PLC TRAINING TUTOR0001.pdf

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Table of Contents

C o u r s e O v e r v iew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-1

Course Objectives 0-1Course Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0-t

Who Should A tte nd 0-2

P rerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0-2

Outline 0-2

Meeting Cours e Obje ctives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0-2

S tudent M aterials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0-3

Application Overview 0-3

Lessons

Id en t i f y in g S LC 500 TM S ys tem C o m p o n en ts 1-1

W hat Y ou W ill Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

S L C 500 S ys tem O verview 1-1

Befo re Y ou Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

F ixed Hardware S ystem ,' 1-2

Modular Sys tem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Processors 1-2

Chassis 1-2Power Supplies 1-3

1/ 0 Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Remote 1/ 0 Example 1-4

S igna l F low T hrough the S L C 500 S ystem 1-4Exercise 1-5

How Did Y ou Do? 1-5

G et t i n g S ta r te d w i th RSL o g ix 500 ™ So f tw a r e 2 -1

What Y o u W ill L earn 2-1

Key Te rms 2-1Before Y ou Begin . . . .. . 2-1

RSLogix 500 D is pla y 2-1

Pro ject T ree. . . .. . 2-1

P rog ram F ile s 2-2

Project DocumentatiJ n 2-3

R S Logix 500 H elp S ystem 2-3

Rev is ion Notes 2-4

C ompres se d B ackup md A uto-B ackup F iles 2-4

Here's How 2-5

Exercise 2-5How Did Y ou Do? 2-6



ii Table of Contents

Do wn lo ad in g , G o in g On lin e, an d Sav in g U s in g R SL og ix 500 So f tw ar e 3 ·1

What Y ou W ill Learn 3-1

Key Terms 3-1

Before Y ou Begin 3-1

C ommunication Options 3-2

DH+ n .< C onnections 3-2

Example: DH+ Network 3-2

DH -485 Network C onnections 3-3

E xample: DH -485 Network 3-3

R S -232 (S erial) C onnection 3-3

Example: R S -232 C onnection 3-4

E E P ROM Memory Module 3-4

Memory Module Autoload 3-4

Here's How 3-5

E xercise 3-5


M on it o ri n g an d En te r in g D a ta U s in g RSL og ix 500 So f tw a re . . . . . . . . . . . . . . . . .. 4·1

What Y ou W ill Learn 4-1

K ey Terms 4-1

Before Y ou Begin 4-1

Data F ile Types 4-2

Address F ormat 4-2

Address E xamples 4-3.

S ymbols 4-3

Example: S ymbols 4-3

A ddres s F ormats in R S L ogix 500 S o ftware 4-4

I/O C onfiguration . 4-5

Data F iles 4-6

Here 's H ow . 4-6

Determining and Monitoring Discrete Input and Output A ddresses 4- 7

Determin ing and Monito ring Ana log Input and O utput Addresses 4-8

Monito ring and En te ring Inte ge r a nd S tatus Data 4-9

C reating and U sing a C ustom D ata Monitor 4-9

E xercise A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

How Did Y ou Do? 4-15E xercise B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

I/O C onfiguration 4-16


E xercise A 4-20

Answers 4-20

E xercise B 4-20

In te r p re t i n g B i t In s t r u c t i o ns U s in g R SL og ix 500 So f tw ar e .. . .. . . . . . . . . . . . . .. 5.1

W hat Y ou W ill Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . 5-1

P roces so r Opera ting Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Before Y ou Begin 5-1

Logical C ontinuity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1



Table of Contents iii

C onditional Instructions 5-2

Output Instructions 5-2

P ro ce ss or Mode s 5-2

Here's How 5-3

X IC , X IO , and OTE Ins tructions in S e rie s a nd B ra nc hed 5-3

Start/S top (Sea l-In) C i rcuit 5-3

X IC , X IO , and O T E Ins tructions U sing B inary, T imer, a nd Counte r B its 5-4

OTL , OTU, and OSR Ins tructions 5-4

Exercise 5-4

H ow Did Y ou Do? 5-6

Exercise 5-7

Answers 5-7

In t e r p r e t in g T im er an d C o u n t e r In s t r u c t io n s U s i n g R SL o g ix 500 So f tw ar e . . . . . .. 6 ·1

W hat Y ou W ill L earn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Key Te rms 6-1

Befo re Y ou Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

T imer and Coun te r In structions 6-1

Maximum P re se t a nd A cc umula te d V alue s 6-2

Here's How 6-3

Example: T imer O n-D ela y (TON) 6-3

Example : T imer O ff-D ela y (TO F ) 6-3

Example: R e te ntive T ime r (R TO ) a nd Re se t(R ES ) 6-4

E xample : C ount U p (C T U ) 6-4

Example: C ount D own (C T D) 6-5

Exercise 6-5


Exercise 6-8

Answers 6-8

D o c u m en t i n g an RSL o g ix 500 P r o jec t 7 ·1

What Y o u W ill L earn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Documentation Options 7-1

Befo re Y ou Beg in 7-1

Here's How 7-1

Exercise 7-2


Exercise 7-4

Answers 7-4

In te r p r e t i n g C o m p ar is o n In s t r u c tio ns U s in g RS L o g ix 500 S o f tw ar e . . . . . . . . . . . . 8 ·1

What Y o u W ill L earn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Comparison Instructions 8-1

Befo re Y ou Begin 8-1

L imit Tes t (UM) Ins truction 8-1

Here's How 8 - 2Example: EQU and NEQ Ins truc tio ns 8-2

Examp le : L E S and LEQ Ins truc tio ns 8-2



iv Table of Contents

Example: G EQ and GR T Instructions 8-3

Example: L lM Instruction 8-3

E xercise 8-3


Answers 8-6

In t e rp r e t in g Da t a H an d l in g In s t r u c t io n s U s in g RSL o g ix 500 So f tw a r e 9 -1

W hat Y ou W ill Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Data Handling Instructions 9-1

B efore Y ou B egin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

K ey Terms 9-1

Instruction O peration 9-2

Here's How 9-2

E xample: F R O and TOO Instructions 9-2

Example: MOV and MVM Instructions 9-3

E xample: C O P a nd F L L Ins tructions 9-3

E xercise 9-4


E xercise 9-6

Answers 9-6

In te rp r et in g P ro g ra m C ontrol Instructions U s in g RSL o g ix 500 So f tw a r e 10 -1

What Y ou W ill L earn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Processor O perating C ycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

B efore Y ou B egin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Key Te rms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

P rogram C ontrol Instructions 10-2

Subroutines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-3

M C R Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

Here's How ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-4

Example: Inte rpre ting S u broutine s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

Example: Interpreting J M P and LBL Instructions 10-5

Example: Interpreting MCR Instructions 10-5

Examp le : Inte rp re ting TNO Ins truction 10-5

Examp le : Inte rp re ting SUS Ins truction 10-6

E xercise 10-6

H ow Did Y ou Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-8

E xercise 10-10

Answers 10-10

Sear c h in g L ad d e r L o g ic U s in g RSL o g ix 500 So f tw a r e . . . . . . . . . . . . . . . . . . . .. 11 -1

W hat Y ou W ill Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1

S earch Options 11-1

Befo re You Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11-1

Here's How 11-1



Table of Contents v

Exercise 11-2

H ow D id Y ou D o? 11-3

Exercise 11-4

Answers 11-4

Fo rc in g In p ut s an d Ou tp ut s U s in g RSL o gix 500 So f twa r e 12·1·W hat Y ou W ill Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

When to us e F orcing 12-1

Befo re Y o u Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1

F a cto rs to C o ns ide r B efo re U s ing F o rcing 12-1

Safety P recaution 12-1

Ru les fo r Fo rc ing 12-2

Here's How 12-2

Exercise 12-3

H ow D id Y ou D o? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12-3

Exercise 12-4

Answers 12-4

Ed it i n g L ad de r L og ic U s in g R SL og ix 500 So f twa r e 13·1What Y ou W ill L earn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1

Offline vs. On line Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13-1

Before Y ou B egin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13-1

Ed it Zone Markers 13-2

Safety Precau tion 13-2

Here's How 13-2

Exercise 13-3

H ow D id Y ou D o? 13-5

Exercise 13-6

Answers 13-6

P r in ti n g U sin g R SL og ix 500 So f twa r e 14.1What Y ou W ill L earn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14-1

P rint Options 14-1

Before Y ou Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14-1

Here's How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14-1

Exercise 14-1

H ow D id Y ou Do? 14-2

T ro ub les ho o t in g N ois e·R ela ted P ro b lem s U s in g R SL og ix 500 So f twa r e 15.1W hat Y ou W ill Learn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-1

1747S LC 500 Prog rammab le Contro lle rs T roub leshooting Gu ide 15-1

Before Y ou B egin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1

Initia lT roubles hooting Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-1

No ise Diagnosis 15-2

Correcting Noise-R elated P roblems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-3

Grounding " 15-3

Wiring and Ground ing Gu idelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15-4

I ncoming Power ~. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-4



vi Table of Contents

C ommunication 15- 5

DH -485 C able C onnections 15-5

DH+ C able C onnections 15-5

Inputs and O utputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

Heat 15-6

Here's How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

E xample One . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-6

E xample Two 15-6

E xercise 15- 7

How Did Y ou Do 15-7

E xercise 15-8

Answers 15-8

For Further Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-8

T ro ub les ho o t in g P r o ces so r an d Po wer Su pp ly P r o b lem s

U s in g RSL o g ix 500 So f tw are 16 ·1Wha t Y o u W ill L ea rn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

1747 S LC 500 P rogrammable C ontrollers Troubleshooting G uide 16-1

Before Y ou Begin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1

Initial T roubleshooting Actions 16-1

P rocessor and Power S upply D iagnosis and Correction 16-2

Modular P rocessor F ront P anel 16-2

P rocess or B attery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-3

P ower S upply 16-3

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . 16-4

Here's How 16-4E xercise 16-4

How Did Y ou Do? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-6

E xercise 16-8

Answers 16-8

Tr ou b le s ho o tin g D is c re te 1 / 0 P ro b lem s U s in g RSL o g ix 500 So f tw a re 17 ·1

W hat Y ou W ill L earn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1

1747 S LC 500 P ro grammable Contro lle rs T ro ub le sh oo ting Guide . . . . . . . . . . . . . . . . . . . . . . . . . .. 17-1

B efore Y ou B egin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17-1

Initia l Troubleshooting Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1Discrete 1 /0 Diagnosis and C orrection 17-2

S tatus and F use Indicators 17-2

Here's How . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-3

E xercise 17-3


E xercise 17-12

Answers 17-12

T ro u b les h oo t in g A n alo g 1 / 0 P ro b lem s U s in g RSL o g ix 500 So f tw a re 18 ·1

W hat Y ou W ill L earn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-11747 S LC 500 P rogrammable C ontrollers T roubleshooting Guide 18-1

B efo re Y ou Beg in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1



Table of Contents vii

Initia l Troubleshooting Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1

Analog 1 1 0 D iagnos is and Co rrection 18-2

Diagnostic Tests 18-2

Here's How .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18-4

Exercise 18-4


Exercise 18-8

Answers 18-8

T ro u b les h o o tin g a nd M ain ta in in g In te gr at ed P rac t i c eU s in g RSL o gix 500 So f tw are .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 ·1

What Y o u W ill L earn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19-1

Exercise 19-1


E xercise 19-6

Answers 19-6



v i i i Table of Contents

- - .



Course Overview

Co u r s e O b j ec t iv e s Upon completion of this course, you will be able to produce a

SLC 500™ system that is operational after a failure or

malfunction by performing these tasks:

• Troubleshoot noise, 110, and processor problems

• Interpret ladder logic

• Edit and document ladder logic projects

C o u rs e D es c r ip t io n This course provides you with the necessary resources and

hands-on practice to efficiently troubleshoot and maintain

existing SLC 500 systems. You arepresented with asystematic

strategy, contained in an easy-to-follow job aid, inwhich youdiagnose avariety of common system problems. Throughout the

course, you gain experience in using RSLogix 500 TM software to

perform tasks such asmonitoring projects online, editing and

documenting ladder logic, and downloading and backing up

projects.

To assist in effective troubleshooting, you willleam to interpret

bit, timer, counter, comparison, data handling, and control

instructions. Tasks and procedures are demonstrated by the

instructor and hands-on practice is provided using areal-world

application. The course culminates in afinal exercise thatintegrates and reinforces the range of tasks covered during the

course.

Rev. October 1999 © 1999 Allen-Bradley Company, Inc.

r47itro



-2 Course Overview

W ho S h o u ld A t t en d

P r e r e q u i s i t e s

Ou t l i n e

M ee t in g C ou rs e O b jec t i v e s

;: 1999 A l len-B ra dle y C ompany, Inc .

Individuals who areresponsible for troubleshooting and

maintaining SLC 500 systems using RSLogix 500 software

should attend this course.

The following prerequisites are required:• Experience maintaining electrically controlled systems

• Working knowledge of programmable controllers or

completion of theFundamentals of Programmable

Controllers course

• Experience operating apersonal computer within a

Microsoft® Windows 95®or Windows NT™ environment

This course consists of the following lessons:

• Identifying SLC 500 System Components• Getting Started with RSLogix 500 Software

• Downloading, Going Online, and Saving

• Monitoring and Entering Data

• Interpreting Bit Instructions

• Interpreting Timer and Counter Instructions

• Documenting aProject

• Interpreting Comparison Instructions

• Interpreting Data Handling Instructions

• Interpreting Program Control Instructions• Searching Ladder Logic

• Forcing Inputs and Outputs

• Editing Ladder Logic

• Printing

• Troubleshooting Noise-Related Problems

• Troubleshooting Processor and Power Supply Problems

• Troubleshooting Discrete 110 Problems

• Troubleshooting Analog I/O Problems

• Troubleshooting and Maintaining Integrated Practice

The following lesson structure is generally used to facilitate your

ability tomeet the course objectives:

• One lesson is devoted to each task.

• Lessons follow astandard format:

- "What YouWill Learn"-Iesson objectives

- "Before You Begin"--preparatory material

- "Here's How"--demonstration of procedure(s)

- "Exercise"--opportunity to perform new skills

- "How Did You Do?"--feedback on performance

R ev . October 1999

r47itro



-4 Course Overview

• The area cooled by the unit is divided into four cooling zones,

each with its own air damper:

- A push button in each zone opens (turns on) the damper of

that zone.

- The timer resets each time anew zone damper opens.

- Due to system limitations, only two dampers can be open

at atime.

As you progress through the course, you will use three different

versions of the project: cool_I, cool_2, and cool_3:

• In the cool_l project, the damper for zone 1automatically

opens when the system turns on.

• In the cool_2 and cool_3 projects:

- The dampers for zones 1and 2 automatically open when

the unit turns on.

- A call for cooling in athird zone automatically closes thezone that was open the longest.

;-. 199 9 A llen -Bradley Company, Inc. R ev. Oc tobe r 1999

r47itro



Lesson 1

W h at Y o u W i l l L ea r n

B e fo re Y o u B eg in

S LC 5/04 N

P rocessor

Rev. October 1999

Ident ifying SLC 500 ™ SystemComponents

Given aSLC 500 workstation, you will be able to identify the

components of amodular SLC 500 system

SL C 500 S y stem O ver v iew

The SLC 500 system includes avariety of processor and network

options:

W orkstation

oP LC-5®P roc ess or

S LC 5/04 N

Processo r

P an elV iew N

T erminal

17 46 R emote

1/ 0

S LC 5/03N

P rocessor

S LC 5/02 N

Processor

(£ 1999 A llen-Bradley Company, Inc.

r47S S ys



1-2 Identifying SLC 500 rn System Components

F ix ed H ar d w ar e S ys te m

SLC 500 fixed processors combine the power supply, processor,

and I/O into one unit and are available with the following

options:

• 20, 30, or 40 digital I/O points

• Two-slot expansion chassis

M o d u la r S ys te m

The modular system includes the following components:

P ower S upply P rocessor 1/ 0 Modules

~\ • . . . . fC \ m:1_t-

~ III•r__ 1:1

_1:1 ·~C

- . . .- < X > O O O O C I

@"""-"""'" ~

- --

ld ld

Chass is

Processors

Modular processors include the following:

• SLC 5/01 Th4 processor


• SLC 5/03™ processor



Chassis

Chassis, which house the processor and I/O modules, are

available in four sizes:

• 4-Slot

• 7-Slot

• 10-Slot• 13-Slot

~' 1999 A l len-Bradley Company, Inc . R ev . Oc tobe r 1999

r47ssys



Identifying SLC 500'" System Components 1-3

Additionally, chassis can be connected together to increase the

I/O available to aprocessor:

1 74 6-C 7 o r -C 9

Cha s s i s

In te rc o n ne ct C ab le-.

fO\ ma

~ fII fII rr -a -a . -. . .-c

t;;Il~"-~

~

~

Id Id

fO\ rs :a

liiIIIrr -a -·a-a - . .-c

~AUN1RA:UY

~-Id IQ !

Power Supplies

Three AC and one DC power supplies are available:

• AC:

- 2A at SVDC

- SA at SVDC

- lOA at SVDC

• DC 3.6A at SVDC

I/O Modules

The I/O modules used by asystem will vary depending on the

application, including:

• Discrete

• Analog

• High-Speed Counter• Stepper Controller

• Servo Positioning

• Communication

• Remote I/O

R ev. October 1999 e 1999 A llen-Bradley O om pan y . ln c .

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1-4 Identifying SLC 500"" System Components

Remote r/(l ~xampl"

R I - G g O O P r g O " l g r

•

1747 -SN

0__

1 77 1- R e m o te 1 /0 Ne tw o r k

S ig na l F lo w Th r o u gh t h e SL C 500 Sy s tem

The following diagram outlines the sequence of events from theactivation of machine or process inputs to the energizing of

machine or process output devices:

I n p u t

De v i c e s

I n p u t

M o d u l e sP r o c e s s o r

M em o r y

O u tp u t O u tp u t

M o d u les D ev ic es

0:4/ 0

1: 3 /0

P r o g r am

~ 3 roF i l e s ~ 4 8

~ •:3{7 0:4 /1~/ (

1: 3{7

C Com~uter

'2 1999 A l len-B ra dle y C ompan y, Inc . R ev. O c to be r 19 99

r47ssys



Identifying SLC 500'" System Components 1-5

E x e r c i s e In this exercise, you will identify the components of your SLC

500 workstation.

Directions:

Identify and check off the components that comprise your SLC500 workstation:

1. Chassis:

o4-slot

o7-slot

o 10-slot

o 13-slot

o Interconnect cable

2. Power supply:

o 1746-P1

o 1746-P2

o 1746-P3

o1746-P4

3. Processor:

05/01

05/02

05/03

05/04

05/05

4. I/O modules:

oDiscre te input modu les

oDiscre te output modu les

oAnalog modules

o Removab le te rm inal b lock s o r w iring a rms

How D id Y o u D o ? If you have any questions, ask your instructor for assistance.

R e v . O c to b er 1 99 9 © 1 99 9 A lle n -B r ad le y C o m p a ny , In c .

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1-6 Identifying SLC 500,. System Components

;; 1999 A l len-Bra dle y C ompan y. Inc . R ev. O ctober 1999

r47ssys



Lesson2

Getting Started with RSLogix500 ™ Software

W hat Y o u W il l L ea rn Given an RSLogix 500 project on disk, you will be able to

perform these actions:

• Open aproject

• Navigate through aproject

• Configure the display

• Use the help system

• Save aproject, including entering arevision note

• View aproject revision history

• Create and restore auto and compressed backup files

B efo re Y ou B eg in K ey Ter m s

Save: Write acopy of aproject to the non-volatile memory of a

computer. Non-volatile memory retains projects when power is

removed from the computer.

I m p o r t a n t : If the project already exists on the computer, savingwill overwrite it.

Backup File: The ladder logic and database files for the projectcompressed into asingle file with an .RSl extension.

Restore: Decompress (open) abackup file.

Auto-Backup File: Ladder logic file automatically created by

the RSLogix 500 software at regular intervals andeach time a

project is saved.

R SL o g ix 5 00 D is p lay

The RSLogix 500 display includes the following elements:

• Windows Toolbar

• Program/Processor Status Toolbar

• Instruction Toolbar

• Project Window

• Ladder Window

• Results Window

Project Tree

The RSLogix 500 project tree contains the following folders:

R ev. O ctober 1999 ; .Q ' 1999 Allen·Brad ley Company, Inc.

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2- 2 Getting Started with RSLogix 500 ,. Software

Program Files

Program files contain the ladder logic that controls inputs and

outputs:

F o rc d~B ~sdJ "d .ustc i M " l 5 at a Morlitors

r !r J :::J ~!!Iba$e' : J i ~ ~ i i ~ : ; w ' ; : : ?

'; 1999 A llen -B radley C ompany, Inc. R e v. O c to be r 19 99

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2-4 Getting Started with RSLogix 500NSoftware

R e vi s i o n N o t es

Revision notes outline the changes made to aproject:

C om p res sed B ac ku p an d A u to -B ac ku p F i les

The Open dialog box also displays compressed and auto-backup

files:

A u t o - B a c k u p

F i l es

C omp r e s s e d

B a ck u p F il e

~ 1999 A llen- B radley Company, Inc . R e v. O c to be r 19 99

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Getting Started with RSLogix500N Software 2-5

H ere 's H ow To perform the following actions:

• Maximize, restore, and size windows

• Return windows to the default size and orientation

• Open multiple program files

- In the same ladder window

- In separate ladder windows

• Split the Ladder window using the split bar

• Go to aspecific rung using ~earch--+ Goto ...

• Configure the display:

- Address format

- Documentation

- Colors and fonts

• Save aproject, including entering arevision note

• View aproject revision history

• Select the auto-backup option and restore an auto backup file

• Backup (compress) aproject

• Restore acompressed backup file

As your instructor demonstrates these procedures, follow along

in the RSLogix 500 Procedures Guide.

Ex er c is e In this exercise, you familiarize yourself with the layout of the

RSLogix 500 software, navigate through aproject, and configure

the display:

1. Start the RSLogix 500 software

2. Restore the projects specified by your instructor from the

exercise disk to afolder designated by your instructor (e.g.,

cool projects, wash projects).

3. Open one of the projects that you restored in Step 2. (e.g.,

cool_1, wash_1).

4. Locate the elements of the RSLogix 500 main window called

out in the appendix of theRSLogix 500 Procedures Guide

5. Maximize and restore the Project window and Ladder

window.

6. Increase the size of the Ladder window so that it partially

covers the Project window, and then return thewindows to thedefault setting.

7. Open additional program files in the existing Ladder window.

8. Split the Ladder window into two panes.

9. Display several tool tips (e.g., Zoom In).

10. Select an instruction and display the help regarding that

instruction. Repeat this step for adifferent instruction.

Rev. O ctober 1999 © 1999 A ll en-Bradley Company, Inc .

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2-6 Getting Started with RSLogix 500 ~ Software

11. Display the View Properties dialog box and set the following

options:

OK ~ f k H : ~ ! ~ : : . J H e l p I

12. Change the text and background colors for several ladder

logic elements and then return the display to the default

colors.

13. Using Search- Goto ... , go to different rungs in the project,

including rungs from different program files (e.g., 3:1).

14. Verify that the auto-backup and prompt for revision note

options are selected.

15. Save the project and enter a revision note.

16. View the project revision history.

17. Restore the most recent auto backup file of the project.

18. Backup (compress) the project and store it in the folder

designated in Step 2.

19. Close the project.

Ho w D id Y o u D o ? If you have any questions, ask your instructor for assistance.

~.. 1999 A l len-B ra dle y C ompany, Inc. R ev . Oc tober 1999

r47star



Lesson3

D o w n l o ad in g , G o i n g O n l i n e , a n dSaving Using RSLogix 500 ™

Software

W h a t Y o u W il l L ea r n Given acomputer and RSLogix 500 projects on anetwork, you

will be able to perform these actions:

• Select and connect cables

• Configure communication drivers

• Assign aproject node address

• Download aproject

• Go online to the intended project

• Save an online project

B efo re Y o u B eg in K ey Te rm s

Offline: Regarding RSLogix 500 projects, viewing aproject

residing on the hard disk of acomputer.

Online: Regarding RSLogix 500 projects, viewing aproject

residing in aSLC 500 Th4 processor.

Driver: A software subroutine that enables asoftware

application to communicate with ahardware device.

E x am p le : D r i v e r

RSLogix 500 software requires adriver to communicate with

the communications port of acomputer.

Node: Address of adevice, such as aprocessor or computer, on a

network. Each device must have aunique node address.

Baud: The speed at which data is transferred across acommunication link, such as between aprocessor and computer.

Download: Transfer acopy of aproject from acomputer to a

processor.

I m po r t a n t : Downloading overwrites the current project in theprocessor.

Save: Write acopy of aproject to the non-volatile memory of a

computer. Non-volatile memory retains projects when power is

removed from the computer.

I m po r t a n t : If the project already exists in the computer, savingwill overwrite it.

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3-2 Downloading, Going Online, and Saving Using RSLogix 500'" Software

Upload: Write acopy of aproject to the volatile memory of

computer. When power is removed from acomputer, projects in

volatile memory are erased

EEPROM (Memory Module): A module that can be inserted

into aSLC 500 processor to maintain acopy of the project incase the processor experiences either of these situations:

• Memory corruption

• Extended power loss

C om m u n ic at i o n O p t io n s

Depending on the processor, you can go online using several

options:

Co m m u n ic a t io n5/01 5/02 5/03 5/04 5/05

Op t io n

Ethemet vDH +'" vDH-485 v v

RS-232(Serial) v v v

DH+ Connections

DH+connections enable you to go online to any processor on a

DH+network from one connection point:

• Uses channel 1of an appropriate processor• Requires 1784-PCMK, -KT, -KTX, or -KTXD

communication card

• Uses bauds up to 230.4K bits/second

• Allows amaximum of 64 (0- 77 octal) nodes

Example: DH+ Network

IB M ® ·C ompa t i b l e C om p u t e r

w i t h 1 78 4·K T X

D

I BM ·C ompa t lb le C om pu t e r

w i th 1 78 4-K T X D

A dd re s s 77

A dd res s 76

A d d r e s s 5

A dd re s s 23

A d d re s s 13 A d d r e s s 15

~. 1999 A llen -Bradley C ompany, Inc. R ev . Oc tobe r 1999

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Downloading, Going Online, and Saving Using RSLogix 500'" Software 3-5

H er e's H o w To establish acommunication link with aspecified processor by

performing these actions:

• Select and connect cables (See "Going Online to aSLC 500

Project" in the procedures guide.)

• Configure communication drivers

• Assign aproject node address

• Download aproject

• Go online to the intended project

• Save an online project


in theRSLogix 500 Procedures Guide.

Exe r c i s e In this exercise, you will configure communication drivers,

download, go online, and save aSLC 500 project using two

communication options.

1. Connect the 1784 communication card of your computer to

the SLC 500 processor of your workstation.

2. In the Linx software, configure the appropriate

communication driver using the parameters specified by yourinstructor.

3. Open version one of the appropriate exercise project (e.g.,

cool_I, wash_I) and assign the node address specified by

your instructor. (If you did not restore the project from the

exercise disk, do so at this time.)

4. Download the project to the SLC 500 processor of your

workstation and go online.

5. From the Online toolbar, verify processor node number.

6. Save the project and enter arevision note.

Rev. October 1999 © 1999 Allen-Bradley Company, Inc.

r47sgoo



3-6 Downloading, Going Online, and Saving Using RSLogix 500N Software

7. If your workstation is networked, go online to adifferent SLC

500 processor.

8. Go online to the processor of your workstation using an

RS-232 connection.

9. When you have verified that your computer is online, gooffline.

Ho w D id Y o u D o ? If you have any questions, ask your instructor for assistance.

; 1999 A llen-B radley C ompany . Inc . Rev. October 1999

r47s900



4-2 Mon itoring and E ntering Data Us ing R S Logix 500 W Software

D at a F ile T yp es

F il e T y p eF il e N u m b er

D a ta S t o re d(Res e r v ed )

Output 0 State o f output te rm ina ls

Input 1 State o f input te rm ina ls

Status 2 Controlle r operati on in fo rmation

Binary 3 I nte rna l relay log ic

Timer 4Timer accumulator, preset, and status

values

Counter 5Counter accumulator, p re set, and s ta tus

values

Control 6Length, position, a nd s ta tu s o f

appl ication speci fic instructions

Integer 7 Pos itiv e o r negative who le numbe rs

Floatin g P o in t' 8Pos itiv e o r negative numbe rs that

in clude the dec imal poin tASC I I'

String'None A lphanumeric characters

*S LC 5/03 O S 30 1, O S302 and S LC 5/04 processors only

Except for the output, input, and status files, additional files can

becreated as needed, up to atotal of 255 files.

A d d res s F or m at

Use the following format to address individual elements, words,

and bits:

F i l e T y p e F i l e N u m b e r E lem en t N u m b e r W or d N u m b e r

~ \ / / / N u m b e ,X F : E .W /B

E l e m e n li . , \ \W o r d D e li m i te r\

B i t D e li m i te r

For output, input, and status file addresses, the file number can

beomitted.

If an element contains one word, the word number can be

omitted.

~ 1999 All en -B radley C ompany, Inc. R ev . O ctober 1999

r47smon



Monitoring and Entering Data Using RSLogix 500 '" Software 4-3

Address Examples

Discrete I/O device wired to terminal 6 of an input module in slot

3:

1 : 3 .0 /6

Bit 15of element 1 in the status file:

S 2 : 1 /1 5

Element 10of integer file 7:

N 7 : 1 0

S y m b o ls

A symbol is an alphanumeric name that is assigned to an address

to identify the function of the address. A symbol must meet these

conditions:

• Unique to an address

• Up to 20 characters in length

Example: Symbols

A d d r e s s

I s~mbol SWITCH_O COIL _O

~ 1:3.0/0 0: 4. O lO----j f -- _ - - - - - -- - -- - ( _ )- -

You can use asymbol in place of an address to perform thesetasks:

• Entering or editing ladder logic

• Monitoring and entering data

• Searching for an instruction

R ev . O ctobe r t999 © 1 9 99 A l le n - B ra dle y C o m pa n y , ln c .

r47smon



Monitoring and Entering Data Using RSLogix 500 ~ Software 4-5

1 /0 Con f i g u r a t i o n

The project tree can beused to display the I/O configuration:

R ev. October 1999 © 1999 Al len-B ra dle y C ompany, Inc .

r47smon



4-6 Monitoring and Entering Data Using RSLogix 500'" Software

D a ta F il es

Data f iles can be opened using the project tree:

H ere 's H ow To monitor and enter data by performing these actions:

• Determine the address of an I/O point

• Monitor adata file

• Toggle abit

• Enter new data

• Create acustom data monitor

• Enter new data using acustom data monitor

As your instructor demonstrates these procedures using the

following examples, follow along inAppendix C and D of the

1747 SLC 500 Programmable Controllers Troubleshooting Guide

and in theRSLogix 500 Procedures Guide.

~. 1999 All en-Bradley C ompany, Inc. R ev . O cto be r 19 99

r47smon



Monitoring and Entering Data Using RSLogix 500'" Software 4-7

Determining and Monitoring Discrete Input and Output

Addresses

00

o

Rev. October 1999 © 1999 Allen-Bradley Company, Inc .

r47smon




6. Address = _

OUTPUT

CD~

OWER

ANALOG

L.

-- '

~

(0·2VOC

( 1) D C C OM

. - -~

(010010

P)ANlCO I.4r-

~

(21 O UT ,

(31 A N L C O ldr-

0 (')OUT 2r-

0 (5A NlCO M

---~!6\OUT3}-

--~[7) A N l C QLt~

[ : J " '"

H o w D i d Y o u D o ? Turn to theendof the lesson for the answers. If you haveany

questions, ask your instructor for assistance.

Rev. October 1999 @ 1999 Al len-Bradley Company,lnc.

r47smon




Workstatlon Device P rolect S ymbol Address

Dis cre te I nput 8 O FF _ PS _ZONE_1

Dis cre te I nput 9 O N P S ZONE 1- - -

D isc re te Input 10 O F F _ P S _ ZO NE _ 2

D is cre te I nput 11 ON P S ZONE 2- -

D is cre te I nput 12 O F F P S ZONE 3- -

D isc re te Input 13 ON P S ZONE 3- - -

D isc re te Input 14 O F F P S ZONE 4- - -

D is cre te I nput 15 ON P S ZONE 4- -

Ana log Input 1 S UP A IR THE RM STAT

S CD Output 1 T IMER D IS P LAY

D is cre te Ou tput 0 O UT DAM PE R

Discrete O utput 2 S TAR T COO L T IME

Discrete Output 3 C OOL T IME DN

Discrete O utput 4 C OOL T IME R E S E T

Discrete Output 5 S TAG E 1 COMP--

D is cre te Ou tput 6 S TAG E 2 COMP--

Discrete Output 9 DAMP E R ZONE 1

D is cre te Ou tput 11 DAMP E R ZONE 2

D is cre te Ou tput 13 DAMP E R ZONE 3

Discrete O utput 15 DAMP E R ZONE 4

Ana log O utput 1 A IR TE MP GAGE

2. Go online to the cool_l project of your workstation. (If you

did not restore and download the project from the exercise

disk, do so at this time.)

3. Select the Remote Run mode

4. In the SET_COOL _TIME thumbwheel, enter 30 (minutes).

5. Monitor the input data file.

R ev . O ctob er 1999 ~ 19 9 9 A l le n - B ra d le y C om p a n y , In c .

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6 .

Radix Value

B inary 000000000011 0000

Octal 60

Decimal 48

Hex/BCD 3 0

8 .

M in imum dec imal va lu e

32767 (D epe nding o n yo ur w orks ta tio n, it m ay be

slightly less.)

o

Maximum dec imal v alu e

10.

M in imum tempera tu re (C )

1000

(D ep end ing o n yo ur w orks ta tio n, ~may b e

slightly less.)Maximum tempera tu re (C )

The temperature is also displayed on AIR_TEMP _GAGE. Each

VDC equals 100 C.

R ev. Oc tobe r 1999 © 1999 A llen· B radley Company, Inc.

r47smon



Lesson 6

Interpret ing Timer and CounterInstructions Using RSLogix 500 ™

Software

W h at Y ou W il l L ea r n Given an RSLogix 500 project, you will be able to interpret timer

and counter instructions.

B efo re Y ou B eg in K e y T e r m s

Accumulated Value (ACC): The number of elapsed time

intervals or counted events.

Preset Value (PRE): The number of time intervals or events tobe counted.

Timebase: The interval at which the timer instruction

increments. For SLC 5/01"'" processors the timebase is 0.01

second. For SLC 5/02"'" , 5/03 .",. 5/041M, and 5/05"'" processors,

the timebase can be set at either 0.01 or 1.0 second.

Status Bits: Bits that are set or reset indicating the status of an

instruction.

T im e r an d C ou n te r In s t r u c ti o n s

The following table outlines the function of timers and counters:

T his ins truc tion ... W he n the

Name MnemonicP e rfo rms this func tio n • .•

rung ...

T ime rTON Is true C ounts time base intervals

O n-Delay

T ime rTO F

C ha nge s fro m trueCounts time base intervals

O ff-Delay to false

Is true C ounts timebase intervalsRetentive

R TO Is fa ls e o r a po werT ime r

cyc le occu rsRe ta in s th e a ccumula te d valu e

C hanges from Increments the accumulated

false to true valueC ount Up C TU

Is fals e o r a po wer


Change s from Decrements the accumu la ted

Count false to true value

DownC TD

Is fals e o r a pow er


R e se ts th e a cc umula te d value

a nd s ta tus bits o f a time r or

R eset R E S Is true counter

N ote: D o not use with a T OFtimer.

Rev. October 1999 ~ 1999 Allen-Bradley Company, Inc.

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6-8 Interpreting Timer and Counter Instructions Using RSLogix 500t Software

A n s w e r s E xe r c i s e

3. COOL_TIME _RESET ison for two seconds (200 x 0.01)

after either ON OFF CYCLE or NEW ZONE are turned on.- - -

4. START COOL TIME is turned on three seconds after- -ON_COMMAND is turned on, as long as COOL_TIME_DN

is off. When either ON COMMAND turns off or

COOL_TIME_DN turns on, START_COOL_TIME will turn

off.

5. OUT_DAMPER, which opens and closes the outside air

damper, is turned on as soon as ON_COMMAND is turned

on, as long as COOL_TIME _DN isoff. When either

ON_COMMAND turns off or COOL_TIME_DN turns on,

OUT_DAMPER will remain on for three seconds, then turn

off.

6. T4:11.ACC will hold its value.

7. T4:11.ACC is reset to zero when Rung 2:23 goes true,

enabling the RES instruction. In this case, T4: 11 is

programmed to run as afree-running timer as long as

COMPRSSRS ENABLE is on.

8. C5:1 counts up once everyone hour. T4:11IDN is turned on

after CU_HOURS times for 3600 seconds (1hour). When

T4:11IDN turns on, C5:1 counts up, CU_HOURS is reset

(Rung 2:23), and CU_HOURS starts timing again.

9. Zero or one. When C5:0.ACC is greater than one, C5:01DN

turns on and any further zones cannot be opened.

10. ZONES_OPEN _CNT counts down each time either T4:6, 7,

8, or 9 start timing. The timer must stop timing, making the

rung false again, before ZONES_OPEN _CNT can count

down again

11. T4:7m is on for 0.04 seconds (the timer is timing) after

ON_COMMAND _ZONE _2 is turned off. It is used to send apulse to Rung 2:21 and decrement ZONES_OPEN_CNT.

2 1999 A llen-B radley C ompany, Inc. R ev . O c to be r 1 99 9

r47sitc



9-2 Interpreting Data Handling Instructions Using RSLogix 500N Software

In s t ru c t i o n O p e ra ti on

The following table outlines the operation of specific data

handling instructions:

T h is In s tr u ct io n ... P er f orm s th is ac tio n w h en It s r u n g Is

N am e M n em o n ic t r u e ...

Convert fromC onverts the s ourc e va lue fro m B eD to

F R D de cim al a nd e nte rs the re su lt in th eBC D

destination

C o nve rt to B C D TOOCo nve rts the s ou rc e va lue from d ec im al to

B C D a nd e nters the re sult in the destination

Move MOV En te rs th e sou rce valu e in to th e d es tin atio n

M as ke d M ove MVME nte rs the unma sked bits o f a s ourc e value

into the destination

C o py F ile C O PE nte rs d ata from th e s ou rc e file in to the

destination f ile

F i ll F i le F LL E nte rs the s ource va lue into e ac h e lem ent of

the des tination file

H er e 's H ow Using the following examples, your instructor will demonstrate

interpreting data handling instructions.

Example: FRD and TOn Instructions

....--FRD

F rom BeD I---

Source 1:1.0

OOOO h<Dest W:6

5<

SW I T C H _ O

....--TOD_1 r

T o BeD I---L

Source W:6

5<

Dest 0:2.0

O O O O h<

.~ 1999 A llen-Bradlev C ompany, Inc. R ev . October 1999

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10-10 Interpreting Program Control Instructions Using RSLogix 500'" Software

A n s w e r s E x er c is e

2. When Rung 2:5 is true (T4:0/DN in on), program execution

continues with rungs 4:0-3, and then returns to Rung 2:6.

3. When Rung 2:5 isfalse (T4:0/DN is off) program executioncontinues with Rung 2:6, skipping program file 4.

6. If Rung 2:8 isfalse (T4:0/DN is on) program execution

continues with Rung 2:9.

7. If Rung 2:8 istrue (T4:0/DN isoff), program execution jumps

to Rung 2:12.

9. When Rung 2:0 is false (ALL_SHUT_OFF ison), all

non-retentive outputs are turned off, which includes both

compressors.

10. No. Since CU_HOURS is anon-retentive output, it will reset

when Rung 2:0 is false.

11. When ALL_SOOT_OFF turns on, any open dampers will

close (turn off). See answer 9.

12. In afalse MCR zone (i.e., The MCR rung that starts the zone

is false.), counters retain their values.

1999 A llen -B radley C omp any. Inc. R ev . O ctob er 1 999

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Lesson 12

W hat Y o u W il l L ea rn

B efo re Y ou B eg in

Forcing Inputs and OutputsUsing RSLogix 500 ™ Software

Given an RSLogix 500 project, you will be able to force inputs

and outputs on and off.

W hen to u se Fo rc in g

Forcing can be used for any of the following situations:

• Checking the field wiring

• Checking functionality of field output devices

• Testing aportion of the program logic

• Simulating inputs that have not been wired

F ac to rs to C on s id er B efo re U s in g F or c in g

Consider these factors before forcing:

• Potential danger to personnel

• Machine response to forced I/O

• Possible effects on other portions of themachine/process

• Company policy concerning forcing I/O (Is authorization

required?)

S a fe ty P r ec a u t io n

A'ITENTION: Use EXTREME CAUTION when using forcing. All

force functions can result in sudden machine movement, possiblyinjuring personnel or damaging equipment. If forces are established,enabling forces will enable all forces without prompting. If forces areenabled, any additional forces will take effect immediately. Beforeproceeding, verify the status of forces, verify that you are online to thecorrect processor, notify personnel of the proposed changes, and take

adequate safety precautions.

Rev. October 1999 \S 1999 Al len-Bradley Company, Inc.

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13-2 Editing Ladder Logic Using RSLogix 500 ~ Software

Ed i t Z o n e M ark er s

The following table outlines the zone markers used by the

RSLogix 500 software:

e Entering or editing

Th is m ar k e r ... S ig n i f ies a r u n g th a t y o u are ...

ior1* I nse rting in to the pro je ct

r o r R *Re pla cing by the rung immedia tely preceding it, which

is ma rked w ith a n i

D* De le ting from the pro je ct

* Upper-case markers only apply to online editing in the Remote

Run mode. When edits are accepted, lower-case i and rmarkers

change to upper-case markers.

Sa fe t y P rec au t io n

ATfEN'TION: Use extreme caution when editingladder logic online. Any errors can injure personneland damage equipment. Before editing ladder logiconline perform the following actions:

•Check if editing ladder logic online is permittedby your company.

•Evaluate if changes must bemade online.•Assess how machinery will respond to changes.•Check and recheck proposed changes foraccuracy.

•Notify all personnel of changes.

Her e 's H o w To modify an RSLogix 500 project by performing these actions:

• Enter arung, instruction, and address or symbol

• Edit an instruction

• Enter abranch

• Verify ladder logic

• Edit ladder logic online:

- Remote Program mode- Remote Run mode


in the RSLogix 500 Procedures Guide.

~ 1999 A J len-B rad ley C ompany, Inc. R ev . O c to ber 1999

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13-8 Editing Ladder Logic Using RSLogix 500'" Software

0003

0004

COMPRSSRS_ENABLE

B3:015

9 .

Simulst~d Adjuat.ableTimingR~sy

ClI_SECONDS

T9:O,'DN TON»: TimerOnD~s~1 ~EN'

Timer W:O

TirneBase 1.0 ':DN~

Pr ea et e ; o c :

Accum 3·1<

COOL_TIME

CTU~CU~

Counter 05::2

Pr eo ! '! e o t 10": ~DN>-

Accurn · 1 . • :

~----------------------------------------------------------~:END)--

; 1999 A llen·Bradley C ompan y, Inc. R ev. O ctobe r 1999

r47sedd



Lesson 15

Troubleshooting Noise-RelatedProblems Using RSLogix 500 ™

Software

W h a t Y o u W il l L ea r n Given apreviously operational SLC 500 TM system, you will be

able to describe the indications and corrective actions regarding

noise-related problems.

B e fo r e Y o u B eg in 1747 SL C 500 P ro g r am m a b le C on tr o l l e rs T ro u b le s h o o t in g

G u i d e

Use the 1747 SLC 500 Programmable Controllers

Troubleshooting Guide to diagnose and correct problems

occurring with apreviously operational SLC 500 modular

system. The troubleshooting guide provides the following

information:

• Safety precautions and warnings

• A flow chart outlining troubleshooting decisions and actions

• Reference information for completing steps

• Hardware and software procedures used in diagnosing

problems

Refer to your troubleshooting guide as your instructor reviewsthe following sections:

• Layout of Guide

• Safety Precautions

• Legend

Initial Troubleshooting Actions

The "Getting Started" section of the troubleshooting guide

outlines the initial actions that you should perform whenever a

malfunction or failure occurs:

1. Ask the operator what happened when the failure occurred.

2. If the problem has occurred before, try the same corrective

action(s).

3. Rule out as the cause or repair all apparent machine or

process problem(s).

R e v . O c to be r 1 99 9 © 1 9 99 A l le n - B ra dle y C o m pa ny , In c .

r 4 7 s n o i



Troubleshooting Noise-Related Problems Using RSLogix 500"" Software 15-5

C o mm u n ic a t io n

Determine if communication networks areproperly wired:

• Are cables correct for all connections?

• Do 1747-AJCs connect each device on aDH-485 network?

• Is termination jumper at each physical end of the DH-485

network?

• Is DH-485 network cable shield grounded at one end?

• Is termination resistor at each physical end of the DH+TM

network?

• Are communication cables not running in wireways with

power wires?

• Do communication cables cross power wires at 90 degree

angles?

DH-485 Cable Connections

174 7 -A IC SLC 5 /02 TM an d 5 /03 T M P r o c e s s o r s

DH+ Cable Connections

SLC 5 /04 T M P r o c e s s o r s

\ /

e r m i n a t io n

Res i s to r

R ev. October 1999 © 1999 Al len-Bradley Company, Inc .

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17-6 Troubleshooting Discrete I/O Problems Using RSLogix 500 N Software

3. Operator in zone 3 reports the following: "I press the button

to open the air damper and let cool air in, but it doesn't open."

According to the wire label, zone 3damper's symbol is

DAMPER_ZONE_3. At the module, its status indicator is off.

Online, the ladder logic displays as follows:

flILAO 2· M A U l CtlTIU.. I!IlIIjII3

OH]8_l0NE.1

130i9

0014

I<EW.ZO~E.OSR8J 016

OIR f----1

ON_P9_l0IlE.2

130/11

ON'p8_l0IlE.3

1 3 om

ON_P~_:::OflE.4

130/15

flLAO 2 . MAlt. CtlTRL IlIilI3

00 I~

flEW_ZOtiE_DPEtl

EOU----,

lO 11G_lOlJE_DPEN

sou

S(lurce Cl r·l7 11:,

3<

144JON

Il<LJ

~ 1999 Al len ·B rad ley C ompany. Inc.

O",,",PER.ZONE_3

o 4.0/l?

Sourct!

3<

[lest HT ts

1<

L !.L J

Corrective action(s):

o Check the power to on the terminal

block. -----o If this is an output module, check the field power to themodule on the terminal block.

oVerify field wiring to-------

oCheck for proper operation.

oReseat module and verify operation.

o If the problem persists, replace module----

R ev . Oc tober 1999

r47sdid



Troubleshooting Analog I/O Problems Using RSLogix 500'" Software 18-3

Test output devices with an output source:

+

[ Actuatort---

Test analog input devices with either an ammeter or avoltmeter:

V o l t ag e M o d u l e C u r r e n t M o d u l e

Voltmeter

+

_LNP \

POWER =ANALOG

'0 O IIN O .

~ I I INO-

~ 21 ANLCOM

~ 311N 1+

~ ~INI -

~ 51 ANLCOM

~ 611N 2.

~ I7IIN2 -

~ S IAN LCOM

~91 IN 3.

101 IN 3-

~ I1lAN L C Q1,""

Ammeter

+

_1Nl'

POWER =ANALOG

~101IN O .

~ IIIN O -

~ 21ANLC OM

~

3 IN I.

4 11 N 1-

~ 51ANLC OM

~ 611N 2t

imIN2-

S IANLCO M

911N 3.

~ 10l1N3 -

~ IIIANLC O~'- ='-.

Disconnected +/

D isconnected / /

r--~= ///

Test analog input modules with an output source:

INPUT

POWER =+1

+ !ANALOG

~ t:: .. .

Volta ge OR Curre nt

I~-------- ~Sensor

- (01 IN 0+

Source - ~ (11IN O-

r0lo ---------- ~ 12 1 ANLCOM

- I 0 131 IN 1+

~ 4) IN 1-

~ I (51ANLCOM

~ I(6)IN 2+

~LmIN2-

~ 1(8)ANLCOM

~ L ffiiIN 3+

~I(10) IN 3-

~ I (I1)ANLCOM

R

Re v. October 1999 © 1999 Al len-Bradley Company, Inc.

r475 10 9



18-4 Troubleshooting Analog I/O Problems Using RSLogix 500~ Software

H ere 's Ho w To troubleshoot analog I/O problems:


in the 1747 SLC 500 Programmable Controllers Troubleshooting

Guide.

Exe r c i s e

eIn this exercise, you will work through several analog I/O

problems for the cool_2 project that relate to the following report

by anoperator: "The temperature gauge does not agree with the

actual air temperature and appears to bemalfunctioning."

The following information is provided for your reference as you

complete the exercise:

Takes the value from the analog input that measures the temperature of

the supplv air (1:7.0) and displays it on the supply air temperature gauge

(0:7.0) as a temperture between 0 . 100 degrees C .

.~alog supply air

temperature gauge

---M 0V----------,1--------------1 tl.~)ve -

Source SUP _ .A J R_TH ERMST.A T

1 7 5 8 4 <Dest .AJR_Ts..~P_GAG E

1 7 5 9 4 <

.; 1999 A llen -Bradley C ompany, In' R ev. Oc tobe r 1999

r47s l09



18-6 Troubleshooting Analog I/O Problems Using RSLogix 500'" Software

4. At the SLC 500 chassis you find both the power supply LED

and themodule power LED are on (Tab 6), but the data file

does not show the data changing.

A. Which tab would you refer to next?

; 1999 A l len-B ra dle y C ompan y, Inc . R e v. O c to be r 19 99

r475109



Troubleshooting Analog I/O Problems Using RSLogix 500 'M Software 18-7

B. While completing the steps from that tab, you determine

that the meter does not show achange that corresponds

to achange in the output address. What would you do to

resolve the problem?

C. While completing the steps from that tab, you find the

module light on but the meter does not show achangethat corresponds to achange in the input device. What

you would do to resolve the problem?

D . If the meter referred to in Step C. does show achange

that corresponds to achange in the input device, to which

tab would you refer to next?

Ho w D id Y o u D o ? Turn to the end of the lesson for the answers. If you have any


R ev . O ctober 1999 © 1999 Allen-Bradley Company.lnc.

r475109



18-8 Troubleshooting Analog I/O Problems Using RSLogix 500'" Software

A n s w e r s E x e r c i s e

1. Tabs 3and 6

2. Remove power from the power supplies and I/O devices for

module 7.

Reseat module 7.

If problem persists, replace module 7.

3 .

A. Tab 6A

B. Shut down the system.

Reseat module 7.

If problem persists, replace module 7.

C. Tab 6C

4 .

A. Tab 7. The ladder logic takes the data from

SUP_AIR_THERMSTAT, an analog temperature input,

and moves it to AIR_TEMP _GAGE, the analog

temperature gauge.

C. Repair and or replace input device or wiring.

Check cable routing.

D. Tab 7A

.~. 1999 Allen-B radley C ompany, Inc. R ev . October 1999

r47slog



Lesson 19

Troubleshooting and MaintainingIntegrated Practice UsingRSLogix 500 ™ Software

W h a t Y o u W i l l L ea rn Given amalfunctioning SLC 500'" system, you will produce an

operational system and perform routine project maintenance.

E x e r c is e After aroutine maintenance shut-down, you areassigned to test

and verify that the cool_3 project operates correctly.

Additionally, engineering has provided ahard-copy markup of

ladder logic changes that you must make onlineonce the system

is up and running.

As you proceed with the exercise, follow these guidelines:

• Correct any problems you identify.

• Clear any faults that may occur.

• To assist in determining the addresses of symbols, display the

cross-reference report and sort it by symbols.

• Perform forcing procedures asneeded.

• Make the recommended edits online.

• If required, use the backup copy of the cool_3 project,

included on the exercise disk.

Directions:

1. Go online to the cool_3 project of your workstation.

2. Test the operation of the cool_3 project by completing thefollowing checks:

A. Place the processor in Remote Run mode.

B. Verify that DAMPER_ZONE_l and DAMPER_ZONE_2

are open (on).

C. In thumbwheel SET_COOL_TIME, enter atime intervalof 60minutes.

D. Press START and verify that OUT_DAMPER opens

(turns on).

E. Verify that TIMER_DISPLAY is incrementing. (It

increments is one minute intervals.)

AIR_TEMP _GAGE is calibrated so that each one VDC equalsl O° e .

F. Verify that analog output AIR_TEMP _GAGE correctly

registers the temperature supplied by analog inputSUP AIR THERMSTAT:

R ev. O cto be r 1 99 9 © 1999 Al len-Bradley Company, Inc.

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19-2 Troubleshooting and Maintaining Integrated Practice Using RSLogix SOONSoftware

- When SUP_AIR_THERMSTAT is all the way to the

left, AIR_TEMP _GAGE indicates zero (0° C).

- When SUP_AIR_THERMSTAT isall the way to the

right, AIR_TEMP _GAGE indicates full scale (100° C).

G. Verify that the first compressor, STAGE_l_COMP, andFAN turn on at 35° C.

H. Verify that STAGE_1_ COMP and FAN turn off at 30° C.

I. Verify that the second compressor, STAGE_2_COMP,

turns on at 50° C.

J. Verify that STAGE_2_COMP turns off at 45° C.

K. Momentarily turn on (then off) ON_PB_ZONE_3 and

verify the following:

- DAMPER_ZONE_3 opens (turns on)

- DAMPER_ZONE_2 closes (turns off)

L. Momentarily turn on (then off) ON_PB_ZONE _4 and


- DAMPER_ZONE_ 4 opens (turns on)

- DAMPER_ZONE _1 closes (turns off)

M. Momentarily turn on (on then off) ON_PB_ZONE _1 and


- DAMPER_ZONE_l opens (turns on)

- DAMPER_ZONE_3 closes (turns off)

N. Momentarily turn on (then off) ON_PB_ZONE_2 and


- DAMPER_ZONE_2 opens (turns on)

- DAMPER_ZONE_ 4 closes (turns off)

O. Verify that thefollowing occurswhen thetimer times out:

To expedite the time-out, in SET_COOL _TIME, enter avalue

one minute greater than the current display on

TIMER DISPLAY.

- STAGE_l_COMP and STAGE_2_COMP, if on, turn

off

- After the compressors turn off, outside air damper

closes

3. Once the system checks out according to Step 2., create a

custom display that monitors the following addresses:

• B3:0/5

• I:1.0TWl (in hexadecimal radix)

• N7:22

• N7:23

• N7:24

• C5:2.PRE

4. In N7:23, enter 15.

~ 1999 A llen-B radley C ompany, Inc. R e v. O c to be r 1 99 9

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19-4 Troubleshooting and Maintaining Integrated Practice Using RSLogix 500N

Software

Timer Input Checkd' When thumbwheel value is 15-60 mnutes. enters value in system timer preset (C5:2.PRE)

~

~ ~ ' i t ? Test i~thu~~wheelf'\ "f\~ value IS with m

C C '" l im it s'0(1\ COOL_TIME_INPUT

L1M --_(Of ~ -- j Limt Test.~~ Low L im

~.

Length of timecooling unit willrun

-- MOV-

High Lim

N7:230<

N7:220<

N7:24

0<1

SourceN7:2~ f--

0<1C5:2.PRE

IS<

- Move

Test Dest

When thumbwheel value is less than IS mnutes. enters 15mnutes in system timer preset (CS:2.PRE)Test ifthumbwheelvalue is less thanlimtCOOL TIME INPUT---LES----

Less Than (A<B)

Source A N7:22

0<N7:23

0<


. MOV

MoveSource

Source B Dest15<

When thumbwheel value is greater than 60 mnutes. enters 60 mnutes in system timer preset (C5:2.PRE)Test ifthumbwheelvalue is greaterthan limtCOOL TIME INPUT---GRT---

Greater Than (A>B)

Source A N7:22

0<N7:24

0<

N7:240<

C5:2.PRE I15<,

Source B

Length of timecooling unit will

/

runMOV

Move

/

Source

Dest

C. Using the custom display created in Step 3., test the edits

to ensure that they perform as described in the

accompanying documentation.

D . If the edits perform as required, assemble the rungs.

E. Enter the accompanying documentation.7. Save the project and enter arevision note.

8. Backup the project, storing the backup in the folder identified

by your instructor.

H o w D i d Y o u D o ? Turn to the end of the lesson for the answers. If you have any


f: 1999 A llen -Bradley C ompany, Inc. R ev. O c to be r 1999

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Troubleshooting and Maintaining Integrated Pract ice Using RSLog ix 500'" Software 19-5

R ev. O ctober 1999 © 1999 Al len -B rad ley C ompany, Inc.

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19-6 Troubleshooting and Maintaining Integrated Practice Using RSLogix 500'" Software

A n s w e r s

0002

0003

0004

E x e r c i s e

System Timer Adjustment andDisplayVerifies that thumbwheel input isthe same for two program scans

First Pass TIME IN CHECKS2:1115 -- --EQU

--, ,- EqualSource A

0000

Source B

---~--

0001

COOL TIME INPUT---FRD-

- -- From BCDN7:20

21<1:1.021<

Source

Des!

TIME IN CHECK~MOV--

I ~~~~eI Source

Dest

Timer Input Check: When thumbwheel value is 15-60mnutes. enters value in system timer preset (C5:2.PRE)

Test ifthumbwheelvalue iswithinlimtsCOOL TIME INPUT

-LIM-

~- - - L imit TestLow Lim N7:23 ,

Test0<

N7:220<

N7:240<1

High Lim

Length of timecooling unit willrun--MaYMoveSource

f----TW1 I

0015h<N7:22 I

O<!

TW1 I

21<1N7:20 i

21< I-----,

N7:220<1

C5:2.PRE I15<

When thumbwheel value is less than 15mnutes. enters 15mnutes in system timer preset (C5:2.PRE)Test ifthumbwheelvalue is less thanlimtCOOL TIME INPUT,-----=-LES --~

I LessThan (A<B) f-

I Source A N7:22 I0<

N7:23 I0<1

Source B

Dest


I

M~~OV ---- L~

Source N7:23 !

0<Dest C5:2.PRE

15<

When thumbwheel value isgreater than 60mnutes. enters 60mnutes insystem timer preset (C5:2.PRE)Test ifthumbwheel

value is greaterthan limtCOOL TIME INPUT

r----Gr~a?e~~an (A;s)i,Source A N7:22

0<Source B N7:24

0<J


_~~OV

I ::~~ce, Dest

; 1999 Allen-Bradley Company, Inc.

N7:240<

C5:2.PRE15<

R ev. October 1999

r47sfip

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