Digital Input I6 (+24 VDC into this

terminal activates input) 120 VAC duplex outlets J1 Switched by PLR Q1 relay output 120 VAC duplex outlets J2 Switched by PLR Q2 relay output 120 VAC duplex outlets J3 Switched by PLR Q3 relay output 120 VAC duplex outlets J4 Switched by PLR Q4 relay output

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Figure 3: PLR Demo Board, TB1 Detail

TB1-12 TB1-1

Appendix A: Wiring Diagram Sketches

Appendix B: FBD PLR Test Program Listing

1 Hz Blinker logic

Fast motor on-timeis limited to 11 seconds.

Yellow lampblinks whendoor openor solenoidpre-enabled.

Door Switch S1

I01

Reset Pushbutton S5

I05

B05

B04

M02

B03

mode: 1Timer: 2Cur Value1: 0.00Pre Value1: 0.50

B01

mode: 1Timer: 1Cur Value1: 0.00Pre Value1: 0.50

B06

Pushbutton S2

I02

Fast Motor M1

Q01

B08

Pushbutton S3

I03

Slow Motor M2

Q02

B09

Yellow Lamp

Q03

B10

M01

B02

B07

Pushbutton S4

I04

Red Toggle Switch

I06

B11

Analog Compare

B12

mode: 5Analog: 1Cur Value1: 0.00Ref Value: 5.00

Top Pot R4

Ai01

value:1.72

High01

B17

Show Analog Inputs

H01

B21

Solenoid Timer

B25

mode: 5Timer: 6Cur Value1: 0.00Pre Value1: 11.00

B26

H03

Door 120V Caution

H04

B27

B28

B33

B34

Title:

Company Name:

Programmer:

Remark:

Version:

Date:

Page:

PLR Demo Unit

LeTourneau University

J. Walter Koblich

4.0

05MAR2009

1

2 Hz Blinkerlogic

Solenoid on-timeis limited to 5 seconds.

Yellow lampblink rateis 1 Hz or2 Hz and iscontrolledby AI1.

Solenoid

Q04

B13

B14

M03

B15

mode: 1Timer: 3Cur Value1: 0.00Pre Value1: 1.00

B16

mode: 1Timer: 4Cur Value1: 0.00Pre Value1: 1.00

M04

B18

B19

Solenoid Timer

B20

mode: 5Timer: 5Cur Value1: 0.00Pre Value1: 5.00

B22

B23B24 Solenoid Time

H02

Solenoid Warning

H05B29

B30

B31

Door Switch Message Interlock

B32

Title:

Company Name:

Programmer:

Remark:

Version:

Date:

Page:

PLR Demo Unit

LeTourneau University

J. Walter Koblich

4.0

05MAR2009

2

Title:

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PLR Demo Unit

LeTourneau University

J. Walter Koblich

4.0

05MAR2009

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Label Function Parameters

Input:I01

Door Switch S1

Input:I02

Pushbutton S2

Input:I03

Pushbutton S3

Input:I04

Pushbutton S4

Input:I05

Reset Pushbutton S5

Input:I06

Red Toggle Switch

Ainput:Ai01

Top Pot R4

Output:Q01

Fast Motor M1

Output:Q02

Slow Motor M2

Output:Q03

Yellow Lamp

Output:Q04

Solenoid

Title:

Company Name:

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Remark:

Version:

Date:

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PLR Demo Unit

LeTourneau University

J. Walter Koblich

4.0

05MAR2009

4

Label Function Parameters

H(Output type: Display)H01

Show Analog Inputs

H(Output type: Display)H02

Solenoid Time

H(Output type: Display)H03

H(Output type: Display)H04

Door 120V Caution

H(Output type: Display)H05

Solenoid Warning

Marker:M01

Marker:M02

Marker:M03

Marker:M04

High:High01

Timer(On delay timer mode 1 ): 0.50SecB01

And:B02

Timer(On delay timer mode 1 ): 0.50SecB03

NOTB04

RS:B05

RS:B06

RS:B07

RS:B08

Title:

Company Name:

Programmer:

Remark:

Version:

Date:

Page:

PLR Demo Unit

LeTourneau University

J. Walter Koblich

4.0

05MAR2009

5

Label Function Parameters

AndE:B09

NOTB10

And:B11

Analog(Reference value <=Ax): 5.00VB12

Analog Compare

RS:B13

NOTB14

Timer(On delay timer mode 1 ): 1.00SecB15

Timer(On delay timer mode 1 ): 1.00SecB16

OR:B17

NOTB18

And:B19

Timer(Flash timer mode 1): 5.00SecB20

Solenoid Timer

AndE:B21

RS:B22

NandE:B23

NOTB24

Timer(Flash timer mode 1): 11.00SecB25

Solenoid Timer

OR:B26

OR:B27

Title:

Company Name:

Programmer:

Remark:

Version:

Date:

Page:

PLR Demo Unit

LeTourneau University

J. Walter Koblich

4.0

05MAR2009

6

Label Function Parameters

AndE:B28

And:B29

NOTB30

NOTB31

And:B32

Door Switch Message Interlock

NandE:B33

OR:B34

Title:

Company Name:

Programmer:

Remark:

Version:

Date:

Page:

PLR Demo Unit

LeTourneau University

J. Walter Koblich

4.0

05MAR2009

7

H01 H02 H03 H04

H05 H06 H07 H08

H09 H10 H11 H12

H13 H14 H15