Skills Canada National Competition · Skills Canada National Competition Specification Day 1 – Material portion of the project 19 – Automation and Control / Post - Secondary May

Skills Canada National Competition Specification Day 1 – Material portion of the project

19 – Automation and Control / Post - Secondary May 27-30, 2015 - Saskatoon

MAT Day 1 v3.2 2 May 2015

1.0 - INTRODUCTION

1.1 – GENERAL ........................................................................................................................ 3

1.2 – STEP A: INSTALLATION OF ELECTRICAL RACEWAYS AND COMPENTS AS PER SPEC. ............. 3

1.3 – STEP B: WIRING AN AUTOMATED PROCESS WITHIN A PANEL ............................................... 3

1.4 – STEP C: PROGRAMMING THE AUTOMATED PROCESS .......................................................... 3

1.5 – STEP D: TROUBLESHOOTING ............................................................................................ 3

2.0 - CONDUCTORS

2.1 – SIZE AND USE ................................................................................................................... 4

2.2 – COLOUR CODE ................................................................................................................ 4

3.0 - GENERAL DESCRIPTION

3.1 - Process Diagram…………………………………………………………………………..…5

4.0 - INPUT AND OUTPUTS

4.1 - Technical Details ....................................................................................................... 7

4.2 - Input Table ................................................................................................................. 7

4.3 - Output Table .............................................................................................................. 8

5.0 - PROJECT

5.1 - Power Layout ............................................................................................................. 9

5.2 -Input/Output Diagram ...............................................................................................10

5.3 - Back Panel Layout ...................................................................................................11

5.4 - Door Layout ..............................................................................................................12

5.5 - Wall Layout ...............................................................................................................13


1.0 INTRODUCTION

1.1 – General

With this challenge, we will assess your: a) Ability to analyze technical data. b) Quality of wiring. c) Capacity to implement an automatic process. d) Troubleshooting techniques. e) Abilities for error detection.

1.2 – Step A: Installation of Electrical Raceways and Components as per specifications

Part of all process type projects is the installation of the raceways and components that function as inputs and outputs. We will assess the quality of your installation, interpretation of site drawings, and precision of equipment placement.

1.3 – Step B: Wiring an automated process within a panel

As a technician, you should have the ability to completely wire a system and make the necessary modifications. We will assess the quality of your manual work, the organization of components, use of materials provided.

1.4 – Step C: Programming the automated process

You are provided with a function, and you must program the automated process with your PLC and the VFD provided. The system must be functional, and adhere to the instructions.

1.5 – Step D: Troubleshooting

Your ability to detect and solve problems will be assessed.


2.0 – Conductors

2.1 – Size and use

1. Power connections must be 14 AWG gauge.

2. Control conductors must be 16 AWG gauge.

3. Any exceptions to paragraphs 1 & 2 will be specifically mentioned on the drawings.

4. Ground connections must be used for grounding purposes only.

2.2 – Colour Code

The following colour code must be used to distinguish circuits: 1. Single phase Identified Conductor White

Line Black

2. Three phase Identified Conductor White Line Red, Black, Blue

3. DC Control Blue 4. AC Control Identified Conductor White

Line Red

5. Grounding Green

6. Input/Output 16/3 Cable White, Black, Red

7. Motor Connections 16/4 Cable White Black

Red Green

3.0 – General Description

The current theme of going green and sustainability, Skills Competition Canada (SCC) is aiming to include plastic recycling in our venue. To reduce our impact on the environment, SCC has acquired equipment for a plastic recycling process, and the electrical department was made responsible for preparing the automation project. You are assigned to execute the project developed by the engineers at HCPlastics.


3.1 – Process diagram


4.0 - Input and Outputs

4.1 Technical Details:

Inputs

Emergency Stop The system is equipped with a general Emergency Stop button.

The Emergency Stop button mounted on the Control Panel Door will be used in conjunction with a 120VAC relay (non-PLC) to create a Master Control Relay/Emergency Stop Circuit. The 120VAC relay will be equipped with both normally-open and normally-closed contacts, as required.

When the Emergency Stop button is depressed, The Master Control Relay/Emergency Stop Circuit will de-energize all of the PLC’s outputs.

All of the PLC’s outputs shall remain de-energized until the Emergency Stop button is reset. Once the Emergency Stop button is reset all controls will operate as normal. See Input Table for Input designations

Outputs

For details of the location of the outputs, see the attached drawings. See Output Table for Output designations.


4.2 - Inputs

The following tables are a recommended assignment of the inputs and outputs for your programmable control. As controllers vary in how they are connected and function, you must check your particular PLC to see if these assignments are suitable.

Input Detail Symbol Contact

Type

PLC inputs

Assignment

Information supplied at state «1»

Emergency Stop PB1

NC In0 Emergency stop button not operated

Stop PB2 NC In1 Button not pressed

Start/Jog (Manual) PB3 NO In2 Button pressed, start process

Jog Cycle Select PB4 NO In3 Button pressed, cycle jog control

Manual mode SS1_1 NO In4 Manual mode selected

Automatic Mode SS1_2 NO In5 Auto mode selected

Small Pellet Size Select SS2_1 NO In6 Small selected, button pressed

Large Pellet Size Select SS2_2 NO In7 Large selected, button pressed

Low Level Main Bulk Storage Tank

LS1 NO In8 Storage tank level ok

Low Level Silo LS2 NO In9 Silo tank low level ok

Upper Level Silo LS3 NO In10 Silo tank upper level reached

Weigh Scale Barrel Present PD1 NO In11 Weigh Scale Barrel Present


4.3 - Outputs

Output Detail Symbol PLC outputs

Assignments

Action at state «1»

Tower Lamp Red

L1

Q0

-½ second flash when E-Stop Pressed -Solid Red when Stop is Pressed

Tower Lamp Green

L2

Q1

-Solid when process is running -Flashes to indicate which Manual jog cycle is selected

Tower Lamp Amber

L3

Q2

-Barrel weigh scale set point active

Panel Lamp Amber

L4

Q3

-Small Pellet Size Selected

Panel Lamp Amber

L5

Q4

-Large Pellet Size Selected

Panel Lamp Green

L6

Q5

-Extruder is running

Motor Contactor K1

K1

Q6

-Vacuum Pump contactor energized

Motor Contactor K2

K2

Q7

-Extruder Motor contactor energized

Solenoid 1 Relay

R1

Q8

-Solenoid open when energized-Green lamp -Solenoid closed when de-energized-Red Lamp

Solenoid 2 Relay

R2

Q9

-Solenoid open when energized-Green lamp -Solenoid closed when de-energized-Red Lamp

VFD Digital Input 1

R3

Q10

-VFD runs motor at 1650RPM

VFD Digital Input 2

R4

Q11

-VFD runs motor at 550RPM


Wall Project for 21st National Skills CompetitionCompetition in Saskatoon, Saskatchewan 2015

Sk ill : T ra de 19 Autom ation a nd Control

Sc ale : Not to S cal e

Da te: M arch 2015

Desig ner: Derek O llen

Dra wing N o: NS C2015_WP_E N

Rev: 1.0 Pag e: 1

PowerFlex

AC 100-240V

+ + - -

DC 24V/5A

L1 N

L1 L2 L3 N GN

D - 14

- 15

AC 100-240V

L1 N

PLC L1 N GND

PB1 MCR

Power Supply

F1 F2 F3 F4 CB1 CB2 CB3

M13~

M23~

M33~

Power Layout

MCR R1 R2

F5

S11~

S21~

PLC power May be fed from 24VDC

Power Supply or 120VAC

Utility Supply

MAT Day 1 v3.2 10 May 2015

Wall Project for 21st National Skills CompetitionCompetition in Saskatoon, Saskatchewan

Sk ill: T ra de 19 Autom ation a nd Control


Da te: M arch, 2015


Dra wing N o: NS C2015_WP_EN

Rev: 1.0 Pag e: 5

Input Module 16DII/1 I/2 I/3 I/4 I/5 I/6 I/7 I/9 I/10 I/11 I/12 I/13 I/14 I/15COMCOM I/0 I/8

Output Module 16DOQ/1

COMC1Q/0

AC/DCQ/2 Q/3C1 Q/4 C1 C1Q/5 Q/6 Q/7 Q/8 C1 Q/9 Q/10 C1 Q/11 C1Q/12 Q/13 Q/14 C1 C1Q/15 Q/16

R G A A A C C R

Not

Used

PB1 PB2 PB3 PB4 SS1_1 LS1 LS2 LS3SS1_2 SS2_1 SS2_2 PD1

G

L1 L2 L3 L4 L5 L6 K1 K2

R

R1 R2

DATA

+

DATA

-

PLC

PLC

COMAC/DCDATA

+

DATA

-

Input/Output Chart

MCR

R R

R3 R4

02 03 04 05 0601 07 08 09 10 11 12 13 14 15 16

VFD Control Terminal Block

R3 R4

MAT Day 1 v3.2 11 May 2015

K1

F1 F2


Skill: Trade 19 Automation and Control

Scale: Not to Scale

Date: March, 2015

Designer: Derek Ollen

Drawing No: NSC2015_WP_EN

Rev: 1.0 Page: 1

PowerFlex

K2

F3 F5 CB1 CB2 CB3

MCR

R1 R2

Back Panel Layout

AC 100-240V

+ + - -

DC 24V/5A

L1 N

DC Power Supply

F4

R4R3

INPUT

+ -

PLC + -

MAT Day 1 v3.2 12 May 2015


Sk ill : T ra de 19 Autom ation a nd Control


Da te: M arch, 2015


Dra wing N o: NS C2015_WP_EN

Rev: 1.0 Pag e: 1

150

19

01

90

95PB1

L4

SS2_

95 95

L1

L3

G

A

R

10

0

L2

19

0

9595

PB2 PB3 PB4

L5 L6

SS1_21

Q1

Door Layout

21

95

75

48

0

C

MAT Day 1 v3.2 13 May 2015

LS1

S2_1

PD1

1. Control Box2. 6" Wire Cable Tray3. 4" Wire Cable tray4. Stack light5. Limit Switch 16. Limit Switch 27. Limit Switch 38. Solenoid 1 Position Indicator9. Solenoid 2 Position Indicator10. Weight Sensor11. Socket K112. Socket K213. Socket VFD14. 120/208V 20A TL Plug15. Disconnect16. ½” EMT17. ½”PVC

1

2 2

3

4

5

10

11

14

15

Wall Project for 21st National Skills Competition

Competition in Saskatoon, Saskatchewan 2015

Skill: Trade 19 Automation and Control

Scale: Not to Scale

Date: March, 2015

Designer: Derek Ollen

Drawing No: NSC2015_WP_EN

Rev: 1.0 Page: 1

16 16 17 17S2_2

Wall Project

700mm

800mm

550mm

400mm

800mm

LS37

300mm

LS26

350mm

500mm

2150mm

1100mm

S1_1S1_2

100mm

8

1700mm

9

150mm

2000mm

575mm

100mm

1550mm

100mm

25mm

25mm

1312

Skills Canada National Competition · Skills Canada National Competition Specification Day 1 – Material portion of the project 19 – Automation and Control / Post - Secondary May

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