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
MAT Day 1 v3.2 3 May 2015
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.
MAT Day 1 v3.2 4 May 2015
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.
MAT Day 1 v3.2 5 May 2015
3.1 – Process diagram
MAT Day 1 v3.2 6 May 2015
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.
MAT Day 1 v3.2 7 May 2015
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
MAT Day 1 v3.2 8 May 2015
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
MAT Day 1 v3.2 9 May 2015
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
Sc ale : Not to S cal e
Da te: M arch, 2015
Desig ner: Derek O llen
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
Wall Project for 21st National Skills CompetitionCompetition 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
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
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_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
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