Labworks Book GP313

GP313- Process Instrumentation
and Control Lab sheet

Name: …………………………………………………………………………………………………………………….
Register Number: …………………………………………………………………………………………………..
Course / Session: …………………………………………………………………………………………………
……………………

PROCESS INSTRUMENTATION & CONTROL GP313

BIBLIOGRAPHY

MOHD TAUFIK REZZA BIN MOHD FOUDZI

Place of Birth : Bota, Perak

Education 1) BEng (Hons) Electrical- Mechatronic (UTM)

Working : 2007- Present (2012)
Experience

MOHD HUZAIMI BIN HUSSIN

Place of Birth : Kuala Kedah, Kedah

Education 1) BEng (Hons) Electrical (UiTM)

Working : 2005 - Present (2012)
Experience

MOHAMAD MAWARDI BIN RUSTAM

Place of Birth : Ipoh, Perak

Education 1) BEng (Hons) Instrumentation & Control (UTEM)

Working : 2009 - Present (2012)
Experience

DEPARTMENT OF PETROCHEMICAL ENIGINEERING Page i

PROCESS INSTRUMENTATION & CONTROL GP313

PREFACE

Process Instrumentation and Control laboratory provides a “hands-on” environment that is
crucial for developing students’ understanding of theoretical concepts. Instrumentation and
Control laboratory is housed with different instruments like temperature measurement, level
detection, pressure measurement, flow measurement etc and different types of valves, e.g.,
solenoid valves, servo valves, etc. On different panels or rigs these are arranged in different
control configurations to achieve specific control objectives.

By involving students in this process instrumentation and control laboratory, they will
understand the process engineering fields’ process and will be able to make a selection of the

most suitable unit to be used in a process depending on certain factors.

Department of Petrochemical Engineering
POLITEKNIK KUCHING SARAWAK

DEPARTMENT OF PETROCHEMICAL ENIGINEERING Page ii

PROCESS INSTRUMENTATION & CONTROL GP313

REFERENCES

1. OMRON A Beginner’s Guide to PLC (1999)
2. Process Control System Control of temperature, flow and filling level

workbook, Festo Didactic GmbH & Co. (1997)
3. Lessons In Industrial Instrumentation ,Tony R. Kuphaldt (2000)

4. OMRON, CQM1H PLC Manual (2000)

5. Process Instrumentation and Control Handbook, Third Edition, Douglas
M.Considine and Glenn D.Considine (1985)

6. Instruction Manual, PCT14- Pressure Control Accessory, Armfield
Engineering Teaching and Research Equipment (2001)

7. Instruction Manual, PCT10SC- Electrical Console, Armfield Engineering
Teaching and Research Equipment (2001)

8. Mechatronics Electronic control systems in Mechanical and Electrical
Engineering, Third Edition, W.Bolton (2003)

DEPARTMENT OF PETROCHEMICAL ENIGINEERING Page iii

PROCESS INSTRUMENTATION & CONTROL GP313

WORKSHOP SAFETY REGULATION

YOUR SAFETY IS OUR PRIORITY
Workshop areas are in themselves very safe places providing that sensible and safe working
practices and behaviour are followed at all times. The moment that we try to take short cut, we
put ourselves and other people at risk of injury. Each one of us is responsible for ensuring that all
times safe working procedures are being followed.
IMPORTANT : If, for whatever reason, you do injure yourself, then it must be reported to your
lecturer IMMEDIATELY . The lecturer will investigate the extent of the injury and ensure you
receive prompt and appropriate treatment.
Please read the following guidelines carefully:

1. All injuries, however small, MUST be reported to your lecturer immediately.
2. SHOES must be worn at all times. Training, track or soft shoes will not protect your feet.
3. DO NOT run anywhere in the workshop or other areas
4. Any breakages must be reported. DO NOT use faulty, damaged or broken equipment.
5. Loose clothing & hair are potential dangers, make sure that cuffs, ties and sleeves are

secured so that they cannot become caught in machinery or equipment. (Long hair must
be tied back securely)
6. Goggles or visors MUST be worn at all times and particularly when using ALL
machinery, or when working on any other risky processes.
7. Protective clothing is provided for your use. It must be worn at all times in the workshop.
8. Never distract anyones attention whilsts they are operating any machinery /equipment.
9. ALWAYS use tools and equipment for their intended purpose. Don’t make do, that is
when accidents will occur.
10. Carry tools, materials and equipment with care around the workshop.
11. Keep your working area clean and tidy. When you have finished using a handtool or
piece of equipment, always return it to the correct place-so the next user can find it.
12. Tools and equipment should never be used as weapons, either as defence or attack.
Serious and immediate action will be taken against anyone who becomes involved in
such an incident.

DEPARTMENT OF PETROCHEMICAL ENIGINEERING Page iv

PROCESS INSTRUMENTATION & CONTROL GP313

13. Special care must be taken when using plastics, solvents, varnishes and adhesives.
Powerful and harmful vapours can be given off. Read/follow instructions carefully and
use fume extraction.

14. SPILLAGES : If there is a spillages or accident involving a substance eg a solvent or an
adhesive) you must report any such incident to your lecturer immediately.

15. CLEANING : It is your job to clean up your workspace at the end of each session. All
tools and equipment must be returned to their correct places and wastematerials must be
disposed of in the bins provided. Safety glasses must be returned to the correct place.

16. HAND WASHING : At the end of each workshop session, you must wash your hands.
17. NEVER work alone. You are not permitted to work unsupervised, at any time in the

department.

THESE SAFETY RULES ARE DESIGNED TO PROTECT YOU, THEY ARE IN NO
WAY INTENDED TO RESTRICT YOUR WORK. PLEASE FOLLOW THEM
CAREFULLY, IF IN DOUBT-ASK FIRST

DEPARTMENT OF PETROCHEMICAL ENIGINEERING Page v

PROCESS INSTRUMENTATION & CONTROL GP313

PRACTICE MARKING SCALE

Practice 5% @ Good – Prepared Lab Book and Calculator.
Preparation 3% @ Medium – Incomplete Preparation.
0% @ Weak – Does not prepare anything.
(5%)

Teamwork 5% @ Good - Proactive, able to answer questions, follow procedure, arranging tools
(5%) & seats.
3% @ Medium – Fulfilled some of the aforementioned criteria.

0% @ Weak – Does not fulfill any of the aforementioned criteria.

a) Circuit Connection (10%)
15% @ Good – Neat and correct circuit connection.
10% @ Medium – Correct circuit connection but untidy.
5% @ Weak – Incorrect circuit connection and requires a lot of lecturer’s assistant.

Skill (40%) b) Tools usage (10%)
15% @ Good – Skillful in tools usage.
10% @ Medium – Lack of skills in tools usage.
5% @ Weak – Unable to use tools and requires a lot of lecturer’s assistant.

c) Data Acquisition (15%)
15% @ Good - Skilful in acquiring data.
10% @ Medium - Lack of skill in acquiring data .
5% @ Weak - Unable to acquire data and requires a lot of lecturer’s assistant .

d) Safety (5%)
5% @ Good – Implement safety while doing experiment.
3% @ Medium – Lack of safety precautions while doing experiment.

0% @ Weak – Does not implement safety while doing experiment

Practice Report According to Report Marking Scheme provided.
(50%)

DEPARTMENT OF PETROCHEMICAL ENIGINEERING Page vi

PROCESS INSTRUMENTATION & CONTROL GP313

Practice Marking Guidelines

No. Assesment Comments
Criteria

1. Practice Assessing students preparation upon starting practice
Preparation
Example:-
- Bringing along calculator, multimeter and lab book.
- Prepared calculations, if any.

2. Skill Assessing student’s capabilities while doing practice
3. Teamwork
Example:-
- Circuit Connection
- Tools usage
- Data acquisition, such as drawing waveforms, reading calues

of Volt/Div, Time/Div on the oscilloscope etc.
Assessing student’s teamwork while running a practice

Example :-
- Being passive/pro active
- Able to answer questions asked by lecturer
- Following procedures as told
- Arranging tools after usage
- Tidying tables
- Arranging chairs etc.

Assessing lab reports according to provided standards.

4. Practice Report A report should contain the following:-
- Title
- Objektive
- Tools
- Related Theories
- Procedure
- Result
- Discussion
- Conclusion

DEPARTMENT OF PETROCHEMICAL ENIGINEERING Page vii

PROCESS INSTRUMENTATION & CONTROL GP313

PRACTICE REPORT MARKING FORMAT

1. Practice Title & Front Page : ( 10 marks )
Stating the practice’s title.

2. Practice Objective : ( 5 marks )

Listing out required objectives.

3. Listing Tools : ( 5 marks )
Listing tools used.

4. Introduction : ( 10 marks )

Explain in detail about the practice which includes theories, diagrams and equations

involved.

5. Procedure : ( 10 marks )

Explain step by step of the procedures using passive words. May also include schematic

diagram.

6. Result : ( 20 marks )

Recording practice results gained in form of chart or table.

7. Discussion : ( 20 marks )

i) Attached questions

- Answering the questions based on their results.

ii) If the are no questions attached

- Relate the result of the experiment with learnt theories through evidencing by

calculated formulas.

8. Conclusion : ( 20 marks )

Summaries from the experiment, in terms of:

i) Title elaboration
ii) Results gained through the experiment
iii) Proving result using theories learnt and some calculations
iv) Differences between the results gained than through calculations(theory). Stating

factors that disrupt the expected result.

9. Comment :

To be filled by lecturers involved.

DEPARTMENT OF PETROCHEMICAL ENIGINEERING Page viii

PROCESS INSTRUMENTATION & CONTROL GP313

CONTENTS

BIBLIOGRAPHY.........................................................................................................................i
Preface ………………………………………………………………….…………….......….......ii
References………………………………………………………………..…………........….…...iii
Workshop Safety Regulation........................................................................................................iv
Format and Practice Marking Scale………………………………...…….……………............vi
Experiment 1: Calibration Of A Pressure Gauge Against Dead Weight Tester ...….............1
Experiment 2: Control Valve Operation By I/P Converter .......................................................6
Experiment 3: To Control Pressure In Process Pipe Through On/Off Action Controller ......9
Introduction of Programmable Logic Controller……………….……………................….......15
Experiment 4: Apply The Basic Function Using PLC- CJ2M Trainer Kit……..…………….39
Experiment 5: Apply The Timer Using PLC- CJ2M Trainer Kit ………………….…………43
Experiment 6: Apply The Counter Function Using PLC- CJ2M Trainer Kit………….…….48

DEPARTMENT OF PETROCHEMICAL ENIGINEERING Page ix

EXPERIMENT 1 : CALIBRATION OF A PRESSURE GAUGE GP313

AGAINST DEAD WEIGHT TESTER

Objectives:

1. To test the pressure gauge for calibration accuracy using dead weight
tester

2. To investigate the linearity of the pressure gauge

Apparatus:

1. Dead Weight Tester
2. Pressure Gauge

Introduction:
Nagman‘s Dead Weight Testers Model H3000 Series provides a means of testing
pressure indicating instruments for calibration accuracy. The design uses the piston gauge
principle in which an applied pressure within the system balances a known mass applied
to a piston of known effective area. In the comparison mode the DWT can be used to
compare the readings of a test instrument directly with those of a standard instrument.

The DWT comprises base plate / manifold with one or two piston assemblies (depending
on the pressure range of the particular model), test port for instrument mounting, a fluid
reservoir and a ram screw for pressure generating mechanism and priming pump (for
priming and generating of minimum pressure), set of stainless steel weights of known
mass. Standard accessories provided with the DWT.

The DWT has four adjustable feet to enable the unit to be correctly leveled. This ensures
that the pistons are in the vertical plane, essential for both accuracy and reliable
performance.

2.0 Safety symbols
This manual contains a number of safety symbols designed to draw your attention to
instructions that must be followed when using the instrument, as well as any risks involved.

1

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 1 : CALIBRATION OF A PRESSURE GAUGE GP313

AGAINST DEAD WEIGHT TESTER

2.1 Safety Instructions

Read this manual carefully before using the instrument. Please follow the
instructions and procedures described in this manual. They are designed to allow
you to get the most out of your Dead Weight Tester and avoid any personal injuries
and /or damage to the instrument. Failure to observe the below warnings could
result in serious damage to Piston / Cylinder assembly.

Warning
 Do not remove base plate / manifold from pistons when pressure is
applied.
 Do not use spanners on Quick fit adapters (finger tight all the way
down is all that is required).
 Do not touch piston operating surfaces (they could become damaged).
 Do not remove cover.
 Do not transport Dead Weight Tester with oil in the system.
 Do not rotate weight stack in the top or bottom position, especially
by motor.
 Do not allow fluid level to fall below the recommended minimum level.

3.0 Installation

Testing a pressure gauge for calibration accuracy using dead weight tester

3.1 Filling the Fluid reservoir

Fill the fluid reservoir as follows: 2

1. Place the DWT on a rigid clean surface with its front less than 40mm from the
edge to allow for the rotation of the capstan.

2. Unscrew and remove the reservoir valve screw and spring
3. Remove the reservoir cover and fill the reservoir with fluid to the top of the

nut on the center of the reservoir.
4. Replace the reservoir cover.

3.2 Leveling

1. Place the DWT in the surface and adjust the four adjustable feet as per the
spirit level the bubble must be in the center of the small black circle and the
DWT must not rook.

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 1 : CALIBRATION OF A PRESSURE GAUGE GP313

AGAINST DEAD WEIGHT TESTER

4.0 Priming

1. Unscrew fully the Ram screw
2. Open the Needle valve of the Reservoir
3. Operate Priming pump to remove the air bubbles in the system.
4. Close the Needle valve.

Procedures:

5.1. Operational Procedure
1. Grasp the weight stack firmly in both hands.
2. Turn the weight stack clockwise (viewed from above) at a speed of approximately

1 revolution per second, taking care to avoid trapping the hands between the
weights and the test instrument.

5.2. Low Pressure Piston Mode (Procedure is same if single piston)

Proceed to operate in this mode as follows:

1. Ensure that priming sequence has been carried out. 3
2. Fit the instrument under test to a Test Station using the appropriate adaptor. Screw

the adaptor to the test station fully clockwise
3. Close reservoir valve screw (fully clockwise)
4. Place the first weight on to the weight carrier.
5. For minimum pressure apply pressure by Ram itself.
6. For maximum pressure apply pressure by priming pump up to 5 KPa then apply

the pressure by Ram screw until the weight floats with the lower edge of the first
weight aligned between the upper and lower mark in the indicator rod.
7. Rotate the weight stack
8. Close the Isolating valve.
9. With the weights floating and spinning, the pressure generated in the system will
be the pressure marked on the weights plus the pressure on the weight carrier.
10. Read the reading from the test station and fill in the table below.
11. Stop the weight stack spinning before adding or removing weights.
12. Increase pressure by screwing the ram in (clockwise).
13. Reduce pressure by screwing the Ram out (anticlockwise).
14. To reduce pressure to zero, screw the Ram fully out and open the isolating valve.
15. Unscrew the reservoir valve four turns anticlockwise.
16. Remove weights from the weight carrier.
17. Place the next weight on the weight carrier.
18. Repeat step 5 to 17.

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 1 : CALIBRATION OF A PRESSURE GAUGE GP313

AGAINST DEAD WEIGHT TESTER

Result/Analysis
Calibration :

% error

Trial Papplied Pmeasured Pmeasured % error = (Observed Value – True Value) x100

(kPa) (Ibin2) (kPa) True Value

1

2

3

4

5

6

7

8

9

10

Conversion Table :

bar inch of
kilopascal

psi (lbf/in2) water
(39.2F,4C) (kPa)

bar 1 14.503 77 401.474 100.0

psi (lbf/in2) 0.068 947 27.680 7 6.894 757
57 1

kilopascal (kPa) 0.01 0.145 037 7 4.014 74 1

4

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 1 : CALIBRATION OF A PRESSURE GAUGE GP313

AGAINST DEAD WEIGHT TESTER

From the results obtained, plot Papplied (kPa) vs Pmeasured (kPa)
i)
ii) discuss on linearity of the output over the range from
minimum to maximum pressure and % error calculated.

Recommendation/ Conclusion:

…………………………………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………….

5
DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 2 : CONTROL VALVE OPERATION BY I/P CONVERTER GP313

Objectives:

1. To demonstrate the operation of control valve.

2. To calibrate the I/P converter

3. To investigate the linearity and hysteresis of the I/P converter.

Apparatus:

1. Pressure Gauge
2. I/P Converter
3. Miniature Control Valve
4. Pneumatic Bench

Procedures: 6

Calibrate the I/P Converter

1. Connect the compressed air supply to the inlet.

2. Remove the I/P metal cover which seal the zero and span adjusting control on the
I/P converter. Note the span control on the I/P converter is called ‘Range’.

3. Adjust the current output to 0% (4mA). The value of current will be shown on
ammeter.

4. Adjust the zero output on the I/P converter to give a reading of 3psig on gauge
attach at I/P converter. The pneumatic control valve should be just on the point of
closing which that value is 0%.

5. Adjust the current output to 100% (20mA). The value of current will be shown on
ammeter.

6. Adjust the span (Range) control on the I/P converter to give a reading of 15psig
on gauge. The pneumatic control valve should be fully open.

7. Repeat the minimum and maximum setting until no further adjustments of the
zero and span controls is required.

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 2 : CONTROL VALVE OPERATION BY I/P CONVERTER GP313

Operate the Control Valve

8. Adjust the current output to 100% (16mA).

9. Adjust the controller output from 100% to 0% in reduces of 25% and record the
reading pressure on gauge.

Investigate Linearity and Hysteresis

10. Adjust the current output to 4mA.

11. Confirm that the corresponding output from the I/P converter is 3psig on gauge.

12. Adjust the current output to adjust the lifting of control valve from 0% to 100%
in steps of 25% and record the corresponding current from the I/P converter on
gauge. Repeat by reducing inputs to the I/P converter.

13. Plot the input (current value) versus the output (lifting of control valve) for
increasing and declining inputs to determine the linearity and hysteresis of the I/P
converter.

Results/Observations: Current (mA) Pressure (PSIG)
PV (%)
100
75
50
25
0

7
DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 2 : CONTROL VALVE OPERATION BY I/P CONVERTER GP313

Control Valve Current Rising Current Falling
(%)
0 (mA) (mA)
25
50
75
100

Analysis/ Discussion:
1. Explain the purpose of I/P converter in process control.
………………………………………………………………………………………………

2. Explain the purpose of calibration in this process control.
………………………………………………………………………………………............

3. Refer to your plotting graph, discuss how the hysteresis exist in this measurement.
………………………………………………………………………………………............

Recommendation/ Conclusion:
…………………………………………………………………………………………………………………………………………………………………
…………………………………………………………………………………………………………………………………………………………………
………………………………………………………………………………………………………………………………………………………………….

8

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 3 : TO CONTROL PRESSURE IN PROCESS PIPE THROUGH GP313

ON/OFF ACTION CONTROLLER

Objectives:
1. To demonstrate the operation of simple closed loop system.
2. To calibrate the pressure transducer.
3. To measurement the pressure in process pipe.

Apparatus:
1. Electrical Console, PCT10SC
2. Pressure Control Accessory, PCT14

Introduction:
On/off control
The technical term for a control algorithm that merely checks for the process variable exceeding
or falling below setpoint is on/off control. In colloquial terms, it is known as bang-bang control,
since the manipulated variable output of the controller rapidly switches between fully “on” and
fully “off” with no intermediate state. Control systems this crude usually provide very imprecise
control of the process variable. Consider our example of the shell-and-tube heat exchanger, if we
were to implement simple on/off control:

9

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 3 : TO CONTROL PRESSURE IN PROCESS PIPE THROUGH GP313 10

ON/OFF ACTION CONTROLLER

As you can see, the degree of control is rather poor. The process variable “cycles” between the
upper and lower setpoints (USP and LSP) without ever stabilizing at the setpoint, because that
would require the steam valve to be position somewhere between fully closed and fully open.

Procedures:

Calibrate the Pressure Transducer

1. Ensure the manual control valves of V1, V2, V3, V5 and V6 in fully closed
position.

2. Open the manual control valve of V4.

3. Connect the pressure sensor to the input of signal conditioner and the voltmeter to
the output from the signal conditioner as shown in the equipment set-up diagram
in Figure 2.0.

4. Connect the compressed air supply to the inlet.

5. Adjust the V2 until it fully closed and gauge P5 will indicate the equivalent or
almost to 0psig (The pressure in the system will be atmospheric).

6. Use the trim tool to adjust the zero control on the conditioning module to give
reading of 0.00V on the voltmeter.

7. Set the pressure in the system to maximum required which 8.0psi on gauge P5 by
adjusting valve V2.

8. After the pressure is steady, adjust the span control on the conditioning module to
give a reading of 1.0V on the voltmeter.

9. Repeat the minimum and maximum setting until no further adjustments of the
zero and span controls is required.

Operate the ON/OFF Action Controller

10. Ensure the manual control valve of V4 and V6 in fully closed position.

11. Open the manual control valve of V3 and V5.

12. Connect the power inlet of air compressed to relay output of controller as shown
in the set-up diagram in Figure 3.0.

13. Adjust the V1 to give 22psig on gauge P1.
14. To entry the controller’s configuration mode, please refer to set-up mode note.

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 3 : TO CONTROL PRESSURE IN PROCESS PIPE THROUGH GP313

ON/OFF ACTION CONTROLLER

15. Set the controller’s set point to 50% and ON/OFF differential to 10%.

16. Adjust the V2 for small volume of pressure from inlet and record the condition of
air compressor either turned ON or OFF, and reading of gauge P5 every 5
seconds.

17. Change the controller’s set point to 40% and ON/OFF differential to 5%.

18. Adjust the V2 for small volume of pressure from inlet and record the condition of
air compressor either turned ON or OFF, and reading of gauge P5 every 1
minutes.

19. Sketch the graph Pressure and ON/OFF compressor condition versus time
domains.

Results/Observations:

Set point: 50% ON/OFF differential: 10%

Time (sec) Pressure (Psig), P5 ON/OFF Air compressor

0

5

10

15

20

25

30

35

40

45

50

55 11

60

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 3 : TO CONTROL PRESSURE IN PROCESS PIPE THROUGH GP313

ON/OFF ACTION CONTROLLER

Set point: 40% ON/OFF differential: 5%

Time (sec) Pressure (Psig), P5 ON/OFF Air compressor

0

5

10

15

20

25

30

35

40

45

50

55

60

Analysis/ Discussion:
1. Explain the effect to ON/OFF control if changing the value of ON/OFF differential.

......................................................................................................................................................
2. Explain the function of transducer in this experiment.

......................................................................................................................................................

12

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 3 : TO CONTROL PRESSURE IN PROCESS PIPE THROUGH GP313

ON/OFF ACTION CONTROLLER

Recommendation/ Conclusion:
……………………………………………………………………………………………………………………………………………………………….…
………………………………………………………………………………………………………………………………………………………………….
………………………………………………………………………………………………………………………………………………………………….

Figure 2.0

13

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

EXPERIMENT 3 : TO CONTROL PRESSURE IN PROCESS PIPE THROUGH GP313

ON/OFF ACTION CONTROLLER

Connect to power inlet of compressed air

14

Figure 3.0

DEPARTMENT OF PETROCHEMICAL ENGINEERING | POLITEKNIK KUCHING SARAWAK

PROCESS INSTRUMENTATION & CONTROL GP313

INTRODUCTION

Programmable logic controllers, also called programmable controllers or PLCs, are solid-state
members of the computer family, using integrated circuits instead of electromechanical devices
to implement control functions. They are capable of storing instructions, such as sequencing,
timing, counting, arithmetic, data manipulation, and communication, to control industrial
machines and processes. Figure 1.1 illustrates a conceptual diagram of a PLC application.

Figure 1.1: PLC conceptual application diagram. 15

Programmable controllers have many definitions. However, PLCs can be thought of in simple
terms as industrial computers with specially designed architecture in both their central units (the
PLC itself) and their interfacing circuitry to field devices (input/output connections to the real
world).

INPUT DEVICES

Intelligence of an automated system is greatly depending
on the ability of a PLC to read the signal from the various
types of automatic sensing and manual input field devices.

Push buttons, keypad and toggle switches, which form the
basic man-machine interface, are types of manual input
device. On the other hand, for detection of work piece,
monitoring of the moving mechanism, checking on
pressure,
Figure 1.2: Small PLC with built-in
I/O and detachable, handheld
programming unitD. EPARTMENT OF PETROCHEMICAL ENGINEERING|POLITEKNIK KUCHING SARAWAK

PROCESS INSTRUMENTATION & CONTROL GP313

liquid level and many others, the PLC will have to
tap the signal from the specific automatic sensing
devices like proximity switch, limit switch, photo
electric sensor and so on. Types of input to the
PLC would be of ON/OFF logic or analogue.
These input signals are interfaced to PLC through
various types of PLC input module.

Figure 1.3: PLC system with high-
density I/O

(64-point modules).

Figure 1.4: Input device for PLC

OUTPUT DEVICES 16

An automatic system is incomplete and the PLC system is virtually paralysed without means of
the interface to the field output devices. Some of the most commonly controlled devices are
motors, solenoids, relay indicator, buzzers and etc. Through activation of motors and solenoids
the PLC can control from a simple pick and place system to much complex servo positioning
system. These type of output devices are mechanism of an automated system and so its direct
effect on the system performance.

However, other output devices such as the pilot lamp, buzzer and alarms are merely meant for
notifying purpose. Like input signal interfacing, signal from output devices are interfaced to the
PLC through the wide range of PLC output module.

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PROCESS INSTRUMENTATION & CONTROL GP313

Figure 1.5: Output Device for PLC

Principle Operation of PLC
A programmable controller, as illustrated in Figure 1.6, consists of two basic sections:

 the central processing unit
 the input/output interface system

Figure 1.6: Programmable controller block diagram.

The central processing unit (CPU) governs all PLC activities. The following three components, 17
shown in Figure 1.7, form the CPU:

 the processor
 the memory system

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PROCESS INSTRUMENTATION & CONTROL GP313

 the system power supply

The operation of a programmable controller is
relatively simple. The input/ output (I/O)
system is physically connected to the field
devices that are encountered in the machine or
that are used in the control of a process. These
field devices may be discrete or analog
input/output devices, such as limit switches,
pressure transducers, push buttons, motor
starters, solenoids, etc. The I/O interfaces
provide the connection between the CPU and
the information providers (inputs) and
controllable devices (outputs).

Figure 1.7: Block diagram of major CPU components

OMRON PLC - Hands-On Programmable Logic Controller Training With the PLC

PLC Electrical Wiring Example

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PROCESS INSTRUMENTATION & CONTROL GP313

Window Based Programming Software CX-Programmer -OMRON
To write our programming to PLC, we have many ways to doing it. We can use the methods
below:

 Tech pendant
 EPROM writer
 Computer (using software)
For our course, we prefer to use window based programming software CX-Programmer to write
ladder program to our PLC. To execute this program, double click on CX-Programmer icon like
below figure.

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Then the CX-Programmer interface will be appear as shown below.

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Start up with CX-Programmer

1. Select New Project from File menu (Figure 1). You should get the pop-out window as in
Figure 2 below. Select the correct Device Type which is CJ2M. You can also insert your own
name for the Device Name if required.

Figure 1

Figure 2 21

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2. Click the Settings to ensure that the selected CPU type is CPU11, then click OK to continue,
in Figure 3

Figure 3

3. Now, ensure that the “Network Type” is set to “USB”, as shown in Figure 4. Click “OK” to
continue. You should get the next window with the Ladder window, as shown in Figure 5
below.

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Figure 3

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PROCESS INSTRUMENTATION & CONTROL GP313

Figure 4
4. We will now test the communication link between the PLC and the host PC. You should

see that the status of the PLC is ‘Offline’ if there is no communication link between the
PLC & PC. Ensure that the USB cable is connected between the PLC CPU unit and the
computer USB port. Switch On power supply power to the PLC unit. Your PC must be
able to detect the PLC USB communication, if not the necessary USB driver may need to
be installed.
5. Now, select the PLC menu from the tool bar and selects “Work Online”, as shown in
Figure 5 You should get the pop out menu as in Figure 6.

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Figure 5
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Figure 6

6. We assumed that your PLC is connected to the computer’s USB. Click OK to continue.
Then you should obtain the window’s communication status or PLC mode as in Figure 7
with the current communication status shown. The status can be of Run or Stop/Program
mode. This shows that the PLC has established a communication link with the host PC.

If the current PLC mode is in Run mode, then it shows that the PLC is executing the
program which is residing or pre-programmed into its memory. This manual will briefly
shows you some example how to change the PLC mode, as discussed later.

Figure 7

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TUTORIAL EXERCISE : Programming, Downloading & Executing A Sample Basic I/O
Program Using The PLC-PC Interface

We will try to enter a simple basic I/O ladder diagram using the CX-Programmer software.

Program name: Basic I/O

Description: To read input value from the input switches (SW00~SW15) & output the result to
lamps (L00~L15).

Ladder Program: As shown in Figure 8.

Figure 8
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a. Launched the CX Programmer software. You should get the CX-Programmer Window display

interface as in Figure 9 below:

Figure 9
b. Go to File → New, as shown in Figure 10. The windows as in Figure 11 should pop up.

Figure 10

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Figure 11
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c. Ensure that the ‘Device Type’ is set to CJ2M, click Device Type ‘Settings’ and choose
CPU11. Click OK to proceed. Also ensure that the ‘Network Type’ is set to ‘USB’, as shown

in Figure 12 to Figure 14.

Figure 12

Figure 13

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Figure 14

d. Now, ensure that the “Network Type” is set to “SYSMAC WAY”, as shown in Figure 14.
Click “OK” to continue. You should get the next window with the Ladder window, as shown
in Figure 15 below.

Figure 15 28

e. Now, move your mouse cursor to the ‘Open Contact’ drawing tool & click on it once, as
shown in Figure 16.

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Figure 16

f. Then, move your cursor to the position on the ladder working where you want to place the
symbol (as dictated by the blue color highlight box). Click once to place that particular
component. You should get the pop up message window, as shown in Figure 17 below.

Figure 17

g. Key in the designated bit address, for example 0.00 for input switch SW00. Click ‘OK’ to
continue. You will get another comment window that required a text comment for that
previous input symbol (Figure 18). You can just ignore it and click ‘OK’ to continue or type
in the comment and click ‘OK’. This will put a NO (normally open) switch on to the PLC
input bits, as in Figure 19

Figure 18

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Figure 19

h. The “blue-box” will jump to the next ladder location & request the next input. Select the
“new coil” which is a normally-open output symbol using the cursor & move it to the
particular place within the blue box. (Figure 20)

Figure 20 30

i. Again you are required to key in the output address bit allocated for this lamp. Key in 1.00
& click OK. Then fill in the comment box and press ‘OK’ to continue, as shown in Figure
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Figure 21
j. Continue to draw the ladder diagram by moving on to the next ladder network downwards.

Just select the “cursor” label and point and click to the next beginning section of the lower
network, as in Figure 22.

Figure 22
k. Continue drawing the ladder diagram until you have reached the last entry. Figure 23 shows

the complete ladder diagram for this basic I/O program.

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Figure 23 32

l. Once you have finished the last line, you can “optionally” input an ‘END(01)’ function to
tell the compiler that you program has ended. To do this, move your cursor to the PLC New
Instruction icon and click on it, as shown in Figure 24. Key-in ‘END’ and click OK to

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finish, as shown in Figure 25. It is ok if you do not wish to input this ‘END’ instruction
when using this CX-Programmer to create your ladder diagram program.

Figure 24

Figure 25
m. Save the project by going to File →Save As. Enter the filename BasicIO.
n. Go to the PLC toolbar, selects Work Online. You will see a message window, click ‘YES’

to continue the connection to the PLC, as shown in Figure 26.

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Figure 26
o. Once the connection is OK (the PLC will either be in the RUN mode or STOP/Program

mode, then go to PLC →Transfer →To PLC, as shown in Figure 27.
In the “Download Options” menu, just select the Program(s) option and click ‘OK’ When
the window in Figure 28 appears, just click ‘Yes’. The file will be downloaded to the PLC,
as shown in Figure 29 ~ Figure 30. If there is any error message, just clear them &
download again.. The file will be downloaded to the PLC, as shown in Figure 28 ~ Figure
30.

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Figure 27

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Figure 28

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Figure 29

Figure 30
p. To run the downloaded program, go to PLC →Operating Mode → select RUN, as shown

in Figure 31.

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Figure 31
When you see the pop up menu as in Figure 32, just click ‘Yes’ to continue. Your PLC will
switch to “run”mode.

Figure 32
Observation: Use the input switches to simulate on/off condition & display the results on the
corresponding lamps.
PROGRAM MONITORING OPTION: As your PLC is in the ‘RUN’ mode, you can also
monitor the status of all the I/O components along with its ladder circuit on the computer
monitor by switching the “MONITOR” option to on. To do this, go to PLC → Monitor →click
‘Monitoring’ , as shown in Figure 33.

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Figure 33
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Figure 34 shows the ladder window in monitoring mode. The green lines indicates current
flowing along that dedicated circuit.

Figure 34

To switch off this monitoring mode, just go to PLC → Monitor → click ‘Monitoring’ , as shown
in Figure 33 above.

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EXPERIMENT 4: APPLY THE BASIC FUNCTION USING PLC- CJ2M GP313

TRAINER KIT

Objectives:
1. To write the ladder diagram program using CX- Programmer.
2. To apply the basic function using CX-Programmer.
3. To upload the program through CX-Programmer to PLC-CJ2M Trainer Kit.

Apparatus:
1. CX-Programmer Software
2. PLC-CJ2M Trainer Kit

Procedures:
1. Open the CX-Programmer program and follow the guide from Introduction of CX-
Programmer note.
2. Write the ladder diagram for execute the basic logic following the truth table below:

Table 4.1 39

3. Upload your ladder program through USB cable to PLC.

4. Ensure the program you write can able to execute the following tasks.

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TRAINER KIT

5. If you program success to execute the following tasks, you need to write your program at
PLC program list and input/output list.

Results/Observations:

Input/ Output List

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