Instructor Guide. 401: Programmable Logic Controllers Module 2: Advanced Programming Systems

Transcription

1 Instructor Guide 401: Programmable Logic Controllers Module 2: d Programming Systems

2 Elevator Escalator Programmable Logic Controllers Table of Contents Overview SLC500 Series Processor Operation.. Ladder Logic Programs Introduction to LogixPro500 Simulation Software.... Introduction to RSLinx/RSLogix500 software..... Running Projects on a PLC-5 or SLC500 processor Summary 1

3 Elevator Escalator Programmable Logic Controllers Icons Used In This Guide Agenda Topic # Topic Title Duration Overview SLC500 Series Processor Operation Ladder Logic Programs 20 Minutes 20 Minutes 20 Minutes 4 5 Introduction to LogixPro500 Simulation Software Introduction to RSLinx/RSLogix500 software 6 Running Projects on a PLC-5 or SLC500 Processor 7 Summary 240 Minutes 90 minutes 20 minutes 20 minutes Total Time: 430 Minutes 2

4 Elevator Escalator Programmable Logic Controllers Overview Purpose The purpose of this module is to: Provide the participant with a conceptual understanding of programmable logic controllers (PLC) for elevator and elevators. Objectives At the end of this lesson, the transit elevator/escalator trainee will be able to: Discuss safety and authority-specific procedures Discuss the safety integrity levels for control devices Describe ladder logic Identify the main components of a PLC Identify the principles of programming a PLC Materials Mandatory Optional Make sure you have the following PowerPoint Presentation Lesson Plan Quizzes Pencils You may also want the following for optional activities: Chalk board with chalk, large paper with marker, etc. Internet connection Lab, simulator or out of service elevator Specific transit authority related procedures and guidelines 3

5 Module Length:430 min Time remaining: 430 min This section: 20 min (4 slides) Section start time: Section End Time: REVIEW introduction slides Welcome to the course on Programmable Logic Controllers PPT slides 1 4

6 Module Length:430 min Time remaining: 430 min This section: 20 min (4 slides) Section start time: Section End Time: REVIEW module objectives Today we will discuss the: -SLC500 Series Processor Operation -Ladder Logic Programs -Introduction to LogixPro500 Simulation Software -Introduction to RSLinx/RSLogix500 software -Running projects on a PLC-5 or SLC500 processor PPT slide 2 5

7 Module Length:430 min Time remaining: 430 min This section: 20 min (4 slides) Section start time: Section End Time: REVIEW key terms Lets take a look at some of the key words we will be defining as move through this module: -Accumulated value -Examine If Closed (XIC) -Examine if Open(XIO) -Count Up (CTU) -Count Down (CTD) -Done (DN) -Latch (OTL) -Output Energize (OTE) -Preset Value -Program Mode -Remote Program Mode -Remote Run Mode -Reset (RES) -Retentive Timer On (RTO) -Run Mode -Run Mode Store Function PPT slide 3 6

8 Module Length:430 min Time remaining: 430 min This section: 20 min (4 slides) Section start time: Section End Time: REVIEW key terms Lets take a look at some of the key words we will be defining as move through this module: -Single Step Test Mode -Test Mode -Timer On Delay (TON) -Timer Off Delay (TOF) -Unlatch (OTU) PPT slide 3 7

9 Module Length:430 min Time remaining: 430 min This section: 20 min (4 slides) Section start time: Section End Time: ASK SMALL GROUP ACTIVITY WRITE Thinking back to other courses or just in general, who can recall how a PLC functions? [Allow participants to think for a minute and perhaps discuss with a partner ideas as well as write down any ideas. Discuss participant responses and if possible list them on a chalk board or similar.] PPT slide 4 paper Chalk board or large paper 8

10 Module Length: 430 min Time remaining: 410 min This section: 20 min (1 slides) Section start time: Section End Time: Allen Bradley is the manufacturer of a family of modular processors called the SLC500. This family (SLC 5/01, 5/02, 5/03, 5/04, and 5/05) increases in features as the numbers increase. PPT slide 5 SLC 5/01 This processor has an instruction set that is the same as the SLC500 fixed controller. It contains 3 chassis, 30 modular slots, 52 programming instructions, no remote I/O, and can scan 8 milliseconds per K (thousands) instructions. SLC 5/02 This processor has 71 programming instructions, 4K memory, increased diagnostics, 4096 I/O, DH-485 communications and can scan 4.8 milliseconds per K instructions. 9

11 Module Length: 430 min Time remaining: 410 min This section: 20 min (1 slides) Section start time: Section End Time: SLC 5/03 This processor has an instruction set that includes a clock, Flash EEPROM, a RS-232 port, ability to edit online, ability to select operating modes, floating point math, 107 programming instructions, additional memory, 960 I/O, and can scan in 1 millisecond per K instructions. SLC 5/04 This processor is similar to the SLC 5/03 with the addition of a PLC 5 DH+ network, more memory, a choice of communications channel, and it can scan at.9 milliseconds per K instructions. SLC 5/05 This processor contains all of the SLC 5/04 features but it has an Ethernet port instead of a DH+ port. PPT slide 5 10

12 Module Length: 430 min Time remaining: 410 min This section: 20 min (1 slides) Section start time: Section End Time: The SLC500 series processors operate in the following modes: Program mode this allows the PLC to make edits to the instructions by adding or deleting instructions Run Mode this is when the PLC is executing the instructions that it has been programmed to perform. Also called a processor scan or sweep. Remote Run Mode this is when the processor is operated by a key switch to change modes from run to program Remote Program Mode this is when the processor is put in program mode from a remote programming device Test Mode this is when the processor is testing the program inputs without energizing the outputs. PPT slide 5 11

13 Module Length: 430 min Time remaining: 410 min This section: 20 min (1 slides) Section start time: Section End Time: Single Step Test Mode this allows the processor to test selected rungs and verify ladder operation without energizing outputs. Run Mode Store Function this allows the processor to transfer program logic, data tables, and system configurations to another running PLC processor. PPT slide 5 12

14 Module Length: 430 min Time remaining: 390 min This section: 20 min (2 slides) Section start time: Section End Time: Ladder logic programs are software programs that provide PLCs with instructions. These programs require instructions to be input into a computer and then downloaded to a PLC. PPT slide 6 SLC500 Series Instruction Set the ladder logic programs that are downloaded unto the PLC provide instructions to the PLC. This programming language is called the instruction set. The SLC500 series contains a number of instruction sets based on the type of functions that the PLC needs to perform. These include relay-type, timer, counter, compare, compute logical, conversion, bit modify and move, etc. (more sets can be found in your book). For the purposes of this course, we will be only covering relay type, timer, and counter. 13

15 Module Length: 430 min Time remaining: 390 min This section: 20 min (2 slides) Section start time: Section End Time: Relay-type instructions these are considered basic instructions and are used to monitor and control the status of bits in a data table. These instructions include: XIC Examine if Closed If the bit is ON, the logic is set to true and it enables the output instruction XIO Examine if Open If the bit is OFF, the logic is set to true, and it will not enable the output instruction OTE Output Energize if the input conditions are true, the OTE instructions are enabled. If the input conditions are false, it will disable the OTE instructions. OTL Latch this instruction can only be used to turn on a bit. If the input conditions are true, then this instruction will be enabled. Note: Even if the input conditions become false, this instruction will stay enabled. PPT slide 6 14

16 Module Length: 430 min Time remaining: 390 min This section: 20 min (2 slides) Section start time: Section End Time: OTU Unlatch this instruction can only be used to turn off a bit. This is normally paired with the OTL instruction to turn the bit off. PPT slide 6 Timer Instructions These are basic instructions that lets you program the processor to energize outputs based on time or a certain number of events. To use this instruction, you have to provide the processor with the timer structure number, the timer file number, and the timer file type. The time base, which includes the preset and accumulated value, will instruct the timer how to operate. The preset value tells the processor the number it must reach before it can set the bit to done (DN). The accumulated value is how much the processor has counted during the processing. These functions are controlled by: 15

17 Module Length: 430 min Time remaining: 390 min This section: 20 min (2 slides) Section start time: Section End Time: TON Timer On Delay this instruction tells the processor to turn an output on or off after the timer has reached a certain time interval. It starts once the input instructions are true and stops when the accumulated value equals the preset values, the instructions are false, or a reset instruction resets the timer. TOF Timer Off Delay this instruction tells the processor to turn an output on or off after the rung has been off for a certain amount of time. This starts when the instructions are false and stops when the accumulated value equals the preset values, the instructions are true, or a reset instruction resets the timer. PPT slide 6 16

18 Module Length: 430 min Time remaining: 390 min This section: 20 min (2 slides) Section start time: Section End Time: RTO Retentive Timer On this instruction turns an output on or off after the timer has been on for a certain amount of time. It starts timing when the input instructions are true so that means it continuously update the accumulated value until it reaches its specified number. Counter Instructions - Counter instructions are used to count. Counter is the address in the counter area of data storage that uses the address format: counter (file type), counter file number (3-999), and counter structure number (0-999). Based on these counter instructions, preset value, and accumulated value the count will determine an output. The three most commonly used counter instructions are: PPT slide 6 17

19 Module Length: 430 min Time remaining: 390 min This section: 20 min (2 slides) Section start time: Section End Time: CTU Count Up this instructs the processor to count upwards. Each time the rung goes from false to true, the count will go up by one. When the count is equal to or higher than the preset value it will be set to DN which will initiate the output. The accumulated value is retentive but it can be reset by a RES instruction. CTD Count Down - this works like the CTU instruction except that the count goes down when the rung goes true and the Done bit is activated as long as the accumulated value is greater than the preset value. RES Reset this instruction is used to reset both the counter and the timer values. PPT slide 7 18

20 Module Length: 430 min Time remaining: 370 min This section: 240 min (1 slides) Section start time: Section End Time: Ladder logic programs are software that provide instructions to PLCs. For this course we will be using a $35 software called LogixPro500 from a company called The Learning Pit. PPT slide 8 What exactly is LogixPro? LogixPro is actually 3 programs in one. It allows you to create and edit ladder logic programs, it allows you to download ladder logic programs and run them, and it shows you a simulation of how the ladder program would work on a real Allen Bradley PLC. For this section we will be getting our feet wet with some LogixPro500 tutorials and student exercises. to lab to complete tutorials 19

21 Module Length: 430 min Time remaining: 370 min This section: 240 min (1 slides) Section start time: Section End Time: Proceed to computer and use the LogixPro tutorial provided in the coursebook PPT slide 8 20

22 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: Now that we have some experience, lets talk about the actual software that is used on an Allen Bradley PLC. This software is called RSLinx/RSLogix500 and is created by Rockwell Automation. While most of you in your daily jobs will not have to worry about programming an Allen Bradley PLC with this software, this section will provide you with an overview of how to set up a PLC using the RSLogix software. We will talk about the communications set up, uploading and downloading an existing project, and creating and downloading an existing project. PPT slide 9 21

23 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: After the RSLinx/RSLogix500 software has been installed on your computer, you will need to set up your communications. To set up your communications you will need to left click on the Start button to bring up the START menu. Highlight the PROGRAMS menu. Highlight the ROCKWELL SOFTWARE menu. Highlight the RSLINX file folder. Left click the RSLinx icon. Locate Available Driver Types menu and left click once. Left click on RS-232 DFI Devices. This brings up a window prompting you to choose a name for the new driver, Left click the OK button once. PPT slides 10,11, 12 22

24 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: When you click OK button you should see a Configure Allen-Bradley DFI Communications Device window. Left click the Auto-Configure button. If all of the previous steps have been done properly, you should see the following message: Auto-Configure successful. PPT slides 13, 14 Click the OK button which takes you back to the Configure Drivers window. Under Configure Drivers you should see the following message: AB DFI-1 DH485 Sta:0 COM1: RUNNING. Left click on the Close button to return to the RSLinx screen. 23

25 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: Now its time for Step 2 of the communications setup. Bring up the START menu again. Highlight PROGRAMS, ROCKWELL SOFTWARE, RSLOGIX. Left click RSLOgix500 to bring up the RSLogix Project Screen. PPT slides 15, 16 Select Tools from the Main Menu Toolbar. Select Options to bring up the System Options window. Left click the System Communications tab. Left click the pull down arrow in the Current Settings sections. Left click the AB_DFI-1. Change the node address to 1 in the Processor Node section. Left click the Apply button. 24

26 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: The communications setup is now complete. Lets check to make sure it has been successful. Left click the Who Active button in the System Options menu which will bring up the RSLinx screen. You should see two icons: the workstation and the processor icon. Left click OK in the communications menu. Left click ok in the system options menu. Close the Systems Option menu. Once the communications has been set up, you should be able to upload and open projects on the software. To upload an existing project, left click on the OFFLINE pull down menu located in the RSLogix500 home screen. This will bring up the Processor status menu. Left click on Upload. PPT slides 17, 18 25

27 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: A Going to Online Programming Window state should appear. Left click the Create New File bar. An uploading processor image window will appear. After the files have been created, you will see the following message: Do you want to go Online? Left click on the Yes button and it should go online. When you select Yes, the program will be in the Remote Run mode if the key switch is in the vertical position. Check the program out. Observe the Input instructions in the ladder diagram when the input states are changed. PPT slides 19, 20 26

28 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: Left click on the Offline pull down arrow in the Processor Status bar. This will bring up a window asking you to Save changes untitled? Left click the Yes button. This will bring up the Save Program As window. Change the file name to DEMO and left click the Save button. PPT slides 21, 22 This will bring up a warning that the Data Table Values have changed. It will prompt you to Upload Data Table values before saving. Left click the Yes button once. After clicking Yes, it should return you back to the main screen. Left click on File on the Main Menu toolbar. Left click Close. 27

29 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: Now lets open an existing project. Left click on the Open project file folder in the main menu toolbar. This will bring up the Open/Import SL500 window. The SLC Library will contain a list of all of your projects. Highlight and left click on DEMO. Left click Open and the DEMO project should come up on the Project view screen. Close the software by left clicking on the close button in the top right corner of the screen. Now lets create and download projects. When creating projects,y ou will use the same instruction sets that you used during the Logix500 simulations. To begin creating a project, you first must Left click on the New icon in the main menu toolbar. PPT slides 23, 24 28

30 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: This will bring up the Select Processor Type window. If necessary, scroll down until you locate: 1747-L53IE 5/03 (or whatever processor you have). Left click on the correct processor and click OK. Next, locate the Project Tree and left click twice on the IO configuration icon. This will bring up the IO configuration icon. The top picture depicts the slots in a Processor and the way that they are addressed. In the IO Configuration menu there will already be a slot rack selected by default. Select the appropriate rack that is attached to your trainer. PPT slides 24, 25 29

31 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: Once the slot is highlighted (Tia to finish based on slide) PPT slides 26, 27 Left click on the Read IO Configuration button and wait for the software to configure your I/O. This will bring up a Read IO Config from Online Processor Window. You must have your PLC trainer powered up and the processor connected to the computer before proceeding to the next step. Left click the Read IO Config button and wait for the software to configure your I/O. The configuration should now be complete and all modules should appear as assigned. Close the window once the configuration is complete. 30

32 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: To program XIC, XIO, and XTE instructions, use the knowledge that you gained in the LogixPro 500 simulations. Once you have finished creating your simple program, SAVE the program with a naming convention that you decide. To verify that you have completed the programming correctly, close the file then open it again. The project should begin. To download the project you just created, go to the OFFLINE menu and highlight DOWNLOAD. This will bring up the REVISION note screen, click OK. Click Yes to proceed with Download. When all the files have downloaded, click Yes to go Online. The Run Mode screen will pop up and it will ask you if you want to be placed in PGRM mode. PPT slides 28, 29 31

33 Module Length: 430 min Time remaining: 130 min This section: 90 min (23 slides) Section start time: Section End Time: Select Yes to place it in PGRM mode. If asked to Apply Channel Configuration to Online Processor, select Don t Apply. It will then ask you to change back to Run Mode, select Yes. When asked if you want to go Online, select Yes. PPT slide 29 32

34 Module Length: 430 min Time remaining: 40 min This section: 20 min (2 slides) Section start time: Section End Time: In the previous module you were introduced to RSLinx and RSLinx500 software. You configured the simulation PLC by using drivers which means that you established communications between the computer and the PLC. RSLinx and RSLogix500 are software packages that are sometimes referred to as drivers. A driver is a program that controls a device. In order to begin running one of these programs on a PLC, you need to have an Allen Bradley computer connecting cable (1747, 1784, or other recommended type), RSLinx/RSLogix500 software installed on your computer, and the original or modified instructional (batch) program (on disk or USB Flash Drive). PPT slide 30 33

35 Module Length: 430 min Time remaining: 40 min This section: 20 min (2 slides) Section start time: Section End Time: Please note that when connecting the computer to the Allen Bradley PLC, you should always follow all warnings and instructions from the Allen Bradley manual. Consult with your supervisor and your property s procedures regarding electrical power safety and PLCs. Once you have gathered all of the appropriate tools and ensured safety, you should follow the following steps: Step 1: Backup your original/modified file and store it in a safe place (not on the computer or tablet which you are connecting to the PLC-a separate disk or USB Flash Drive) PPT slide 30 34

36 Module Length: 430 min Time remaining: 40 min This section: 20 min (2 slides) Section start time: Section End Time: Step 2: Go to the Control Panel on your computer/tablet. Check the serial port settings to ensure that the baud rate (bits per second) of your COM (communications) port are set as high as possible (57600). Note: This is the baud rate for a computer. PPT slide 30 Step 3: Turn OFF power to the PLC. Connect the serial port of your computer to the 9-pin serial port on the SLC500 processor with the Allen Bradley provided cable. Connect the proper cable and turn on the PLC. Step 4: Turn the key operated switch on the processor to the PROG (program) position. If you do not have RSLInx software installed, install it now. After you install RSLInx software you are now ready to configure it for your computer and PLC. 35

37 Module Length: 430 min Time remaining: 40 min This section: 20 min (2 slides) Section start time: Section End Time: Step 4 (cont): Follow the directions and steps in your manual for your PLC. PPT slides 30,31 To start installation after major work on a PLC, you will need a medium blade screwdriver, programming equipment (computer and software programs) and proper network interface and cables. In your book there is a chart that references the correct network interfaces for SLC500 series processors. Once you have made sure that you have the proper network interface associated with the proper cable you can begin installation. 36

38 Module Length: 430 min Time remaining: 40 min This section: 20 min (2 slides) Section start time: Section End Time: Step 1: Make sure all power is OFF. Insert the processor into slot 0 of the 1746 chassis. Inserting the processor into another slot will not allow the processor to operate. Make sure to remove all of the protective wrap after installing the processor as failing to remove the wrap will result in the power supply overheating. Step 2: Apply power to the processor by energizing the chassis with care. Step 3: Check the chassis power supply and processor LED indicators. The power supply should be ON and the fault LED indicator should be flashing. Please refer to the chart in your book for signs of the LED light indicator status. PPT slide 31 37

39 Module Length: 430 min Time remaining: 40 min This section: 20 min (2 slides) Section start time: Section End Time: Step 4: Follow the manufacturers instructions for loading programming software. PPT slide 31 Step 5: Establish communications to the processor. We have an XX processor so to establish communications we would (refer to coursebook and inserti nstructions for appropriate processor). Step 6: Match the communications parameters of the software to match the default parameters of the software. Refer to the coursebook and insert instructions for appropriate processor. 38

40 Module Length: 430 min Time remaining: 20 min This section: 20 min (2 slides) Section start time: Section End Time: Lets recap what we went over in this module. In this module we talked at the SLC500 series processors that include the SLC 5/01, 5/02, 5/03, 5/04, and 5/05 series and their functionality. We discusses the different operation modes these processors which include Program mode, run mode, remote run mode, remote program mode, test mode, single-step test mode, and run mode store function. We discussed ladder logic programs and the different instruction sets that PLCs can use. These instruction sets included relay-type, timer, counter, and compare instructions to name a few. PPT slide 32 39

41 Module Length: 430 min Time remaining: 20 min This section: 20 min (2 slides) Section start time: Section End Time: We then moved on to explain the relatively cheap software LogixPro500, which is a simulation program that functions like the real Allen Bradley software. Using this simulation, we did some hands on tutorials where we learned how to use relay type, counter, and timer instructions to simulate different scenarios within the program. Once we finished with the hands on tutorial we moved on to a tutorial on how to actually install the RSLinx/RSLinx500 software from Allen Bradley. This included instructions on how to install and set up the communications for this program, upload a project, open an existing project, create a project, download a project, use programming instructions, and download and go online. PPT slide 32 40

42 Module Length: 430 min Time remaining: 20 min This section: 20 min (2 slides) Section start time: Section End Time: Once we finished that tutorial, we discussed how to connect the PLC to the computer correctly and how to start installation of the RSLInx software after you have done work on the PLC. PPT slide 33 41

43 Module Length: 430 min Time remaining: 20 min This section: 20 min (2 slides) Section start time: Section End Time: ASK Now lets see what you can remember. PPT slide 34 SMALL GROUP ACTIVITY Ask Which of the following is NOT a SLC500 Series Operation? a. Program Mode b. Run Mode Store Function c. Reset Mode d. Test Mode The correct answer is c. Reset Mode. Reset is an instruction, not a mode. 42

44 Module Length: 430 min Time remaining: 20 min This section: 20 min (2 slides) Section start time: Section End Time: ASK Now lets see what you can remember. PPT slide 35 SMALL GROUP ACTIVITY Ask Which of the following are contained in the relay-type instruction set a. Timer Off Delay b. Examine if Open c. Preset d. Count Up The correct answer is b. Examine if Open. Timer Off Delay is a timer instruction, Count Up is a Counter instruction, and preset is not an instruction at all. 43

45 Module Length: 430 min Time remaining: 20 min This section: 20 min (2 slides) Section start time: Section End Time: ASK Now lets see what you can remember. PPT slide 36 SMALL GROUP ACTIVITY Ask One of the first steps to setting up the communications in the RSLinx/RSLogix500 software is: a. Selecting the RS-232 DFI Device b. Locating the Available Driver c. Opening the RSLinx menu d. Opening the Rockwell software menu The correct answer is d. Opening the Rockwell software menu. While they are all steps you first have to open the Rockwell Automation software menu which actually contains the RSLinx/RSLogix500 software. 44