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This document has been converted from Word 97 (which
has not done a perfect job) but this may give you an idea of our Allen
Bradley Rockwell training
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Training Notes on Allen Bradley
PLC5 & SLC 500
(DOS)
Contents
Section 1 Document History *
Section 2 Allen Bradley PLC5 and SLC 500 Training *
2.1 Introduction *
2.2 What is a PLC? *
2.3 Example PLC5 Layout *
2.4 SLC 500 example Layout *
2.5 Another Example PLC Layout *
Section 3 PLC 5 Programming *
3.1 Programming Software *
3.2 Starting the Programming Software *
3.3 Keyboard Notes *
3.4 Program Structure *
3.4.1 File 2 *
3.4.2 Passing Parameters *
3.4.3 Data *
3.5 Ladder *
3.6 Editing in the PLC *
Section 4 Memory Types *
4.1 PLC 5 Datatype Addressing *
4.1.1 Digital Inputs *
4.1.2 Digital Outputs *
4.1.3 Digital Bits *
4.1.4 Timers *
4.1.5 Counters *
4.1.6 Other Addressing *
4.2 SLC 500 Datatype Addressing *
4.2.1 Digital Inputs *
4.2.2 Digital Outputs *
4.2.3 Digital bits (Both PLC5 and SLC 500) *
4.2.4 Timers (both PLCs) *
4.2.5 Counters *
4.2.6 Other Addressing *
4.3 PLC 5 Datatype limitations *
4.4 Useful System PLC5 Memory Areas *
4.5 Useful System SLC 500 Memory Areas *
Section 5 Using the Programming Software *
5.1 Introduction *
5.2 Creating a New Program *
5.3 Initiating a new PLC *
5.4 Creating/Editing a Ladder internal File *
5.5 Adding a Ladder rung *
5.6 Copying a rung from another rung *
5.7 Deleting a Segment *
5.8 Data Monitor - To display data on-line *
Section 6 Simple PLC Editing *
Section 7 Searching *
7.1 Overview *
7.2 Searching in ladder mode *
7.2.1 PLC 5 Search screen *
7.2.2 SLC 500 Search screen *
7.3 Search Limitations *
7.4 Displaying Live Ladder Information *
7.5 Force Variables *
Section 8 Processor Status and Clearing Faults *
8.1 Clearing Major faults: *
8.1.1 PLC 5 status *
8.2 SLC 500 Processor Status *
8.3 Clearing Faults *
Section 9 Starting and Stopping the PLC *
9.1 Starting the PLC *
9.2 Stopping the PLC *
Section 10 Timers *
10.1 Timer Boxes *
10.2 Timer Presets *
10.3 Timer Types *
Section 11 Counters *
11.1 Count Up Counter *
11.2 Retentive Counters *
Section 12 Analogue Inputs *
12.1 PLC 5 Introduction *
12.2 PLC 5 BTR Parameters *
12.3 PLC 5 Data File Parameter *
12.4 PLC 5 Analogue Input BTW *
12.5 BTW Data Usage *
12.6 SLC 500 Analogue Inputs *
Section 13 Analogue Outputs *
13.1 PLC 5 Introduction *
13.2 PLC 5 BTW Parameters *
13.3 PLC 5 BTW Data Usage *
13.4 SLC 500 Analogue Outputs *
Section 14 EPROM Programming *
14.1 EPROM Types *
Section 15 Fault Finding *
15.1 Introduction *
15.2 LEDs *
Section 16 Documentation *
16.1 Introduction *
Section 17 Backing up and Restoring the PLC Program *
17.1 Backing up the PLC *
17.2 Restoring the PLC program *
Section 18 Cross Reference and Reports *
18.1 Generating a report *
18.2 Viewing/Printing Reports *
Section 19 Comparison with Other PLCs *
19.1 Mitsubishi Timers *
19.2 Mitsubishi Counters *
19.3 Siemens Timer Types *
19.3.1 SP 'Pulse' Timer *
19.3.2 SE 'Extended Pulse' Timer *
19.3.3 SD (SR) 'On Delay' Timer *
19.3.4 SS 'Latched On Delay' Timer *
19.3.5 SF 'Off Delay' Timer *
19.3.6 Back to Back timers *
19.4 I/O Descriptions *
Appendix 1 - Abbreviations Used *
Appendix 2 - Y2K Compatibility *
Section 1 Document History
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Revision |
Comments |
Date |
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0.0 |
Initial Writing Filename AB-TR-01.WP |
10 March 1999 |
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1.0 |
Initial Client Issue Filename AB-TR-04.WP |
11 March 1999 |
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1.1 |
Update to include SLC 500 series Filename AB-TR-06.DOC |
9 November 1999 |
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1.2 |
Minor modifications Filename AB-TR-07.DOC |
15th may 2000 |
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Section 2 Allen Bradley PLC5 and SLC 500 Training
2.1 Introduction
This document details training information for Allen Bradley PLC 5 PLCs using 6200 Programming Software. Also included is information about the SLC 500 series.
2.2 What is a PLC?
A PLC (Programmable Logic Controller) is effectively a computer with I/O. The I/O (input/output modules) are a method of getting signals from the outside world into the computer and back again. The I/O are generally robust (so they can cope with noise and spikes). Also available are intelligent I/O cards (which effectively have a computer on the I/O card) and communication cards (which talk to other computers and graphic systems).
Allen Bradley PLCs are among the top selling PLCs around the world. They are very reliable and robust PLCs.
There are two main series of PLCs. The larger PLCs are called the "PLC 5" series and the smaller PLCs are called the "SLC 500" series. While the PLCs have different amounts of memory and varying speed the main reason for choosing the type of PLC is the amount of I/O required on the project.
2.3 Example PLC5 Layout
This diagram shows a typical PLC 5 rack layout.
+------------------------------------------+ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ P ¦C ¦I ¦I ¦I ¦I ¦I ¦I ¦I ¦I ¦I ¦ ¦ ¦ S ¦P ¦/ ¦/ ¦/ ¦/ ¦/ ¦/ ¦/ ¦/ ¦/ ¦ ¦ ¦ U ¦U ¦O ¦O ¦O ¦O ¦O ¦O ¦O ¦O ¦O ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ +------------------------------------------+
The abbreviations are explained in this table:
|
Abbreviation |
Description |
|
PSU |
Power Supply Unit |
|
CPU |
Central Processor Unit |
|
I/O |
I/O cards |
The PSU supplies power for the PLC system. The CPU is the ‘brains’ behind the system, and contains the ladder program. The I/O cards are the interface to the outside world.
2.4 SLC 500 example Layout
+-------------------+ ¦ ¦ ¦ ¦ ¦ ¦ ¦ P ¦C ¦I ¦I ¦I ¦ ¦ S ¦P ¦/ ¦/ ¦/ ¦ ¦ U ¦U ¦O ¦O ¦O ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ +-------------------+
These computer cards are normally wider but shorter than the PLC 5 series.
2.5 Another Example PLC Layout
CPU
(ladder) AI ETHERNET I/O LINK
CARD <---CARDS--->AO CARD CARDS
+--------------------------------------------------------+
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ++ ¦ ¦ ¦ ¦
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦ ¦
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦ ¦
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ++ ¦ ¦ ¦ ¦
¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦
¦ ¦ ++ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ++ ¦ ¦ ¦ ¦
¦ ¦ ¦¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦ ¦
¦ ¦ ¦¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦¦ ¦ ¦ ¦ ¦
¦ ¦ ++ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ¦ ++ ¦ ¦ ¦ ¦
+--------------------------------------------------------+
Section 3 PLC 5 Programming
3.1 Programming Software
This document trains personnel specifically in the following version of programming software for the PLC 5:
+------------------------- PLC-5 PROGRAMMING SOFTWARE -------------------------+ ¦ ¦ ¦ A 6200 Series Software Product ¦ ¦ ¦ ¦ Copyright 1986, 1994, Allen-Bradley Company, Inc. ¦ ¦ All Rights Reserved ¦ ¦ ¦ ¦ Release 5.0 ¦ ¦ ¦ ¦ This software is licensed to: Company JACOBS BAKERY LTD ¦ ¦ Location SITE ELECTRICAL DEPARTMENT ¦ ¦ LONG LANE, AINTREE, LIVERPOOL ¦ ¦ Serial Number: ¦ ¦------------------------------------------------------------------------------¦ ¦ Wed Mar 10, 1999 9:44:05 am ¦ ¦------------------------------------------------------------------------------¦ ¦ Terminal Address:77 Current Device: 1784-KT (DH+) PLC Address:2 ¦ +------------------------------------------------------------------------------+
and this SLC 500 programming software
+------------ SLC-500 ADVANCED PROGRAMMING SOFTWARE ---- RELEASE 6.01 --------+ ¦ ¦ ¦ Rockwell Software Incorporated, Copyright 1989-1995 ¦ ¦ ¦ ¦ 9323 - PA2E ¦ ¦ ¦ ¦ All Rights Reserved ¦ ¦ ¦ ¦ ¦ ¦ This software is licensed to: ¦ ¦ The JACOBS BAKERY Ltd ¦ ¦ ¦ ¦ ¦ ¦------------------------------------------------------------------------------¦ ¦ Thr Nov 18, 1999 Current Offline File: 2819F1 9:34:41 am ¦ ¦------------------------------------------------------------------------------¦ ¦ TERM Address:N/A Current Device:Full-Duplex PROC Address:N/A ¦ +------------------------------------------------------------------------------+
Some information for the previous versions is also included here.
3.2 Starting the Programming Software
This section details how to start the programming software on the PC.
|
Step |
Description |
|
1 |
Turn on the programmer/PC |
|
2 |
Move to the IPDS directory cd \IPDS |
|
3 |
Start the software ABMENU This should give a menu selection for the various PLC packages on your PC |
|
4 |
If this doesn't work try (for the PLC 5): cd\ipds\attach\plc5 it and this for the SLC 500: cd\ipds\attach\slc500 ap |
3.3 Keyboard Notes
Usually function keys F1 to F10 are used for all functions. The other important keys are:
ENTER (accept)
ESC (abort)
3.4 Program Structure
These PLCs can use a block structure. If used correctly this can be a great aid to structuring your programs in a modular manner. This may sound like jargon but effectively it means you can simplify your programs to aid maintenance by personnel other than the programmer.
Basic Example of Ladder File Layout:
%T%P PROGRAM DIRECTORY FOR PROCESSOR: V5TEST %P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P[ OFFLINE ]%P%P%P%W
%Q File Name Type Size(words) %Q
%Q──────────────────────────────────────────────────────────────────────────────%Q
%Q 0 system 10 %Q
%Q 1 undefined 6 %Q
%Q 2 ladder 7 %Q
%Q %Q
%Q %Q
%Q %Q
%Z%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%]
The block structure has great advantages for large programs but is still beneficial for smaller PLCs.
These are the types of Ladder Files:
|
File |
Description |
|
2 |
Main Starting Block (normally) |
|
3 |
subroutines |
When the PLC powers up it will normally run block 2 (it can run other blocks but this is very rare).
A larger example:
%T%P PROGRAM DIRECTORY FOR PROCESSOR: D1_BM1E %P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P[ OFFLINE ]%P%P%P%W
%Q File Name Type Size(words) %Q
%Q──────────────────────────────────────────────────────────────────────────────%Q
%Q 0 D1_BM1B system 182 %Q
%Q 1 17Sep1996 undefined 4 %Q
%Q 2 Main ladder 69 %Q
%Q 3 Startup ladder 5 %Q
%Q 4 General ladder 47 %Q
%Q 5 Spare ladder 5 %Q
%Q 6 Station6 ladder 56 %Q
%Q 7 UpperLower ladder 202 %Q
%Q 8 TEBelt ladder 81 %Q
%Q 9 StorageB1 ladder 64 %Q
%Q 10 StorageB2 ladder 62 %Q
%Q 11 StorageB3 ladder 62 %Q
%Q 12 StorageB4 ladder 57 %Q
%Q
%Z%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%]
3.4.1 File 2
This block can control the calling of other blocks - the best programs are laid out with just calls to other blocks in File 2
Startup Control
%Q Startup %Q
%Q Control %Q
%Q % JSR───────────────% %Q
%_─────────────────────────────────────────────────────────%$JUMP TO SUBROUTINE% ─%b
%Q %Prog file number 3% %Q
%Q %Input parameter % %Q
%Q %Return parameter % %Q
%Q %──────────────────% %Q
General Control
%Q General %Q
%Q Control %Q
%Q % JSR───────────────% %Q
%_─────────────────────────────────────────────────────────%$JUMP TO SUBROUTINE% ─%b
%Q %Prog file number 4% %Q
%Q %Input parameter % %Q
%Q %Return parameter % %Q
%Q %──────────────────% %Q
Here, Ladder File 3 and 4 are called consecutively. File 3 contains details of line Startup and file 4 contains general control information.
Always use low numbers for ladder files first as each file which is blank (even when it is not used or even configured) takes up memory.
3.4.2 Passing Parameters
Subroutines can pass parameters. This is detailed in the advanced course. On Allen Bradley PLCs this is not often used but can be very powerful when used correctly.
3.4.3 Data
Data areas are a very important part of the PLC program. These contain obvious items like setpoints and timers but also the inputs and outputs (both analogue and digital).
3.5 Ladder
Ladder looks like this:
BM1 Start Validation Control
============================
PC CHECK PART 1
%Q PEC %PEC %PEC %TEB DSB/TEB %Q
%Q PULL NOSE %LOWER %UPPER %Loading conveyors %Q
%Q OK FROM %STORAGE %STORAGE %End empty %Q
%Q ST.6 %BELT %BELT. EXIT%Photocell %Q
%Q %(EXIT) %(off=full)% %Q
%Q I:002 I:002 I:002 I:003 B3 %Q
%_────] [────────] [────────] [────────] [──────────────────────────────( )─────%b
%Q 07 12 13 00 200 %Q
A Timer rung looks like this:
Power on startup delay
%Q START %BM1 ON Validation %Q
%Q VALIDATION% On Time %Q
%Q delay %Q
%Q O:001 I:001 % TON───────────────% %Q
%_────] [────────] [──────────────────────────────────%$TIMER ON DELAY % ─(EN)─%b
%Q 00 02 %Timer T4:10% %Q
%Q (4:6) (16:9) %Time base 0.01% ─(DN) %Q
%Q %Preset 60% %Q
%Q %Accum 61% %Q
%Q %──────────────────% %Q
3.6 Editing in the PLC
Allen Bradley has a strange edit cycle - after editing you have to 'Test' the edits and then 'Accept' the edits. This is shortcut to:
F9, F8, F10, F8
This can be a bit annoying. It is designed to allow you to quickly test your edits and then abort them if they don't work. Very silly, rarely useful.
Section 4 Memory Types
These are the main types of PLC memory:
|
Type |
Memory |
Description |
|
0 |
S |
Processor System Area |
|
1 |
I |
digital inputs |
|
2 |
O |
digital outputs (letter O here!) |
|
3 |
B |
(Binary) Flag bits |
|
4 |
T |
Timers |
|
5 |
C |
Counters |
|
6 |
R |
Complex Instruction System Area |
|
7 |
N |
Integer |
|
8 |
F |
Floating Point |
|
D |
BCD (hex) data |
Binary Flags (B) are generally used for digital information (but can easily be used for analogue information if required) and Integers (N) for Analogue Information. Data are retentive (ie they keep their data when the mains is switched off).
All files 9 and above can be configured as required. Note that you can delete file 8 and reinstate it as integer (and so on) but THIS IS A BAD IDEA so don't do it!
4.1 PLC 5 Datatype Addressing
All computer systems are very precise about ‘syntax’. This means you must type correctly!
4.1.1 Digital Inputs
Example Inputs addressing (octal)
I0/0
I32/7
I32/10
I32/17
Invalid Input addressing
I8/0
I9/0
I7/8
I0/9
I3/18
4.1.2 Digital Outputs
Example Outputs addressing (octal)
O0/0
OI32/7
OI32/10
O32/17
Invalid Output addressing
O8/0
O9/0
O7/8
O0/9
O3/18
4.1.3 Digital Bits
Example Bit Addressing:
B3:0/0 B3/0
B3:1/0 B3/16
B3:2/0 B3/32
B3:3/0 B3/48
Invalid Bit Addressing:
B3:0/16
B3:1/16
4.1.4 Timers
Example Timer Addressing
T4:0.PRE (preset value integer)
T4:0.ACC (current (accumulated) value integer)
T4:100/dn (expired bit)
T4:123/en (enabled bit)
T4:99/tt (enabled but not expired bit)
4.1.5 Counters
Example Counter Addressing
C5:0.PRE (preset value integer)
C5:0.ACC (current (accumulated) value integer)
C5:10/dn (Counter expired bit)
4.1.6 Other Addressing
System Area Addressing
R6:0 (more details in advanced course)
Integer area
N7:0 (integer addressed)
N7:0/5 (bit addressed)
N9:123/5 (bit addressed)
N11:123 (integer addressed)
Floating Points area
F8:0 (fp addressed)
F11:123 (fp addressed)
4.2 SLC 500 Datatype Addressing
4.2.1 Digital Inputs
Example Inputs addressing (octal)
I:0/0
I:32/7
I:32/10
I:32/17
Note the (very annoying) addition of the colon!
Invalid Input addressing
I0/0 (yes this is allowed on the PLC 5!)
I32/7
I32/10
I32/17
I8/0
I9/0
I7/8
I0/9
I3/18
And yes, it is extremely annoying that it's incompatible with the PLC 5 series!
4.2.2 Digital Outputs
Example Outputs addressing (octal)
O:0/0
O:32/7
O:32/10
O:32/17
More colons!
Invalid Output addressing
O8/0
O9/0
O7/8
O0/9
O3/18
O0/0
OI32/7
OI32/10
O32/17
4.2.3 Digital bits (Both PLC5 and SLC 500)
Example Bit Addressing:
B3:0/0 B3/0
B3:1/0 B3/16
B3:2/0 B3/32
B3:3/0 B3/48
Invalid Bit Addressing:
B3:0/16
B3:1/16
4.2.4 Timers (both PLCs)
Example Timer Addressing
T4:0.PRE (preset value integer)
T4:0.ACC (current (accumulated) value integer)
T4:100/dn (expired bit)
T4:123/en (enabled bit)
T4:99/tt (enabled but not expired bit)
4.2.5 Counters (both PLCs)
Example Counter Addressing
C5:0.PRE (preset value integer)
C5:0.ACC (current (accumulated) value integer)
C5:10/dn (Counter expired bit)
4.2.6 Other Addressing (both PLCs)
System Area Addressing
R6:0 (more details in advanced course)
Integer area
N7:0 (integer addressed)
N7:0/5 (bit addressed)
N9:123/5 (bit addressed)
N11:123 (integer addressed)
Floating Point area
F8:0 (fp addressed)
F11:123 (fp addressed)
4.3 PLC 5 Datatype limitations
There are some (but not many, compared to other PLCs) limitations on datatypes.
You can have one type of memory per block (ie you can have N9:0 but then cannot have B9:0, or vice versa).
The maximum data word number is generally limited to 1000 words per block, ie you can have N7:0 to N7:999 (100 words) but not N7:1000.
You can only create or delete data memory offline OR when the PLC is stopped (this is a real pain!).
SLC 500 Datatype limitations
The maximum data word number is limited to 256 words per block, ie you can have N7:0 to N7:255 (256 words) but not N7:256.
4.4 Useful System PLC5 Memory Areas
|
Address |
Description |
|
S:018 |
Real time clock (Year) |
|
S:019 |
Real time clock (Month) |
|
S:020 |
Real time clock (Day) |
|
S:021 |
Real time clock (Hour) |
|
S:022 |
Real time clock (Minutes) |
|
S:023 |
Real time clock (Seconds) |
4.5 Useful System SLC 500 Memory Areas
|
Address |
Description |
|
S:39 |
Real time clock (Year) |
|
S:38 |
Real time clock (Month) |
|
S:37 |
Real time clock (Day) |
|
S:40 |
Real time clock (Hour) |
|
S:41 |
Real time clock (Minutes) |
|
S:42 |
Real time clock (Seconds) |
Section 5 Using the Programming Software
5.1 Introduction
This section details a few of the most common editing facilities in the programming software.
5.2 Creating a New Program
This is the first step in setting up a PLC (as far as Software is concerned).
|
Step |
Description |
|
1 |
(From the Main Menu) Offline Configr F4 |
|
2 |
Enter a Filename (eg JACOBS) and press ENTER |
|
It should ask you to confirm a "NEW archive file" |
|
|
3 |
You now have to enter the PLC type and revision and so on. Check these against the PLC you have. |
|
4 |
You will now have the basic file layout (page 6) |
|
5 |
Ensure you are on File 2 (Ladder) and press Monitor File F8 |
|
6 |
Now go to EDIT (F10) and insert a rung (F4) then insert an instruction (F4) |
5.3 Initiating a new PLC
Often, when first programming a PLC, the memory will be corrupted. In this case you must delete the PLC memory as follows:
|
Step |
Description |
|
1 |
Clear Major Faults (Section 8) |
|
2 |
Clear Minor Faults (Section 8) |
|
3 |
Restore a Program (Section 17) |
5.4 Creating/Editing a Ladder internal File
This allows you to create a new subroutine or block of software. To create a file do the following:
|
Step |
Description |
|
1 |
From the Program Directory (section 6) |
|
2 |
F1 Proc Functions |
|
3 |
F6 Create Lad Fl |
|
4 |
Enter the number (use low numbers to save memory) and press enter |
|
5 |
The ladder file should now appear |
5.5 Adding a Ladder rung
To add a new rung
|
Step |
Description |
|
1 |
Press F10 Edit |
|
2 |
Press F3 to append OR F4 to insert (note F3 will continue to append rungs) |
5.6 Copying a rung from another rung
You can copy a rung only offline or when the PLC is stopped.
|
1 |
F10 Edit |
|
2 |
F8 Advanced Editing |
|
3 |
F1 to select the area to copy |
|
4 |
F3 to COPY the area |
|
5 |
Move to the area you want the copied rungs to go to |
|
6 |
F4 Paste |
5.7 Deleting a Segment
|
Step |
Description |
|
1 |
F10 Edit |
|
2 |
Press F6 Delete Rung |
Note that offline this will happen immediately, online it will require the test cycle.
5.8 Data Monitor - To display data on-line
This enables you to see the data being set while the program is running. Note this is available when offline or on-line.
|
Step |
Description |
|
1 |
F8 Data Monitor |
|
2 |
F5 Specify Address |
|
3 |
Select data type |
Section 6 Simple PLC Editing
This is a very simple rung:
%Q BM1 Speed Bit %Q
%Q Control 16 %Q
%Q Line No5 %Q
%Q I:033 B114 %Q
%_────] [───────────────────────────────────────────────────────────────( )─────%b
%Q 04 52 %Q
To generate this rung do as follows:
|
1 |
F10 Edit |
|
2 |
F4 insert rung |
|
3 |
F4 insert instr(uction) |
|
4 |
F1 XIC (eXecute if Closed, ie if the signal is ON then rung is performed) |
|
5 |
Enter the address (I33/4 here) |
|
6 |
F3 OTE (output control) |
|
Enter the address (B114/52 here) |
|
|
7 |
Press Enter until you see F10 Accept |
|
8 |
F10 Accept |
|
9 |
If you are online you will have to perform the test/accept cycle |
Note that the text labels are configured via the "F5 Document" key.
Section 7 Searching
7.1 Overview
This powerful feature is very useful. SLC 500 searching similar but just that bit less user friendly.
7.2 Searching in ladder mode
This function applies equally to online and offline.
|
Step |
Description |
|
1 |
Press F6 Search |
7.2.1 PLC 5 Search screen
The following screen should appear
%T%P Search %P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%W
%Q F1 Search Type : SEARCH INST/ADDR Search Scope : GLOBAL %Q
%Q Search Direction : DOWN Search Wrap : ON %Q
%Q Search For : %Q
%Z%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%]
%Q I:000 B3 I:002 B3 %Q
%_──] [───] [───] [────────────────────────────────────────────────────────( )──%b
%Q 00 31 00 0 %Q
%Q %Q
%_────────────────────────────────[END OF FILE]─────────────────────────────────%b
%Q %Q
Press a function key for desired searching function or enter a search string.
(File 2: Rung 0)
Rem Prog Forces:None Edits:None 5/40 File JACOBS
Search Search Current Current Prev Instr Search Save
Type Instruc Operand String List Config Config
F1 F4 F5 F6 F7 F8 F9 F10
Check the information in bold type. This will stay the same after you change it, but if ti is wrong the search may not do what you want (ie you can search backwards, and also you can set it NOT to 'wrap' around when it gets to the bottom).
Enter what you want to search for and press F4 Search. Some examples of what you can search for:
|
You type |
it searches for: |
|
I0/0 |
first occurrence of input 0/0 |
|
xic q32/0 |
first occurrence of XIC q32/0 |
|
TON t4:0 |
TON instruction for timer T4:0 |
|
T4:0 |
first occurrence of timer 4:0 (ie TON, T4:0/dn etc.) |
|
B3:0 |
first occurrence of any bits B3/0 to B3/15 |
|
N7:0 |
first occurrence of N7:0 or any bits N7:0/0 to N7:0/15 |
|
AFI |
first occurrence of AFI instruction |
SLC 500 searches are not quite as flexible.
7.2.2 SLC 500 Search screen
The following screen should appear
%T%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%W
%Q F1 Search Type : SEARCH INST/ADDR F7 Scope : GLOBAL %Q
%Q F2 Search For : F8 Direction : DOWN %Q
%Q F9 Wrap : ON %Q
%Z%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%P%]
%Q PLUSB PLUSB %Q
%Q I:1 I:1 % JSR───────────────% %Q
%_────]/[────────] [───────────────────────────────────────%$JUMP TO SUBROUTINE% ─%b
%Q 160 160 %SBR file number 67% %Q
%Q (67:5) (67:5) %──────────────────% %Q
%Q STARTUP %Q
%Q % JSR───────────────% %Q
%_─────────────────────────────────────────────────────────%$JUMP TO SUBROUTINE% ─%b
%Q %SBR file number 3% %Q
%Q %──────────────────% %Q
%Q % LES────────────────────% 2 %Q
%_─%$LESS THAN % ─────────────────────────────────────────────(JMP)──%b
%Q %Source A STARTUPC.ACC% %Q
Press a function key
(file 2, rung 0)
offline no forces EDITS: NONE File 2819F1
SEARCH SEARCH START TOGGLE TOGGLE TOGGLE SAVE
TYPE FOR SEARCH SCOPE DIRECT WRAP CONFIG
F1 F2 F5 F7 F8 F9 F10
This is just that bit less friendly. to search, do the following:
|
Step |
Description |
|
1 |
Press F2 Search For |
|
2 |
Enter the reference to search for (as above) |
|
3 |
Press F5 Search |
Other minor differences in the way it interprets variables are also present - just check the variable entered in the cyan "Search for" title at the top of the screen!
7.3 Search Limitations
All searching online is (rather oddly) done in the PLC itself. Some limitations and bugs are present in the searches of some PLCs. Some PLCs will NOT allow you to search for bits with an instruction, ie:
You can search for XIC I0/0 but NOT just every occurrence of I0/0
The bigger (more expensive) PLCs are much better.
Sometimes (on some PLCs) the search will get to the wrong place - normally the right place is just to the right, and another search will find it!
7.4 Displaying Live Ladder Information
Unlike other PLCs this is shown always when you are online. It is a bit slow to update however.
Normally "green" indicates the current is flowing and white means it isn't. If you have a black and white screen then get a colour one. The software works very badly in mono.
7.5 Force Variables
This page is used to force inputs and outputs while the PLC is running. It is normally done to 'fix' bad signals but GREAT CARE MUST BE TAKEN not to force E-stops for example!
|
Step |
Description |
|
1 |
Press F9 Force |
|
3 |
Select inputs (F9) or outputs (F10) |
|
4 |
Type a '1' to force on or a '0' to force off |
|
5 |
PLC5:Press F6 Enable (F8 to confirm) SLC 500:Press F7 Enable (F8 to confirm) |
IMPORTANT NOTE:
Forced variables do NOT always appear to be forced in the ladder program - this can be very confusing!
To remove forces either :
PLC 5: F7 Disable (plus F8 to confirm)
SLC 500: F8 Disable (plus F8 to confirm)
or
F4 Remove All
Preferably BOTH!
Section 8 Processor Status and Clearing Faults
8.1 Clearing Major faults:
Major faults stop the PLC program (ie crash it!). Normally these require fault diagnostics and repair before resetting.
To clear processor faults on both PLC5 and SLC500:
|
Step |
Description |
|
1 |
F7 General utility |
|
2 |
F2 Processor Status |
This screen gives lots of information about the PLC, including the time and date.
8.1.1 PLC 5 status
Processor Status
Fault code: 0
Where faulted: 0:0
Major fault: 00000000 00000000
Minor fault 1: 00000000 00000000
2: 00000000 00000000
Processor status: 00000011 10001000 Mode switch in remote
27 20 17 10 7 0
I/O status btx full: 00000000 00000000 00000000
rack fault: 00000000 00000000 00000000
I/O control reset: 00000000 00000000 00000000
inhibit: 00000000 00000000 00000000
Arithmetic flags: S:0 Z:0 V:0 C:0
RTC date: 0000-00-00 RTC time: 00:00:00
Processor checksum: 0x0000 Indexed addressing offset: 0
EEPROM: TRANSFER ON BAD RAM Resident I/O chassis addr: 1-SLOT
Memory: UNPROTECTED Ram Backup: ENABLED
Press a function key, page up or page down, or enter a value.
S:12 = %ˆ
Rem Prog Forces:ENABLED 5/40 File JACOBS
Proc Clear Clear
Config Min Flt Maj Flt
F2 F9 F10
8.2 SLC 500 Processor Status
EXT PROCESSOR STATUS 00000010 00001000 REAL TIME CLOCK DATE: 07-25-1900
EXT MINOR FAULT 00000000 00000000 TIME: 03:21.09
DISCRETE INPUT INTERRUPT
SUBROUTINE FILE: 0 MASK: 00000000
INPUT SLOT: 0 COMPARE VALUE: 00000000
ENABLED: 1 PRESET: 0
EXECUTING: 0 RETURN MASK: 00000000
PENDING: 0 ACCUMULATOR: 0
OVERFLOW: 0 LAST SCAN [ms]: 0
LOST: 0 MAX. SCAN [ms]: 0
PROCESSOR OPERATING SYSTEM USER PROGRAM
CATALOG #: 541 CATALOG #: 401 FUNCTIONAL TYPE: 1025
SERIES: B SERIES: A FUNCTIONAL INDEX: 35
REVISION: 3 F.R.N.: 5
USER RAM SIZE: 16
FLASH EEPROM SIZE: 512
Press a key or enter value, press Alt-H for help
S:37 =
offline forces DISABLED formatted decimal addr File 2819F1
PAGE PAGE GLOBAL SPECIFY NEXT PREV
UP DOWN STATUS ADDRESS FILE FILE
F1 F2 F4 F5 F7 F8
Note that there are several other pages…..
8.3 Clearing Faults
As you see from both the above examples, the real time clock is completely wrong! Most of the PLCs are Millennium compatible (see appendix 2), but generally (apart from Jacob's 1D) the real time clock is not used.
To clear faults:
F10 Clear Major Fault
|
S:11/ |
Description |
|
0 |
Bad User Program File |
|
1 |
Illegal Operand Address |
|
2 |
Programming Error |
|
3 |
SFC Fault |
|
4 |
Program Assembly Error |
|
5 |
Powerup Protection Fault |
|
6 |
Channel 3 Device Fault |
|
7 |
User Generated Fault |
|
8 |
Watchdog Timer Fault |
|
9 |
Bad System Configuration |
|
10 |
Hardware Error |
|
11 |
MCP does not exist or is not ladder |
|
12 |
PII does not exist or is not ladder |
|
13 |
STI does not exist or is not ladder |
|
14 |
Bad Fault Program |
|
15 |
Non Ladder File |
Some Minor PLC 5 Faults are:
|
S10/9 |
no MCP was configured to run |
|
S10/6 |
Memory Cartridge battery low |
|
S10/1 |
DH+ Table Changed |
|
S10/0 |
Battery is bad or missing |
|
S17/9 |
Duplicate node address |
|
S17/7 |
Error not defined |
Some useful PLC 5 Processor Status bits are:
|
S1/8 |
Forces Enabled |
|
S1/9 |
Forces present |
|
S1/11 |
Performing online programming |
|
S1/15 |
1st scan of ladder program |
Section 9 Starting and Stopping the PLC
9.1 Starting the PLC
WARNING! Ensure personnel are not working on the line since devices may start!
To Start the PLC:
|
Step |
Description |
|
1 |
Press F1 Mode |
|
2 |
Select F3 Run Mode |
|
3 |
Confirm with F8 Yes |
9.2 Stopping the PLC
To Stop the PLC:
|
Step |
Description |
|
1 |
Press F1 Mode |
|
2 |
Select F1 Program Mode |
|
3 |
Confirm with F8 Yes |
Section 10 Timers
10.1 Timer Boxes
A timer in Ladder format looks like this:
Power on startup delay
%Q START %BM1 ON Validation %Q
%Q VALIDATION% On Time %Q
%Q delay %Q
%Q O:001 I:001 % TON───────────────% %Q
%_────] [────────] [──────────────────────────────────%$TIMER ON DELAY % ─(EN)─%b
%Q 00 02 %Timer T4:10% %Q
%Q (4:6) (16:9) %Time base 0.01% ─(DN) %Q
%Q %Preset 60% %Q
%Q %Accum 61% %Q
%Q %──────────────────% %Q
SLC 500 timers are the same:
Flavour Screw B eye delay off.
%Q T4:120 I:1 % TOF───────────────% %Q
%_────] [──────] [────────────────────────────────────%$TIMER OFF DELAY % ─(EN)─%b
%Q DN 165 %Timer T4:20% ─(DN) %Q
%Q (4:12) %Time Base 0.01% %Q
%Q %Preset 600% %Q
%Q %Accum 600% %Q
%Q %──────────────────% %Q
The Parameters are explained below:
|
Parameter |
Description |
|
left part of rung |
Timer Input Condition |
|
"Timer" |
Timer number (eg 10 in block T4 as above) |
|
Time Base |
number of seconds per 'preset, 0.01 seconds above |
|
Preset |
Timer preset value (in time base units, 0.6 seconds here) |
|
Accum |
Current timer value (in time base units 0.61 seconds here) |
|
EN |
Set if timer enabled |
|
DN |
Set if timer expired |
The DN bit is then used as follows:
UPPER STORAGE BELT START OUTPUT
Loading (T4:21 & T4:25)
OR
unloading (B3/24)
%Q Run DSB %Upper %Power On %LOWER %Upper UPPER %Q
%Q for this %Storage %Delay On %STORAGE %STORAGE STORAGE %Q
%Q long when %Belt %Timer %BELT. %BELT. ???? BELT %Q
%Q row from %loading % %MOTOR %MOTOR START %Q
%Q Station 6 %from Stn 6% %OVERLOAD %OVERLOAD %Q
%Q T4:21 T4:25 T4:10 I:004 I:004 O:001 %Q
%_─────] [────────] [───────] [────────] [────────] [──────────────────( )─────%b
%Q TT DN DN 14 15 05 %Q
%Q (7:2) (7:0) (4:7) %Q
10.2 Timer Presets
The timebase is normally 0.01 seconds or 1 second. Choose 1 second when accuracy is not important (since it is more obvious what the timer is doing)
10.3 Timer Types
Whereas some PLCs have lots of different timer types, Allen Bradley only has 2, but then, this is all you need.
To generate a pulse timer:
%Q I:000 % TON───────────────% %Q
%_──] [───────────────────────────────────────────────%$TIMER ON DELAY % ─(EN)─%b
%Q 00 %Timer T4:0% %Q
%Q %Time base 1.0% ─(DN) %Q
%Q %Preset 5% %Q
%Q %Accum 0% %Q
%Q %──────────────────% %Q
%Q T4:0 O:000 %Q
%_──] [────────────────────────────────────────────────────────────────────( )──%b
%Q TT 00 %Q
%Q (2:0) %Q
This timer ensures that the output will be on for five seconds after the input comes on, and then go off again, ie:
% ─────────────────────────────────────────%
Input ───% %──────────
Timer Length <--------------->
% ───────────────%
Timer Output ───% %────────────────────────────────────
If the input goes off before the timer expires, the timer output goes off;
% ────%
Input ───% %───────────────────────────────────────────────
Timer Length <--------------->
% ────%
Timer Output ───% %───────────────────────────────────────────────
A delay timer is done as follows:
%Q I:000 % TON───────────────% %Q
%_──] [───────────────────────────────────────────────%$TIMER ON DELAY % ─(EN)─%b
%Q 00 %Timer T4:0% %Q
%Q %Time base 1.0% ─(DN) %Q
%Q %Preset 5% %Q
%Q %Accum 0% %Q
%Q %──────────────────% %Q
%Q T4:0 O:000 %Q
%_──] [────────────────────────────────────────────────────────────────────( )──%b
%Q DN 00 %Q
A minor difference in ladder, but very different in action:
When the input is on, the timer counts and when it expires, the timer output is on until the input goes off.
% ─────────────────────────────────────────%
Input ───% %──────────
Timer Length <--------------->
% ─────────────────────────%
Timer Output ───────────────────% %──────────
If the input goes off before the timer expires, the timer is completely reset and the output never comes on.
% ────%
Input ───% %───────────────────────────────────────────────
Timer Length <--------------->
Timer Output ────────────────────────────────────────────────────────
AB also supply retentive timers:
%Q I:000 % RTO───────────────% %Q
%_──] [───────────────────────────────────────────────%$RETENTIVE TIMER ON% ─(EN)─%b
%Q 00 %Timer T4:1% %Q
%Q %Time base 1.0% ─(DN) %Q
%Q %Preset 5% %Q
%Q %Accum 0% %Q
%Q %──────────────────% %Q
%Q I:000 T4:1 %Q
%_──] [───────────────────────────────────────────────────────────────────(RES)─%b
%Q 01 %Q
The timer will count up as long as the input I0/0 is on. When it is off, unlike the other timer (TON) this RTO timer will just freeze. When I0/0 has been on for a total of 5 seconds here, no matter how much time it was off, the timer will have expired and the DN bit will be set.
The timer must be reset with the "RES" instruction to make it start again.
Section 11 Counters
There are two types of counters - count up and count down. Normally you will use a count up counter.
11.1 Count Up Counter
%Q I:000 % CTU───────────────% %Q
%_──] [───────────────────────────────────────────────%$COUNT UP % ─(CU)─%b
%Q 00 %Counter C5:0% %Q
%Q %Preset 100% ─(DN) %Q
%Q %Accum 0% %Q
%Q %──────────────────% %Q
%Q C5:0 O:000 %Q
%_──] [────────────────────────────────────────────────────────────────────( )──%b
%Q DN 00 %Q
%Q (2:2) %Q
This counter counts up every time a rising edge is seen on the input. When the counter reaches 100 here, the output is turned on.
Count down counters work in a similar manner.
11.2 Retentive Counters
Counters are always retentive.
Section 12 Analogue Inputs
12.1 PLC 5 Introduction
This is a brief overview of analogue inputs:
Analogue input cards require a BTR and sometimes a BTW instruction to configure them.
Read Analogue Input information
%Q BTR & BTW %Q
%Q Toggle %Q
%Q Timer 87 %Q
%Q T4:87 % BTR────────────────────% %Q
%_────] [────────────────────────────────────────%$BLOCK TRANSFER READ % ─(EN)─%b
%Q DN %Rack 03% %Q
%Q (2:371) %Group 4% ─(DN) %Q
%Q %Module 0% %Q
%Q %Control block B96:0% ─(ER) %Q
%Q %Data file B108:1% %Q
%Q %Length 20% %Q
%Q %Continuous N% %Q
%Q %───────────────────────% %Q
12.2 PLC 5 BTR Parameters
The parameters used here are:
|
Rack |
Physical Rack Number |
|
Group |
Group ie slot number in the rack |
|
Module |
Module number, this is either 0 or 1 (which depends on 'slot' addressing). If the required slot addressing is single then '0' is left hand and '1' is right hand, otherwise it is always '0'. |
|
Control Block |
Control data required (stores rack number etc, DO NOT CHANGE!) |
|
Data File |
Start address for data from AI module |
|
Length |
Length of data in Data file |
|
Continuous |
Sometimes No, but can be Yes, generally based on required speed of inputs and loading of CPU |
12.3 PLC 5 Data File Parameter
This uses 20 words, as follows (into a B block here):
|
Data File B108: |
Description |
|
1 |
Diagnostics |
|
2 |
Data under range for channels 1-16 |
|
3 |
Data over range for channels 1-16 |
|
4 |
Polarity for channels 1-16 |
|
5 |
Channel 1 Value |
|
6 |
Channel 2 Value |
|
7 |
Channel 3 Value |
|
8 |
Channel 4 Value |
|
9 |
Channel 5 Value |
|
10 |
Channel 6 Value |
|
11 |
Channel 7 Value |
|
12 |
Channel 8 Value |
|
13 |
Channel 9 Value |
|
14 |
Channel 10 Value |
|
15 |
Channel 11 Value |
|
16 |
Channel 12 Value |
|
17 |
Channel 13 Value |
|
18 |
Channel 14 Value |
|
19 |
Channel 15 Value |
|
20 |
Channel 16 Value |
12.4 PLC 5 Analogue Input BTW
A corresponding BTW sets up the ranges:
Write Analogue Input scaling Information
%Q BTR & BTW %Q
%Q Toggle %Q
%Q Timer 88 %Q
%Q T4:88 % BTW────────────────────% %Q
%_────] [────────────────────────────────────────%$BLOCK TRANSFER WRITE % ─(EN)─%b
%Q DN %Rack 03% %Q
%Q (2:372) %Group 4% ─(DN) %Q
%Q %Module 0% %Q
%Q %Control block B106:0% ─(ER) %Q
%Q %Data file B107:1% %Q
%Q %Length 37% %Q
%Q %Continuous N% %Q
%Q %───────────────────────% %Q
12.5 BTW Data Usage
This uses 37 words, as follows (into a B block here):
|
Data File B107: |
Description |
|
1 |
Range type selection channels 1 to 8 |
|
2 |
Range type selection channels 9 to 16 |
|
3 |
Real time sampling, filter etc. |
|
4 |
sign bits min scaling values channels 1-16 |
|
5 |
sign bits max scaling values channels 1-16 |
|
6 |
Channel 1 Minimum Scaling Value |
|
7 |
Channel 1 Maximum Scaling Value |
|
8 |
Channel 2 Minimum Scaling Value |
|
9 |
Channel 2 Maximum Scaling Value |
|
10 |
Channel 3 Minimum Scaling Value |
|
11 |
Channel 3 Maximum Scaling Value |
|
12 |
Channel 4 Minimum Scaling Value |
|
13 |
Channel 4 Maximum Scaling Value |
|
14 |
Channel 5 Minimum Scaling Value |
|
15 |
Channel 5 Maximum Scaling Value |
|
16 |
Channel 6 Minimum Scaling Value |
|
17 |
Channel 6 Maximum Scaling Value |
|
18 |
Channel 7 Minimum Scaling Value |
|
19 |
Channel 7 Maximum Scaling Value |
|
20 |
Channel 8 Minimum Scaling Value |
|
21 |
Channel 8 Maximum Scaling Value |
|
22 |
Channel 9 Minimum Scaling Value |
|
23 |
Channel 9 Maximum Scaling Value |
|
24 |
Channel 10 Minimum Scaling Value |
|
25 |
Channel 10 Maximum Scaling Value |
|
26 |
Channel 11 Minimum Scaling Value |
|
27 |
Channel 11 Maximum Scaling Value |
|
28 |
Channel 12 Minimum Scaling Value |
|
29 |
Channel 12 Maximum Scaling Value |
|
30 |
Channel 13 Minimum Scaling Value |
|
31 |
Channel 13 Maximum Scaling Value |
|
32 |
Channel 14 Minimum Scaling Value |
|
33 |
Channel 14 Maximum Scaling Value |
|
34 |
Channel 15 Minimum Scaling Value |
|
35 |
Channel 15 Maximum Scaling Value |
|
36 |
Channel 16 Minimum Scaling Value |
|
37 |
Channel 16 Maximum Scaling Value |
12.6 SLC 500 Analogue Inputs
These are totally incompatible with the PLC 5 series. It's all done with an SCP instruction.
An example is:
%Q LOADCELL Actual %Q
%Q INPUT Weight %Q
%Q %Q
%Q % LIM───────────────% % SCP────────────────────% %Q
%_─%$LIMIT TEST % ───────────────────────────────%$SCALE W/PARAMETERS % ─%b
%Q %Low Lim 3277% %Input I:4.1% %Q
%Q % % % 8196% %Q
%Q %Test I:4.1% %Input Min. 3277.000% %Q
%Q % 8196% % % %Q
%Q %High Lim 16384% %Input Max. 16384.00% %Q
%Q % % % % %Q
%Q %──────────────────% %Scaled Min. 0.000000% %Q
%Q I:4.1 - (5:0) % % %Q
%Q %Scaled Max. 272000.0% %Q
%Q % % %Q
%Q %Scaled Output F8:3% %Q
%Q % 116005.2% %Q
%Q %───────────────────────% %Q
The instruction SCP reads and scales the analogue input (which, in it's raw form is just another word of I/O). This particular AI is a 4-20mA and the raw data is scaled 3277 (4mA) up to 16384 (20mA). Here we have rescaled this to 0 to 272,000 engineering units.
Section 13 Analogue Outputs
13.1 PLC 5 Introduction
This is a brief overview of analogue outputs:
These use BTW instructions as before:
Analogue Output Card
====================
AO 1 = Main Drive Plant Speed (B111:1)
AO 2-4 = Spare (B111:2 to B111:4)
%Q BTR & BTW %Q
%Q Toggle Bit %Q
%Q B3 % BTW────────────────────% %Q
%_────]/[────────────────────────────────────────%$BLOCK TRANSFER WRITE % ─(EN)─%b
%Q 1791 %Rack 03% %Q
%Q (2:424) %Group 6% ─(DN) %Q
%Q %Module 0% %Q
%Q %Control block B110:0% ─(ER) %Q
%Q %Data file B111:1% %Q
%Q %Length 5% %Q
%Q %Continuous N% %Q
%Q %───────────────────────% %Q
13.2 PLC 5 BTW Parameters
The parameters used here are:
|
Rack |
Physical Rack Number |
|
Group |
Group ie slot number in the rack |
|
Module |
Module number, this is either 0 or 1 (which depends on 'slot' addressing). If the required slot addressing is single then '0' is left hand and '1' is right hand, otherwise it is always '0'. |
|
Control Block |
Control data required (stores rack number etc, DO NOT CHANGE!) |
|
Data File |
Start address for data from AI module |
|
Length |
Length of data in Data file |
|
Continuous |
Sometimes No, but can be Yes, generally based on required speed of inputs and loading of CPU |
13.3 PLC 5 BTW Data Usage
This uses 5 words, as follows (into a B block here):
|
Data File B111: |
Description |
|
1 |
Channel 1 Output Value |
|
2 |
Channel 2 Output Value |
|
3 |
Channel 3 Output Value |
|
4 |
Channel 4 Output Value |
|
5 |
Configuration Word |
|
6 |
Channel 1 Minimum Range |
|
7 |
Channel 1 Maximum Range |
|
8 |
Channel 2 Minimum Range |
|
9 |
Channel 2 Maximum Range |
|
10 |
Channel 3 Minimum Range |
|
11 |
Channel 3 Maximum Range |
|
12 |
Channel 4 Minimum Range |
|
13 |
Channel 4 Maximum Range |
The configuration word can change the data format from integer (B or N type) to BCD (D type).
13.4 SLC 500 Analogue Outputs
These are very similar to SLC 500 analogue inputs, an example is:
%Q Start SPEED %Q
%Q Flag REFERENCE %Q
%Q %Q
%Q B3 % SCP────────────────────% %Q
%_────] [─────────────────────────────────────────────%$SCALE W/PARAMETERS % ─%b
%Q 7 %Input N9:29% %Q
%Q (6:14) % 4989% %Q
%Q %Input Min. 0% %Q
%Q % % %Q
%Q %Input Max. 16384% %Q
%Q % % %Q
%Q %Scaled Min. 0% %Q
%Q % % %Q
%Q %Scaled Max. 32767% %Q
%Q % % %Q
%Q %Scaled Output O:4.1% %Q
%Q % 9974% %Q
%Q %───────────────────────% %Q
Here the output is scaled and written to with the SCP instruction.
Section 14 EPROM Programming
14.1 EPROM Types
EEPROMs are available on some CPUs. Usage is beyond the scope of this manual.
Section 15 Fault Finding
15.1 Introduction
As with all PLCs you are advised to back up regularly and often. It is always possible with any PLC to lose your program especially when learning a new PLC and your backups should be well up to date!
15.2 LEDs
The PLCs have red fault LEDs. When this is lit, the PLC will have stopped, so check the Major fault listing.
You can check major and minor faults through Processor Status (page 24).
Section 16 Documentation
16.1 Introduction
A simple phrase which applies to all PLC languages is to Tag everything! Every time you use a new bit, byte or word add a tagname at the same time. This will make everyone's job much easier in the long term.
All documentation is done through the "F5 Documnt" key.
Thereafter use the following keys:
|
Key |
Description |
|
F1 Rung Comment |
Enter a rung comment |
|
F3 Address Comment |
Changing item comment |
|
F6 Modify Symbol |
Changing symbol for item |
Section 17 Backing up and Restoring the PLC Program
17.1 Backing up the PLC
To back up the PLC program
|
1 |
F4 Program Directory |
|
2 |
F2 Save/restore |
|
3 |
Save |
You may get a silly message which informs you the PLC is running and data may change. Simply press F8 to confirm
17.2 Restoring the PLC program
This is normally only done if the CPU has lost its' memory. The CPUs and I/O modules are very resilient and possibly the most reliable (in terms of hardware) of all the PLC manufacturers.
To restore a PLC program from Disk, first ensure the most up to date file is present on your PLC in the following directory:
\IPDS\ARCH\PLC5
|
1 |
F4 Program Directory |
|
2 |
F2 Save/restore |
|
3 |
Restore |
You may get messages about different PLC types when you are loading a new CPU. This can normally be ignored (as long as you haven't used instructions not available on the CPU).
Section 18 Cross Reference and Reports
18.1 Generating a report
A cross reference can be generated for the PLC program:
|
Step |
Description |
|
1 |
(From Main menu) F8 reports |
|
2 |
It's better to do them offline, so make sure a backup has been done |
|
3 |
Select the filename if it is not correct (F4), then: |
|
4 |
F3 Create Offline |
|
5 |
Turn off all reports ("F4 Reset Reports") |
|
6 |
Cursor down to Program Cross Reference and press "F3 Toggle Report" |
|
7 |
Report and general options may have to be changed for specific printers |
|
8 |
F1 Create Reports |
This will create a report in the following directory:
\IPDS\LIS\PLC5
18.2 Viewing/Printing Reports
This file can then be printed or viewed as follows:
|
Step |
Description |
|
1 |
(From Main menu) F8 reports |
|
2 |
F8 Print/view |
|
3 |
cursor to required file |
|
4 |
F3 Select |
|
5 |
F10 to view, F1 to print |
Section 19 Comparison with Other PLCs
19.1 Mitsubishi & Siemens Timers
The main difference here is the timers - Mitsubishi timers are like the Siemens SD timers (the AB TON timers). This simple 'failed to start timer'...
;Start pump 1 failed timer %
%Y430 K50 %
79 % ─%$ % ──────────────────────────────────────────────────────────────(T50 )%$
%RUN PUMP1 %
%PUMP1 START %
% TIMER %
% %
;alarm if pump fails to start %
%T50 X407 M74 %
82 % ─%$ % ───%$/% ─%,──────────────────────────────────────────────────────( )──%$
%PUMP1 PUMP1% PUMP1 %
%START RUNNG% FAILD %
%TIMER % %
% % %
%M74 X411 % %
% ─%$ % ───%$/% ─% %$
%PUMP1 PUMP1 %
%FAILD RESET %
...is the equivalent in Siemens of this:
SEGMENT 1 0000 (SD Timer)
! T 50
!Q 4.3 +-----+
+---] [---+-!T!-!0!
!KT 050.1 --!TV BI!-
! ! DE!-
! ! !
! ! !
! +-!R Q!-
! +-----+
SEGMENT 2 0009
!
!T 50 -I.KEYREM F 7.4
+---] [---+---]/[---+---------+---------+---------+---------+---------+--( )-!
! !
!F 7.4 -I.U15T !
+---] [---+---]/[---+
Mitsubishi timers have lower presets than Siemens Timers (ie Siemens can time a greater length than Mitsubishi PLCs).
19.2 Mitsubishi Counters
Mitsubishi counters are always count down.
19.3 Siemens Timer Types
There are five different timers in Siemens. You will normally use an SD (AB TON) timer, and often use an SP timer. You will rarely, if ever, use the other types of timers.
All the timers are described as follows:
19.3.1 SP 'Pulse' Timer
This is one of the two most commonly used timers (the other is the SD timer). When the input is on, the timer output is on until the timer expires when the timer output goes off;
% ─────────────────────────────────────────%
Input ───% %──────────
Timer Length <--------------->
% ───────────────%
Timer Output ───% %────────────────────────────────────
If the input goes off before the timer expires, the timer output goes off;
% ────%
Input ───% %───────────────────────────────────────────────
Timer Length <--------------->
% ────%
Timer Output ───% %───────────────────────────────────────────────
19.3.2 SE 'Extended Pulse' Timer
This timer goes on when the input goes on and remains on for a fixed time (ignoring the state of the input).
% ─────────────────────────────────────────%
Input ───% %──────────
Timer Length <--------------->
% ───────────────%
Timer Output ───% %────────────────────────────────────
If the input goes off before the timer expires, the timer output does not go off until the timer has expired;
% ────%
Input ───% %───────────────────────────────────────────────
Timer Length <--------------->
% ───────────────%
Timer Output ───% %────────────────────────────────────
19.3.3 SD (SR) 'On Delay' Timer
The SD timer is probably the most commonly used timer. This timer was called SR with older Siemens programming software and the abbreviation SR sometimes appears even in the latest software. When the input is on, the timer counts and when it expires, the timer output is on until the input goes off.
% ─────────────────────────────────────────%
Input ───% %──────────
Timer Length <--------------->
% ─────────────────────────%
Timer Output ───────────────────% %──────────
If the input goes off before the timer expires, the timer is completely reset and the output never comes on.
% ────%
Input ───% %───────────────────────────────────────────────
Timer Length <--------------->
Timer Output ────────────────────────────────────────────────────────
19.3.4 SS 'Latched On Delay' Timer
This timer goes on a fixed time after the input goes on (even if the input goes off again).
% ───────────────────────────%
Input ───% %────────────────────────
Timer Length <--------------->
% ──────────────────%
Timer Output ───────────────────% %─────────────────
% %
Timer Reset ─────────────────────────────────────%%───────────────
Note that this timer must be reset before it can start again. This is very similar to the AB RTO retentive timer.
If the input goes off before the timer expires, the timer output still comes on after the preset time.
% ────%
Input ───% %────────────────────────────────────────────
Timer Length <--------------->
% ─────────────────%
Timer Output ───────────────────% %───────────────
% %
Timer Reset ─────────────────────────────────────%%──────────────
19.3.5 SF 'Off Delay' Timer
This timer output comes on when the input comes on and goes off a fixed time after the input goes off.
% ──────%
Input ───% %─────────────────────────────────────────────
Timer Length <--------------->
% ──────────────────────%
Timer Output ───% %─────────────────────────────
19.3.6 Back to Back timers
To make two back to back timers (ie a pulse on-pulse off timer pair) use two SD timers:
SEGMENT 1 0000
! T 10
!T 11 +-----+
+---]/[---+-!T!-!0!
!KT 005.2 --!TV BI!-
! ! DE!-
! ! !
! ! !
! +-!R Q!-
! +-----+
T 10 = T.OnPls ON Pulse timer
SEGMENT 2 0009
! T 11
!T 10 +-----+
+---] [---+-!T!-!0!
!KT 005.2 --!TV BI!-
! ! DE!-
! ! !
! ! !
! +-!R Q!-
! +-----+
!
! :BE
T 10 = T.OnPls ON Pulse timer
T 11 = T.OffPls Off Pulse timer
The first timer (timer 10 here) controls the length of the off pulse and the second timer (timer 11) controls the length of the ON pulse. To use this in you program use the contact;
T10
-] [-
which will be on for 5 seconds every 10 seconds in the example above.
19.4 I/O Descriptions
|
Mitsubishi |
Description |
Siemens |
ab |
|
X |
Digital Inputs |
I (or E) |
I |
|
Y |
Digital outputs |
Q (or A) |
O |
|
M |
Internal Flags |
F (or M) |
B |
|
D |
datawords |
DW |
N |
|
T |
Timers |
T |
T |
|
C |
Counters |
C (or Z) |
C |
|
X |
Analogue Inputs |
PW or OW |
D and N |
|
Y |
Analogue Outputs |
PW or OW |
D and N |
|
M |
System Flags |
RS |
S or R |
The alternative letters for Siemens are for the German versions, which pop up now and again due to little bugs in the programming software.
Warning!
Do not use the Siemens System Flags (RS) unless you know exactly what you are doing!
Appendix 1 - Abbreviations Used
|
Description |
|
|
AI |
Analogue Input |
|
AO or AQ |
Analogue Output |
|
C |
Counter |
|
CPU |
Central Processor Unit |
|
DO or DQ |
Digital Output |
|
DW |
Dataword |
|
EPROM |
Erasable Programmable Read Only Memory |
|
EEPROM |
Electronically Erasable Programmable Read Only Memory |
|
I |
Single Digital Input |
|
O or Q |
Single Digital Output (letter O here!) |
|
PLC |
Programmable Logic Controller |
|
PSU |
Power Supply Unit |
|
S |
Processor System Area |
|
T |
Timer |
Appendix 2 Y2K Compatibility
Allen Bradley known Y2K Issues
|
Product(s) |
Issue/Note Description |
|
1775-LP |
The PLC-3 will rollover and have an accurate leap year in power-up mode only. The PLC-3 clock function, during power down, will hold the time and date at its last value prior to power down (assuming the battery is capable of holding data). Upon re-application of power, the time and date will need to be re-set. The PLC-3 did not rollover or recognise leap year in power down mode prior to 1/1/2000 and will not after 1/1/2000. NOTE: The user program in the PLC-3 is completely backed by the battery. |
|
1785-LT4 |
The processors pass all the tests except leap year in powered down mode. The processor, if set to 2/28/2000 and powered down through the date change, will power up with 3/1/2000. If the power remains ON through the date change, the correct leap day is displayed. This is not unique to the Year 2000. Expanded tests shows the same results for 1988, 1992, and 1996. The important thing to remember is that this does not stop the processor from running unless the application code relies on the date for execution. There will be no fix for these processors. |
|
5730-CPU1 |
The DEC MicroVAX is Year 2000 Ready, but you must have a Ready version of Open VMS. The versions of Open VMS that are Year 2000 Ready are 5.5-2, 6.2 or 7.1. If you do not have one of these versions, there are enhancement kits available to update your system from Digital. For information, please see their web site at www.digital.com |
|
Industrial |
This product will not roll over to the Year 2000 on its own. After 12/31/99 the date must be manually set on the computer. Once this is done, the computer will continue to recognise the proper date. |
|
Standard |
If you are doing date comparisons: |
|
Enhanced PanelView Hardware (refer to table) |
If you are doing date comparisons: |
|
PanelBuilder |
PanelBuilder software does not utilize the time or date in the software. The time and date stamping is done by the operating system. The PanelBuilder files save this information and display it in the format dictated by the operating system. Therefore PanelBuilder has no control when it comes to file saving and the year 2000. |
|
1770-RG |
The 1770-RG will rollover and have an accurate leap year in power-up mode only. The 1770-RG does not have battery backup which holds the time and date. When a power cycle occurs, the time and date are lost and need to be re-entered. The 1770-RG did not rollover or recognise leap year in power down mode prior to 1/1/2000 and will not after 1/1/2000. |
|
1771-DMC |
The 1771-DMC, 1, 4 does not roll over to the Year 2000. You must order new firmware. |
|
1771-DSX |
If 1771-DSX2, 4 is in power down mode on or after 12/31/99, when it is powered up, the date will not have properly rolled over from 12/31/99 to 1/1/2000. Upon powering up, the unit must be manually set to the current date. Once the date has been manually set after 1/1/2000, it will thereafter continue to recognise the proper date, including leap year dates. |
|
1336T Force |
The 1336 Force does not recognise leap year. You must use drive tools to reset the date. The 1336 Force did not recognise leap year prior to 1/1/2000 and will not after 1/1/2000. The date function in the 1336 Force is only a 2 digit format. |
|
1395 |
The 1395/1396 will rollover and have an accurate leap year in power-up mode only. The 1395/1396 does not have battery backup which holds the time and date. When a power cycle occurs, the time and date are lost and need to be re-entered. The 1395/1396 did not rollover or recognise leap year in power down mode prior to 1/1/2000 and will not after 1/1/2000. |
|
Medium |
Medium Voltage products are often customer engineered and have many components installed to meet specific customer/application needs. All MV products should be reviewed for components which may have a real time clock. Any such items should be investigated for Year 2000 Readiness. This can be done by contacting the component manufacturer or Rockwell Automation Medium Voltage Product Support personnel at |
|
1785-O5E |
Map Manager software can only be run on 286/386 computers. Since the 286/386 computers are not Year 2000 Ready, this product will not be Year 2000 Ready. |
|
6500-PS7TS/A |
Install Patch Disk: For the ProSet 700 Patch files and instructions, please see our website at www.ragts.com/y2k and follow these steps: |
|
6500-PS600 |
Year 2000 Rollover Fix: For the ProSet 600 Year 2000 Rollover fix instructions, please see our web site at www.ragts.com/y2k and follow these steps: |
|
2755-DH5 |
The 2755-DH5 terminals hardware works correctly, but since it is programmed in |
|
2706-Bxxx |
The DL20 has the prefix "19" hard coded for the print command. The internal clock only has 2 digits which is then attached to the hard coded "19". For example, in the year 2001, the DL20 will see the date as "01". However, when the date is printed of the printer port only, the date will read 1901. This is only seen from the printer port to a printer. All other uses of the clock will show month/day/year where the year will be shown as "01". |
|
3100-DRC |
Year is always handled with two digits. When the date is set by SETDAT, the date skips the leap day (not when set by CLI). The date can be set 00-02-29 by SETDAT or CLI on the leap day. |
|
3100-DGC |
Year is always handled with two digits. In the year 2000, the date skips over the leap day 29.2.2000; it cannot even be set from the keyboard. In other leap years, the leap day is29.2.2000; it cannot even be set from the keyboard. In other leap years, the leap day is handled properly. |
|
3251-DMS2 |
The program displays the date in 2 digit format only. Printouts will only show a 2 digit year. |
|
System Access Manager (SAM) |
If using the ICOM Graphic Logistics package, certain graphics pages can not be compiled while running under VDOS. Pages compiled successfully under DOS. |
|
2100-xxxxx |
CENTERLINE Motor Control Centres are custom build for each customer. To determine Year 2000 Readiness of one of these products, the customer must provide us with the Catalogue No./Serial No. listed on the product. Please see the diagram below to locate where this information is on each machine. Once this information has been obtained, please call 414-382-2000 and ask for the Year 2000 Help Desk. |
|
1756-PLXC |
ProcessLogix Release 200 (R200) will contain Windows NT 4.0 service pack 4. Service pack 4 fixes Microsoft bugs related to Year 2000 in the Internet Explorer and Networking areas. Rockwell Automation will be shipping ProcessLogix Release 200 in May 1999. Rockwell Automation has a migration plan for upgrading existing customers to ProcessLogix Release 200. |
|
2711E-ND1 |
The following are known issues with the PanelView e File Transfer Utility 32 version 4.x and versions 5.00 to 5.12. |
|
2711E-ND1 |
In PanelBuilder 1400e Version 5.12 and earlier, dates on or after 1/1/2000 in printed reports will be formatted incorrectly with a leading "1" in the year field. For example, January 1, 2001 would print as "1/1/101" instead of "1/1/01". |
|
2711-KA1 |
If the terminal date of a PanelView 1200 has been set (via the terminal config screen or by the PLC) to a date on or after 1/1/2000, the day-of-the-week word sent to the controller when using the "Time and Date to PLC Controller" option will be incorrect. If the terminal rolls over from 12/31/1999 to 1/1/2000 on its own, the day-of-the-week value will remain correct. Only after a manual date change on or after 1/1/2000 will this error occur. |
|
1403-MMxxx |
To Order the Firmware upgrade, follow these steps: |
|
8600 AT90 |
These products are no longer manufactured by Rockwell Automation, they are now a product of OSAI. Please refer to www.osai.co.uk/usa/y2k/products.shtml for information on the specific Y2K issues. All Year 2000 information and product upgrades are the responsibility of OSAI. However, if your company is located in the U.S. or Canada, OSAI has contracted with Rockwell Automation to provide upgrade services to customers in the U.S. or Canada. |
|
2711-KC1MC |
The trend object displays February 29, 2000 as March 1, 2000. The dates are displayed as follows: |