instructor guide - transit training · elevator –escalator programmable logic controllers...

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…………………………………………………………………………………………………………


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


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

Elevator – Escalator – Programmable Logic Controllers

DO SAY Materials Needed

Instructor’s Guide

In your own words:

Instructor’s Notes

4

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




In your own words:


5

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





In your own words:


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





In your own words:


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





In your own words:


8

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





In your own words:


9

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: ________




In your own words:


10

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





In your own words:


11

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





In your own words:


12

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





In your own words:


13

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





In your own words:


14

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





In your own words:


15

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





In your own words:


16

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





In your own words:


17

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





In your own words:


18

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





In your own words:


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





In your own words:


20

PPT slide 8 Proceed to computer and use the LogixPro

tutorial provided in the coursebookREVIEW slide





In your own words:


21

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





In your own words:


22

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





In your own words:


23

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





In your own words:


24

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





In your own words:


25

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





In your own words:


26

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





In your own words:


27

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





In your own words:


28

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





In your own words:


29

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

REVIEW slide





In your own words:


30

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

REVIEW slide





In your own words:


31

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





In your own words:


32

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

REVIEW slide





In your own words:


33

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





In your own words:


34

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





In your own words:


35

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





In your own words:


36

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





In your own words:


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.

REVIEW slide





In your own words:


38

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

REVIEW slide





In your own words:


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.

REVIEW slide





In your own words:


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.

REVIEW slide





In your own words:


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

REVIEW slide





In your own words:


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.


ASK





In your own words:


43


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.


ASK





In your own words:


44


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.


ASK


instructor guide - transit training · elevator –escalator programmable logic controllers...

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