Beginning, Advanced, Comprehensive Levels · Select Ladder Diagrams (Ladsim version 2) in the Files...
Transcript of Beginning, Advanced, Comprehensive Levels · Select Ladder Diagrams (Ladsim version 2) in the Files...
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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
Files\Bytronic\Ladsim3 directory. Select Ladder Diagrams (Ladsim version 2) in the Files of type drop-down box. Click on the LADSIM 2 file.
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.
Manufacturing Processes Directions
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
Exit. 16. Go to the next section in the presentation.
Manufacturing Processes Directions
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
Files\Bytronic\Ladsim3 directory. Select Ladder Diagrams (Ladsim version 2) in the Files of type drop-down box. Click on the LADSIM 3 file.
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, 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
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.
Manufacturing Processes Directions
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
Exit. 16. Go to the next section in the presentation.
Manufacturing Processes Directions
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
Files\Bytronic\Ladsim3 directory. Select Ladder Diagrams (Ladsim version 2) in the Files of type drop-down box. Click on the LADSIM 4 file.
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, 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
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
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.
Manufacturing Processes Directions
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.)
5. The metal peg will pass through the sort area detector and metal peg detector and
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.
Manufacturing Processes Directions
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
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. 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.
Manufacturing Processes Directions
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.)
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
6. 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. 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.
Manufacturing Processes Directions
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.
12. 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. In the Filename box enter a filename (no more than eight characters long). 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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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
the Preset box. Select Latched on Delay Timer for the Timer Style and then click on OK. Rung 11 is complete.
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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
runs the ICT. Both conveyors are on.
Manufacturing Processes Directions
40 Module Guide
Lesson 5, Writing a Program (continued) 36. 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.
37. When all the components have passed by the sensors, turn off the conveyors by
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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
runs the ICT. Both conveyors are on.
Manufacturing Processes Directions
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.
22. When all the components are assembled, turn off the conveyors by pressing the red
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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
click on OK. Rung 17 is complete.
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.
Manufacturing Processes Directions
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.
31. Add Rung 19. 32. Add a Normally Open Contact control to the left of Rung 19. Select OP3 and then
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.
Manufacturing Processes Directions
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.
45. Add Rung 23. 46. Add a Normally Closed Contact control to the left of Rung 23. Select IP5 and then
click on OK. 47. Add a Normally Open Contact control next to the Normally Closed Contact control
you just added. Select F2 in the Flags box and then click on OK.
Manufacturing Processes Directions
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
External Device. Click on the Run Diagram button. 51. On the Industrial Control Trainer, push the green Start button. The program now
runs the ICT. Both conveyors are on.
Manufacturing Processes Directions
Module Guide 51
Lesson 6, More Programming (continued) 52. 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.
53. When all the components have passed by the sensors, turn off the conveyors by
pressing the red Stop button on the ICT. 54. Click on the Stop Diagram button. Exit the LADSIM software by first clicking on File
and then on Exit. Go to the next section in the presentation.
Manufacturing Processes Directions
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.
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. 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.)
5. The metal peg will pass through the sort area detector and metal peg detector and
proceed to the feeder chute, where it stops on the belt conveyor.
Manufacturing Processes Directions
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.
7. Click on the belt conveyor button on the ICT3 Interactive Program and watch the
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.
Manufacturing Processes Directions
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"
icon that appears in the upper right corner of your screen. 14. Go to the next section in the presentation.
Manufacturing Processes Directions
Module Guide 55
Comprehensive Level
Lesson 3, 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.
Manufacturing Processes Directions
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.)
5. The metal peg will pass through the sort area detector and metal peg detector and
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.
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.
Manufacturing Processes Directions
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.
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.
Manufacturing Processes Directions
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
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. Go to the next section in the presentation.
Manufacturing Processes Directions
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.)
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
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 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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
18. 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. In the Filename box enter a filename (no more than eight characters long). 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.
Manufacturing Processes Directions
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.
24. 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. In the Filename box enter a filename (no more than eight characters long). 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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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
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.
Manufacturing Processes Directions
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
the Preset box. Select Latched on Delay Timer for the Timer Style and then click on OK. Rung 11 is complete.
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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
click on OK. Rung 2 is complete.
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.
Manufacturing Processes Directions
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
you just added. Select F3 in the Flags box and then click on OK.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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
External Device. Click on the Run Diagram button. 53. On the Industrial Control Trainer, push the green Start button. The program now
runs the ICT. Both conveyors are on.
Manufacturing Processes Directions
Module Guide 83
Lesson 7, Writing a Program (continued) 54. 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.
55. When all the components have passed by the sensors, turn off the conveyors by
pressing the red Stop button on the ICT. 56. Click on the Stop Diagram button. Exit the LADSIM software by first clicking on File
and then on Exit. 57. Go to the next section in the presentation
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
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.
Manufacturing Processes Directions
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
runs the ICT. Both conveyors are on.
Manufacturing Processes Directions
Module Guide 87
Lesson 8, 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.
22. When all the components are assembled, turn off the conveyors by pressing the red
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.
32. Add Rung 16. 33. Add a Normally Closed Contact control to the left of Rung 16. Select IP4 and then
OK.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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.
Manufacturing Processes Directions
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
click on OK. Rung 17 is complete.
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.
Manufacturing Processes Directions
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.
55. Add Rung 19. 56. Add a Normally Open Contact control to the left of Rung 19. Select OP3 and then
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.
Manufacturing Processes Directions
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.
69. Add Rung 23. 70. Add a Normally Closed Contact control to the left of Rung 23. Select IP5 and then
click on OK. 71. Add a Normally Open Contact control next to the Normally Closed Contact control
you just added. Select F2 in the Flags box and then click on OK.
Manufacturing Processes Directions
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
External Device. Click on the Run Diagram button. 75. On the Industrial Control Trainer, push the green Start button. The program now
runs the ICT. Both conveyors are on.
Manufacturing Processes Directions
94 Module Guide
Lesson 8, More Programming (continued) 76. 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.
77. When all the components have passed by the sensors, turn off the conveyors by
pressing the red Stop button on the ICT. 78. Click on the Stop Diagram button. Exit the LADSIM software by first clicking on File
and then on Exit. 79. Go to the next section in the presentation
Manufacturing Processes Directions
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.
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. 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.)
5. The metal peg will pass through the sort area detector and metal peg detector and
proceed to the feeder chute, where it stops on the belt conveyor.
Manufacturing Processes Directions
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.
7. Click on the belt conveyor button on the ICT3 Interactive Program and watch the
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.
Manufacturing Processes Directions
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.
13. 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. 14. Go to the next section in the presentation.
Manufacturing Processes Directions
98 Module Guide
Manufacturing Processes Directions
Module Guide 99
LADSIM3 Main Menu