PLC PROGRAMMING RSLOGIX 5000 PDF
Introduction Everything You Need to Know About Men and Relationships Is Right Here 1 1 THE MIND-SET Act Like a Lady, Thi. PLC Programming With RSLogix - Free ebook download as PDF File .pdf), Text File .txt) or read book online for free. In an industrial setting, the initial PLC programming is done offline and then later Rockwell Software RSLogix is used to program the Allen-Bradley.
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control action (0=reverse (SP-PV); 1=direct (PV- SP)). Use this locator to find the applicable Logix controllers instruction Specify PLC-2 Messages. programming skills using the industry-standard RSLogix PLC programming convention as Logix to provide a seamless transition from PLCLogix. Figure 3 describes the basic procedure for programming PLC. Ladder Logic programming with RSLogix and RSEmulator . resourceone.info
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This is the experiment scenario: There will be a special battery charger that charges only Lithium ion batteries I have that already. Right-click on the blue tag name field. From the dropdown menu, choose New System Enable. The tag we are defining here is simply a bit, so we can accept the default values in the dialog box. In fact, we really dont need to add a description, as the tag name itself is pretty self-explanatory. Click OK. We know from the Project Scope that the system must stop if there is a fault.
We are not sure of the details of all those faults yet, but we do know that we will summarize those faults somewhere in the program. It will result in a bit. We will use the address tag SystemFault for that bit. We also know that we want the SystemEnable to be on if we do not have a fault. Bear with me here and it will make sense. Click and drag the XIO examine if open tool button from the User menu down to the new rung.
Place it just to the right of the E-stop input. Double-click on the tag filed and type SystemFault in the box. It should look like this:. By the way, if you forget to define that tag, RSLogix will remind you when you accept the rung edits. Lets see what we have. The logic of the rung works just like an electrical circuit. That is exactly what we want. We will work out the fault logic later.
We need to accept the current rung. Right-click on the rung number 0 and this dropdown appears. We have completed the first rung in the program. You may wonder why the SystemFault instruction is highlighted green. This is because the value of the SystemFault tag is 0. Therefore, the instruction is highlighted. You should note that these colors are highly configurable. In fact, I have seen many different color schemes. Just keep in mind that you may look at someone elses laptop and find blue, for example, has been configured to highlight a bit that is true.
Starting a Batch Cycle The Project Scope said that the operator may start a batch by pressing the Start Batch pushbutton on his console. Lets start with that input. Right-click on the last rung and choose Add Rung. Click and drag the XIC examine if closed tool button from the User menu to the left side of the new rung. Click on the tag name field above the instruction and navigate through the tag groups until you find the input Local: This is the Start Batch PB1 pushbutton.
Click and drag the OTE output energize tool button from the User menu down to the new rung. We are creating a new tag that indicates the system is currently batching.
Label this tag SystemBatching. Right-click on the tag, select New SystemBatching and accept the defaults. If the operator chooses, he may stop the batch. We will make use of the Stop Batch pushbutton. Navigate through the tag groups until you find the input Local: This is the Stop Batch PB2 pushbutton. We dont want the operator to be able to start a batch if the System Enable bit is not on.
We will add that by dragging the XIC examine if closed tool button side of the new rung. RSLogix lets us quickly assign a tag to this bit by dragging the bit name from another rung. As you drag the tag name box, you will see gray rectangles appear, indicating that these are potential places to assign the tag. As the cursor gets nearer to a target, that target icon changes to a green oval. This rung we are creating will work much like a traditional motor starter circuit that uses a contact from the motor starter wired in parallel with the start button to hold in the coil.
We need to wire the contact in parallel with the start button. We do this with a branch instruction. Click on the blue section of the branch and drag it to the target to the right of the Start Batch PB1 instruction. As you are dragging, it looks like this. There is a quick way to do that. This is called a latching rung. If the SystemEnable bit is on, the SystemBatching bit can be latched by momentarily pressing the Start Batch pushbutton. The SystemBatching bit will stay on and the rung will remain latched until the Stop Batch pushbutton is pressed or the SystemEnable bit goes off.
Thinking ahead, though, we know that the system will stop the batch automatically after it has pumped all the finished product to the filling lines. We are not sure how we will know that yet, but we know we need a bit to unlatch the rung. Notice how the rung has become too long to be contained on one line, so RSLogix is putting the OTE instruction below and re-routing the connecting line.
It is accurate, but a little confusing. You can get around this by a couple of ways. You can set the Zoom factor under the View menu to get the rung to appear on one line.
That is what we will do here. We dont have a real need to see the Controller Organizer right now, anyway. Batching Steps As you recall from the project scope, there are a number of steps needed to create the finished product. They are: Adding City water 2.
Adding chemical QR 3. Adding chemical KM 4. Blending the mixture with the agitator 5. Pumping the finished product to the filling lines. Before we do that, though, we need to add another permissive bit.
We will tag that bit SystemReady. We know that if the system is enabled but not currently batching, it is ready to begin a batch.
We need insert a new rung and create a SystemBatching and SystemReady bit. Add a new rung and program it as shown in Rung 2. You can see how Rung 2 should look in the picture below. The SystemReady bit will be on when the system is enabled, but not batching.
The instructions will work on the same bit address, but are typically found on different rungs. The batch will be started when the operator pushes the Start Batch button. We will latch that bit and label it Step 1. Insert a new rung at the bottom of the ladder. Click and drag the XIC examine if closed tool button from the User menu to the left side of the new branch.
Drag the SystemBatching tag from Rung 2 to the new instruction. To save some typing, you can copy and paste instructions.
Click on the rung number for Rung 3. The instruction is duplicated on Rung 3. Click and drag the OTL output latch tool button from the User menu to the right side of the new branch. Type in the tag name BatchStep1 and define the new tag. However, what if the button is pressed if the system is already batching and in another step? To prevent that from happening, we will make sure that the only way the system can enter Step 1 is if it is not in another step already.
Define all the new tags Type in the appropriate descriptors. Verify the rung. You may wonder why we chose not to use the OTL output latch instruction in Rung 1. Many times, it is a matter of personal choice; sometimes a traditional latching rung is better than using an OTL. In Rung 1, we were able to keep all the logic affecting the SystemBatching bit on one rung. This makes it easier to read and a little more condensed. Some people view a traditional latch as a bit safer.
Its your call, though. The Tag Database In looking at Rung 3, we see that some descriptions are a bit lacking. The SystemBatching tag name explains what the bit does, but the Batch Step tag names dont tell us much. We need to add some descriptions. You remember the actions for each Batch Step: We can then add the text Adding City Water to the description box, as is shown below. Since we have three more tags to define, lets take a look at the tag database.
First, though, we need to know that RSLogix has different categories for tags. Rockwell calls this attribute of a tag Data Scope. There are controller tags, or global tags, that can be used by all the tasks and programs in the PLC. There are program tags, or local tags, that can be used only by an individual program.
When tags are created as we have done, this is the default. Lets take a look at the tags we have so far in the Tag Monitor. Here are the tags we created as we wrote the program. One note, though; use care when you are editing tags in this table.
Many times, there is no undo available. There are a couple of ways to scale a value we get from an analog input in RSLogix We can scale the value within the program, or we can do the scaling right in the card. There are advantages and disadvantages to both methods. Scaling in the card is simple and straightforward, but once the card is configured, the configuration cannot be changed unless the PLC is taken offline.
This is not good for processes that must run continuously. Scaling in the program is more difficult, but adjustments to the scaling algorithm can be made while the PLC is still running. In our case, as in many batching applications, the process does not have to run continuously. For example, when the mixing tank is full, we could shut down the PLC and manually run the pump that empties the tank.
This window would give us more than enough time to re-configure the analog card. To configure our IF8 analog input card, we need to know what signal type we have coming from our sensors, the range of the signals we get from our sensors and the engineering units for each sensor. Lets start with the scales. Setting up the Analog Input Card to Calculate Tank Weight Scales are for these types of applications usually consist of a standalone unit that is calibrated by the manufacturer of the scales.
The unit usually has a display that shows the actual weight and an output that can be fed to a PLC. Lets assume that the output of our unit has been calibrated for VDC. Zero volts equals 0 pounds, and 10 volts equals pounds. Now we know the signal type is DC voltage, the range is and the engineering units are pounds.
Click on the Configuration tab and you will see this. Youll see that Channel 0, which is our Scales channel, is selected. Click on the dropdown menu for Input Range and select 0V to 10V. Change the Low Signal field to 0. Change the High Engineering field to Change the Low Engineering field to 0.
That is all we really need to do. However, we are going to take advantage of the fact that there is a filter available.
This filter smoothes input transitions. Set the Digital Filter field to ms. Zero volts indicate the tank is empty. Ten volts indicates the tank is at its full mark, hopefully a safe distance from its actual maximum capacity.
The engineering unit used for the tank level is percentage. Again, that is all we really need to do, but we will set the Digital Filter field to ms. Scroll down and add a new rung at the bottom of the ladder.
We will open the city water valve in this rung, so we want to make sure that it is still safe and desirable to open the valve. That is, make sure that there are no faults, the E-Stop button has not been pressed and the Stop Batch pushbutton has not been pressed. Insert an XIC. We could drag the tag SystemBatching from Rung 3, but lets add it by using the dropdown tag menu on the instruction.
Double-click on the tag name field above the instruction. At this point, you could type the tag name and press enter to assign the tag to this instruction. Scroll down until you find the SystemBatching tag. Select it and press enter. RSLogix gives you a number of ways to assign a tag name.
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Use whatever is easiest for the particular situation. Insert an OTE for the city water valve Local: Remember that we want to put lbs.
Source A in the instruction is the Tank Weight. Click on the blue tag field and scroll through the tags until you find Local: Press enter.
Source B is our setpoint, which as you recall from the Project Scope is lbs. Enter for Source B. The LEQ instruction will remain true as long as the tank weight does not exceed lbs. We will make use of the fact that we know the system is currently in Step 1, but the Mixing Tank has enough water lbs to go to the next step.
Rung 5 works like this: As a result, the bit BatchStep1 is unlatched turned off and BatchStep2 is latched turned on.
Take a moment to make sure you understand how as the weight in the tank rises past , the City Water valve is turned off and the system transitions to Step 2. Step 2 Adding Chemical KM Step 2 will be similar to Step 1, so rather than creating new rungs from scratch, we are going to copy and paste the rungs from Step 1.
Click on the rung number for Rung 4. A green bar surrounds both rung number blocks. You now have new rungs, 6 and 7. We will start with rung 6. Change BatchStep1 to BatchStep2 in this instance, just double-click on the tag name and change the 1 to 2 and press enter.
Assign that to the OTE. It should look like this.
This means that not only do we have to open a valve, but we also have to turn on a pump. Next, we will wait to turn on the pump until the valve is verified to be open by limit switch LS-QR2. As a failsafe, we will look at limit switch LSQR1 to make sure it is not indicating the valve is closed.
Right-click on Rung 6 and choose Add Rung. Double-click on Rung 7.
Type in the following string: XIC Local: Change the latch and unlatch outputs to increment the system to Step 4. It should look like this after you have made the changes and verified the rungs. Step 4 Blending After all the ingredients are in the Mixing Tank, we have to run the Agitator for 3 minutes. We will set up a timer to run for 3 minutes. When the timer is done, we will increment the system to Step 5. That will turn off the Agitator. Start by inserting a new rung at the bottom. Insert an XIC instruction with the address of B3: Insert an XIC instruction with the address B3: Click and drag the TON tool button down to the right side of the new rung.
This type of timer is called a Timer On Delay. As soon as the instructions preceding it are true, it will begin timing. The Enable bit EN will turn on. After it reaches its Preset value, the Done bit DN will turn on. First, we have to assign a tag name to the timer. Double-click on the Timer field in the instruction. Type AgitatorRunTime for the tag name. Define the new timer tag name, as you cannot assign presets until you do this.
The time base for the TON instruction is always 1 msec. We want to time for 3 minutes, or seconds, so we will enter a preset of Double-click on the Preset field and type Leave the accumulated value at 0, as this will be changed as the timer begins timing. To run the Agitator, insert a new rung at the bottom.
Click on the User tab of the tool button menu and drag an XIC instruction to the first marker of the new rung. We will use the Enable bit EN of the timer for the tag.
To assign a timers enable bit, double-click on the tag name field for the new XIC instruction and navigate to the EN enable bit of the timer.
The enable bit of a timer is on only when the timer is enabled. In Rung 12, for example, if the SystemBatching bit turns off, or the Batch Step 4 bit turns off, the timer will no longer be enabled. Consequently, its enable bit, AgitatorRunTime. EN will turn off. We will turn off the timer by incrementing the system to the next step when the timer is done. Insert a new rung at the bottom and drag an XIC to the first marker. We will assign the Done bit DN of the timer to this instruction.
It is formatted just like the Enable bit, except you use. DN as the suffix. Tag this instruction as AgitatorRunTime. We will use the same method to increment the system to Step 5 that we have used previously. Drag an OTU instruction to the last marker in the rung. Tag the instruction to be Step 4, which is BatchStep4. Insert a new branch around the OTU by dragging a Branch tool button to the marker in front of the output.
Grab the right leg of the branch and move it to the marker after the output. Now, when the timer is done and AgitatorRunTime. DN turns on, it will unlatch Step 4 and start Step 5. Lets save ourselves some typing and copy all of Step 3. Click on Rung 9. Click on the last rung.
Change the tag of the output instruction to Local: We want to pump until the Mixing tank is empty. We will use the Ultrasonic Level Sensor to determine if the tank has liquid in it. We will use a GEQ instruction to accomplish this. Type GEQ for Greater than or equal to in that space. Change Source A of the instruction to Local: This is the address of the scaled level sensor.
We may be tempted to put a value of 0 into Source B, but that could be risky. First, pumping the tank dry might be hard on the pump. Second, because of drift in the level sensor, we might never get a reading of zero in some instances. Put a 3 in for the value of Source B.
Change Rung 16 to show the correct valve, limit switches and pump addresses. Since this is the last step in the batching process, we will use Rung 17 to increment out of Step 5 and complete the batching cycle.
Copy the GEQ instruction from Rung Delete the other GEQ from Rung 17 the one that references the tank weight. Right-click on the OTL L instruction in the bottom branch. Change the tag to BatchComplete. This is the batch complete bit. The screen should look like this. When the system enters Step 5, the Mixing Tank will be nearly full. When the valve has been opened and verified by the limit switches, the pump will run.
It will trip the latch in Rung 1 and turn off the SystemBatching bit. Faults The program may be complete in an operational sense, but we need to add the logic to detect faults. Valve Position Faults We were told in the Project Scope that the valve position must be verified by the limit switches within 2 seconds.
We will use an individual timer for each valve to accomplish this. Type in the logic as shown below. We must accommodate the two conditions that indicate a fault. The first is that the valve was told to open, but did not open. The second fault condition is that the valve was told to close, but did not close.
Remember that the limit switches on the valves are electrically normally open and will be physically held closed by the valve when it is in position. When the valve is open, we should get a signal to the input Local: When the valve is closed, we should get a signal to the input Local: We use the XIO examine if open instruction. We want to know if we do not get a signal from the limit switches when we should.
An XIO instruction used on an input will always be true if there is no signal on the input. Lets look at how it handles the first fault condition the valve was told to open, but did not open. This creates an undesirable condition and the timer will begin timing. The screenshot below shows what the state of the instructions would be after 1 second of the valve being instructed to open, but LS-CW2 not yet being activated.
You can see that the City Water valve is being told to open, as Local: The timer has begun timing and has reached, or accumulated, 1 second.
DN will come on and turn on the SystemFault bit in Rung Consequently, Rungs 1 and 2 will become false and the system will stop batching. Lets look at the other condition; that is, the valve was told to close, but did not close. That is accomplished in the branch in Rung If the valve output is not on but the limit switch is not activated, then the timer will begin and generate a fault. Sometimes it gets confusing when you are working with the XIO instruction. The logic is inverted and you have to flip some things around in your head.
The logic we have used here to detect a valve fault is fairly standard and its use is widespread. The nice part about this logic is that it is pretty easy to troubleshoot. You can physically look at the valve to see if it is open or closed.
Then, you can look at the input you are receiving from the limit switch. If you are getting a fault when you should not, then just invert the instruction for the limit switch. Lets create the fault timers for the remaining valves. This is the screenshot for the QR valve and KM valve fault logic.
To complete our fault logic, we need to add the Liquid High Level alarm. Console Status Indicators Pilot Lights I have held off putting the logic in for the Pilot Lights in an effort to keep the text as simple as possible. Now that you understand how the system operates, we can go back through the program and add the pilot lights. The first is the System Ready PL1 pilot light. Find Rung 2 in the logic.
Insert a branch around the SystemReady output. Put an OTE instruction on the bottom rung of the new branch and tag it Local: With this logic, the light will come on when the SystemReady bit is on. System Fault We need to add a little logic to the System Fault pilot light. This light needs to stay on after it detects a fault; otherwise, the system will stop, the light may go out and the operator wont know there was a fault. Add the rung as shown below. Adding Rung Comments A good rung comment explains in plain language what the rung is supposed to do.
These are very valuable. First, it is a way to double-check your own work. I have been surprised at the number of times I have found a mistake in my logic as I was writing the rung comments! Second, it helps a person who is unfamiliar with the program quickly learn how the program is supposed to work. Finally, it adds value to your finished program. A well-documented program is worth more money to a client or your company than a program that is not documented.
They can even get you out of a jam. If you have to troubleshoot a system 6 months after you first programmed it, I can guarantee that you will not remember every reason for every line of code you wrote. If you have written code in some other language before, you certainly can understand the value of documenting your work. Lets use a rung from our program as an example. Right-click on the rung number 7 and choose Edit Rung Comment.
The rung comment box appears above the rung. Type this in the Rung Comment field: Turn on the "Adding QR" pilot light. Notice that you dont have to put details such as PLC tags in the rung comment just document the concept of the rung. First, backup up your original file and put it in a safe place. Connecting to a ControlLogix processor is done through Ethernet, the same way you connect a PC across a network.
Consult a trained professional who is able to assist you. You simply plug your computer into a open port on the switch. Navigate to the PLC to which you would like to connect. When you are successful, the Upload and the Download buttons on the right will become available; they will no longer be grayed out.
You will then be able to download your program by following the prompts. Let me say that I have greatly oversimplified this process. To be frank, this is where many people have problems.
Sometimes connecting to a PLC is as easy as finding an Internet site in your browser. Other times, it can be an incredibly frustrating experience, due to no fault of your own. Do what you can to prepare yourself by asking others about connecting to this particular PLC, making sure your computer can connect to a similar PLC, and so on.
Anybody who has ever connected to a PLC has had problems; they will understand your position. There was one instance where the firmware in a particular PLC was not compatible with the version of RSLogix I was running in my laptop.
It took a call to Rockwells Tech Support to sort out the problem. They were very helpful, and it wasnt long before I was connected. RSLogix Emulate Rockwell offers a nifty way to simulate going online. You can test your program at your desk, without being connected to a PLC.
The software that allows you to do this is called RSLogix Emulate If you dont have it installed on your computer, I highly recommend that you do so.
Choose Virtual Backplane. Change the Controller Type in the Batching Program Before you can emulate a ladder logic project, you must configure the project's controller type to use the emulator.
The emulator needs to have the processor in Slot 1. The Controller Properties window opens. Close the window. Starting with the module in Slot 3, right-click on each module in the controller organizer and bump the slot number up by one, until the configuration is as shown below:.
Click the Download button to send the file to the emulator. The next step is to go online. Find the mode drop-down menu in the upper left. It currently says Offline.
That is OK for now. Switch the processor to Run Mode with the dropdown menu just to the left of where it currently says Rem Prog. Please note that if you were connected to a PLC that is operating a machine, you would take much greater care when switching to Run Mode. The three modes work this way: RSLogix can only monitor the program and data.
No downloads or changes to the program can be mode. Most often, the key switch is left permanently in this position. Hide the Controller Organizer and your screen looks like this. We could have chosen Test Mode. This is a special mode that allows the program to run, but disables all outputs.
PLC Programming with RSLogix 5000
This would be a good practice if we were on an actual start-up and personnel and equipment safety was an issue. It seems we have a system fault. Again, a true state is indicated by the green highlight on the instruction. Lets find out why we have a system fault.
Right-click on the SystemFault tag name in Rung 0. Choose Find All System Fault. A new window appears at the bottom, showing links to all the occurrences of SystemFault. Click on the link that contains the OTE. We can see that the valve fault timers have timed out, turned on their respective done bits DN and caused a system fault.
In the lower branch of Rung 21 you can see that the input Local: Normally, of course, if we were telling the valve to close, we would get a signal from the limit switch on the input. We are going to have to temporarily disable the system fault bit so that we can test the remainder of the program. We will do this by putting a jumper across the SystemFault instruction in Rung 0. Close the search window at the bottom of the screen. The rung you are editing is a copy of Rung 0 and has the letter i to the left.
The rung shown below has the letter r to the left, indicating that the PLC is still running this rung. Small squares on the rung indicate potential landing spots for the branch. As you near a spot, the icon changes to a green circle. When the cursor is near the landing spot in front of the SystemFault bit, release the mouse button.
Click and drag the right part of the branch and place it to the right of the SystemFault instruction. This is warning you that, among other things, the change cannot be undone without reediting the rung, at least there is no undo.
Click the Yes button. You see that the letters to the left of the rungs are gone. The PLC is now processing Rung 0 with the new logic. However, the SystemEnable bit is still off. RSLogix allows you to toggle the state of a bit. It will remain toggled unless logic, or voltage on an input, forces it to another state. Right-click on the instruction.
Now, the E-stop input instruction is true, as indicated by the green highlight. The system is now enabled. Take a moment to think of the equivalent hardwired relay circuit that would generate the same function as Rung 0. The coil for relay SystemFault is energized, so the normally closed contacts of SystemFault are open.
However, we have placed a jumper across this set of contacts. This energizes the coil of the SystemEnable relay. You see that the SystemBatching bit becomes true and the latch is now active. Toggle it again to the off state to simulate how the pushbutton actually works. Look at Rung 4. The first two instructions look right, as the system is batching and we are in Batch Step 1. Both of these are highlighted. The outputs are also true.
You have to mentally compare the numbers yourself to see if the instruction is true. Even though the start pushbutton has been released, the latch instruction will stay on. The program has incremented to the next step. During your testing, you will continue this sequence until the specified weight for each ingredient is reached.
As the ingredients are added, the tank weight rises. When all the ingredients have been added, the batch is blended and sent to the filling lines. In a real-world start-up scenario, you would verify each step of the process and confirm that the program functions as specified in the original Project Scope. Editing in Run Mode As happens many times, though, there is a change in the project procedure. The Process Engineer indicates that there may be a possibility of supplying too much finished product to this tank and that it could overflow.
He decides the storage tank should have a high level switch mounted in it. If the level in the storage tank gets too high, he wants you to disable the Mixing Tank pump. We still have spare inputs available. Lets use Local: It is decided that the high level switch will be wired in the failsafe mode; that is, the level switch will be closed until a high level is reach.
When wired in that fashion, if the wiring to the switch fails, you will not receive a signal from the storage tank pump and the PLC will stop the Mixing Tank Pump. The system will not run until the problem is corrected. Scroll to Rung Double-click on the rung number. A column of is will appear. The rung is now open for editing. Click and drag the XIC tool button to the first marker after Local: When the marker turns green, release the mouse button.
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You may also click on the tag field. A dialog for the new tag opens.
In this case, we can accept the defaults and click the OK button. Your online edit is now complete. The Mixing Tank pump will not run unless it receives a signal from the Filling Line Storage tank indicating the tank is ready to receive finished product.
If you want to cancel your current edits, click the tool to the immediate right of the Accept Pending Program Edits tool. This is called Cancel Pending Program Edits.
However, before you go into Run Mode, make sure that the E-stop circuit works properly. I have not included wiring diagrams in this book, but most codes state that all control power is removed if the E-Stop button is pressed. The three categories of stop functions shall be as follows:Can you tell me why my plc keeps shutting off my servo on a tree cnc mill, sometimes it will run for days without doing it, and then at times I can reset the servo and it will kick right back off, sometime I can mill an hr or so and just kicks off the servos.
Add the rung as shown below. For example, lets look at LS-CW1. GH on Tue, Click and drag the XIC tool button to the first marker after Local:
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