Beginning, Advanced, Comprehensive Levels · Select Ladder Diagrams (Ladsim version 2) in the Files of type drop-down box. Click on the LADSIM 1 file. 3. Click on OK. 4. Now click

Tech-Design

Manufacturing Processes Beginning, Advanced, Comprehensive Levels

Module Guide

Edition 1 37668-E0

FIRST EDITION

First Printing, July 2005

Copyright 2005 Lab-Volt Systems, Inc.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form by any means, electronic, mechanical, photocopied, recorded, or otherwise, without prior written permission from Lab-Volt Systems, Inc. Information in this document is subject to change without notice and does not represent a commitment on the part of Lab-Volt Systems, Inc. The multimedia Tech-Design software and other materials described in this document are furnished under a license agreement or a nondisclosure agreement. The software may be used or copied only in accordance with the terms of the agreement.

ISBN 0-86657-332-1 Lab-Volt and Tech-Design are registered trademarks of Lab-Volt Systems, Inc. WindowsTM is a trademark of Microsoft Corp. IBM is a registered trademark of International Business Machines Corporation. All other trademarks belong to their respective owners.

Lab-Volt License Agreement By using the software in this package, you are agreeing to become bound by the terms of this License Agreement, Limited Warranty, and Disclaimer. This License Agreement constitutes the complete agreement between you and Lab-Volt. If you do not agree to the terms of this agreement, do not use the software. Promptly return the multimedia (CD-ROM) compact discs and all other materials that are part of Lab-Volt's multimedia Tech-Design product within ten days to Lab-Volt for a full refund or credit. 1. License Grant. In consideration of payment of the license fee, which is part of the price you paid for this Lab-Volt product, Lab-Volt, as Licensor, grants to you, the Licensee, a nonexclusive, nontransferable license to use this copy of the CD-ROM software with the corresponding curriculum resources. Lab-Volt reserves all rights not expressly granted to the Licensee. 2. Ownership. As the Licensee, you own the physical media on which the CD-ROM is originally or subsequently recorded or fixed, but Lab-Volt retains title to and ownership of the software programs recorded on the original compact disc and any subsequent copies of the CD-ROM, regardless of the form or media in or on which the original and other copies may exist. This license is not a sale of the original software program of Lab-Volt's CD-ROM or any portion or copy of it. 3. Copy Restrictions. The CD-ROM software and the accompanying materials are copyrighted and contain proprietary information and trade secrets of Lab-Volt. Unauthorized copying of the CD-ROM even if modified, merged, or included with other software or with written materials is expressly forbidden. You may be held legally responsible for any infringement of Lab-Volt's intellectual property rights that is caused or encouraged by your failure to abide by the terms of this agreement. You may make copies of the CD-ROM solely for backup purposes provided the copyright notice is reproduced in its entirety on the backup copy. 4. Permitted Uses. This CD-ROM, Instructor Guide, and all accompanying documentation is licensed to you, the Licensee, and may not be transferred to any third party for any length of time without the prior written consent of Lab-Volt. You may not modify, adapt, translate, reverse engineer, decompile, disassemble, or create derivative works based on the Lab-Volt product without the prior written permission of Lab-Volt. Written materials provided to you may not be modified, adapted, translated, or used to create derivative works without the prior written consent of Lab-Volt. 5. Termination. This agreement is effective until terminated. It will terminate automatically without notice from Lab-Volt if you fail to comply with any provisions contained herein. Upon termination you shall destroy the written materials, Lab-Volt's CD-ROM software, and all copies of them, in part or in whole, including modified copies, if any. 6. Registration. Lab-Volt may from time to time update the CD-ROM. Updates can be made available to you only if a properly signed registration card is filed with Lab-Volt or an authorized registration card recipient.

7. Miscellaneous. This agreement is governed by the laws of the State of New Jersey. Limited Warranty and Disclaimer This CD-ROM software has been designed to assure correct operation when used in the manner and within the limits described in the Tech-Lab® Multimedia Installation & User’s Guide. As a highly advanced software product, it is quite complex; thus, it is possible that if it is used in hardware configurations with characteristics other than those specified in Tech-Lab® Multimedia Installation & User’s Guide or in environments with non-specified, unusual, or extensive other software products, problems may be encountered by a user. In such cases, Lab-Volt will make reasonable efforts to assist the user to properly operate the CD-ROM but without guaranteeing its proper performance in any hardware or software environment other than as described in the Tech-Lab® Multimedia Installation & User’s Guide. This CD-ROM software is warranted to conform to the descriptions of its functions and performance as outlined in the courseware documentation. Upon proper notification and within a period of one year from the date of installation and/or customer acceptance, Lab-Volt, at its sole and exclusive option, will remedy any nonconformity or replace any defective compact disc free of charge. Any substantial revisions of this product, made for purposes of correcting software deficiencies within the warranty period, will be made available, also on a licensed basis, to registered owners free of charge. Warranty support for this product is limited, in all cases, to software errors. Errors caused by hardware malfunctions or the use of non-specified hardware or other software are not covered. LICENSOR MAKES NO OTHER WARRANTIES OF ANY KIND CONCERNING THIS PRODUCT, INCLUDING WARRANTIES OR MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. LICENSOR DISCLAIMS ALL OBLIGATIONS AND LIABILITIES ON THE PART OF LICENSOR FOR DAMAGES, INCLUDING BUT NOT LIMITED TO SPECIAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH THE USE OF THE SOFTWARE PRODUCT LICENSED UNDER THIS AGREEMENT. Questions concerning this agreement and warranty and all requests for product repairs should be directed to Lab-Volt field representative in your area. LAB-VOLT SYSTEMS, INC. P.O. Box 686 Farmingdale, NJ 07727 Attention: Program Development Phone: (732) 938-2000 or (800) LAB-VOLT Fax: (732) 774-8573 Technical Support: (800) 522-4436 Technical Support E-Mail: [email protected]

Manufacturing Processes Table of Contents

Module Guide i

Introduction ................................................................................................................... 1

Directions....................................................................................................................... 3

Beginning Level ......................................................................................................... 3 Lesson 2, ICT3 Interactive Program..................................................................... 3 Lesson 3, LADSIM................................................................................................ 6 Lesson 4, Demonstrating Sensors........................................................................ 7 Lesson 5, The Assembly Process ........................................................................ 9 Lesson 6, Inspecting Assembled Parts............................................................... 11

Advanced Level ....................................................................................................... 13 Lesson 2, Reviewing the ICT3 Interactive Program............................................ 13 Lesson 3, Programming Ladder Logic................................................................ 16 Lesson 4, Bottling Plant Program ....................................................................... 23 Lesson 5, Writing a Program .............................................................................. 33 Lesson 6, More Programming ............................................................................ 41 Lesson 7, Manually Controlling the ICT.............................................................. 52

Comprehensive Level .............................................................................................. 55 Lesson 3, ICT3 Interactive Program................................................................... 55 Lesson 4, LADSIM.............................................................................................. 58 Lesson 5, Programming Ladder Logic................................................................ 59 Lesson 6, Bottling Plant Program ....................................................................... 66 Lesson 8, More Programming ............................................................................ 84 Lesson 9, Manually Controlling the ICT.............................................................. 95

LADSIM3 Main Menu............................................................................................... 99

Manufacturing Processes Table of Contents

ii Module Guide

Manufacturing Processes Introduction

Module Guide 1

INTRODUCTION This Module Guide contains the directions that you will use when you are completing lesson activities. The multimedia curriculum will direct you to this guide and a specific activity. The directions are titled and are organized by Lesson. The table of contents will guide you to the appropriate page.

Manufacturing Processes Introduction

2 Module Guide

Manufacturing Processes Directions

Module Guide 3

DIRECTIONS

Beginning Level

Lesson 2, ICT3 Interactive Program 1. Place one plastic ring and one metal peg on the chain conveyor.

2. When the ICT3 Interactive Program first opens, it defaults to the Manual mode, if it is

not in the Manual mode, click on the switch so it faces the Manual position. 3. From the ICT3 Interactive Program, click on the button that controls the chain

conveyor on the ICT.


4 Module Guide

Lesson 2, ICT3 Interactive Program (continued) 4. When the plastic ring passes the sort area detector (notice the sensor indicators on

the ICT3 Interactive Program) double-click on the sort solenoid button on the ICT3 Interactive Program to try to push the ring down the assembly chute. Don't worry if you miss, you will get another chance at it. (You must double-click the sort solenoid button because if you only single click on this button, the solenoid does not retract.)

5. The metal peg will pass through the sort area detector and metal peg detector and

proceed on to the feeder chute where it stops on the belt conveyor. 6. Double-click the rotary solenoid button on the ICT3 Interactive Program. This will

release the plastic ring into the assembly hopper. Take a look at the ICT3 screen and notice that the assembly hopper-full detector is lit.

7. Click on the belt conveyor button on the ICT3 Interactive Program and watch the

metal peg and the plastic ring get assembled. Look at the ICT3 screen to see all the sensors light up as the assembled component passes each one.

8. From the ICT3 Interactive Program, click on the chain conveyor button and the belt

conveyor button to turn them off.


Module Guide 5

Lesson 2, ICT3 Interactive Program (continued) 9. Do the same activity a few times following the same steps. Each time you do it, take

notice of the computer screen to watch the appropriate sensors light up. Take turns with your partner.

10. When you are finished, close the ICT3 Interactive Program by clicking on the x icon

that appears in the upper right corner of your screen. 11. Go to the next section in the presentation.


6 Module Guide

Lesson 3, LADSIM You will now run a program that will turn on both the chain and belt conveyors when the Start button on the Industrial Control Trainer (ICT) is pressed. It will also turn off the conveyors when the Stop button on the ICT is pressed. Let’s see if it works. 1. From the Main menu click on File and then Open Diagram. 2. The Open Diagram dialog box appears. Make sure you are in the c:\Program

Files\Bytronic\Ladsim3 directory. Select Ladder Diagrams (Ladsim version 2) in the Files of type drop-down box. Click on the LADSIM 1 file.

3. Click on OK. 4. Now click on Control from the Main menu and then on External Device. Click on the

Run Diagram button.

5. On the Industrial Control Trainer, push the green Start button. The program now

runs the ICT. Both conveyors are on. Turn off the conveyors by pressing the red stop button on the ICT.

6. Click on the Stop Diagram button from the Main menu. (Remember, if you place

your cursor over a button on the screen, the name of that button will pop-up.) 7. When you are finished, exit the LADSIM software by first clicking on File and then on

Exit. 8. Go to the next section in the presentation.


Module Guide 7

Lesson 4, Demonstrating Sensors 1. From the Main menu click on File and then Open Diagram. 2. The Open Diagram dialog box appears. Make sure you are in the c:\Program


3. Click on OK. 4. You will now simulate the program on the computer before you actually test it using

the ICT. Click on Simulations from the Main menu and then click on Bytronic ICT3. Click on the Run Diagram button from the Main Menu.

5. The Bytronic ICT3 window appears. Click on the Start button that appears in this

window. 6. Click on the picture of the plastic rings and on the picture of the aluminum pegs to

load them on the chain conveyor in the Bytronic ICT3 window. (NOTE: you must wait until the component you just clicked on passes the pictures of the components before you select another one to be added to the chain conveyor.)

7. You'll see from the simulation that the chain conveyor will lift the components to a

higher level. Once they are at this higher level, the plastic rings will be detected by an infrared sensor and will be ejected by a solenoid down the assembly chute. The aluminum pegs will continue on the conveyor and will be deflected down the feeder chute.


8 Module Guide

Lesson 4, Demonstrating Sensors (continued) 8. Click on the Stop button that appears in the Bytronic ICT3 window. Click on the Stop

Diagram button from the Main Menu. The simulation ends. You will now test the program with the ICT.

9. Now click on Control from the Main menu and then on External Device. 10. Click on the Run Diagram button from the Main Menu. 11. On the Industrial Control Trainer, push the green Start button. The program now

runs the ICT. Both conveyors are on. 12. Place the plastic rings and the aluminum pegs on the chain conveyor. The chain

conveyor will lift them to a higher level. You will see that once they are at this higher level, the plastic rings will be detected by an infrared sensor and will be ejected by a solenoid down the assembly chute. The aluminum pegs will continue on the conveyor and will be deflected down the feeder chute.

13. When all the components have passed by the sensors, turn off the conveyors by

pressing the red Stop button on the ICT. 14. Click on the Stop Diagram button from the Main Menu. 15. When you are finished, exit the LADSIM software by first clicking on File and then on



Module Guide 9

Lesson 5, The Assembly Process 1. From the Main menu click on File and then Open Diagram. 2. The Open Diagram dialog box appears. Make sure you are in the c:\Program








higher level, then the plastic rings will be detected by an infrared sensor and will be ejected down the assembly chute. The aluminum pegs will continue on the conveyor. They will be deflected down the feeder chute and automatically fed onto the belt conveyor. The assembly hopper-full detector will determine whether or not the plastic ring hopper is empty. If it is, a rotary solenoid will dispense a plastic ring from the assembly chute into the hopper. When the aluminum peg passes the hopper, it engages the hole in the plastic ring and the two are assembled.

8. Click on the Stop button that appears in the Bytronic ICT3 window. Click on the Stop



runs the ICT. Both conveyors are on.


10 Module Guide

Lesson 5, The Assembly Line (continued) 12. Place the plastic rings and the aluminum pegs on the chain conveyor. The chain

conveyor will lift them to a higher level, then the plastic rings will be detected by an infrared sensor and will be ejected down the assembly chute. The aluminum pegs will continue on the conveyor. They will be deflected down the feeder chute and automatically fed onto the belt conveyor. The assembly hopper-full detector will determine whether or not the plastic ring hopper is empty. If it is, a rotary solenoid will dispense a plastic ring from the assembly chute into the hopper. When the aluminum peg passes the hopper, it engages the hole in the plastic ring and the two are assembled.

13. When all the components are assembled, turn off the conveyors by pressing the red

Stop button on the ICT. 14. Click on the Stop Diagram button from the Main Menu. 15. When you are finished, exit the LADSIM software by first clicking on File and then on



Module Guide 11

Lesson 6, Inspecting Assembled Parts 1. From the Main menu click on File and then Open Diagram. 2. The Open Diagram dialog box appears. Make sure you are in the c:\Program








higher level, then the plastic rings will be detected by an infrared sensor and will be ejected down the assembly chute. The aluminum pegs will continue on the conveyor. They will be deflected down the feeder chute and automatically fed onto the belt conveyor. The assembly hopper-full detector will determine whether or not the plastic ring hopper is empty. If it is, a rotary solenoid will dispense a plastic ring from the assembly chute into the hopper. When the aluminum peg passes the hopper, it engages the hole in the plastic ring and the two are assembled. Sensors positioned along the belt conveyor will check for correct assembly. Components that have not been assembled will be ejected by a solenoid into a scrap or recycle bin, but correctly assembled components pass into a finished parts tray.

8. Click on the Stop button that appears in the Bytronic ICT3 window. Click on the Stop





12 Module Guide

Lesson 6, Inspecting Assembled Parts (continued) 12. Place the plastic rings and the aluminum pegs on the chain conveyor. The chain

conveyor will lift them to a higher level, then the plastic rings will be detected by an infrared sensor and will be ejected down the assembly chute. The aluminum pegs will continue on the conveyor. They will be deflected down the feeder chute and automatically fed onto the belt conveyor. The assembly hopper-full detector will determine whether or not the plastic ring hopper is empty. If it is, a rotary solenoid will dispense a plastic ring from the assembly chute into the hopper. When the aluminum peg passes the hopper, it engages the hole in the plastic ring and the two are assembled. Sensors positioned along the belt conveyor will check for correct assembly. Components that have not been assembled will be ejected by a solenoid into a scrap or recycle bin, but correctly assembled components pass into a finished parts tray.

13. When you are finished, turn off the conveyors by pressing the red Stop button on the

ICT. 14. Click on the Stop Diagram button from the Main Menu. 15. Exit the LADSIM software by first clicking on File and then on Exit. 16. Go to the next section in the presentation.


Module Guide 13

Advanced Level

Lesson 2, Reviewing the ICT3 Interactive Program 1. Place one plastic ring and one metal peg on the chain conveyor.





14 Module Guide

Lesson 2, Reviewing the ICT3 Interactive Program (continued) 4. When the plastic ring passes the sort area detector (notice the sensor indicators on

the ICT3 Interactive Program), double-click on the sort solenoid button on the ICT3 Interactive Program to try to push the ring down the assembly chute. Don't worry if you miss, you will get another chance. (You must double-click the sort solenoid button. If you only single click this button, the solenoid does not retract.)


proceed to the feeder chute, where it stops on the belt conveyor. 6. Double-click the rotary solenoid button on the ICT3 Interactive Program. This will

release the plastic ring into the assembly hopper. Take a look at the ICT3 screen, and notice that the assembly hopper-full detector is lit.


Module Guide 15

Lesson 2, Reviewing the ICT3 Interactive Program (continued) 7. Click on the belt conveyor button on the ICT3 Interactive Program and watch the



conveyor button to turn them off. 9. Do the same activity a few times following the same steps. Each time, watch the

computer screen to see the appropriate sensors light up. Take turns with your partner.

10. When you are finished, close the ICT3 Interactive Program by clicking on the "X"

icon that appears in the upper right corner of your screen. 11. Go to the next section in the presentation.


16 Module Guide

Lesson 3, Programming Ladder Logic 1. From the Main Menu, click and hold the Normally Open Contact button and then

drag it to the left side of the rung. Release the mouse. (NOTE: there is a printout of this Main Menu graphic at the end of the Module Guide – refer to it when you are performing the activities.)


Module Guide 17

Lesson 3, Programming Ladder Logic (continued) 2. The Inputs window appears. Click in the circle next to IP0. Click on OK.

3. The Ladder Rung with a numbered Normally Open Contact symbol appears. You will

now place another Normally Open Contact symbol on the rung to the right of the first one. Click and hold the Normally Open Contact button and drag it to the right of the first one. Release the mouse.

4. From the Inputs window, click on the circle next to IP1 then click on OK. (NOTE: if

you clicked on the wrong number, click Cancel and try it again.) 5. You are now going to add an output symbol. This will be positioned on the far right of

the rung. Click and hold the Output button and then drag it to the right of the rung. Release the mouse.


18 Module Guide

Lesson 3, Programming Ladder Logic (continued) 6. The Outputs window appears. Click on the circle next to OP0 and then click on OK.

The ladder AND function is complete.

7. Save your program by clicking on File and then Save Diagram. The Save As window

appears. You will save the program in the C:\Program Files\Bytronic\Ladsim3 directory. If you are not in that directory, double-click on the C:\ folder, then double-click on the Program Files, then double-click on the Bytronic folder, and finally double-click on the Ladsim3 folder. In the Filename box enter a filename (no more than eight characters long). Click on OK.

SIMULATING THE PROGRAM 1. You will now simulate the AND ladder function that is displayed in the LADSIM

window. Click on the Control button from the Main Menu and select Debugger. The Debugger window appears.


Module Guide 19

Lesson 3, Programming Ladder Logic (continued) 2. Click on the Run Diagram button from the Main Menu. 3. Click on the IP0 button. The first contact on the ladder rung will change to red

indicating that it is switched "on."

4. Now click on the IP1 button. The second contact on the rung will also turn red and

the OP0 output on the Debugger window will turn red indicating that is energized. The output on the rung will also turn red.

5. Click on the Stop Diagram button from the Main Menu to stop the simulation. PROGRAMMING OR AND NOT LADDER FUNCTIONS 1. To program the OR function, you will modify the AND function that you just

completed. You need to first delete the second symbol (IP1). From the Main Menu, click on Edit and then select Delete Control. Click on the IP1 symbol. The following prompt appears: "Are you sure you want to Input IP1?" Click on Yes.


20 Module Guide

Lesson 3, Programming Ladder Logic (continued) 2. You will now add a branch. From the Main Menu, click on Edit and select Add

Branch. The figure below shows you where you should begin and end the branch.

3. Once you finish the branch, a dialog box appears asking you if this branch is correct.

If you have positioned the branch correctly (see the graphic below), click on Yes. If you have not positioned the branch correctly, click on No and try again.

4. When you click on Yes, the branch is added.


Module Guide 21

Lesson 3, Programming Ladder Logic (continued) 5. From the Main Menu, click and hold the Normally Open Contact button and drag it to

the branch. Number the contact IP1 and then click on OK.


appears. You will save the program in the C:\Program Files\Bytronic\Ladsim3 directory. In the Filename box enter a filename (no more than eight characters long). Click on OK.

7. Next, simulate the program by clicking on the Control button from the Main Menu

and selecting Debugger. The Debugger window appears. 8. Click on the Run Diagram button from the Main Menu. 9. Test the rung. Begin by first seeing what the output is (OP0) on the Debugging

window when IP0 and IP1 are open (0). Is it energized? Now click on the IP0 button to close it (1) while keeping the IP1 button open (0). The first contact on the ladder rung (IP0) turns red and the second rung (IP1) stays the same. The output turns red indicating that it is energized.

10. When you are finished with your test, click on the Stop Diagram button from the

Main Menu.


22 Module Guide

Lesson 3, Programming Ladder Logic (continued) 11. You will now modify the OR ladder program to create a NOT function. Click, hold,

and drag the Normally Closed Contact button to the right of the other contacts. Number this contact IP2 and then click on OK.



13. Now click on the Control button and select Debugger. Make sure IP0 and IP1 are off

(switch is up). Click on the Run Diagram button. You will see immediately that the normally closed contact IP2 is already covered red, indicating power. But note that the output is off. This is because the power flow is left to right and it would require IP0 and IP1 to be switched on to obtain power to the output.

14. Click on the Stop Diagram button when you are finished testing. 15. Click on File and then Exit to exit the program. 16. Go to the next section in the presentation.


Module Guide 23

Lesson 4, Bottling Plant Program 1. You will begin by adding a command to start conveyors 1 and 2 moving

continuously. Click, hold, and drag the Output button from the Main Menu to the right side of Rung 0. When you release the mouse button the Outputs window appears.

2. Select OP0 and then click on OK. 3. Click, hold, and drag the Output button directly below the output you just created

(OP0). The graphic below shows where you must place this control. (NOTE: if you make a mistake, click on Cancel and then try again.)

4. Select OP4 from the Outputs window and click on OK. Rung 0 is complete.

5. You will now add a new rung. Click on the Add Rung button. Rung 1 appears below

Rung 0.

6. You will now add the bottle stop sensor (IP0) and the stop bottle piston. Click, hold,

and drag the Normally Open Contact button to the left side of Rung 1. Select IP0 and then click on OK.

7. Next, click, hold, and drag the Normally Closed Contact button to the right of the

Normally Open Contact control. In the Flags box, click on F0. Click on OK. 8. Click, hold, and drag the Latch Output button to the right side of Rung 1. Click on

OP1 and then on OK. 9. You will now add a rung that will activate the bottle filler piston to fill the bottle, once

the stop bottle piston has been activated and the level sensor does not show a full bottle. First click on the Add Rung button to add Rung 2.


24 Module Guide

Lesson 4, Bottling Plant Program (continued) 10. Click, hold, and drag the Normally Open Contact button to the left of Rung 2. Select

OP1 from the Outputs box and then click on OK. Now click, hold, and drag the Normally Closed Contact button to the right of the Normally Open Contact control. Select IP1 from the Inputs box and then click on OK.

11. Click, hold, and drag the Output button to the right of Rung 2. Click on OP3 and then

click on OK. Rung 2 is complete. 12. You will now add a rung to start a timer to allow the filler piston to move out of the

way before the cap is placed on the bottle once a full bottle is detected. Click on the Add Rung button to add Rung 3.

13. Click, hold, and drag the Normally Open Contact button to the left of Rung 3. Select

IP1 and then click on OK. 14. Click, hold, and drag the Timer icon to the right of Rung 3. The Timers window

appears. In the Timers box, click on T1. In the Preset box, enter 2.5. Select Latched On Delay Timer for the Timer Style. Then click on OK. Rung 3 is complete.


Module Guide 25

Lesson 4, Bottling Plant Program (continued) 15. Save your program by clicking on File and then Save Diagram. The Save As window

appears. You will save the program in the C:\Program Files\Bytronic\Ladsim3 directory. If you are not in that directory, double-click on the C:\ folder, then double- click on the Program Files folder, double-click on the Bytronic folder, and finally double-click on the Ladsim3 folder. In the Filename box enter a filename (no more than eight characters long). Click on OK.

16. You will add a rung to activate the cap piston once the time has elapsed and the limit

switch on the cap piston has not been activated. Click on the Add Rung button to add Rung 4.

17. Click, hold, and drag the Normally Open Contact button to the left of Rung 4. In the

Timers box, click on T1/DN and then on OK. 18. Add a Normally Closed Contact control to the right of the Normally Open Contact

control. Click on IP2 and then on OK. Add another Normally Closed Contact control to the right of this one. Click on F0 in the Flags box and then on OK. Add a Normally Open Contact next to this one. Click on OP1 and then on OK.

19. Now add an Output control to the right of Rung 4. Click on OP2 and then on OK.

Rung 4 is complete. 20. You will add a rung to unlatch the bottle stop piston and allow the bottle to continue

once the cap piston limit has been reached. Click on the Add Rung button to add Rung 5.

21. Add a Normally Open Contact control to the left of Rung 5. Click on IP2 and then on

OK. 22. Add an Unlatch Output control to the right of Rung 5. Select OP1 and then OK. Now

add a Latch Output control below the Unlatch Output. Select 0 under the Flags box and then click on OK. Rung 5 is complete.

23. You will now add a rung to reset the flag and timer used once the bottle has moved

away from the bottle sensor. Click on the Add Rung button to add Rung 6. 24. Add a Normally Open Contact control to the left of Rung 6. Select IP3 and then click

on OK. 25. Now add a Reset control to the right of Rung 6. Select T1 and then click on OK. 26. Next add an Unlatch Output control directly below the Reset control. Select 0 in the

Flags box and then click on OK. Rung 6 is complete.


26 Module Guide

Lesson 4, Bottling Plant Program (continued) 27. You will now add another rung to activate the cap winder piston once the bottle has

reached the cap winder. Click on the Add Rung button to add Rung 7. 28. Add a Normally Open Contact to the left of Rung 7. Select IP4 and then OK. 29. Add a Latching Output control to the right of Rung 7. Select OP5 and then OK. Rung

7 is complete. 30. Save your work as you did before.

31. You will now add a new rung to retract the bottle winder piston once the bottle has

reached the counter sensor. Click on the Add Rung button to add Rung 8. 32. Add a Normally Open Contact to the left of Rung 8. Select IP5 and then OK. 33. Add an Unlatch Output control to the right of Rung 8. Select OP5 and then OK. Rung

8 is complete.


Module Guide 27

Lesson 4, Bottling Plant Program (continued) 34. You will now add a rung to set the counter sensor so is counts 3 bottles moving past

it. Click on the Add Rung to add Rung 9. 35. Add a Normally Open Contact control to the left of Rung 9. Select IP5 and then OK. 36. Add a Counter control to the right of Rung 9. Select C1 in the Counters box. Select

Up in the Up/Down box. Enter 3 in the Preset box and then click on OK. Rung 9 is complete.

37. The next rung you add will wait for the bottles to reach the stacker piston once 3

bottles have passed the sensor. Click on the Add Rung button to add Rung 10. 38. Add a Normally Open Contact control to the left of Rung 10. Select C1/UP in the

Counters box and then click on OK. 39. Add a Timer control to the right of Rung 10. Select T2 in the Timers box. Enter 2.5 in

the Preset box. Select Latched on Delay Timer for the Timer Style and then click on OK. Rung 10 is complete.

40. You will now add a rung to set a timer to push the piston once the bottle is in

position. Click on the Add Rung button to add Rung 11. 41. Add a Normally Open Contact to the left of Rung 11. Select T2/DN in the Timers box

and then click on OK.


28 Module Guide

Lesson 4, Bottling Plant Program (continued) 42. Add a Timer control to the right of Rung 11. Select T3 in the Timers box. Enter 5.5 in


43. Save your program as you did before. 44. You will now add a rung to push the piston. Click on the Add Rung button to add

Rung 12. 45. Add a Normally Open Contact control to the left of Rung 12. Select T2/DN and then

OK. Add a Normally Closed Contact right next to it. Select T3/DN and then OK. 46. Add an Output control to the right of Rung 12. Select OP6 and click on OK. Rung 12

is complete. 47. You will now add a rung push the bottles onto the stacker and reset the counter and

timer used, once the timer is finished. Click on Add Rung to add Rung 13.


Module Guide 29

Lesson 4, Bottling Plant Program (continued) 48. Add a Normally Open Contact control to the left of Rung 13. Select T3/DN and click

on OK. 49. Add a Reset control to the right of Rung 13. Select T2 in the Timers box and click on

OK. Add a Reset control directly under this and select T3 and then OK. Add another Reset control under the last Reset control. Select T1 in the Timers box and C1 in the Counters box and click on OK. Rung 13 is complete.

50. Next, you will add a rung to increment a second counter so that 3 rows of bottles can

be detected once the bottles have been pushed onto the stacker. Click on the Add Rung button to add Rung 14.

51. Add a Normally Open Contact control to the left of Rung 14. Select T3/DN in the

Timers box and click on OK. 52. Add a Counters control to the right of Rung 14. Select C2 in the Counters box, UP in

the Up/Down box and enter 3 in the Preset box. Then click on OK. Rung 14 is complete.

53. You will now add a rung to wait 3 seconds before continuing once 3 rows of bottles

have been sent to the stacker. Click on the Add Rung button to add Rung 15. 54. Add a Normally Open Contact control to the left of Rung 15. Select C2/UP and then

click on OK.


30 Module Guide

Lesson 4, Bottling Plant Program (continued) 55. Add a Timer control to the right of Rung 15. Select T4 in the Timers box. Enter 3 in

the Preset box. Select Latched on Delay Timer in the Timer Style box and click on OK. Rung 15 is complete.

56. You will now add a rung that will send the bottles down to conveyor 3 once the timer

has finished. Click on Add Rung to add Rung 16. 57. Add a Normally Open Contact control to the left of Rung 16. Select T4/DN in the

Timers box and click on OK. 58. Add an Output control to the right of Rung 16. Select OP7 and then click on OK.

Rung 16 is complete. 59. Save your program.


Module Guide 31

Lesson 4, Bottling Plant Program (continued) 60. You will now add a rung that will start a timer to allow enough time for the bottles to

automatically move onto conveyer 3. Click on Add Rung to add Rung 17. 61. Add a Normally Open Contact control to the left of Rung 17. Select IP6 and click on

OK. 62. Add a Timer control to the right of Rung 17. Select T5 in the Timers box, enter 10 in

the Preset box, and select Latched on Delay Timer in the Timer Style box. Click on OK. Rung 17 is complete.

63. The last rung will reset the timers and counters used once the timer has finished.

Click on Add Rung to add Rung 18. 64. Add a Normally Open Contact control to the left of Rung 18. Select T5/DN and click

on OK. 65. Add a Reset control to the right of Rung 18. Select T4 and click on OK. Add another

Reset control under the last one. Select T5 and click on OK. Add another Reset control under the last one. Select T1 and C2 and then click on OK. Rung 18 is complete and the program is now complete.


32 Module Guide

Lesson 4, Bottling Plant Program (continued) SIMULATING THE PROGRAM 1. From the Main Menu, click on Simulations and select Bottling Plant. Click on the Run

Diagram button. 2. Watch the simulation. Take notice to how well the timers work. Remember you

programmed 2.5 seconds to allow the filler piston to move out of the way before the cap is placed on the bottle. Also, when 3 bottles have passed the counter sensor, the program waits for the bottles to reach the stacker piston. Then once 3 rows of bottles have been sent to the stacker, the program waits before continuing. Lastly, when the stacker is in position, a timer starts to allow enough time for the bottles to automatically move onto the conveyor 3.

3. When you are done, click on the Stop Diagram button. 4. Click on File and then on Exit. 5. Go to the next section in the presentation.


Module Guide 33

Lesson 5, Writing a Program 1. Add a Normally Closed Contact control to the left of Rung 0. Do you remember how

to do this? Click, hold, and drag the Normally Closed Contact button to the left of Rung 0.

2. In the Inputs window, click on F15 in the Flags box and then click on OK. 3. Add a Latch Output control to the right of Rung 0. Select 15 from the Flags box and

then click on OK. 4. Add an Output control to the right of Rung 0, directly under the Latch Output control

you just added. Select R2 from the Register Bits box and then click on OK. 5. Rung 0 is complete. 6. Click on Add Rung to add Rung 1. 7. Add a Normally Open Contact control to the left of Rung 1. Select IP6 from the

Inputs box and then click on OK. 8. Add another Normally Open Contact control right next to the one you just added.

Select IP7 for the input and then select OK. 9. You will now add a branch directly under the first Normally Open Contact (IP6), as

shown in the graphic below. Click on the Add Branch button. Click under the Normally Open Contact, to the left of Rung 1, to start the branch, and then click under the Normally Open Contact to the right, just before the other NOC begins, to end the branch. If the branch is in the correct place, select Yes. If not, select No and try again.


34 Module Guide

Lesson 5, Writing a Program (continued) 10. To this new branch, add a Normally Open Contact control. Select OP0 for the output

and then select OK. 11. Add an OP control to the right of Rung 1. Select OP0 for the output and then click on

OK. 12. Add another OP control right next to the one you just added. Select OP4 for the

output and then click on OK. Rung 1 is complete.

13. Save your work by selecting File and then Save from the Main Menu. Enter a

filename no longer than 8 characters. Save your program in the C:\Program Files\Bytronic\Ladsim3 directory. Click on OK.

14. You just wrote a program to turn on both the chain (OP0) and belt (OP1) conveyors

when the start button (IP6) on the ICT is pressed. It will also turn off the conveyors when the stop button (IP7) on the ICT is pressed. Let's see if it works.

15. Now click on Control from the Main Menu and select External Device. Click on the

Run Diagram button. 16. Press the green Start button on the ICT. The program now runs the ICT. Both

conveyors are on. Turn off the conveyors by pressing the red Stop button on the ICT.

17. Click on the Stop Diagram button. 18. You will now continue programming more steps.


Module Guide 35

Lesson 5, Writing a Program (continued) 1. You will now add to your program. Click on the Add Rung button to add Rung 2. 2. Add a Normally Open Contact control to the left of Rung 2. Select IP0 for the input

and then click on OK. 3. Add a Latch Output control to the right of Rung 2. Select 3 in the Flags box and then

click on OK. Rung 2 is complete.

4. Add Rung 3 by clicking on Add Rung. 5. Add a Normally Open Contact control to the left of Rung 3. Select F3 in the Flags

box and then click on OK.


36 Module Guide

Lesson 5, Writing a Program (continued) 6. Add a Timer control to the right of Rung 3. Select T5 in the Timers box and enter 3 in

the Preset box. Click on OK. Rung 3 is complete.

7. Add Rung 4. 8. Add a Normally Open Contact control to the left of Rung 4. Select IP1 for the input

and click on OK. 9. Add a Normally Closed Contact control next to the Normally Open Contact control

you just added. Select F3 in the Flags box and then click on OK.


Module Guide 37

Lesson 5, Writing a Program (continued) 10. Add another Normally Closed Contact control next to the one you just added. Select

C1/UP in the Counters box and click on OK. 11. Add another Normally Closed Contact next to the one you just added. Select T1/DN

in the Timers box and click on OK. 12. You will add a branch under the Normally Open Contact control, exactly as it

appears in the graphic below. This branch will start directly under it and to the left. It will end to the right of the C1/UP control, just before the T1/DN control begins. You will do this by first clicking on the Add Branch button. Then by clicking directly under the Normally Open Contact control, to the left, to start the branch; and then clicking between the C1/UP control and the T1/DN control. If the branch is correct, select Yes. If it is not, select No and try again.

13. Add a Normally Open Contact control to this new branch. Select OP1 for the output

and then click on OK. 14. Add an Output to the right of Rung 4. Select OP1 for the output and then click on

OK. Rung 4 is complete. 15. Save your work. 16. Add Rung 5 to your program. 17. Add a Normally Open Contact control to the left of Rung 5. Select T5/DN in the

Timers box and click on OK. 18. Add a Reset control to the right of Rung 5. Select T5 in the Timers box and click on

OK.


38 Module Guide

Lesson 5, Writing a Program (continued) 19. Add an Unlatch Output control directly under the Reset control. Select 3 in the Flags

box and click on OK. Rung 5 is complete.

20. Add Rung 6. Add a Normally Open Contact control to the left of Rung 6. Select OP1 for the output and click on OK.

21. Add a Timer control to the right of Rung 6. Select T1 in the Timers box and enter 1 in

the Preset box. Select Latched on Delay for Timer Style. Click on OK. Rung 6 is complete.

22. Add Rung 7. 23. Add a Normally Open Contact control to the left of Rung 7. Select T1/DN in the

Timers box and click on OK. 24. Add a Counter control to the right of Rung 7. Select C1 in the Counters box, select

UP in the Up/Down box, and enter 5 in the Preset box. Click on OK. Rung 7 is complete.


Module Guide 39

Lesson 5, Writing a Program (continued) 25. Add Rung 8. 26. Add a Normally Open Contact control to the left of Rung 8. Select T1/DN for the

timers and click on OK. 27. Add a Reset control to the right of Rung 8. Select T1 and then OK. Rung 8 is

complete.

28. Save your work. 29. Add Rung 9. 30. Add a Normally Closed Contact control to the left of Rung 9. Select C1/DN in the

Counters box and click on OK. 31. Add another Normally Closed Contact control next to the one you just added. Select

IP2 for the input and then click on OK. 32. Add a Timer control to the right of Rung 9. Select T2 and enter 1 in the Preset box.

Select Latched on Delay for Timer Style. Click on OK. Rung 9 is complete. 33. Save your work.

34. To run this program with the ICT, click on Control from the Main Menu and select

External Device. Click on the Run Diagram button. 35. On the Industrial Control Trainer, push the green Start button. The program now



40 Module Guide

Lesson 5, Writing a Program (continued) 36. Place the plastic rings and the aluminum pegs on the chain conveyor. The chain



pressing the red Stop button on the ICT. 38. Click on the Stop Diagram button. Exit the LADSIM software by first clicking on File

and then on Exit. 39. Go to the next section in the presentation.


Module Guide 41

Lesson 6, More Programming 1. Click on File and then Open Diagram from the Main menu. Click on the file name for

your program and then click on OK. 2. Add Rung 10. 3. Add a Normally Open Contact control to the left of Rung 10. Select T2/DN and then

click on OK. 4. Add a branch under the Normally Open Contact control, exactly like in the graphic

below. Click on the Add Branch button. Begin the branch directly under the NOC control and to the far left. Then end the branch directly under the Normally Open Contact control to the right. If the branch is correct, click on Yes. If it is not, click on No and try again.

5. Add a Normally Open Contact control to the new branch. Select OP2 and then OK. 6. Add a Normally Closed Contact control next to the first Normally Open Contact

control (not the one on the branch). Select T3/DN in the Timers box and click on OK.


42 Module Guide

Lesson 6, More Programming (continued) 7. Add an Output control to the right of Rung 10. Select OP2 and then OK. Rung 10 is

complete.

8. Add Rung 11. 9. Add a Normally Open Contact control to the left of Rung 11. Select OP2 and then

OK. 10. Add a Timer control to the right of Rung 11. Select T3 and enter 1 for the Preset.

Select Latched on Delay Timer for Timer Style. Click on OK. Rung 11 is complete.

11. Add Rung 12. 12. Add a Normally Open Contact control to the left of Rung 12. Select T3/DN and click

on OK. 13. Add a Counter control to the right of Rung 12. Select C1, select DOWN, and enter 5

for the Preset. Click on OK. Rung 12 is complete. 14. Add Rung 13.


Module Guide 43

Lesson 6, More Programming (continued) 15. Add a Normally Open Contact control to the left of Rung 13. Select T3/DN and then

click on OK. 16. Add a Reset control to the right of Rung 13. Select T2 and then click on OK. 17. Add another Reset control directly under the one you just added. Select T3 and then

OK. Rung 13 is complete.

18. Save your work. 19. Now click on Control from the Main Menu and select External Device. Click on the

Run Diagram button. 20. On the Industrial Control Trainer, push the green Start button. The program now



44 Module Guide

Lesson 6, More Programming (continued) 21. Place the plastic rings and the aluminum pegs on the chain conveyor. The chain

conveyor will lift them to a higher level, then the plastic rings will be detected by an infrared sensor and will be ejected down the assembly chute. The aluminum pegs will continue on the conveyor. They will be deflected down the feeder chute and automatically fed onto the belt conveyor. The assembly hopper-full detector will determine whether or not the plastic ring "hopper" is empty. If it is, a rotary solenoid will dispense a plastic ring from the assembly chute into the hopper. When the aluminum peg passes the hopper, it engages with the hole in the plastic ring and the two are assembled.


Stop button on the ICT. 23. Click on the Stop Diagram button. You will now continue adding rungs to your program. 1. Add Rung 14. 2. Add a Normally Closed Contact control to the left of Rung 14. Select IP3 and then

OK. 3. Add a Normally Open Contact control next to the NCC you just added. Select IP8

and then OK. 4. Add an Output control to the right of Rung 14. Select R1 in the Register Bits box and

then click on OK. Rung 14 is complete. 5. Add Rung 15. 6. Add a Normally Closed Contact control to the left of Rung 15. Select IP4 and then

OK. 7. Add a Bit Shift control to the right of Rung 15. In the Register box click on R1. Select

Left in the Left/Right box. In the Bit box, click in the circle next to Flags. Now click on the down arrow under Flags and scroll down to F14. Click on OK. Rung 15 is complete.

8. Add Rung 16. 9. Add a Normally Closed Contact control to the left of Rung 16. Select IP4 and then

OK.


Module Guide 45

Lesson 6, More Programming (continued) 10. Add a Bit Shift control to the right of Rung 16. Select R2 in the Register box. Select

Left in the Left/Right box. Click on Flags in the Bit box. Click on the down arrow under Flags and scroll down to F14. Click on OK. Rung 16 is complete.

11. Save your work. 12. Add Rung 17. 13. Add a Normally Open Contact control to the left of Rung 17. Select R1 and then OK. 14. Add another Normally Open Contact control next to the one you just added. Select

R2 and then OK.


46 Module Guide

Lesson 6, More Programming (continued) 15. Add a branch directly under the two controls you just added. Click on the Add

Branch button. Start the branch directly under the first Normally Open Contact and end it after the other one. If the branch is correct, click on Yes.

16. Add a Normally Open Contact control to the left of this new branch. Click on R1.

Now click on the down arrow that appears in the box next to R1 and select Bit 1. Click on OK.

17. Add a Normally Open Contact control next to the one you just added. Select R2 and

Bit 1 and then OK. 18. Add another branch under these Normally Open Contact controls just as you did

before. 19. Add a Normally Open Contact control to the left of this new branch. Select R1 and

Bit 2 and then OK. 20. Add another Normally Open Contact control next to this one. Select R2 and Bit 2

and then OK.


Module Guide 47

Lesson 6, More Programming (continued) 21. Add another branch under this one as you did before. 22. Add a Normally Open Contact control to the left of this new branch. Select R1 and

Bit 3 and then OK. 23. Add a Normally Open Contact control next to this one. Select R2 and Bit 3 and then

OK. 24. Add an Output control to the right of Rung 17. Select 1 in the Flags box and then


25. Add Rung 18. 26. Add a Normally Open Contact control to the left of Rung 18. Select IP5 and then

click on OK. 27. Add a Normally Closed Contact control right next to the Normally Open Contact

control you just added. Select F1 in the Flags box and then OK. 28. You will now add a branch. Start the branch directly under the Normally Open

Contact control and end the branch right after the Normally Closed Contact control. If the branch is correct, click on Yes.


48 Module Guide

Lesson 6, More Programming (continued) 29. Add a Normally Open Contact control to the new branch. Select OP3 and then OK.

Add a Normally Closed Contact control next to the other Normally Closed Contact control, after the new branch ends. Select T4/DN and click OK.

30. Add an Output control to the right of Rung 18. Select OP3 and then OK. Rung 18 is

complete.


OK. 33. Add a Timer control to the right of Rung 19. Select T4 and enter 1 in the Preset box.

Select Latched on Delay Timer and click on OK. Rung 19 is complete.


Module Guide 49

Lesson 6, More Programming (continued) 34. Save your work. 35. Add Rung 20. 36. Add a Normally Open Contact control to the left of Rung 20. Select T4/DN and then

OK. 37. Add a Reset control to the right of Rung 20. Select T4 and then OK. Rung 20 is

complete.

38. Add Rung 21. 39. Add a Normally Open Contact control to the left of Rung 21. Select IP5 and then OK. 40. Add a Latch Output control to the right of Rung 21. Select 2 in the Flags box and

then OK. Rung 21 is complete. 41. Add Rung 22. 42. Add a Normally Closed Contact control to the left of Rung 22. Select IP5 and then

OK. 43. Add a Normally Open Contact control next to the Normally Closed Contact control.

Select F2 in the Flags box and then OK. 44. Add a Bit Shift control to the right of Rung 22. Select R2, select RIGHT, and click on

Flags. Now click on the down arrow under Flags and select F14. Then click on OK. Rung 22 is complete.


click on OK. 47. Add a Normally Open Contact control next to the Normally Closed Contact control



50 Module Guide

Lesson 6, More Programming (continued) 48. Add an Unlatch Output control to the right of Rung 23. Select 2 in the Flags box and

then OK. Rung 23 is complete.

49. Save your work. 50. To run this program with the ICT, click on Control from the Main Menu and select




Module Guide 51





and then on Exit. Go to the next section in the presentation.


52 Module Guide

Lesson 7, Manually Controlling the ICT 1. You will first do a practice run, and then you will “race the clock” and try to assemble

as many components as you can within a certain time. Place one plastic ring and one metal peg on the chain conveyor.




4. When the plastic ring passes the sort area detector, double-click on the sort solenoid

button on the ICT3 Interactive Program to try to push the ring down the assembly chute. Don't worry if you miss, you will get another chance. (You must double-click the sort solenoid button. If you only single-click this button, the solenoid does not retract.)


proceed to the feeder chute, where it stops on the belt conveyor.


Module Guide 53

Lesson 7, Manually Controlling the ICT (continued) 6. Double-click the rotary solenoid button on the ICT3 Interactive Program. This will

release the plastic ring into the assembly hopper.


metal peg and the plastic ring get assembled.

8. On the ICT3 Interactive Program, click on the chain conveyor button and the belt

conveyor button to turn them off. 9. Do this practice run a few times following the same steps. Take turns with your

partner. 10. After you are done practicing, you will try to assemble as many components as you

can within a certain time frame. You will follow the same steps as before, but this time you will place all the plastic rings and all the metal pegs on the chain conveyor.

11. Take out the stopwatch. Together with your partner decide on a time limit (maybe 1

minute). One partner will take his or her turn while the other partner serves as a time keeper. The timekeeper will keep track of how many components are assembled. During the specified time, the other partner assembles plastic rings and metal pegs and reloads them on the chain conveyor. When it is your turn, you will try to manually control the ICT to assemble as many components as possible within the specified time frame. Then, the partners will switch tasks.


54 Module Guide

Lesson 7, Manually Controlling the ICT (continued) 12. If you have time, you and your partner can work together to share the manufacturing

responsibility. One partner's task will be to properly load the plastic and metal materials on the chain conveyor as the other partrner manually controls the ICT to assemble the components.

13. When you are finished, close the ICT3 Interactive Program by clicking on the "x"



Module Guide 55

Comprehensive Level

Lesson 3, ICT3 Interactive Program 1. Place one plastic ring and one metal peg on the chain conveyor.





56 Module Guide

Lesson 3, ICT3 Interactive Program (continued) 4. When the plastic ring passes the sort area detector (notice the sensor indicators on

the ICT3 Interactive Program), double-click on the sort solenoid button on the ICT3 Interactive Program to try to push the ring down the assembly chute. Don’t worry if you miss, you will get another chance. (You must double-click the sort solenoid button. If you only single-click this button, the solenoid does not retract.)


proceed to the feeder chute, where it stops on the belt conveyor. 6. Double-click the rotary solenoid button on the ICT3 Interactive Program. This will

release the plastic ring into the assembly hopper. Take a look at the ICT3 screen and notice that the assembly hopper-full detector is lit.




conveyor button to turn them off.


Module Guide 57

Lesson 3, ICT3 Interactive Program (continued) 9. Do the same activity a few times following the same steps. Each time, watch the

computer screen to see the appropriate sensors light up. Take turns with your partner.




58 Module Guide

Lesson 4, LADSIM You will now run a program that will turn on both the chain and belt conveyors when the Start button on the Industrial Control Trainer (ICT) is pressed. It will also turn off the conveyors when the Stop button on the ICT is pressed. Let’s see if it works. 1. From the Main menu click on File and then Open Diagram. 2. The Open Diagram dialog box appears. Make sure you are in the c:\Program


3. Click on OK. 4. Now click on Control from the Main menu and then on External Device. Click on the

Run Diagram button.

5. On the Industrial Control Trainer, push the green Start button. The program now

runs the ICT. Both conveyors are on. Turn off the conveyors by pressing the red stop button on the ICT.

6. Click on the Stop Diagram button from the Main menu. (Remember, if you place

your cursor over a button on the screen, the name of that button will pop up.) 7. When you are finished, exit the LADSIM software by first clicking on File and then on

Exit. Go to the next section in the presentation.


Module Guide 59

Lesson 5, Programming Ladder Logic 1. From the Main Menu, click and hold the Normally Open Contact button and then

drag it to the left side of the rung. Release the mouse. (NOTE: there is a printout of this Main Menu graphic at the end of the Module Guide – refer to it when you are performing the activities.)


60 Module Guide

Lesson 5, Programming Ladder Logic (continued) 2. The Inputs window appears. Click in the circle next to IP0. Click on OK.

3. The Ladder Rung with a numbered Normally Open Contact symbol appears. You will

now place another Normally Open Contact symbol on the rung to the right of the first one. Click and hold the Normally Open Contact button and drag it to the right of the first one. Release the mouse.

4. From the Inputs window, click on the circle next to IP1 then click on OK. (NOTE: if

you clicked on the wrong number, click Cancel and try it again.) 5. You are now going to add an output symbol. This will be positioned on the far right of

the rung. Click and hold the Output button and then drag it to the right of the rung. Release the mouse.


Module Guide 61

Lesson 5, Programming Ladder Logic (continued) 6. The Outputs window appears. Click on the circle next to OP0 and then click on OK.

The ladder AND function is complete.


appears. You will save the program in the C:\Program Files\Bytronic\Ladsim3 directory. If you are not in that directory, double-click on the C:\ folder, then double-click on the Program Files, then double-click on the Bytronic folder, and finally double-click on the Ladsim3 folder. In the Filename box enter a filename (no more than eight characters long). Click on OK.

SIMULATING THE PROGRAM 8. You will now simulate the AND ladder function that is displayed in the LADSIM

window. Click on the Control button from the Main Menu and select Debugger. The Debugger window appears.


62 Module Guide

Lesson 5, Programming Ladder Logic (continued) 9. Click on the Run Diagram button from the Main Menu. 10. Click on the IP0 button. The first contact on the ladder rung will change to red

indicating that it is switched "on."

11. Now click on the IP1 button. The second contact on the rung will also turn red and

the OP0 output on the Debugger window will turn red indicating that is energized. The output on the rung will also turn red.

12. Click on the Stop Diagram button from the Main Menu to stop the simulation. PROGRAMMING OR AND NOT LADDER FUNCTIONS 13. To program the OR function, you will modify the AND function that you just

completed. You need to first delete the second symbol (IP1). From the Main Menu, click on Edit and then select Delete Control. Click on the IP1 symbol. The following prompt appears: "Are you sure you want to Input IP1?" Click on Yes.


Module Guide 63

Lesson 5, Programming Ladder Logic (continued) 14. You will now add a branch. From the Main Menu, click on Edit and select Add

Branch. The figure below shows you where you should begin and end the branch.

15. Once you finished the branch, a dialog box appears asking you if this branch is

correct. If you have positioned the branch correctly (see the graphic below), click on Yes. If you have not positioned the branch correctly, click on No and try again.

16. When you click on Yes, the branch is added.


64 Module Guide

Lesson 5, Programming Ladder Logic (continued) 17. From the Main Menu, click and hold the Normally Open Contact button and drag it to

the branch. Number the contact IP1 and then click on OK.



19. Next, simulate the program by clicking on the Control button from the Main Menu

and selecting Debugger. The Debugger window appears. 20. Click on the Run Diagram button from the Main Menu. 21. Test the rung. Begin by first seeing what the output is (OP0) on the Debugging

window when IP0 and IP1 are open (0). Is it energized? Now click on the IP0 button to close it (1) while keeping the IP1 button open (0). The first contact on the ladder rung (IP0) turns red and the second rung (IP1) stays the same. The output turns red indicating that it is energized.

22. When you are finished with your test, click on the Stop Diagram button from the

Main Menu.


Module Guide 65

Lesson 5, Programming Ladder Logic (continued) 23. You will now modify the OR ladder program to create a NOT function. Click, hold,

and drag the Normally Closed Contact button to the right of the other contacts. Number this contact IP2 and then click on OK.



25. Now click on the Control button and select Debugger. Make sure IP0 and IP1 are off

(switch is up). Click on the Run Diagram button. You will see immediately that the normally closed contact IP2 is already covered red, indicating power. But note that the output is off. This is because the power flow is left to right and it would require IP0 and IP1 to be switched on to obtain power to the output.

26. Click on the Stop Diagram button when you are finished testing. 27. Click on File and then Exit to exit the program. Go to the next section in the presentation.


66 Module Guide

Lesson 6, Bottling Plant Program 1. You will begin by adding a command to start conveyors 1 and 2 moving

continuously. Click, hold, and drag the Output button from the Main Menu to the right side of Rung 0. When you release the mouse button the Outputs window appears.

2. Select OP0 and then click on OK. 3. Click, hold, and drag the Output button directly below the output you just created

(OP0). The graphic below shows where you must place this control. (NOTE: if you make a mistake, click on Cancel and then try again.)

4. Select OP4 from the Outputs window and click on OK. Rung 0 is complete.

5. You will now add a new rung. Click on the Add Rung button. Rung 1 appears below

Rung 0.

6. You will now add the bottle stop sensor (IP0) and the stop bottle piston. Click, hold,

and drag the Normally Open Contact button to the left side of Rung 1. Select IP0 and then click on OK.

7. Next, click, hold, and drag the Normally Closed Contact button to the right of the

Normally Open Contact control. In the Flags box, click on F0. Click on OK. 8. Click, hold, and drag the Latch Output button to the right side of Rung 1. Click on

OP1 and then on OK. 9. You will now add a rung that will activate the bottle filler piston to fill the bottle, once

the stop bottle piston has been activated and the level sensor does not show a full bottle. First click on the Add Rung button to add Rung 2.


Module Guide 67

Lesson 6, Bottling Plant Program (continued) 10. Click, hold, and drag the Normally Open Contact button to the left of Rung 2. Select

OP1 from the Outputs box and then click on OK. Now click, hold, and drag the Normally Closed Contact button to the right of the Normally Open Contact control. Select IP1 from the Inputs box and then click on OK.

11. Click, hold, and drag the Output button to the right of Rung 2. Click on OP3 and then

click on OK. Rung 2 is complete. 12. You will now add a rung to start a timer to allow the filler piston to move out of the

way before the cap is placed on the bottle once a full bottle is detected. Click on the Add Rung button to add Rung 3.

13. Click, hold, and drag the Normally Open Contact button to the left of Rung 3. Select

IP1 and then click on OK. 14. Click, hold, and drag the Timer icon to the right of Rung 3. The Timers window

appears. In the Timers box, click on T1. In the Preset box, enter 2.5. Select Latched On Delay Timer for the Timer Style. Then click on OK. Rung 3 is complete.


68 Module Guide

Lesson 6, Bottling Plant Program (continued) 15. Save your program by clicking on File and then Save Diagram. The Save As window

appears. You will save the program in the C:\Program Files\Bytronic\Ladsim3 directory. If you are not in that directory, double-click on the C:\ folder, then double click on the Program Files folder, double-click on the Bytronic folder, and finally double-click on the Ladsim3 folder. In the Filename box enter a filename (no more than eight characters long). Click on OK.

16. You will add a rung to activate the cap piston once the time has elapsed and the limit

switch on the cap piston has not been activated. Click on the Add Rung button to add Rung 4.

17. Click, hold, and drag the Normally Open Contact button to the left of Rung 4. In the

Timers box, click on T1/DN and then on OK. 18. Add a Normally Closed Contact control to the right of the Normally Open Contact

control. Click on IP2 and then on OK. Add another Normally Closed Contact control to the right of this one. Click on F0 in the Flags box and then on OK. Add a Normally Open Contact next to this one. Click on OP1 and then on OK.

19. Now add an Output control to the right of Rung 4. Click on OP2 and then on OK.

Rung 4 is complete. 20. You will add a rung to unlatch the bottle stop piston and allow the bottle to continue

once the cap piston limit has been reached. Click on the Add Rung button to add Rung 5.

21. Add a Normally Open Contact control to the left of Rung 5. Click on IP2 and then on

OK. 22. Add an Unlatch Output control to the right of Rung 5. Select OP1 and then OK. Now

add a Latch Output control below the Unlatch Output. Select 0 under the Flags box and then click on OK. Rung 5 is complete.

23. You will now add a rung to reset the flag and timer used once the bottle has moved

away from the bottle sensor. Click on the Add Rung button to add Rung 6. 24. Add a Normally Open Contact control to the left of Rung 6. Select IP3 and then click

on OK. 25. Now add a Reset control to the right of Rung 6. Select T1 and then click on OK. 26. Next add an Unlatch Output control directly below the Reset control. Select 0 in the

Flags box and then click on OK. Rung 6 is complete.


Module Guide 69

Lesson 6, Bottling Plant Program (continued) 27. You will now add another rung to activate the cap winder piston once the bottle has

reached the cap winder. Click on the Add Rung button to add Rung 7. 28. Add a Normally Open Contact to the left of Rung 7. Select IP4 and then OK. 29. Add a Latching Output control to the right of Rung 7. Select OP5 and then OK. Rung

7 is complete. 30. Save your work as you did before.

31. You will now add a new rung to retract the bottle winder piston once the bottle has

reached the counter sensor. Click on the Add Rung button to add Rung 8. 32. Add a Normally Open Contact to the left of Rung 8. Select IP5 and then OK. 33. Add an Unlatch Output control to the right of Rung 8. Select OP5 and then OK. Rung

8 is complete.


70 Module Guide

Lesson 6, Bottling Plant Program (continued) 34. You will now add a rung to set the counter sensor so it counts 3 bottles moving past

it. Click on the Add Rung to add Rung 9. 35. Add a Normally Open Contact control to the left of Rung 9. Select IP5 and then OK. 36. Add a Counter control to the right of Rung 9. Select C1 in the Counters box. Select

Up in the Up/Down box. Enter 3 in the Preset box and then click on OK. Rung 9 is complete.

37. The next rung you add will wait for the bottles to reach the stacker piston once 3

bottles have passed the sensor. Click on the Add Rung button to add Rung 10. 38. Add a Normally Open Contact control to the left of Rung 10. Select C1/UP in the

Counters box and then click on OK. 39. Add a Timer control to the right of Rung 10. Select T2 in the Timers box. Enter 2.5 in


40. You will now add a rung to set a timer to push the piston once the bottle is in

position. Click on the Add Rung button to add Rung 11. 41. Add a Normally Open Contact to the left of Rung 11. Select T2/DN in the Timers box

and then click on OK.


Module Guide 71

Lesson 6, Bottling Plant Program (continued) 42. Add a Timer control to the right of Rung 11. Select T3 in the Timers box. Enter 5.5 in


43. Save your program as you did before. 44. You will now add a rung to push the piston. Click on the Add Rung button to add

Rung 12. 45. Add a Normally Open Contact control to the left of Rung 12. Select T2/DN and then

OK. Add a Normally Closed Contact right next to it. Select T3/DN and then OK. 46. Add an Output control to the right of Rung 12. Select OP6 and click on OK. Rung 12

is complete. 47. You will now add a rung push the bottles onto the stacker and reset the counter and

timer used, once the timer is finished. Click on Add Rung to add Rung 13.


72 Module Guide

Lesson 6, Bottling Plant Program (continued) 48. Add a Normally Open Contact control to the left of Rung 13. Select T3/DN and click

on OK. 49. Add a Reset control to the right of Rung 13. Select T2 in the Timers box and click on

OK. Add a Reset control directly under this and select T3 and then OK. Add another Reset control under the last Reset control. Select T1 in the Timers box and C1 in the Counters box and click on OK. Rung 13 is complete.

50. Next, you will add a rung to increment a second counter so that 3 rows of bottles can

be detected once the bottles have been pushed onto the stacker. Click on the Add Rung button to add Rung 14.

51. Add a Normally Open Contact control to the left of Rung 14. Select T3/DN in the

Timers box and click on OK. 52. Add a Counters control to the right of Rung 14. Select C2 in the Counters box, UP in

the Up/Down box and enter 3 in the Preset box. Then click on OK. Rung 14 is complete.

53. You will now add a rung to wait 3 seconds before continuing once 3 rows of bottles

have been sent to the stacker. Click on the Add Rung button to add Rung 15. 54. Add a Normally Open Contact control to the left of Rung 15. Select C2/UP and then

click on OK.


Module Guide 73

Lesson 6, Bottling Plant Program (continued) 55. Add a Timer control to the right of Rung 15. Select T4 in the Timers box. Enter 3 in

the Preset box. Select Latched on Delay Timer in the Timer Style box and click on OK. Rung 15 is complete.

56. You will now add a rung that will send the bottles down to conveyor 3 once the timer

has finished. Click on Add Rung to add Rung 16. 57. Add a Normally Open Contact control to the left of Rung 16. Select T4/DN in the

Timers box and click on OK. 58. Add an Output control to the right of Rung 16. Select OP7 and then click on OK.

Rung 16 is complete. 59. Save your program.


74 Module Guide

Lesson 6, Bottling Plant Program (continued) 60. You will now add a rung that will start a timer to allow enough time for the bottles to

automatically move onto conveyer 3. Click on Add Rung to add Rung 17. 61. Add a Normally Open Contact control to the left of Rung 17. Select IP6 and click on

OK. 62. Add a Timer control to the right of Rung 17. Select T5 in the Timers box, enter 10 in

the Preset box, and select Latched on Delay Timer in the Timer Style box. Click on OK. Rung 17 is complete.

63. The last rung will reset the timers and counters used once the timer has finished.

Click on Add Rung to add Rung 18. 64. Add a Normally Open Contact control to the left of Rung 18. Select T5/DN and click

on OK. 65. Add a Reset control to the right of Rung 18. Select T4 and click on OK. Add another

Reset control under the last one. Select T5 and click on OK. Add another Reset control under the last one. Select T1 and C2 and then click on OK. Rung 18 is complete and the program is now complete.


Module Guide 75

Lesson 6, Bottling Plant Program (continued) SIMULATING THE PROGRAM 66. From the Main Menu, click on Simulations and select Bottling Plant. Click on the Run

Diagram button. 67. Watch the simulation. Take notice to how well the timers work. Remember you

programmed 2.5 seconds to allow the filler piston to move out of the way before the cap is placed on the bottle. Also, when 3 bottles have passed the counter sensor, the program waits for the bottles to reach the stacker piston. Then once 3 rows of bottles have been sent to the stacker, the program waits before continuing. Lastly, when the stacker is in position, a timer starts to allow enough time for the bottles to automatically move onto the conveyor 3.

68. When you are done, click on the Stop Diagram button. 69. Click on File and then on Exit. 70. Go to the next section in the presentation.


76 Module Guide

Lesson 7, Writing a Program 1. Add a Normally Closed Contact control to the left of Rung 0. Do you remember how

to do this? Click, hold, and drag the Normally Closed Contact button to the left of Rung 0.

2. In the Inputs window, click on F15 in the Flags box and then click on OK. 3. Add a Latch Output control to the right of Rung 0. Select 15 from the Flags box and

then click on OK. 4. Add an Output control to the right of Rung 0, directly under the Latch Output control

you just added. Select R2 from the Register Bits box and then click on OK. 5. Rung 0 is complete. 6. Click on Add Rung to add Rung 1. 7. Add a Normally Open Contact control to the left of Rung 1. Select IP6 from the

Inputs box and then click on OK. 8. Add another Normally Open Contact control right next to the one you just added.

Select IP7 for the input and then select OK. 9. You will now add a branch directly under the first Normally Open Contact (IP6), as

shown in the graphic below. Click on the Add Branch button. Click under the Normally Open Contact, to the left of Rung 1, to start the branch, and then click under the Normally Open Contact to the right, just before the other NOC begins, to end the branch. If the branch is in the correct place, select Yes. If not, select No and try again.


Module Guide 77

Lesson 7, Writing a Program (continued) 10. To this new branch, add a Normally Open Contact control. Select OP0 for the output

and then select OK. 11. Add an OP control to the right of Rung 1. Select OP0 for the output and then click on

OK. 12. Add another OP control right next to the one you just added. Select OP4 for the

output and then click on OK. Rung 1 is complete.

13. Save your work by selecting File and then Save from the Main Menu. Enter a

filename no longer than 8 characters. Save your program in the C:\Program Files\Bytronic\Ladsim3 directory. Click on OK.

14. You just wrote a program to turn on both the chain (OP0) and belt (OP1) conveyors

when the start button (IP6) on the ICT is pressed. It will also turn off the conveyors when the stop button (IP7) on the ICT is pressed. Let's see if it works.

15. Now click on Control from the Main Menu and select External Device. Click on the

Run Diagram button. 16. Press the green Start button on the ICT. The program now runs the ICT. Both

conveyors are on. Turn off the conveyors by pressing the red Stop button on the ICT.

17. Click on the Stop Diagram button. 18. You will now continue programming more steps.


78 Module Guide

Lesson 7, Writing a Program (continued) 19. You will now add to your program. Click on the Add Rung button to add Rung 2. 20. Add a Normally Open Contact control to the left of Rung 2. Select IP0 for the input

and then click on OK. 21. Add a Latch Output control to the right of Rung 2. Select 3 in the Flags box and then


22. Add Rung 3 by clicking on Add Rung. 23. Add a Normally Open Contact control to the left of Rung 3. Select F3 in the Flags

box and then click on OK.


Module Guide 79

Lesson 7, Writing a Program (continued) 24. Add a Timer control to the right of Rung 3. Select T5 in the Timers box and enter 3 in

the Preset box. Click on OK. Rung 3 is complete.

25. Add Rung 4. 26. Add a Normally Open Contact control to the left of Rung 4. Select IP1 for the input

and click on OK. 27. Add a Normally Closed Contact control next to the Normally Open Contact control



80 Module Guide

Lesson 7, Writing a Program (continued) 28. Add another Normally Closed Contact control next to the one you just added. Select

C1/UP in the Counters box and click on OK. 29. Add another Normally Closed Contact next to the one you just added. Select T1/DN

in the Timers box and click on OK. 30. You will add a branch under the Normally Open Contact control, exactly as it

appears in the graphic below. This branch will start directly under it and to the left. It will end to the right of the C1/UP control, just before the T1/DN control begins. You will do this by first clicking on the Add Branch button. Then by clicking directly under the Normally Open Contact control, to the left, to start the branch; and then clicking between the C1/UP control and the T1/DN control. If the branch is correct, select Yes. If it is not, select No and try again.

31. Add a Normally Open Contact control to this new branch. Select OP1 for the output and then click on OK.

32. Add an Output to the right of Rung 4. Select OP1 for the output and then click on

OK. Rung 4 is complete. 33. Save your work. 34. Add Rung 5 to your program. 35. Add a Normally Open Contact control to the left of Rung 5. Select T5/DN in the

Timers box and click on OK. 36. Add a Reset control to the right of Rung 5. Select T5 in the Timers box and click on

OK.


Module Guide 81

Lesson 7, Writing a Program (continued) 37. Add an Unlatch Output control directly under the Reset control. Select 3 in the Flags

box and click on OK. Rung 5 is complete.

38. Add Rung 6. Add a Normally Open Contact control to the left of Rung 6. Select OP1 for the output and click on OK.

39. Add a Timer control to the right of Rung 6. Select T1 in the Timers box and enter 1 in

the Preset box. Select Latched on Delay for Timer Style. Click on OK. Rung 6 is complete.

40. Add Rung 7. 41. Add a Normally Open Contact control to the left of Rung 7. Select T1/DN in the

Timers box and click on OK. 42. Add a Counter control to the right of Rung 7. Select C1 in the Counters box, select

UP in the Up/Down box, and enter 5 in the Preset box. Click on OK. Rung 7 is complete.


82 Module Guide

Lesson 7, Writing a Program (continued) 43. Add Rung 8. 44. Add a Normally Open Contact control to the left of Rung 8. Select T1/DN for the

timers and click on OK. 45. Add a Reset control to the right of Rung 8. Select T1 and then OK. Rung 8 is

complete.

46. Save your work. 47. Add Rung 9. 48. Add a Normally Closed Contact control to the left of Rung 9. Select C1/DN in the

Counters box and click on OK. 49. Add another Normally Closed Contact control next to the one you just added. Select

IP2 for the input and then click on OK. 50. Add a Timer control to the right of Rung 9. Select T2 and enter 1 in the Preset box.

Select Latched on Delay for Timer Style. Click on OK. Rung 9 is complete. 51. Save your work.

52. To run this program with the ICT, click on Control from the Main Menu and select




Module Guide 83

Lesson 7, Writing a Program (continued) 54. Place the plastic rings and the aluminum pegs on the chain conveyor. The chain




and then on Exit. 57. Go to the next section in the presentation


84 Module Guide

Lesson 8, More Programming 1. Click on File and then Open Diagram from the Main menu. Click on the file name for

your program and then click on OK. 2. Add Rung 10. 3. Add a Normally Open Contact control to the left of Rung 10. Select T2/DN and then

click on OK. 4. Add a branch under the Normally Open Contact control, exactly like in the graphic

below. Click on the Add Branch button. Begin the branch directly under the NOC control and to the far left. Then end the branch directly under the Normally Open Contact control to the right. If the branch is correct, click on Yes. If it is not, click on No and try again.

5. Add a Normally Open Contact control to the new branch. Select OP2 and then OK. 6. Add a Normally Closed Contact control next to the first Normally Open Contact

control (not the one on the branch). Select T3/DN in the Timers box and click on OK.


Module Guide 85

Lesson 8, More Programming (continued) 7. Add an Output control to the right of Rung 10. Select OP2 and then OK. Rung 10 is

complete.


OK. 10. Add a Timer control to the right of Rung 11. Select T3 and enter 1 for the Preset.

Select Latched on Delay Timer for Timer Style. Click on OK. Rung 11 is complete.

11. Add Rung 12. 12. Add a Normally Open Contact control to the left of Rung 12. Select T3/DN and click

on OK. 13. Add a Counter control to the right of Rung 12. Select C1, select DOWN, and enter 5

for the Preset. Click on OK. Rung 12 is complete. 14. Add Rung 13.


86 Module Guide

Lesson 8, More Programming (continued) 15. Add a Normally Open Contact control to the left of Rung 13. Select T3/DN and then

click on OK. 16. Add a Reset control to the right of Rung 13. Select T2 and then click on OK. 17. Add another Reset control directly under the one you just added. Select T3 and then

OK. Rung 13 is complete.

18. Save your work. 19. Now click on Control from the Main Menu and select External Device. Click on the

Run Diagram button. 20. On the Industrial Control Trainer, push the green Start button. The program now



Module Guide 87


conveyor will lift them to a higher level, then the plastic rings will be detected by an infrared sensor and will be ejected down the assembly chute. The aluminum pegs will continue on the conveyor. They will be deflected down the feeder chute and automatically fed onto the belt conveyor. The assembly hopper-full detector will determine whether or not the plastic ring "hopper" is empty. If it is, a rotary solenoid will dispense a plastic ring from the assembly chute into the hopper. When the aluminum peg passes the hopper, it engages with the hole in the plastic ring and the two are assembled.


Stop button on the ICT. 23. Click on the Stop Diagram button. 24. You will now continue adding rungs to your program. 25. Add Rung 14. 26. Add a Normally Closed Contact control to the left of Rung 14. Select IP3 and then

OK. 27. Add a Normally Open Contact control next to the NCC you just added. Select IP8

and then OK. 28. Add an Output control to the right of Rung 14. Select R1 in the Register Bits box and

then click on OK. Rung 14 is complete. 29. Add Rung 15. 30. Add a Normally Closed Contact control to the left of Rung 15. Select IP4 and then

OK. 31. Add a Bit Shift control to the right of Rung 15. In the Register box click on R1. Select

Left in the Left/Right box. In the Bit box, click in the circle next to Flags. Now click on the down arrow under Flags and scroll down to F14. Click on OK. Rung 15 is complete.


OK.


88 Module Guide

Lesson 8, More Programming (continued) 34. Add a Bit Shift control to the right of Rung 16. Select R2 in the Register box. Select

Left in the Left/Right box. Click on Flags in the Bit box. Click on the down arrow under Flags and scroll down to F14. Click on OK. Rung 16 is complete.

35. Save your work. 36. Add Rung 17. 37. Add a Normally Open Contact control to the left of Rung 17. Select R1 and then OK. 38. Add another Normally Open Contact control next to the one you just added. Select

R2 and then OK.


Module Guide 89

Lesson 8, More Programming (continued) 39. Add a branch directly under the two controls you just added. Click on the Add

Branch button. Start the branch directly under the first Normally Open Contact and end it after the other one. If the branch is correct, click on Yes.

40. Add a Normally Open Contact control to the left of this new branch. Click on R1.

Now click on the down arrow that appears in the box next to R1 and select Bit 1. Click on OK.

41. Add a Normally Open Contact control next to the one you just added. Select R2 and

Bit 1 and then OK. 42. Add another branch under these Normally Open Contact controls just as you did

before. 43. Add a Normally Open Contact control to the left of this new branch. Select R1 and

Bit 2 and then OK. 44. Add another Normally Open Contact control next to this one. Select R2 and Bit 2

and then OK.


90 Module Guide

Lesson 8, More Programming (continued) 45. Add another branch under this one as you did before. 46. Add a Normally Open Contact control to the left of this new branch. Select R1 and

Bit 3 and then OK. 47. Add a Normally Open Contact control next to this one. Select R2 and Bit 3 and then

OK. 48. Add an Output control to the right of Rung 17. Select 1 in the Flags box and then


49. Add Rung 18. 50. Add a Normally Open Contact control to the left of Rung 18. Select IP5 and then

click on OK. 51. Add a Normally Closed Contact control right next to the Normally Open Contact

control you just added. Select F1 in the Flags box and then OK. 52. You will now add a branch. Start the branch directly under the Normally Open

Contact control and end the branch right after the Normally Closed Contact control. If the branch is correct, click on Yes.


Module Guide 91

Lesson 8, More Programming (continued) 53. Add a Normally Open Contact control to the new branch. Select OP3 and then OK.

Add a Normally Closed Contact control next to the other Normally Closed Contact control, after the new branch ends. Select T4/DN and click OK.

54. Add an Output control to the right of Rung 18. Select OP3 and then OK. Rung 18 is

complete.


OK. 57. Add a Timer control to the right of Rung 19. Select T4 and enter 1 in the Preset box.

Select Latched on Delay Timer and click on OK. Rung 19 is complete.


92 Module Guide

Lesson 8, More Programming (continued) 58. Save your work. 59. Add Rung 20. 60. Add a Normally Open Contact control to the left of Rung 20. Select T4/DN and then

OK. 61. Add a Reset control to the right of Rung 20. Select T4 and then OK. Rung 20 is

complete.

62. Add Rung 21. 63. Add a Normally Open Contact control to the left of Rung 21. Select IP5 and then OK. 64. Add a Latch Output control to the right of Rung 21. Select 2 in the Flags box and

then OK. Rung 21 is complete. 65. Add Rung 22. 66. Add a Normally Closed Contact control to the left of Rung 22. Select IP5 and then

OK. 67. Add a Normally Open Contact control next to the Normally Closed Contact control.

Select F2 in the Flags box and then OK. 68. Add a Bit Shift control to the right of Rung 22. Select R2, select RIGHT, and click on

Flags. Now click on the down arrow under Flags and select F14. Then click on OK. Rung 22 is complete.


click on OK. 71. Add a Normally Open Contact control next to the Normally Closed Contact control



Module Guide 93

Lesson 8, More Programming (continued) 72. Add an Unlatch Output control to the right of Rung 23. Select 2 in the Flags box and

then OK. Rung 23 is complete.

73. Save your work. 74. To run this program with the ICT, click on Control from the Main Menu and select




94 Module Guide





and then on Exit. 79. Go to the next section in the presentation


Module Guide 95

Lesson 9, Manually Controlling the ICT 1. You will first do a practice run, then you will “race the clock” and try to assemble as

many components as you can within a certain time. Place one plastic ring and one metal peg on the chain conveyor.




4. When the plastic ring passes the sort area detector, double-click on the sort solenoid

button on the ICT3 Interactive Program to try to push the ring down the assembly chute. Don't worry if you miss, you will get another chance. (You must double-click the sort solenoid button. If you only single-click this button, the solenoid does not retract.)


proceed to the feeder chute, where it stops on the belt conveyor.


96 Module Guide

Lesson 9, Manually Controlling the ICT (continued) 6. Double-click the rotary solenoid button on the ICT3 Interactive Program. This will

release the plastic ring into the assembly hopper.


metal peg and the plastic ring get assembled.

8. On the ICT3 Interactive Program, click on the chain conveyor button and the belt

conveyor button to turn them off. 9. Do this practice run a few times following the same steps. Take turns with your

partner. 10. After you are done practicing, you will try to assemble as many components as you

can within a certain time frame. You will follow the same steps as before, but this time you will place all the plastic rings and all the metal pegs on the chain conveyor.

11. Take out the stopwatch. Together with your partner decide on a time limit (maybe 1

minute). One partner will take his or her turn while the other partner serves as a timekeeper. The timekeeper will keep track of how many components are assembled. During the specified time, the other partner assembles plastic rings and metal pegs and reloads them on the chain conveyor. When it is your turn, you will try to manually control the ICT to assemble as many components as possible within the specified time frame. Then, the partners will switch tasks.


Module Guide 97

Lesson 9, Manually Controlling the ICT (continued) 12. If you have time, you and your partner can work together to share the manufacturing

responsibility. One partner's task will be to properly load the plastic and metal materials on the chain conveyor as the other partner manually controls the ICT to assemble the components.




98 Module Guide


Module Guide 99

LADSIM3 Main Menu

Documents

Beginning, Advanced, Comprehensive Levels · Select Ladder Diagrams (Ladsim version 2) in the Files of type drop-down box. Click on the LADSIM 1 file. 3. Click on OK. 4. Now click