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TRANSCRIPT
Instructor Guide
401: Programmable Logic Controllers
Module 2: Advanced Programming Systems
Elevator – Escalator Programmable Logic ControllersInstructor’s Guide
Table of Contents
1
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…………………………………………………………………………………………………………
Elevator – Escalator Programmable Logic ControllersInstructor’s Guide
Icons Used In This Guide AgendaTopic # Topic Title Duration
Total Time:
2
1
2
3
4
Overview
SLC500 Series Processor
Operation
Ladder Logic Programs
Introduction to LogixPro500
Simulation Software
Introduction to RSLinx/RSLogix500
software
20 Minutes
20 Minutes
20 Minutes
240 Minutes
90 minutes5
430 Minutes
6 Running Projects on a PLC-5 or
SLC500 Processor20 minutes
7 Summary 20 minutes
Elevator – Escalator Programmable Logic ControllersInstructor’s Guide
Overview
Purpose The purpose of this module is to:
ObjectivesAt the end of this lesson, the transit elevator/escalator trainee will
be able to:
MaterialsMandatory Make sure you have the following
Optional You may also want the following for optional
activities:
3
Provide the participant with a conceptual understanding
of programmable logic controllers (PLC) for elevator
and elevators.
• PowerPoint Presentation
• Lesson Plan
• Quizzes
• Pencils
• 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
• 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
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Module Length:430 min Time remaining: 430 min This section: 20 min (4 slides) Section start time: ________ Section End Time: ________
Welcome to the course on Programmable
Logic Controllers
Advance
PPT slides 1REVIEW introduction slides
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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
Advance
PPT slide 2REVIEW module objectives
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6
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 3REVIEW key terms
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7
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)
Advance
PPT slide 3REVIEW key terms
Module Length:430 min Time remaining: 430 min This section: 20 min (4 slides) Section start time: ________ Section End Time: ________
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PPT slide 4Thinking 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.]
Advance
ASK
SMALL GROUP ACTIVITY
WRITE
paper
Chalk board or
large paper
Module Length:430 min Time remaining: 430 min This section: 20 min (4 slides) Section start time: ________ Section End Time: ________
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PPT slide 5 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.
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.
REVIEW slide
Module Length: 430 min Time remaining: 410 min This section: 20 min (1 slides) Section start time: ________ Section End Time: ________
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PPT slide 5 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.
REVIEW slide
Module Length: 430 min Time remaining: 410 min This section: 20 min (1 slides) Section start time: ________ Section End Time: ________
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PPT slide 5 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.
REVIEW slide
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PPT slide 5 •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.
Advance
REVIEW slide
Module Length: 430 min Time remaining: 410 min This section: 20 min (1 slides) Section start time: ________ Section End Time: ________
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PPT slide 6 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.
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.
REVIEW slide
Module Length: 430 min Time remaining: 390 min This section: 20 min (2 slides) Section start time: ________ Section End Time: ________
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PPT slide 6 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.
REVIEW slide
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PPT slide 6 •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.
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:
REVIEW slide
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PPT slide 6 •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.
REVIEW slide
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PPT slide 6 •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:
REVIEW slide
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PPT slide 7 •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.
Advance
REVIEW slide
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19
PPT slide 8 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.
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.
Advance to lab to complete tutorials
REVIEW slide
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PPT slide 8 Proceed to computer and use the LogixPro
tutorial provided in the coursebookREVIEW slide
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PPT slide 9 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.
REVIEW slide
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PPT slides 10,11, 12 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.
Advance
Locate Available Driver Types menu and left
click once. Left click on RS-232 DFI Devices.
Advance
This brings up a window prompting you to
choose a name for the new driver, Left click
the OK button once.
REVIEW slide
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PPT slides 13, 14 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.
Advance
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.
Advance
REVIEW slide
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PPT slides 15, 16 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.
Advance
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.
Advance
REVIEW slide
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PPT slides 17, 18 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.
Advance
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.
Advance
REVIEW slide
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PPT slides 19, 20 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.
Advance
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.
Advance
REVIEW slide
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PPT slides 21, 22Left 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.
Advance
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.
Advance
REVIEW slide
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PPT slides 23, 24Now 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.
Advance
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.
REVIEW slide
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PPT slides 24, 25This 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.
Advance
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.
Advance
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PPT slides 26, 27Once the slot is highlighted (Tia to finish
based on slide)
Advance
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.
Advance
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PPT slides 28, 29To 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.
Advance
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.
REVIEW slide
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PPT slide 29Select 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.
Advance
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PPT slide 30In 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).
REVIEW slide
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PPT slide 30Please 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)
REVIEW slide
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PPT slide 30Step 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.
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.
REVIEW slide
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PPT slides 30,31Step 4 (cont): Follow the directions and steps
in your manual for your PLC.
Advance
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.
REVIEW slide
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Instructor’s Notes
37
PPT slide 31Step 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.
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Instructor’s Notes
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PPT slide 31Step 4: Follow the manufacturers instructions
for loading programming software.
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.
Advance
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Elevator – Escalator – Programmable Logic Controllers
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Instructor’s Notes
39
PPT slide 32Lets 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.
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40
PPT slide 32We 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.
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Instructor’s Notes
41
PPT slide 33Once 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.
Advance
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42
PPT slide 34Now lets see what you can remember.
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
Advance
The correct answer is c. Reset Mode. Reset is
an instruction, not a mode.
Module Length: 430 min Time remaining: 20 min This section: 20 min (2 slides) Section start time: ________ Section End Time: ________
ASK
SMALL GROUP ACTIVITY
Elevator – Escalator – Programmable Logic Controllers
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Instructor’s Notes
43
PPT slide 35Now lets see what you can remember.
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
Advance
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.
Module Length: 430 min Time remaining: 20 min This section: 20 min (2 slides) Section start time: ________ Section End Time: ________
ASK
SMALL GROUP ACTIVITY
Elevator – Escalator – Programmable Logic Controllers
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In your own words:
Instructor’s Notes
44
PPT slide 36Now lets see what you can remember.
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
Advance
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.
Module Length: 430 min Time remaining: 20 min This section: 20 min (2 slides) Section start time: ________ Section End Time: ________
ASK
SMALL GROUP ACTIVITY