12

Siemens CPU226
PLC Trainer
Training Manual (A)
Yalong Science & Technology Group Co., Ltd.
PDF "pdfFactory Pro" www.fineprint.cn

Preface
Programmable controller, in brief PLC, and it is a new industrial automatic controller based on
American traditional sequence controllers, microelectronic technology and computer technology in
1960s.
Presently, in China, PLC is used widely in steel and iron, petroleum, chemical industry, electric
power, construction materials, machinery manufacture, automobile, light industry, transportation and
environmental protection. With the advancement of industrial control technologies, PLC is widely used
in industrial production process and automatic control fields. To satisfy the requirements in the society,
many colleges, secondary technical and vocational schools have set up the related courses and subjects.
The PLC application technology is a highly practical subject, only through actual and practical
operations, can students really learn the knowledge and skills. We developed a whole set of PLC trainers,
including PLC controller and 6 types of training models, as well as related ladders and instructions for
students to learn how to make programming. Students also can design and make ladders and programs
according to teaching models.
The controller is Siemens S7-200 CPU226 PLC, compact and reliable, easy to operate. Now we
developed AC 3-phase motor control, automatic washing machine control, stepper motor control,
traffic lighting control, 4-floor elevator control and electrical plating automatic production line control
and so on. The students, through training, can learn and understand various instructions and functions,
to improve programming skills and PLC application capabilities.
The manual is divided into 3 parts, part 1 is to introduce S7-200 programming software, part 2 is
for programming training, and part 3 is to introduce PLC application training.

Content
PART 1. STEP7-MICRO/WIN32 PROGRAMMING SOFTWARE ................................... 1
1. STEP7-MICRO/WIN32 SOFTWARE ............................................................................... 1

2. STEP7-MICRO/WIN32 BRIEF INTRODUCTION .............................................................. 4
3. PROGRAMMING AND OPERATION ................................................................................... 8
4. STEPS .........................................................................................................................11
5. PRECAUTIONS .............................................................................................................11
PART 2. PLC BASIC INSTRUCTION AND TRAINER ..................................................12
1. YALONG PLC TRAINER ...............................................................................................12

2. SIEMENS S7-200 PLC..............................................................................................12
3. PLC BASIC INSTRUCTION TRAINING .............................................................................12
PART 3. PLC TRAINING.................................................................................................16
TRAINING 1. AUTOMATIC WASHING MACHINE CONTROL...................................................16
TRAINING 2. 3-PHASE MOTOR SEQUENCE CONTROL .........................................................20
TRAINING 3. STEPPER MOTOR CONTROL..........................................................................23
TRAINING 4. TRAFFIC LIGHTCONTROL ............................................................................27
TRAINING 5. 4-FLOOR ELEVATOR CONTROL.....................................................................30
TRAINING 6. ELECTRICAL PLATING PRODUCTION CONTROL..............................................34
TRAINING 7. WATER TOWER LEVEL AUTOMATIC CONTROL................................................38
TRAINING 8. AUTOMATIC FORMING MACHINE..................................................................41
TRAINING 9. AUTOMATIC CHARGING SYSTEM ..................................................................44
TRAINING 10. MULTI- LIQUID AUTOMATIC BLENDING .......................................................47
TRAINING 11. AUTOMATIC STEEL ROLLING MACHINE .......................................................50
TRAINING 12. MAILS ALLOCATION MACHINE ...................................................................54
TRAINING 13. IRON TOWER LIGHTING .............................................................................58

Part 1. STEP7-Micro/WIN32programming software
1. STEP7-Micro/WIN32 software
1. Brief description
Programming software STEP7-Micro/WIN32 Version 3.1 is suitable for S7-200 series of PLC
system setting (CPU group), for programs development and real-time monitor operation; Updated
Microwin3.1 SPL V3.1 functions; Toolbox provides users instruction and touch screen TP070 group
software, SP1 and Toolbox software. STEP7-Micro/WIN32 software is based on Windows application
software.
2. Programming software installation
Programming software STEP7-Micro/WIN32 can be installed on PC(man and computer) and
SIMATIC programming PG70. Installation methods are lower:
(1) Installation
PC486 or higher, can install Windows 95 and above operating systems, memory: 8MB and above,
hard disc: 50MB and above.
(2) Installation methods
Click Microwin 3.1Microwin 3.1 SPLToolboxMicrowin 3.11, to install.
3. Establish S7-200 CPU communication
S7-200 CPU and PC communication connection is by special PC/PPL cable, or by MPI card and
common cables. Take PC as the main controller, through PC/PPL cable or MPI card and or some PLC
connection, for equipments communication.
(1) PC/PPL communication
PC/PPL supports PC, according to PPL communication protocol setting special cable, with
communication modules, external braud rate setting switches and the two terminals are RS-232 and
RS-485 ports. PC/PPL RS-232 terminal is connected to computer RS-232 communication port COM1
and COM2 ports, PC/PPL terminal (RS-485) is connected to S7-200 CPU communication port.
(2) MPI communication
MPI card provides a RS-485 terminal port, for straight and network connection, when MPI
communication is established, you can make STEP7-Micro/WIN32 connections to many other
equipment networks, each S7-200 can be the main controller and has each own address. Install MPI
card in PC and PCL, then start installation, the setting file is stored in Windows directory, CPU and
PCRS-485 ports are in cable connection.
(3) Communication parameters setting
The communication parameters setting include S7-200 CPU address, PC software address and
PORT setting. Shown in Diagram1-1-1 is communication parameters setting dialogue block. drag
monitor menu, click communication (M), to show communication parameters. The system programmer

local default address is 0. Remote address is according to actual PC/PPL and PLC address setting, when
other communication parameters modification is needed, double click PC/PPL Cable icon, to modify
setting communication parameters.
Double click
Diagram1-1-1 communication parameters setting dialogue block

4. S7-200CPU power supply
The first step is to provide S7-200 CPU power supply, in Diagram1-1-2 is DC power supply and
AC power supply.
Before assembly and disassembly, you shall turn off power supply.
Diagram1-1-2 CPU-200 power supply
5. RS-232/PPL multi-cable connection

(1) Connect RS-232/PPL RS-232 terminal (PC) to programming equipment communication port.
(2) Connect RS-232/PPL RS-485 terminal (PPL) to S7-200 terminal port O or port I.
(3) Diagram1-1-3 is RS232/PPL multi-cable connection DIP switch.

Diagram1-1-3 RS232/PPL cable connection
6. Download program
(1) You can click download icon, or in command menu, click File>Download to download program.
Refer to Diagram1-1-4.
(2) Click OK to download programs into S7-200.
If S7-200 is working, if you are reminded that the CPU will be in stop mode, click Yes to make
S7-200 in STOP mode.
Diagram1-1-4 download program
S7-200 CPU working mode
S7-200 modes: stop mode and operation mode. CPU panel LED status displays current operation
mode. In stop mode, S7-200 will not run programs, and then you can download programs, data and
CPU system setting. In operation mode, run S7-200 program.
1. S7-200 operation mode

If you want to start in STEP7-Micro/WIN software S7-200 mode, S7-200 mode switch setting is
TERM or RUN, when S7-200 is in RUN mode, run program.
1. Click operation icon or select PLC>RUN.
2. Click Yes to switch mode.
When S7-200 is working, the CPU will run program to make Q0.0 LED indicator light ON and
OFF.
Click
Diagram1-1-5 S7-200 jump operation mode
You can select Debug>Program Status to monitor program, STEP7-Micro/WIN to display running
result, if you want to stop running program, you can click STOP icon or select menu command
PLC>STOP to make S7-200 in STOP mode.
2. Power supply budget:
The S7-200 CPU has an internal power supply, to provide 24V DC power supply for CPU
self\extended modules and other equipments. S7-200 provides all 5V DC logic power supplies for all
extended modules in the system, you shall make your system configured with CPU 5V power supply,
for further modules, if your requirements are higher than CPU power supply capacities, then you have
to clear off some modules or select a better power supply. S7-200 CPU also provides 24V DCsensor
power supply, and the 24VDC can be power supply for input points, extended modules, relay coils or
other equipments, if the equipment power consumption exceeds sensor power supply budget, you have
to prepare another external 24VDC power supply power supply for the system.
2. STEP7-Micro/WIN32 brief introduction
Programming software step 7-micro/win32 basic function is to help users to complete PLC
application programs development, in PLC parameters setting, encryption and monitor functions.
STEP7-Micro/WIN32 programming software, in off-line mode, can be used for program input,
edit, and translation functions.
Programming software, in on-line modes (PLC and programming PC are connected), the upload,
download, communication test and real-time monitor functions are available.
STEP7-Micro/WIN32 window group and functions

STEP7-Micro/WIN32 window main menu includes file, edit, monitor, PLC, debugging, tools,
windows help, line is tools bar shortcut button, other is window information display, as shown in
Diagram 1-2-1.
Window information display is for program data display, browse bar, instruction tree and output
windows display. When in monitor menus, tools bar, browse bar and instruction tree can be shown in
windows; you can select tools bar output windows, to display output windows block. Under the output
windows, is status bar, to show STEP7-Micro/WIN32 status information.
Diagram1-2-1 STEP7-Micro/WIN32window group
View -- common programming buttons:
View-- program block, icon, table, status diagram, data block, system block, intercross reference and
communication button.
Tools-- instruction guide, TD200 guide, position control guide, EM253 control panel and demodulator
guide button;
Instruction tree-- all project objects in current program editor (LAD, FBD or STL), an instruction tree
window. You can operate on all open projects and objects in the branches of the project.
Status diagram-- allow program input, output or variables input, to monitor its status.
Output window-- output information during program or instruction translation. When lists of program
errors are output, it will display corresponding program networks in the program editor window

automatically.
Status bar-- in Micro/WIN32 operation, the operation status information.
Program editor--project editor (LAD, FBN or STL), local variables table and program windows. If
needed, you can extend window, overlay local variables table. Click the labels on the bottom of the
program editor window, and can move among main programs, subprograms and interrupt programs.
Local variables table-- definite and assign local variables (variables in subprograms and interrupt
programs).
Menu
The common or tools shortcut buttons (as shown in Diagram1-2-2). You can select items in the
tools bar.
Diagram1-2-2 tools bar
compile upload Sort Descending
Options
Undo Compile All Dowenload

Sort Descending
Diagram1-2-3 standard tools bar
Toggles Network Comment

Toggle Bookmark
Delete Network
Inser Network
Toggles Dou Comments Toggle Bookmark
Diagram1-2-4 common tools bar

Chart Status Singel Read
Stop Unforce All
Run
Program Status Write All Unforce
Force
Diagram1-2-5 debugging tools bar

Contact-F4 Box-F9
Line Operation
Coil-F6
Diagram1-2-6 LAD instruction tools bar
Allow you to use mouse or keyboard to run instructions. And you can select tools menu, modify
according to your requirements.
1. Main menu and submenu status information
(1) File
Create, open, close, save, save as, import, export, upload, download, page setting, print and
preview.
(2) Edit
Cancel, cut, paste, all select, insert, delete, search, replace, for program modification operation.
(3) View
Monitor menu functions:
You can select program datadisplay window to display various program editors. Such as
statement table (STL), ladder (LAD), function Diagram (FBD);
You can make data block, icon table setting;
Make setting on system block intersection, communication parameters;
Tools bar can be used to select browse bar, instruction tree and output windows;
Zoom in/out;
Program block properties setting.
(4) PLC
PLC menu is used to establish PLC on-line communication, such as to use software to change PLC
work mode, to edit users programs, to clear PLC programs and reset power supply, display PLC
information and make PLC setting.
(5) Debug
Debugg menu has items such as on-line dynamic debugging, single scan, multiply scans, and
program status. Select submenu and monitor menu zoom in/out function.
(6) Tools
Tools menu has a complicate instruction guide (PID, NETR, NETW, HSC instructions) and TD200
setting guide, and TP070 (touch screen) setting.
(7) Windows
Windows menu is used to select window display and display format (ladder, statement table and
various tables).
(8) Help
Help menu can provide S7-200 instruction system and programming software information, has

on-line help, search, access, download functions.
2. Tools bar
Tools bar is in mouse operation, to transform common STEP7-Micro/WIN32 operation in button
form setting into tools bar form setting. You can use Tool bars in View menu to display or hide 4
tools bar: Standard, Debug, common and Instruction tools bars.
3. Navigation Bar
Navigation Bar is a programming button to switch window functions quickly. In the bar,
Navigation Bar in Viewmenu is used to select whther it is open. Navigation Bar incorporates
program block (Program Block), Symbol Table, Status Chart, Data Block, System Block, Cross
Reference, and Communication Icon. Click a button, and then the main window is switched. All
operations in Navigation Bar can be done in Instruction Tree window or View menu.
4. Instruction tree
Instruction tree is a programming instruction tree table. You can use (Instruction Tree) in
Viewmenu to select, shortcuts are in programming and PLC instructions.
5. Output window
Output window is used to display program translation results, such as program block and block
sizes, errors and codes etc. In addition, from Navigation Bar, click system block and communication
button, you can set PLC parameters. Such as setting communication braud rate, PLC power supply data,
memory range, setting input filtering parameters setting, passwork setting and so on.
3, Programming and operation
(1) Project creation (users program)
1, Open created project file

Open created project:
(1) Open file menu, to current project, and open file;
(2) From the file name opened, in current project file list, select. Or in Windows source manager,
tofind a proper directory, project file is avaible in extended file name.
2, Create a new project (file)
Create a new project:
(1) Click create shortcut button;
(2) click create button to create a new file;
(3) Click program block icon, to create a new STEP7-Micro/WIN32 project.
3, Confirm CPU types
Open a project, before writing a program, you can select PLC types. You can confirm CPU types.
in instruction tree, right click project 1(CPU), in pop up dialogue block, left click types (T)pop up
PLC typesdialogue block, select PLC type, and confirm;use PLC menu to select types (T), pop up
PLC type dialogue block, then select a correct CPU type.

(2) Ladder editor
1, Ladder fundamental
The current can flow through a switch, and the coil represents current charged relay or output;
instruction box represents instruction box functions when current flows.
2, Ladder layout principle
The network shall start from contacts, coil or instruction box..
Attention: in each users program, 1 coil or instruction box only can be used for one time, more
coils in serial connection are not allowed.
(3) Ladder input instruction (programming elements)
1, Enter ladder (LAD) editor

In drag monitor menu, click ladder (L), to enter ladder edit status, and click program edit window
display ladder edit icon.
2, Programming elements inputmethods
Programming elements are coils, contacts, and cables. It is normaly is sequence input, you can put
programming elements in the position of the cursors (input instruction), or you can move cursor to any
position to input programming elements.
1
Network1
Network Title(Single row)
2
Network2
Diagram1-3-1ladder instruction
The programming elements input can be done by double click on instruction tree, drag and click
tools bar shortcut keys F4 (contacts), F6(coil), F9(instruction box), or double clilck instruction tree to
select input programming software.
The tools bar has 7 programming keys, the first four are to connect cables, and the latter 3 are
contacts, coil, and instruction box.
The programming elements input is in program edit window, move cursor onto the elements, then
input programming elements. The programming elements input is two methods. By mouse and left
key to input programming elements, for example, input contacts elements, move cursor into
programming area, left key click tools bar contacts button, to show a menu, use mouse to click the
programming elements, push return key, input programming elements, then click programming

elements???, input number; By function keys (F4, F6, F9), shift key and return key to place
programming elements. For example, to place output contacts, push F6 key, pop up a menu, in the menu,
select programming elements (By shift keys to search for programming elements), push return key, the
programming elements will he highlighted, push return key again, cursor will select elements???, input
number, push return key to confirm, then by shift key, to move cursor to next stage, input a new
program. When input address, icon is out of range or and instruction types are not compatible, a read
curve will be shown on bottom.
3, Ladder function instruction input
By instruction tree and double click, input function instruction.
4, Program edit and parameters setting
Cut, copy, paste, insert and delete, character string replace, search.
5, Program translation, upload and download.
(1) Translation
When users program is edited, in CPU menu or tools bar, click translation shortcut button to
carryout program translation, when translation is finished, in output window, translation results are
display, where errors can be shown, you can modify the programs according to prompts, then restart
translation, till no errors in translation.
(2) Download
When translation is finished, click download shortcut button in standard tools bar or drag filemenu,
select download, pop up download dialogue block, select program block, data block, system block to
download, push confirm button, to download the selected content into PLC memory.
(3) Upload
Upload instruction function is tp send PLC programs or data into editor (PC).
To click upload shortcut keys in the standard tools bar or drag file menu select upload, pop up
upload dialogue block. Select program block, data block, system block to upload, in program display
window upload PLC internal program and data.
(4) Program monitor, operation, debugging
1, Program operation
When PLC working mode is in TERM or RUN status, run STEP7-Micro/WIN32 menu command
or click shortcut button to make software setting in CPU working mode.
2, Program monitor
The program editor can monitor programrun process and all elements status and data during PLC
operation.
Ladder monitor function: drag debugging menu, select program status, close contacts. In RUN
status, it can carry out timing and counting process operation, in each cycle, it can output refreshed
status of each element, and it can dynamically display timing, counter current values, in order to
observe program on-line operation dynamically, shown in Diagram 1-3-2.
10

1
Network1 Network Title(Single row)
2
Network2
Diagram1-3-2ladder operationstatus monitor

3, Dynamic debugging
Combined with program monitor operation dynamic display, and analysis on program operation
results, as well as factors effecting program operation, then you can exit program operation and monitor
status, in STOP status, you can carry out program modification, edit, translation, download, monitor
operation, till you obtain the corrent final results.
4, Translation language
SIMATIC instruction and IEC1131-3 instruction select methods, drag tools menu, in pop up
dialogue block, you can select the instruction system.
5, Other functions
STEP7-Micro/WIN32 programming software has PID (close-loop control), HSC (high-speed
counting), NETR, NETW (network communication) and TD200 for guide function.
4, Steps
1. Do electrical circuit wiring.

2. Input STEP7-Micro/WIN32, and translate.
3. Download translated program from PC (STEP7-Micro/WIN32 programming software) to PLC
controller.
4. In PC monitor status, start program debugging.
5. Run program and record.
5, Precautions
1. Turn off power supply before wiring.

2. When circuit is connected, checked by teacher, then you can turn on power supply.
3. All communication cable shall be off.
11

Part 2. PLC basic instruction and trainer
1. Yalong PLC training Trainer
It is composed of Yalong PLC controller and 13 modules.

1. PLC controller: Siemens S7-200 CPU226CN controller, 12V/1A DC power supply. PLC I/O
ports, and knob switches.
2. 13 modules:
(1) Automatic washing machine control (8) Automatic forming machine
(2) 3-phase AC asynchronous motor control (9) Automatic charging system
(3) Stepper motor control (10) Multi-liquid automatic blending
(4) Traffic lightcontrol (11) Automatic steel rolling machine
(5) Elevator control (12) Mails allocator
(6) Electrical plating production linecontrol (13) Iron tower lighting
(7) Water tower level automaticcontrol
3. Controller has wiring sockets. Use cables to connect S7-200 controller.
2.SIEMENS S7-200 PLC brief introduction
Table 2-2-1 SIEMENS S7-200 PLC brief introduction

Digital input 24 input
Digital output 16 output
Digital I/O mapping zone 256 (128 input/128 output)
Analogy I/O maping zone 64(32 input/32 output)
Allowable maximum extended modules 7 modules
Allowable maximum enable modules 7 modules
single-phase counter 6, 30KHz
2-phase counter 4, 20KHz
Pulse output 2 20KHz
Timer quantity 256
1ms 4
10ms 16
100ms 236
Counter quantity 256 (super capacitor and batteries standby)
Time interrupt 2pcs 1ms resolution
Analogy potentiometer 2pcs 8-bit resolution
3. PLC basic instruction training
1. Timer instruction
12

Networkl T37
I0.0
IN TON
+10- PT
Network2
T37 Q0.0
( )
Diagram2-3-1 timer applicationladder
As shown in Diagram 2-3-1, turn on delay timer, timer T37 will start timing, the normaly open
contacts are turned on, drive Q0.0 output; when I0.0 is off, T37 resets, when current value clears, status
bit will be cleared, to recover to initial status. If I0.0 is ON, and is OFF before the time is over, then T37
will reset, and Q0.0 will not output.
2. Counter instruction
Networkl
C1
I0.0
CD CTD
I0.
I0.
I0.1 3 3
2 2
1
CD 0
C
+3- PV Q0.
Diagram2-3-2counter instruction applicationladder andtime sequenceDiagram
When I0.1 is OFF, substractor C1 is changed from 3 to 0.

1 Instruction program
1
Network1
I0.0 I0.1 M0.0

M0.0
2
Network2
I0.2 I0.4 Q0.1

0.3
Diagram 2-3-3 Bit operation instruction application ladder
13

Ladder logic relation: Network 1 M0.0 = (I0.0+M0.0) I0.1
Network 2 Q0.1 = (I0.2+I0.3) I0.4
Network 1: when input I0.0 is set (I0.0=1), input terminal I0.1 is clear (I0.1= 0 I0.1 =1 status),
coil M0.0 is on (internal standard M0.0 is 1), normally open contacts will close, to make I0.0 reset voil
(I0.0=0), M0.0 coil is powered. M0.0 coil is normally contact, I0.1 is ON (I0.1=1 I0.1 =0), M0.0
self-lock circuit is open, coil off.
Network 2: when input I0.2 or I0.3 is set, when I0.4 is clear, and output coil Q0.1 on.
2 Sequence control instruction:
When I0.0 input is on, start S0.0, run program, first step, output Q0.0 is 1(ON red light) Q0.1 is 0
(OFF green light), start timer T37, 2S later, jog jump instruction, S0.1 is 1, S0.0 is 0, program enter the
second step, output Q0.1 is 1 (green light ON), Q0.0 is 0 (red light OFF), in a same time, start timer T38,
2s later, jog instruction, S0.0 is 1, S0.1 is 0, program enter the first step, cycle in this way.
1 16
Network16
Network1
I0.0 0.0 S0.1
S SCR

Network2
2 0.0
Network7
7
SCR
SM0..0 Q0.0
R
Network3
3
Q0.1
SM0..0 Q0.0
S
S T38
Q0.1 IN TON
S
Network8
8 +20- PT
T37
IN TON T38 0.0
+20- PT SCRT
Network4
4
Network9
9
T37 0.1
SCRE
SCRT
5
Network5
SCRE
Diagram2-3-4 sequence control instruction applicationladder
14

3 jump instruction
Netork4
I0.3 4 Network 4
JMP //I0.3 is on, jump to LD I0.3

LBL 4, run JMP 4
Netork5
//Network 5 Network 5
M10.0 Q0.0
Network 5 jumped LD M10.0

Q0.2 Q0.1 Does not run =Q0.0
AN Q0.2
=Q0.1
Netork16 //LBL 4, jump program entry Network16
4
LBL LBL
Network17
Diagram2-3-5jump instruction applicationladder
In Network 4, JUMP makes the program jump over branches (Network 5-15), to LBL 4. N is as
same as the N in LBL command. In the scanning periods during jump, the program stops, and the
status of each out elements in the program never changes, and does not response to any changes in
situations.
15

Part 3. PLC application training
Training 1. Automatic washing machine control
1, Purposes
1, Learn programmer basic operation and programmer input, check and operation.
2, Learn PLC automatic washing machine control fundamental and I/O port connection, PLC
programming and debugging operation.
3, Learn I/O port distribution andI/O port wiringmethods.
4, Learn PLC programming language.
2, components
1, Yalong PLC- controller.

2, Yalong PLC- automatic washing machine control.
3, computer or programmer.
4, Safe cables.
5, PLC serial communication cable.
3, Fundamental
Automatic washing machine working modes:

(1) Push start button, water supply solenoid valve open, water supply indicator light ON.
(2) Push upper limit button, water supply indicator light OFF.
(3) A few seconds later, drain light is ON, drying tank light will be ON and OFF.
(4) Push limit button, drain light OFF, water supply light ON.
(5) Repeat (1) - (4) process
(6) When you push limit button for the third time, buzzer light is ON, 5s later, it is OFF, the whole
process will be fnihsed.
(7) In operation process, push stop button to finish process.
(8) Manual drain button is an independent operation command, push manual drain, and push limit
button.
16

4, I/O
Table 3-1-1 automatic washing machine I/O
Input Output
I0.0 Start button Q0.0 Water supply indicator light
I0.1 Stop button Q0.1 Drain indicator light
I0.2 Upper limit button Q0.2 Forward blend indicator light
I0.3 Lower limit button Q0.3 Back blend indicator light
I0.4 Manual drain button Q0.4 Drying indicator light
Q0.5 Buzzer indicator light
5, I/O circuit
Water supply indicator light
Start
I0.0 Q0.0
Drsin indication light
Stop Q0.1
I0.1 For ward blend
indicator light
Upper limit Q0.2
Back blend
I0.2 indicator light
Q0.3
Lower limit Drying indicator light
I0.3 Q0.4
Buzzer indication light
Drain Q0.5
I0.4
- +
1M 1L
+ -
24V 2M 2L
12V FU
CPU 226 CN
Diagram 3-1-1 automatic washing machine controlI/O circuit

6, Steps
1, Turn off PLC controller power supply, do wiring according to Diagram 3-13-2, do not short
circuit 12V and 24V power supply.
2, Insert power supply cable into PLC controller power supply socket, and insert 220V power
supply socket.
3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer,
download programs into PLC then put PLC in RUN status.
4, Turn on 2.7(2.4, 2.5, 2.6 are off).
5, Training operations are according to working modes operation.
7, Circuit
Connect automatic washing machine control circuit according to Diagram 3-1-2.
8, Questions
1, Washing machine rotates forward, back time are 10s, cycle for 5 times.
17

YL-PC Automatic Washing machine PLC Panel
IN Water
OUT
Forward 1L
upplimit Lowerlimit Drain spply blend Dry Q0.0 Q0.1 Q0.2 Q0.3 2 Q0.4 Q0.5
COM
Start Stop COM Drain Back Buzzer

blend
- 12V +
COM 1M COM 2M M L+
I0.0 I0.1 I0.2 I0.3 I0.4
Diagram 3-1-2 automatic washing machine circuit
19

Training 2, 3-phase motor sequence control
1, Purposes
1, Learn 3-phase motor sequence control fundamental.

2, Learn ladder programming methods and learn instruction programs.
3, Learn I/O port distribution andI/O port wiringmethods.
4, Understand programmer basic operation and programmer input, modification, check and operation.
2, Cmponents

2, Yalong PLC3-phaseasynchronous motor sequence control.
3, Computer or programmer.
4, Safe cables.
3, Fundamental
3-phase motor sequence control:

(1) Turn on forward switch SB1, then push SB1, motor will Y- start, Y operation, 5s later, it starts
operation.
(2) Turn on stop switch SB3, then push SB3, motor will stops.
(3) Turn on back switch SB2, then push SB2, motor will Y- start, Y operation, 5s later, it starts
operation. When it moves forward, it cannot move back; when it moves back, it cannot move forward. Positive
back switching is only available by stop.
(4) Turn on stop switch SB3, then push SB3, motor stops.
4, I/O
Table 3-2-1 3-phase motor sequence control I/O

Input Output
I0.0 Forward start switch Q0.0 KM1
I0.1 Back start switch Q0.1 KM2
I0.2 Stop switch Q0.2 KM
Q0.3 KMY
20

5, I/O circuit
KM1
SB1 Q0.0
I0.0
KM2
SB2
I0.1 Q0.1
KM
SB3 Q0.2
I0.2
1M KMY
Q0.3
24V 2M
CPU 226 CN
1L
12V FU
Diagram 3-2-13-phase motor sequence controlI/O circuit
6, Steps
1, Turn off PLC controller power supply, do wiring according to Diagram 3-13-2, do not short circuit 12V
and 24V power supply.
2, Insert power supply cable into PLC controller power supply socket, and insert 220V power supply socket.
3, Turn on PLC controller power supply, put PLC in STOP status, by computer or programmer, download
programs into PLC then put PLC in RUN status.
4, Turn on 2.6 (2.4, 2.5, 2.7 are off).
5, Operation and observe.
7, Circuit
Connect 3-phase motor sequence control circuit shown in Diagram 3-2-2.
8, Questions
1, Rrequirements: forward start operation for 30s, then stop for 2s, start back operation for 30s, then stop for
2s, repeat.
21

YL-PC Motor Control PLC Panel
OUT
KM1 KM2 1L 0.0 Q0.1 Q0.2 Q0.3
COM
IN
KM KMY
SB1 SB2 SB3 COM
- 12V +
COM 1M COM 2M M L+
I0.0 I0.1 I0.2
Diagram 3-2-23-phase motor sequence control circuit
22

Training 3, Stepper motor control
1, Purposes
1, Learn stepper motor fundamental.

2, Understand how to use stepper ladder instruction programming methods.
3, Understand ladder programming methods and learn instruction programming methods.
4, Learn I/O port distribution and I/O port wiring.
5, Learn programmer basic operation and programmer input, check, modification and operation.
2, Components

2, Yalong PLC- stepper motor demonstration board.
4,Safe cables.
3, Fundamental
1, Stepper motor control requirements are following:

The stepper motor control mode is in 4-phase, 4-step control, each step is 15 rotation, each cycle,
24 steps. When motor is in forward rotation, the power supply time sequence:
DC CB BA AD
When the motor is in back rotation, the power supply time sequence:
AB BC CD DA
2, Stepper motor has some switches, the functions are following:

(1) Start/stop switch--control stepper motor start or stop
(2) Forward /back switch--control stepper motor forward or back
(3) Speed switch--control stepper motor continuous operation and jog operation,
S Stage is jog operation.
N3 Stage is high-speed operation.
N2 Stage is middle-speed operation.
N1 Stage is low-speed operation.
(4) Jog button switch, push jog button 1 time, motor rotates for one step.
4. I/O
23

Table 3-3-1 stepper motor I/O
Input Output
I0.0 Forward/back button Q1.0 A phase
I0.1 Speed 3 stage Q1.1 B phase
I0.2 Speed 2 stage Q1.2 C phase
I0.3 Speed 1 stage Q1.3 D phase
I0.5 Manual button
I0.6 Start/stop button
I0.7 Jog button
5. I/O circuit
Forward and
Back Rotation A
I0.0 Q1.0
N3 B
I0.1
Q1.1
N2 C
I0.2
Q1.2
N1
I0.3 D
Q1.3
Manul
I0.5
+ -
Start 2L
I0.6
3L 12V FU
S I0.7
CPU 226 CN
- +
1M
24V 2M
Diagram 3-3-1 stepper motor I/O circuit
6, Steps
supply socket.
4, Turn on 2.6, 2.7(2.4, 2.5 are off).
5, Training operation:
(1) Make forward /back switch setting is forward.
(2) Select speed stage N1, N2 and N3, make start/stop switch is in start, observe how the motor
works. Push stop button, to stop the motor.
24

(3) Make forward /back switchsetting is back , repeat (2) operation .
(4) Select S stage, enter manual jog mode, start/stop switch setting is in start, push jog button 1
time, motor will rotate for a step. The start/stop switch setting is in stop, make stepper motor to exit
the work status.
7, Circuit
Connect stepper motor control circuit according to diagram 3-3-2.
8, Questions
(1) How to change stepper motor rotation speed.

(2) Make programs to make stepper motor forward 3.5 circles, back 3 circles.
25

YL-PC Stepping Motor PLC Panel
OUT 2L Q1.0 Q1.1 Q1.2 Q1.3 3L

IN A B
N3 N2 N1 S
COM
Forward
Start
Manul Stop and bach COM
rotation C D
COM 1M COM 2M M L+ - 12V +
I0.0 I0.1 I0.2 I0.3 I0.5 I0.6 I0.7
Diagram 3-3-2 stepper motor control circuit
26

Training 4, traffic lightcontrol
1, Purposes
1, Learn traffic light fundamental and operation methods.

2, Learn PLC control PLC I/O connection methods.
3, Learn ladder programming methods and understand instruction programming methods.
4, Larn programmer basic operation and programmer input, check, modification and operation
operation.
2, Components

2, Yalong PLC-traffic lightcontrol.
3, Programmer or computer.
4, Safe cables.
3, Fundamental
Traffic light control:

(1) The start andstop switch S1, S2, are used to control system start and stop. S3 is a shielded
traffic light.
(2) Traffic light display.
When east & west red light is ON, south & north green light is ON, when green light ON time is
finished, the green light flashes for 3 times, each 1s, then the yellow light is ON for 2s, when the south
& north yellow light is OFF, east & west green light is ON, south & north red light is ON, when east &
west green light is ON, when the ON time is finished, green light flashes for 3 times, each 1s, then the
yellow light is ON for 2s, when east & west yellow light is OFF, the east & west red light is ON, and
south & north green light is ONcycle and cycle in this way.
4, I/O
Table 3-4-1traffic lightcontrol I/O
input output
I0.0 Start witch Q0.0 east & westred light
I0.1 Stop sitch Q0.1 east & westgreen light
I0.2 Shielded switch Q0.2 east & westyellow light
Q0.3 south & northred light
Q0.4 south & northgreen light
south & northyellow
Q0.5
light
5, I/O circuit
27

East and west
red light
S1 I0.0 Q0.0
East and west
S2 green light
I0.1
Q0.1
East and west
S3 I0.2
yellow light
Q0.2
South and north
red light
Q0.3
South and north
green light
Q0.4
1M South and north
2M yellow light
24V
Q0.5
1L
2L 12V FU
CPU 226 CN
Diagram 3-4-1traffic lightcontrolI/O circuit

6, Steps
supply socket.
4, Turn on 2.5 (2.4, 2.6, 2.7 are off).
5, Training operation process:
(1) Turn on S1, observe traffic light change.
(2) Turn on shielded switch S3, observe light change, down S3, observe light change.
(3) Turn on stop switch S2, observe light change, down S2, and observe light change.
(4) Compare switch S2 and S3. S2 makes light OFF, S3 makes light temporarily OFF.
7, Circuit
Connect traffic light control circuit according to Diagram 3-4-2.
8, Questions
Requirements: traffic lightcontrol system 7:00~22:00, it works according to training requirements,

22:00~7:00, it changes direction, cycles (in program debugging, time adjustment is 7:00~22:00, 5 min,
22:00~7:00, 2 min). try to modify control program and debug.
28

YL-PC Traffic Automatic and Manul coutrol PLC Panel
OUT
green yellow red 1L Q0.0 Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.5
East
IN West
S1 S2 S3 COM COM
green yellow red

South
North
I0.0 I0.1 I0.2
Diagram 3-4-2 traffic lightcontrol circuit
29

Training 5, 4-floor elevator control
1, Purposes
1, Learn elevator fundamental.

2, Learn multi-input, multi-output, logic relation complicate program control.
2, Components

2, Yalong 4-floor elevator control.
4, Safe cables.
3, Fundamental
1, Elevator input signals and meaning:

(1) Position signals
Position signalsare from sensor SQ1~SQ4. Normally are OFF, when elevator arrives, it is ON.
(2) Instruction signals
The instruction signals are 1 to 4 (K7~K10), composed of 4 instruction buttons. Push a button,
the elevator will move to the corresponding floor.
(3) Calling signals
There are 6 calling signals, composed of K1~K6 calling buttons. Push the calling button, the
elevator will stop. For example, push K3, the passengers on the second floor want to move upward,
push K4, then the passengers want to move downward.
2, Elevator output signals and meanings
(1) Operation direction signals
The operation direction signals are composed of arrow indicator lights, to display elevator
movement direction.
(2) Instruction register signals
Instruction register signals are composed of L11~L14 indicator lights, the corresponding
instruction signals are received (registered). When instruction is run, signals are off. For example, when
the elevator is on the second floor, push 3, L12 is ON, and the signals are received. The elevator will
move upward to the third floor and stop, then L12 OFF.
(3) Calling register signals
There are 6 calling register signals, composed of L1~L6 indicator lights, similar to the instruction
register signals above.
(4) Floor indication signals
30

The signals are the floor positions, composed of 7-segment numberic display, LEDa~LEDg.
3, Analogy elevator operation principle
(1) Receive and register all instruction signals, calling signals, register and output register signals.
(2) According to registered signals, judge whether elevator is moving upward or downward. For
example, when the elevator in the second floor, instruction is for first floor, then it will move downward;
if instruction is for forth floor, it will move upward.
(3) When the elevator receives signals, then it will decide its direction firstly. For example, when
the elevator is in third floor, you can input second floor instruction signal, forth floor instruction signal,
first floor instruction signal. Otherwise, when the elevator moves downward to second floorupward to
the forth floordownward to the first floor; in a same direction, the elevator will move downward to
the second floordownward to the first floor upward to the forth floor. Obviously, in the second
mode, the travel distance is less, so the efficiency is higher.
(4) Same direction stop function. For example, when elevator is in first floor, instruction is floor 4,
it moves upward, when floor 3 calling signal comes, if it upward (K5), when elevator arrives floor 3, it
stops in floor 3; if calling signal is downward (K4), it cannot stop, and it will return to floor 3 and stop.
4, I/O
Table 3-5-1 4-floor elevator control I/O
input output
I0.0 1-floor position Q0.0 Upward indication
switch SQ1
I0.1 2-floor position Q0.1 Downward indication
switch SQ2
I0.2 3-floor position Q0.2 Upward drive
switch SQ3
I0.3 4-floor position Q0.3 Downward drive
switch SQ4
I0.4 1-floor instruction Q0.4 1-floor instruction register
switch K10
switch K9
switch K8
switch K7
I1.0 1-floor upward Q1.0 1-floor upward calling register
button K1
button K3
button K5
I1.3 2-floor downward Q1.3 2-floor downward calling register
button K2
buttonK4
buttonK6
Q1.6 Door close
Q1.7 Door open
31

5, I/O circuit
SQ1 Q0.0 Upward indication

1-floor position switch SQ1 I0.0
2-floor position switch SQ2
SQ2 Q0.1 Downward indication
I0.1
SQ3
3-floor position switch SQ3 Q0.2 M Upward drive
I0.2
SQ4
4-floor position switch SQ4 Q0.3 M Downward drive
I0.3
1-floor instruction switch K10

K10 Q0.4 1-floor instruction register
I0.4
2-floor instruction switch K9
K9 Q0.5 2-floor instruction register
I0.5
3-floor instruction switch K8 K8 Q0.6 3-floor instruction register
I0.6
4-floor instruction switch K7 K7 Q0.7 4-floor instruction register
I0.7
1-floor upward button K1
K1 Q1.0 1-floor upward calling register
I1.0
Q1.1 2-floor upward calling register
2-floor upward button K3
K3
I1.1
Q1.2 3-floor upward calling register
K5
3-floor upward button K5 I1.2
K2 Q1.3 2-floor downward calling register
2-floor downward button K2
I1.3
3-floor downward buttonK4
I1.4
4-floor downward buttonK6
I1.5
Door close
Q1.6
Door open
Q1.7
1M 1L
24V 2M 12V FU
2L
CPU 226 CN
3L
Diagram 3-5-1 4-floor elevator control I/O circuit
6, Steps
2, Insert power supply cable into PLC controller power supply socket, and insert the other end to
220V power supply socket.
4,Turn on 2.5,2.7(2.4,2.6 turn on ).
5, According to fundamentalworking modes operation, observe results.
32

YL-PC 4-Floor Elevator PLC Panel
OUT 1L Q0.0 Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.5 Q0.6 Q0.7
Y0 Y1 Y2 Y3 Y4 Y5 Y6 Y7
12V 0V Q1.0 Q1.1 Q1.2 Q1.3 Q1.4 3L Q1.5 Q1.6 Q1.7
Y10 Y11 Y12 Y13 Y14 Y15 Y16 Y17
- 12V +
COM 1M COM 2M M L+
X0 X1 X2 X3 X4 X5 X6 X7 I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7
X10 X11 X12 X13 X14 X15 COM I1.0 I1.1 I1.2 I1.3 I1.4 I1.5
Diagram 3-5-24-floor elevator control circuit
33

Training 6, Electrical plating production line control
1, Purposes
1, Learn electrical plating production linesequence controlprocess.

2, Learn I/O distribution and wiring.
2, Components

2, Yalong electrical plating production line control.
4, Safe cables.
3, Fundamental
1, Process:
Upper limit
XK1 XK2 XK3
Left
limit
Lower No.1 No.2 No.3

limit
Origin
Diagram 3-6-1electrical plating production linecontrol work process
On the leftside of the electrical plating production line, insert the workpiece and send automatic
start signal, and it will rise and start automatic movement. Then it stops on the position for a period
required, and drops automatically. Each time when it stops, it will stop for a period, then drops
automatically, to finish each procedure on the production line, then it will return to original position
automatically for workpiece insertion again.
2, Work flow chart is following:
Origin: when it is in the initial status, hook is in lower limit position.
Automatic process:starthook upwardupper limit travel switch closesrightward to No. 1
xk1 travel switch closeshook drops into No. 1lower limit travel switch closeselectrical plating
delayhook upward.from No. 3, hook moves upward, leftward to right limit position, and hook
drops to lower limit position (origin).
Continuous mode: when hook returns to origin, delay for a period, it will automaticcally move
34

upward, rightward, cycle and cycle. When you push stop button, it will stop immediately, and it will
stop when it return.
Single cycle: from origin, push startbutton, it will operate for a cycle, then stop in origin. It is
needed to repeat for a second cycle, you shall push start button. when you push stop button, it
immediately stops, push start button, it continues.
Jog: push start button, it will jog each time.
4, I/O
Table 3-6-1electrical plating production linecontrol I/O
input output
I0.0 Upper limit travel switch Q0.0 Rise
I0.1 Lower limit travel switch Q0.1 Drop
I0.2 Left limit Q0.3 Rightward
I0.3 XK1 travel switch Q0.4 Leftward
I0.4 XK2 travel switch Q0.7 Origin
I0.5 XK3 travel switch
I0.6 Origin switch
I0.7 Continuous mode switch
I1.0 Start button
I1.1 Stop button
I1.2 Stepper button
I1.3 Single cycle button
5, I/O circuit
Upper limit
travel switch
I0.0 Rise
Lower limit Q0.0
travel switch
I0.1
Left limit
Drop
I0.2 Q0.1
XK1
I0.3
Rightward
XK2 Q0.3
I0.4
XK3 Leftward
I0.5 Q0.4
Origin switch
I0.6
Origin
Continuous
mode switch Q0.7
I0.7
Start button
I1.0
Stop button
1L
I1.1
2L 12V FU
Stepper button
I1.2
Single cycle
button
I1.3
1M CPU 226 CN
24V 2M
Diagram 3-6-1electrical plating production linecontrolI/O circuit
35

6, Steps
supply socket.
4, Turn on 2.5, 2.6 (2.7, 2.8 are off).
5, Process:
(1) Push origin switch, make it in initial position, then origin indicator light is ON.
(2) Push continuous work switch, thenpush start button, make it continuously work, observe
equipment work process. Push stop button, observe equipment how to stop .
(3) Push single cycleswitch, select single cycleworking modes, push startbutton, a cycle later,
it stops in origin, in work process, push stop button, observe whether it can stop immediately, then
push start button, see whether it continues.
(4) Push jog switch, select jog working modes.
(5) In continuous work, single cycle and jog, push origin button, it will return to origin.
7, Circuit
Connect electrical plating production line control circuit according to Diagram 3-6-2.
36

YL-PCelectrical plating production linecontrol PLC Panel
OUT 1L Q0.0 Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.7

COM Rise Rightward
IN
Continuous Single cycle Stepper Drop Leftward Origin
Origin
mode switch button button switch Start Stop
Upper limit Lower limit Left limit 1 2 3

I0.0 I0.1 I0.2 I0.3 I0.4 I0.5 I0.6 I0.7
I1.0 I1.1 I1.2 I1.3
Diagram 3-6-2 electrical plating production line control circuit
37

Training 7, Water tower level automatic control
1, Purposes
1, Learn water tower level automatic control fundamental.

2, Learn ladder programming methods and instruction programming methods.
2, Components
1, Yalong PLC controller.

2, Yalong PLC water tower level automatic control.
4, Safe cables.
3, Fundamental
Water tower level working modes:

When water tank level is lower than the lower limit level (S4 is ON), the solenoid valve Y opens,
S4 is OFF, and level is higher than lower limit level. When water tank level is higher than the upper
limit level (S3 is ON), the solenoid valve Y closes.
When water tower level is lower than the lower limit level (S2 is ON), pump M works, to supply to
water tower, and S2 is OFF, level is higher than the lower limit level .when water tower level is higher
than the upper limit level (S1 is ON), pump M stops.
When water tower level is lower than lower limit level, and the water tank level is also lower than
lower limit level, pump M will not start.
4, I/O
Table 3-7-1water tower level automatic control I/O

input output
I0.1 water tower upper limit Q0.1 solenoid valve Y
I0.2 water tower lower limit Q0.2 pump M
I0.3 water tank upper limit
I0.4 water tank lower limit
38

5, I/O circuit
water tower upper limit S1 solenoid valve Y

I0.1 Q0.1
water tower lower limit S2 pump M
I0.2 Q0.2
water tank upper limit S3
I0.3
water tank lower limit S4
I0.4
1M 1L
24V 2M CPU 226 CN 12V FU
Diagram 3-7-1 water tower level automatic control I/O circuit

6, Steps
supply socket.
4, Turn on 2.5, 2.6, 2.7 (2.4 is off).
(1) Turn off limit switch S4, solenoid valve Y is ON, lower limit switch S4 resets.
(2) Turn on limit switch S3, solenoid valve Y is OFF, upper limit switch S3 resets.
(3) Turn off limit switch S2, pump M is ON, lower limit switch S2 resets.
(4) Turn on limit switch S1, pump M is OFF, upper limit switch S1 resets.
7, Circuit
Connect water tower level automatic control circuit according to Diagram 3-7-2.
8, Questions
When the water tank level is lower than the lower limit level (S4 is ON), solenoid valve Y opens to
input water, within 3s, switch S4 does not close, then the solenoid valve Y doeas not open, and faults
occur, then indicator light Y flashes.
39

YL-PCwater tower level automatic control circuit PLC Panel
1L Q0.0 Q0.1 Q0.2

IN OUT
S1 S2 S3 S4 COM M Y COM
I0.1 I0.2 I0.3 I0.4
Diagram 3-7-2 water tower level automatic control circuit
40

Training 8, Automatic forming machine
1, Purposes
1, Understand automatic forming machine fundamental.

2, Learn programming software usage and program input, check, modification and operation
debugging.
3, Learn I/O port distribution and I/O ports.
2, Components

2, Yalong PLC automatic forming machine.
4, Safe cables.
3, Fundamental
Automatic forming machine working modes:

(1) Initial status, when materials are put into forming machine, each oil cylinder status is in initial
position, the solenoid valve Y1, Y2, Y4 close (OFF), the solenoid valve Y3 works (ON).position
switchS1, S3, S5 are off (OFF), position switch S2, S4, S6 closes (ON).
(2) Push start button, solenoid valve Y2=ON upper oil cylinder piston moves downward, position
switch S4=OFF. when position switch S3=ON, start left, right oil cylinder (solenoid valve Y3=OFF;
solenoid valve Y1=Y4=ON), A piston moves rightward, C piston moves leftward, position switch S2,
S6 is OFF.
(3) When oil cylinder piston reach terminal, then position switches S1, S5 are ON. Then each oil
cylinder will return to initial position, A, B, C oil cylinder returns (solenoid valve Y1=Y2=Y4=OFF;
solenoid valve Y3=ON), position switch S1=S3=S5=OFF.
(4) When A, B, C oil cylinder will return to origin (position switch S2=S4=S6=ON), the system
will return to the initial position.
(5) Put materials, push start button to restart.
4, I/O
Table 3-8-1 automatic forming machine I/O
input output
I0.0 start Q0.1 solenoid valve 1
I0.1 Position switch S1 Q0.2 solenoid valve 2
I0.2 Position witch S2 Q0.3 solenoid valve 3
I0.3 Position switch S3 Q0.4 solenoid valve 4
I0.4 Position switch S4
5, I/O circuit
41

start solenoid valve Y1
I0.0 Q0.1
S1 solenoid valve Y2
I0.1
Q0.2
S2
I0.2 solenoid valve Y3
Q0.3
S3
I0.3 solenoid valve Y4
Q0.4
S4
I.04
S5
I0.5
S6
I0.6 1L
12V FU
1M 2L
24V 2M
CPU 226 CN
Diagram 3-8-1 automatic forming machine I/O circuit

6, Steps
supply socket.
4, Turn on 2.4(2.5, 2.6, 2.7 are off).
5, Operation:
(1) Turn S1-S6 in OFF status, turn Y3 ON.
(2) When PLC starts, turn on S2, S4, S6.
(3) Turn on start switch 0.0, Y2, Y3.
(4) Make S4=OFF (down), S3=ON (up), Y1, Y2, Y4 ON.
(5) Make S2=S6=OFF (down); make S1=S5=ON (up), Y3 light ON.
(6) Make S1=S3=S5=OFF, S2=S4=S6=ON, Y3 light ON. S1-S6 indicator lights are ON.
7, Circuit
Connect automatic forming machine circuit according to Diagram 3-8-2.
8, Questions
How to carry out automatic counting control?
42

YL-PC Automatic forming machine PLC Panel
IN OUT 1L Q0.0 Q0.1 Q0.2 Q0.3 2L Q0.4

S1 S2 S3 Y1 Y2
COM COM
S4 S5 S6 Y3 Y4
- 12V +
COM 1M COM 2M M L+
I0.1 I0.2 I0.3 I0.4 I0.5 I0.6
Diagram 3-8-2 automatic forming machine circuit
43

Training 9, automatic charging system
1, Purposes
1, Understand automatic charging control system work flow.

2, Learn how to use programming software to make automatic charging control system program.
3, Learn I/Odistribution,I/O connection methods and program operation debugging.
2, Components

2, Yalong PLC automatic charging system.
4, Safe cables.
3, Fundamental
Automatic charging system control:

In initial status, red light L2 is OFF, green light L1 is ON, to allowe vehicle for charging. When
K2, motor M1, M2, M3 is OFF. When vehicle comes (S2 switch is on), L2 is ON, and L1 is OFF, M3
works, motor M2 works when M3 works for 2s, motor M1 works when M2 starts for 2s, delay for 2s,
K2 opens. When vehicle is loaded (S2 OFF), K2 closes, motor M1, delay for 2s, then stops, M2 stops
when M1 stops for 2s, M3 stops when M2 stops for 2s. L1 is ON, L2 is OFF, and vehicle can leave.
S1 is the materials detection switch, when it is full, K2 will open, S1 is cut out, when it is not full,
K1 is open, and K2 will not open.
4, I/O
Table 3-9-1 automatic charging system I/O
Input output
I0.0 Upper limit level switch S1 Q0.0 Supply switch K1
I0.1 Position detection switch S2 Q0.1 switch K2
Q0.2 motor M1
Q0.3 motor M2
Q0.4 motor M3
Q0.5 green light L1
Q0.6 red light L2
5, I/O circuit
44

S1 K1
I0.0 Q0.0
S2 K2
I0.1 Q0.1
M1
Q0.2 M
M2
Q0.3 M
M3
Q0.4 M
L1
Q0.5
1M
24V 2M L2
Q0.6
1L
CPU 226 CN
2L
12V FU
Diagram 3-9-1 automatic charging systemI/O circuit

6, Steps
supply socket.
4, Turn on 2.4, 2.5, 2.7 (2.6 is off).
(1) Start, L1 green light is ON, K1 light is ON.
(2) Upper switch S2 (indicator light ON), L1 green light is OFF, L2 red light is ON, motor M3, M2,
M1 are ON.
(3) Upper switch S1 (indicator light ON), K1 is OFF, K2 is ON.
(4) Lower switch S2 (indicator light ON), motor M1, M2, M3 are OFF, L1 is ON, K1 light is ON,
recver to (1).
7, Circuit
Connect automatic charging system circuit according to Diagram 3-9-2.
8, Questions
According to control requirements above, how to make vehicle counting function?
45

YL-PC Automatic charging system PLC Panel
OUT
IN K1 K2 M1 M2 1L Q0.0 Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.5 Q0.6
COM
S2 S1
L1 L2 M3 COM
I0.0 I0.1
Diagram 3-9-2 automatic charging system circuit
46

Training 10, Multi-liquid automatic blending
1, Purposes
1, Understand multi-liquid automatic blending control system fundamental.

2, Learn ladder programming methods and instruction programming methods.
3, Learn programmer operation and programmer input, check, modification, download, upload and
operation.
2, Components

2, Yalong PLC multi-liquid automatic blending.
4, Safe cables.
3, Fundamental
Multi-liquid automatic blending control requirements:

In initial status, the container is empty, and the solenoid valve Y1, Y2, Y3, Y4 and blender M is
off, level sensor L1, L2, L3 are OFF.
Push start button, solenoid valve Y1, Y2 open, input liquid A and B, level is L2 (L2 and L3 are
ON), stop input (Y1, Y2 is OFF). Open liquid C solenoid valve Y3 (Y3 is ON), input liquid C, when
level rises to L1 (L1 is ON), stop input (Y3 is OFF). Start blender M, blending time is 3s. Then solenoid
valve Y4 starts, drain liquid, when level drops to L3 (L3 is OFF), delay for 5s, Y4 closes. Push start
button to restart.
4, I/O
Table 3-10-1 Multi-liquid automatic control I/O
I/O port Remark I/O port Remark
I0.0 Start Q0.1 solenoid valve Y1
I0.1 L1 Q0.2 solenoid valve Y2
I0.4 T Q0.5 Blender M
Q0.6 Furnance H
47

5, I/O circuit
solenoid valve 1
Q0.1
solenoid valve2
L1
I0.1 Q0.2
solenoid valve3
L2
I0.2 Q0.3
solenoid valve4
L3
I0.3 Q0.4
Blender M
T
I0.4 Q0.5 M
Furnance H
1M Q0.6 H
2M 1L
24V 2L
CPU 226 CN
12V FU
Diagram 3-10-1 Multi-liquid automatic blending I/O circuit
6, Steps
supply socket.
4, Turn on 2.4, 2.5, 2.7 (2.6 is off).
(1) Turn start switch 0.0, solenoid valve Y1, Y2 light ON.
(2) Turn on L3, L2, solenoid valve Y1, Y2 OFF, solenoid valve Y3 ON.
(3) Turn on L1, solenoid valve Y3 OFF, blender M is ON, 5s later, the solenoid valve Y4 is ON.
(4) Turn off L1, L2, L3, delay for 5s, the solenoid valve Y4 is OFF.
7, Circuit
Connect multi-liquid automatic blending circuit according to Diagram 3-10-2.
8, Questions
How to add temperature control function?
48

YL-PC Multi-liquid automatic blending PLC Panel
OUT
Y1 Y2 Y3 1L Q0.0 Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.5 Q0.6
IN
L1 L2
COM COM
L3 T
Y4 M H
I0.1 I0.2 I0.3 I0.4
Diagram 3-10-2 Multi-liquid automatic blending machine circuit
49

Training 11. Automatic steel rolling machine
1, Purposes
1, Learn automatic steel rolling machine system work process.

2, Learn shift register/display circuit fundamental.
3, Learn programmer operation and programmer input, check, modification, download, upload and
operation.
2, Components

2, Yalong PLC automatic steel rolling machine.
4, Safe cables.
3, Fundamental
Automatic steel rolling machinecontrol requirements:

When you push start switch, motor M1, M2 will run. Then motor M3 forward, when steel plate
rolling is finished, S1 signal is OFF, sensor S2 is ON, steel plate arrives, the solenoid valve Y2 works,
motor M3 moves back, S2 is off, S1 is on and the motor M3 will rotate forward. when S1 is off, repeat.
When the third rolling is done, S2 is on, and then it stops. You can restart.
Register/display circuit fundamental is below:
Diagram 3-11-1 register/display circuit fundamental
50

Integrated circuit CD4015 is a 4-bit shift register, function is: 1CP, 2CP is click input terminal,
1CR, 2CR is clear terminal, 1DS, 2DS is serials data input terminal, 1Q0~1Q3, 2Q0~2Q3 is data output
terminal, VDD is positive power supply,VSS is ground.
The circuit input pulse signals are from PLC Y1 port, CD4015 output terminal 1Q0~1Q2,
indicator lights (3 LED). Circuit fundamental is that, when pulse arrives 2CP terminal, 2Q0 is high level.
Then 1Q0 is high level, drive LED (upper) ON. When 2CP receives pulse, 1Q1 is high level, drive LED
is ON, 1Q0 is in high level, if 2CP receives pulse, 1Q2 is high level, drive LED(lower) ON, 1Q0, 1Q1 are
in high level. When 1Q3 is high level, through diode, make 1CPclear, 1Q0~1Q3 is in low level.
4, I/O
Table 3-11-1 automatic steel rolling machine I/O
input output
I0.0 Start Q0.1 Y1
I0.1 Sensor S1 Q0.3 Solenoid valve Y2
I0.2 Sensor S2 Q0.4 Motor M1
Q0.5 Motor M2
Q0.6 Motor M3 forward
Q0.7 Motor M3back
5,I/O circuit
Start Y1
I0.0 Q0.1
S1 Solenoid valve Y2
I0.1 Q0.3
S2 Motor M1
I0.2 Q0.4 M
Motor M2
Q0.5 M
Motor M3 forward
Q0.6 M
Motor M3back
Q0.7 M
CPU 226 CN
1M 1L
2M 2L
24V 12V FU
Diagram 3-12-2 automatic steel rolling machine I/O circuit
51

6, Steps
supply socket.
4, Turn on 2.4, 2.5, 2.7 (2.6 is off).
(1) Turn on Y1, M1, M2 light ON.
(2)Up S1, down S1, Y1, M1, M2 and leftward light is ON (M3 forward).
(3)Up S2, down S2, Y1 lights, Y2 and rightward arrow light is ON(M3 back).
(4)Up S1, down S1, Y1 lights, M1, M2 and leftward arrow light is ON (M3 forward).
(5)Up S2, down S2, Y13 lights, Y2 and rightward arrow light is ON (M3 back).
(6)Up S1, down S1, M1, M2, Y13 lights and leftward arrow light is ON (M3 forward).
(7)Up S2, down S2, whole process is finished.
7, Circuit
Connect automatic steel rolling machine circuit according to Diagram 3-11-3.
8, Questions
According to technical process above, how to add workpiece counting function ?
52

YL-PC automatic steel rolling machine PLC Panel
1L Q0.1 Q0.3 2L Q0.4 Q0.5 Q0.6 Q0.7

IN OUT
S1 0V M1 M3Forward Y1
COM
S2 12V M2 M3Back Y2
I0.1 I0.2
Diagram 3-11-3 automatic steel rolling machine circuit
53

Training 12, mails allocator
1, Purposes
1, Learn mails allocator fundamental and demonstration fundamental.

2, Learn programmer operation and programmer download, upload, check and operation.
2, Components

2, Yalong PLC mails allocator.
3, Programmer (or computer).
4, Safe cables.
3, Fundamental
1, Mails allocator fundamental:

When started, green light L2 is ON, red light L1 is OFF, motor M5 runs, for mails allocation. The
switch S2 is ON, toggle switches are mails number (1.0~1.3 is toggle switch for 1, 2, 4, 8), from toggle
switch, you can read constant 1, 2, 3, 4, 5. If other than the 5 numbers, red light L1 will flash to alarm,
motor M5 stops. Restart, if it is normal, then red light is ON, green light is OFF, motor M5 runs, PLC
samples motor optical encoder S1 pulses (from mails code reader to corresponding box), when mails
arrives allocation box and enter mails box. Then red light is OFF, green light is ON, you can continue
allocation.
2, Fundamental
L1, L2 are red, green indicator lights, S2 switch is code reader, M1-M4 are impellers, and the
indicator light is waiting. The circuit fundamental is shown in Diagram 3-12-1, when switch is OFF,
LED (upper) is ON, LED (lower) OFF, when switch closes, LED (upper) is OFF, LED (lower) is ON.
M5 is the motor, S1 is optical encoder, the pulse circuit is shown below, when a terminal is
connected to the power supply, NE555 starts, pulse signals, through S1 terminal, are for PLC input
terminal to sample.
54

Diagram 3-12-1 mails allocation control system demonstration fundamental diagram
4, I/O
Table 3-12-1 mails allocation control system I/O
Input output
Analogy optical
I0.0 Q0.1 Analogy impeller M1
encoder S1
I0.1 Start Q0.2 Analogy impeller M2
Analogy code
I0.2 Q0.3 Analogy impeller M3
reader S2
Q0.4 Analogy impeller M4
Q0.5 Drive motor M5
Q0.6 Red light L1
Q0.7 Green light L2
5, I/O circuit
Analogy impeller M1
S1 Q0.1 M
I0.0
Analogy impeller M2

I0.1
Q0.2 M
Analogy impeller M3
S2
I0.2
Q0.3 M
Analogy impeller M4
Q0.4 M
Drive motor M5
Q0.5 M
Red light L1
Q0.6
Green light L2
Q0.7
1L
1M 2L
12V FU
2M
24V CPU 226 CN
Diagram 3-12-2 mails allocation control systemI/O circuit
55

6, Steps
supply socket.
4, Turn on 2.4, 2.5 (2.6, 2.7 is off).
(1) 1.0-1.3, the binary number shall be within 1-5 (1.0, 1.1, 1.2, 1.3 is 1, 2, 4, 8).
(2) Push 0.1, L2, M5 is ON.
(3) L1 is ON, L2 is OFF, when it recovers, L2, L5 are ON.
(4) Then you can recheck mails.
7, Circuit
Connect mails allocation control system circuit according to Diagram 3-12-3.
8, Questions
How to add vehicle counting function according to control requirements above?
56

YL-PC mails allocator PLC Panel
IN OUT
S1 M1 M2 M3 M4 M5 1L Q0.0 Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.5 Q0.6 Q0.7
S2 12V 0V L1 L2
I0.0 I0.2
Diagram 3-12-3 mails allocatorcircuit
57

Training 13. Iron tower lighting
1, Purposes
1, Learn hwo to use function instructions.

2, Understand 7-segment decoder fundamental.
3, Learn I/O distribution and connection methods.
4, Learn programmer operation and programmerdownload, upload, check and operation.
2, Components

2, Yalong iron tower lighting module.
4, Safe cables.
3, Fundamental
Iron tower lighting control requirements:

Automatic lighting, a light each time in sequence, and students can design various patterns.
4, I/O
Table 3-13-1 iron tower lighting I/O
Output output
Q0.0 Color light L1 Q1.1 7-segment decoder A
Q0.1 Color light L2 Q1.2 7-segment decoder B
Q0.2 Color light L3 Q.13 7-segment decoder C
Q0.3 Color light L4 Q1.4 7-segment decoder D
Q0.4 Color light L5 Q1.5 7-segment decoder E
Q0.5 Color light L6 Q1.6 7-segment decoder F
Q0.6 Color light L7 Q1.7 7-segment decoder G
Q0.7 Color light L8
Q1.0 Color light L9
58

5, I/O circuit
7-segment decoderA Color light L1

Q1.1 Q0.0
7-segment decoderB Color light L2
Q1.2 Q0.1
7-segment decoderC Color light L3
Q1.3 Q0.2
7-segment decoderD
Color light L4
Q1.4 Q0.3
7-segment decoderE Color light L5
Q1.5 Q0.4
7-segment decoderF Color light L6
Q1.6 Q0.5
7-segment decoderG Color light L7
Q1.7 Q0.6
Color light L8
Q0.7
Color light L9
Q1.0
1L
2L 12V FU
CPU 226 CN 3L
Diagram 3-13-1 iron tower lightingI/O circuit
6, Steps
supply socket.
4, Turn on 2.4, 2.5, 2.7 (2.6 is off).
5, Start automatic lighting, one light each time; from botton to top, then from top to bottom.
7, Circuit
Connect iron tower lighting circuit according to Diagram 3-13-2.
8, Questions
1, How to change lighting time interval?

2, How to make a same lighting color ON and OFF in a same time?
59

YL-PC iron tower PLC Panel
1L Q0.0 Q0.1 Q0.2 Q0.3 2L Q0.4 Q0.5
IN OUT
A E L6 L1
B F L7 L2
C G L8 L3
D H L9 L4
Q0.6 Q0.7 3L Q1.0 Q1.1 Q1.2 Q1.3
COM L5
Q1.4 Q1.5 Q1.6 Q1.7
COM 2M M L+ - 12V +
Diagram 3-13-2 iron tower lighting circuit
60

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Siemens CPU226

Training Manual (A)

Yalong Science & Technology Group Co., Ltd.

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1. STEP7-MICRO/WIN32 SOFTWARE ............................................................................... 1

PART 2. PLC BASIC INSTRUCTION AND TRAINER ..................................................12

1. YALONG PLC TRAINER ...............................................................................................12

PART 3. PLC TRAINING.................................................................................................16

TRAINING 1. AUTOMATIC WASHING MACHINE CONTROL...................................................16

TRAINING 2. 3-PHASE MOTOR SEQUENCE CONTROL .........................................................20

TRAINING 3. STEPPER MOTOR CONTROL..........................................................................23

TRAINING 4. TRAFFIC LIGHTCONTROL ............................................................................27

TRAINING 5. 4-FLOOR ELEVATOR CONTROL.....................................................................30

TRAINING 6. ELECTRICAL PLATING PRODUCTION CONTROL..............................................34

TRAINING 7. WATER TOWER LEVEL AUTOMATIC CONTROL................................................38

TRAINING 8. AUTOMATIC FORMING MACHINE..................................................................41

TRAINING 9. AUTOMATIC CHARGING SYSTEM ..................................................................44

TRAINING 10. MULTI- LIQUID AUTOMATIC BLENDING .......................................................47

TRAINING 11. AUTOMATIC STEEL ROLLING MACHINE .......................................................50

TRAINING 12. MAILS ALLOCATION MACHINE ...................................................................54

TRAINING 13. IRON TOWER LIGHTING .............................................................................58

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Diagram1-1-1 communication parameters setting dialogue block

Diagram1-1-2 CPU-200 power supply

5. RS-232/PPL multi-cable connection

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Diagram1-1-4 download program

S7-200 CPU working mode

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Diagram1-1-5 S7-200 jump operation mode

2. STEP7-Micro/WIN32 brief introduction

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Diagram1-2-1 STEP7-Micro/WIN32window group

View -- common programming buttons:

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Diagram1-2-2 tools bar

compile upload Sort Descending

Undo Compile All Dowenload

Diagram1-2-3 standard tools bar

Toggles Network Comment

Toggles Dou Comments Toggle Bookmark

Diagram1-2-4 common tools bar

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Diagram1-2-6 LAD instruction tools bar

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3, Programming and operation

(1) Project creation (users program)

1, Open created project file

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1, Enter ladder (LAD) editor

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Diagram1-3-2ladder operationstatus monitor

1. Do electrical circuit wiring.

1. Turn off power supply before wiring.

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1. Yalong PLC training Trainer

It is composed of Yalong PLC controller and 13 modules.

2.SIEMENS S7-200 PLC brief introduction

Table 2-2-1 SIEMENS S7-200 PLC brief introduction

3. PLC basic instruction training

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