LogixPro

Automatic Control of Batch Mixing

Utilizing PLC Counters

Exercise #1 -- Filling the Batch Mixing Tan
From the Simulations Menu at the top of the screen, Select the Batch Mixing Simulation.
Using your knowledge of PL counters, design a program to meet the following
re!uirements"
#hen the Start switch $%"&'() is pressed, pump P& will *e energi+ed and the tank
will start to fill. ,he pulses generated *y Flowmeter & should *e used to increment
a counter.
#hen the count reaches a -alue where the tank is approximately .(/ full, the
pump is to *e shut0off and and the control panels FULL light is to *e energi+ed.
,he filling operation is to halt immediately if the stop switch is pressed.
#hile testing, utili+e the 12eset Simulation1 and the 12eset ,imers and ounters1
entries in the Simulations menu to re0start your program.
,o make it a little easier to see what is happening with the counter, you might want to add
the following rung to the end of your program.
%f correctly entered, the ,34 $,o B4) instruction will take the integer -alue in the counters
accumulator, con-ert it to Binary oded 4ecimal, and then mo-e $copy) this B4 -alue to
the control panel L54 display $3"6). ,he ,34 instruction can *e located in the
ompute'Math group of instructions in the 5dit Panel. Be sure to alter the Source entry to
match the counter num*er you are using.

Exercise #! -- Em"t#ing the Batch Mix Tan
Modify your program so that it meets the following additional re!uirements"
,he mixer will run for 7 seconds once the tank is full.
#hen the mixing is complete, drain pump P8 is to *e started and the tank is to *e
drained. Flowmeter 8 will *e employed to decrement the existing counter, and
draining will *e allowed to continue till the counters accumulator reaches +ero.
3nce the tank is empty again, pressing the Start switch will cause the se!uence to
repeat.

Exercise #$ -- Continuous %"eration
Modify your program so that the filling and emptying se!uence will repeat continuously
once it has *een started *y the initial pressing of the Start switch.
5nsure that the 2U9 light is energi+ed when the mixer or either pump is running.
,he S,:94B; light should light and the process should halt when the Stop *utton
is pressed.
,he process should restart where it left off if the the Start *utton is pressed
following a Stop.
LogixPro
A&'ance& Automatic Control of Batch Mixing
A Programma(le Batch Mixing )#stem
Exercise #1 -- )ingle Batch Mo&e of %"eration
Using your knowledge of PLs, design a program to meet the following criteria"
*hen the $ "osition )elector )+itch is in "osition ,A,- the *atch mixing
process will run in a single *atch mode. ,he operator may start the *atch mix
se!uence *y momentarily pressing the Start Switch.
3nce a *atch se!uence has *egun, the se!uence may *e stopped and resumed
at any time using the Stop and Start switches.
,he tank is to *e filled with a mixture o*tained from the separate fill lines utili+ing
fill pumps P& and P<. : counter will track the !uantity of product o*tained from
Line & $P&) while the remainder will come from Line < $P<). ,he mixture ratio of the
product will *e controlla*le *y ad=usting the counter>s preset. ,he tank is to *e
filled to the point where the ?i0Le-el sensor goes true.
#hen filling is complete, the Full light will turn 3n. ?eater 3"<'(6 and Mixer 3"<'((
will *e started allowing the mixture to *egin heating. ,hermostat %"&'(< will *e
employed to control the temperature.
,he mixer will continue to run for 6 seconds after the mixture reaches the desired
temperature. #hen the mixer stops, pump P8 will *e used to drain the product
from the tank. ,he tank will *e drained to the point where the Lo0Le-el sensor
trips.
3nce emptied, a new single *atch se!uence may again *e started *y pressing the
Start Switch while the Selector switch is in position 1:1.

Exercise #! -- Multi"le Batch Mo&e of %"eration
5nhance your program to include the following features"
*hen the $ "osition )elector )+itch is in "osition ,B,- the process will
produce multiple *atches, ,he num*er of *atches produced will *e operator
selecta*le, and the current *atch count will *e displayed on the ontrol panel>s
L54 display.
,he operator will *e a*le to enter the desired *atch count using the control panel
thum*wheel switches.
,he operator will *e a*le to set the product ratio *y entering the desired product
one percentage -ia the control panel thum*wheel switches.
%t is your responsi*ility to make the operator interface as simple and fault tolerant as
possi*le.