Wb_203_01 RS Logix 5000 Basic

Rockwell RSLogix 5000 Basic Training Document

Course Introduction

1

Subject Introduction

2

Hardware

3

Software

4

Installation

5

Troubleshooting

6

Exercises

7

This Training Document is intended for Training purposes only, and must not be used for any other purpose. The Training Document does not replace any instructions or procedures (e.g. OM, MM, TeM, IM, SPC) intended for specific equipment, and must not be used as such. Note! For safe and proper procedures, refer to the equipment specific documentation.

Name: ................................................................................................................

8

9 Technical Training Centre Lund, Sweden WB-203-01 Issue 1/0702

10

1 Course Introduction

Technical Training Centre

Information regarding Safety Regulations at the Technical Training Centre in Lund This list summarizes a number of items which may concern you, as a participant in this training course. Read the list, and if anything remains less than clear, or if you have any questions, feel free to contact your instructor. 1. Study and follow the sections on Safety in the course literature, for instance the OM, MM and EM. 2. You are entitled to ask persons who have no business to be near the machine, to stay at distance, for safety reasons. 3. Never touch any other machines than those used in your own training course. 4. There may be cables which are still electrically live, although they have been disconnected from their terminals. 5. In some machines, safety switches may be bridged or disconnected, for training reasons. 6. Find out exactly where the emergency stop switches for the machine as well as the conveyor are located. 7. When starting a machine, the person doing the starting must make absolutely sure that this does not expose anyone else to danger. 8. Certain chemicals, used in your training course, may be hazardous to your health and constitute a danger of fire or explosion. Make sure you know how such chemicals are marked and how to handle them. 9. It is strictly prohibited to wear rings, watch, or necktie when working with the machine. This prohibition also applies to loose-fitting clothes or anything else that might get caught in the machinery. 10. A first aid kit and stretcher are kept in the machine hall. 11. Study the information on what to do in case of fire and which escape routes to follow. A diagram of escape and evacuation routes is posted in every classroom. 12. If you observe or discover anything that might jeopardize safety, immediately tell your instructor.

Technical Training Centre 1/9701

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Course Information TC-4058 Rockwell RSLogix 5000 Basic Course Length

x

5 days

Target Group

x x

Tetra Pak Technicians Customer Technicians

Previous Knowledge

x

Good computer skills in MS Windows environment.

Course Objectives

x

To obtain a basic understanding of how the various components in the control system are constructed and work in combination. To be able to perform program changes. To be able to locate faults and replace defective components. To be able to perform program transfers.

x x x

CourseContent/Subjects

x x x x x x x

Fundamentals of RSLogix 5000, RSLinx, RSNetworks for DeviceNet, RSLogix 5000 Compare. System hardware components and their function. Communicating with a Controller. Organizing data. Entering, Editing and Verifying Ladder Logic. Communicate with a remote modules through Ethernet and DeviceNet. Practical exercises with simulator.

Last modified: Feb 7, 2007

2 Subject Introduction 1 Brief PLC history . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-01131 2 PLC Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-01132


Brief PLC history In the late 1960's Programmable Logic Controllers, PLCs, were first introduced. The primary reason for designing such a device was to eliminate the large cost involved in replacing the complicated relay based machine control systems. Since relays are mechanical devices they also have a limited lifetime which required strict adhesion to maintenance schedules. Troubleshooting was also quite tedious as so many relays are involved. These ’new controllers’ also had to be easily programmed by maintenance and plant engineers. The answers were to use a programming technique most people were already familiar with and replace mechanical parts with solid-state ones: - Ladder programming.

Tetra Pak PLC history Allen-Bradley

TPMC

In the beginning of 1980`s Tetra Pak started to replace relay based automation with PLC systems - Allen-Bradley was the chosen supplier.

After having problems with delivery times, processor speed and expensive communication/programming equipment Tetra Pak decided to change PLC supplier in the end of 1980´s. Nothing good enough was found on the market so Tetra Pak decided to develop its own PLC system together with a Swedish company SattControl AB. The name of the new PLC was TPMC (Tetra Pak Machine Controller).


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Training Document. For training purpose only.

1

In the middle of the 1990`s GE Fanuc was introduced as the PLC system in Tetra Pak machines because it was much cheaper and more easy to program than TPMC.

GE Fanuc

Still today we are using GeFanuc for new filling line machines but there is big ongoing change to move over to Rockwell Automation (Allen-Bradley hardware). The reason is that Tetra Pak in the beginning of this millennium decided to evaluate available PLC systems in the NAP (New Automation Platform) project. Rockwell was selected as the preferred supplier at that time so that’s why we have it today.

Rockwell Automation

ControlLogix

In this new platform we combine an integrated hardware system that controls motion and logic with a software that include all parts needed to program this. Ladder logic is not the only programming language any more. Other languages are also used: • ST, Structured text • SFC, Sequential Function Chart • Function Block Diagram UML-Software modelling structure is used to organize our newly developed programs in the same way for all machines used in the line.

CompactLogix

2

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PLC Basics Programmable Logic Controllers (PLC’s), also referred to as Programmable controllers, are in the computer family. They are used in commercial and industrial applications. A PLC monitors inputs, makes decisions based on its program, and controls outputs to automate a process or machine. This course is meant to supply you with basic information on the functions and configurations of PLC’s.

Drive motors

Pumps

Lights

Photo sensors


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Push-buttons

1

PLC’s consist of input modules or points, a Central Processing Unit (CPU), and output modules or points. • An input accepts a variety of digital or analog signals from various field devices (sensors) and converts them into a logic signal that can be used by the CPU. • The CPU makes decisions and executes control instructions based on program instructions in memory. • Output modules convert control instructions from the CPU into a digital or analog signal that can be used to control various field devices (actuators).

Basic PLC operation

A programming device is used to input the desired instructions. These instructions determine what the PLC will do for a specific input. An operator interface device allows process information to be displayed and new control parameters to be entered.

Input Module

Output Module

CPU Central Processing Unit

Operator Interface

Programming Device

Push buttons (sensors), in this simple example, connected to PLC inputs, can be used to start and stop a motor connected to a PLC through a contactor (actuator).

PLC

Input

Push buttons

2

Motor

Output

Contactor

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Hard-wired control

Prior to PLC’s, many of these control tasks were solved with contactor or relay controls. This is often referred to as hard-wired control. Circuit diagrams had to be designed, electrical components specified and installed, and wiring lists created. Electricians would then wire the components necessary to perform a specific task. If an error was made the wires had to be reconnected correctly. A change in function or system expansion required extensive component changes and rewiring.

Circuit Diagram K

Q

L1 M 3~

L2 L3

Stop

PLC’s

Advantages


Start

Q

K

The same, as well as more complex task, can be done with a PLC. Wiring between devices and relay contacts is done in the PLC program. Hard-wiring, though still required to connect field devices, is less intensive. Modifying the application and correcting errors are easier to handle. It is easier to create and change a program in the PLC than it is to wire and rewire a circuit. • • • • • •

Smaller physical size than hard-wire solutions Easier and faster to make changes PLC’s have integrated diagnostics and override functions Diagnostics are centrally available Applications can be immediately documented Applications can be duplicated faster and less expensively

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Number Systems Since a PLC is a computer, it stores information in the form of On or Off conditions (1 or 0), referred to as binary digits (bits). Sometimes binary digits are used individually and sometimes they are used to represent numerical values. Various number systems are used by PLC’s. All number systems have the same three characteristics: digits, base, weight. The decimal system, which is commonly used in everyday life, has the following characteristics:

Ten digits Base Weights

Decimal system

0, 1, 2, 3, 4, 5, 6, 7, 8, 9 10 1, 10, 100, 1000, ...

The binary system is used by programmable controllers. The binary system has the following characteristics:

Two digits Base Weights

Binary system

0, 1 2 Powers of base 2 (1, 2, 4, 8, 16, ...)

In the binary system 1’s and 0’s are arranged into columns. Each column is weighted. The first column has a binary weight of 20. This is equivalent to a decimal 1. This is referred to as the Least Significant Bit (LSB). The binary weight is doubled with each succeeding column. The next column, for example, has a weight of 21, which is equivalent to a decimal 2. The decimal value is doubled in each successive column. The number in the far left hand column is referred to as the Most Significant Bit (MSB). In this example, the most significant bit has the binary weight of 27. This is the equivalent to a decimal 128.

Most Significant Bit

4

Least Significant Bit

27

26

25

24

23

22

21

20

128

64

32

16

8

4

2

1

0

0

0

1

1

0

0

0

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Converting binary to decimal

The following steps can be used to interpret a decimal number from a binary value. 1. Search from right to left (least significant to most significant bit) for 1’s 2. Write down the decimal representation of each column containing a 1 3. Add the column values In the following example, the fourth and fifth column from the right contain a 1. The decimal value of the fourth column from the right is 8, and the value of the fifth column from the right is 16. The decimal equivalent of this binary number is 24. The sum of all the weighted columns that contain a 1 is the decimal number that the PLC has stored.

128

64

32

16

8

4

2

1

0

0

0

1

1

0

0

0 8 + 16 24

In the following example the fourth and the sixth columns from the right contain a 1. The decimal value of the fourth column from the right is 8, and the value of the sixth column from the right is 32. The decimal equivalent of this binary number is 40.

128

64

32

16

8

4

2

1

0

0

1

0

1

0

0

0 8 + 32 40


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Each binary piece of data is a bit. Eight bits make up one byte. Two bytes, or 16 bits, make up one word.

Bits, bytes, and words

Bit 32768 16384 8192 4096 2048 1024

0

0

0

1

1

0

512

256

128

64

32

16

8

4

2

1

0

0

0

0

1

1

1

0

0

0

Byte Word

Programmable controllers can only understand a signal that is On or Off (present or not present). The binary system is a system in which there are only two numbers, 1 and 0. Binary 1 indicates that a signal is present, or a switch is On. Binary 0 indicates that a signal is not present, or a switch is Off.

Logic 0, logic 1

PLC Input 1

Off Logic 0

24 VDC

PLC Input 1

On Logic 1

24 VDC

6

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Hexadecimal

Hexadecimal is another system used in PLC’s. The hexadecimal system has the following characteristics:

16 digits Base Weights

0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, F 16 Powers of base 16 (1, 16, 256, 4096, ...)

The ten digits of the decimal system are used for the first ten digits of the hexadecimal system. The first six letters of the alphabet are used for the remaining six digits.

A = 10 B = 11 C = 12

D = 13 E = 14 F = 15

The hexadecimal system is used in PLC’s because it allows the status of large number of binary bits to be represented in a small space such as on a computer screen or programming device display. Each hexadecimal digit represents the exact status of four binary bits. To convert a decimal number to a hexadecimal number the decimal number is divided by the base of 16. To convert decimal 28, for example, to hexadecimal:

2810 1610

= 110 r 1210 => 1C16

Decimal 28 divided by 16 is 1 with a remainder of 12. Twelve is equivalent to C in hexadecimal. The hexadecimal equivalent of decimal 28 is 1C. The decimal value of a hexadecimal number is obtained by multiplying the individual hexadecimal digits by the base 16 weight and then adding the results. In the following example the hexadecimal number 2B is converted to its decimal equivalent of 43. 161

160 160 = 1

2

B

161 = 16 B = 11 11 x 1 = 11 2 x 16 = 32 43


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Signed integers

The simplest method to represent negative numbers is to use one bit of the PLC word as the sign of a number while the remainder of the word gives its magnitude. It is general convention to use the most significant bit as the sign bit, and a logic 1 will indicate a negative, whereas a logic 0 a positive number.

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Bits for magnitude Bit for sign: 0 = positive, 1 = negative

Thus a 16-bit PLC word allows numbers in the range ±32.767 to be expressed. This simple method is referred to as Sign Plus Magnitude Notification. However, the number zero has two valid representations in this format:

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

+0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

-0

1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

This is usually undesired, and therefore a more commonly used representation for negative numbers is the 2s Complement format. This format is used with the GE Fanuc 90-30 PLC for signed integers. In the twos complement format, using a 16 bit word, the number -X is represented as 216 -X. This means that, as with sign plus magnitude numbers, the most significant bit becomes the sign bit and if is set, the corresponding number is negative. Thus a 16 bit PLC word allows numbers in the range of -32.768 to +32.767 and zero is represented uniquely:

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

-32.768

1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

+32.767

0

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

0

8

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To obtain the negative number of a positive number in the 2s complement system two steps are necessary. First, the number is bit by bit complemented, i.e. each bit equal to 0 of the original number is changed to a one, and each one of the original number is changed to a zero. This process is called taking the 1s complement of a number. Second, the complemented number is incremented by one. This process can also be used in the reverse way to obtain a positive number from an original negative one. In the following example the number +37 is 2s complemented to -37.

+37

-37

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

0

0

0

0

0

0

0

0

0

1

0

0

1

0

1

sign bit 0 = positive

1

1

1

1

1

1

1

1

1

1

0

1

1

0

1

0

1s complemented

+1

incrementing by 1

1

1

1

1


1

1

1

1

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1

1

0

1

1

0

1


1

sign bit 1 = negative

9

BCD code

BCD code (Binary Coded Decimal) is a way is a way to express decimal numbers in binary format. When a BCD code is used, each decimal figure (0-9) is coded separately.

0

0000

1

0001

2

0010

3

0011

4

0100

5

0101

6

0110

7

0111

8

1000

9

1001

Thus, four bits are required to express 0-9 in BCD. Consequently, 16 bits suffice to write numbers from 0 to 9999. In the example below the number 4729 is written in BCD format. 16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

0

1

0

0

0

1

1

1

0

0

1

0

1

0

0

1

4

10

7

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2


9


Conversions of numbers

The following chart shows a few numeric values in decimal, binary, and hexadecimal representation.

Decimal


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Binary

Hexadecimal

BCD

0

0

0

0

1

1

1

1

2

10

2

10

3

11

3

11

4

100

4

100

5

101

5

101

6

110

6

110

7

111

7

111

8

1000

8

1000

9

1001

9

1001

10

1010

A

0001 0000

11

1011

B

0001 0001

12

1100

C

0001 0010

13

1101

D

0001 0011

14

1110

E

0001 0100

15

1111

F

0001 0101

16

1 0000

10

0001 0110

17

1 0001

11

0001 0111

18

1 0010

12

0001 1000

19

1 0011

13

0001 1001

20

1 0100

14

0010 0000

126

111 1110

7E

0001 0010 0110

127

111 1111

7F

0001 0010 0111

128

1000 0000

80

0001 0010 1000

510

1 1111 1110

1FE

0101 0001 0000

511

1 1111 1111

1FF

0101 0001 0001

512

10 0000 0000

200

0101 0001 0010


11

12

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3 Hardware 1 Logix 5000 platforms . . . . . . . . . . . . . . . . . . . . . . . . . TM-01133


Logix 5000 platforms RSLogix 5000 is the software used to interact with a number of different hardware platforms. The two platforms mainly used in Tetra Pak machines are: • ControlLogix™ • CompactLogix™ All Logix 5000 platforms use the same software for communication and editing.

ControlLogix Platform The main components of a ControlLogix system are shown in the following graphic: Power supply LED

Chassis

Power supply

Analog I/O modules Controller

Digital I/O modules

Communication modules

Controller

ControlLogix modules can be located anywhere in the chassis. There is no specific slot for the controller. It is also possible to have more than one controller in a chassis. In some Tetra Pak machines this is used for speed reason. One controller is handling the motion part of the machine and the other one the I/O part. It is also possible to have two controllers running the same program in parallel. If one stops the other one continues and keep the machine running. This function is called redundancy enabled and is not used in Tetra Pak machines.


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ControlLogix Chassis The ControlLogix platform has chassis in the following sizes: • 4-slot • 7-slot • 10-slot • 13-slot • 17-slot Chassis size is set up when you configure a new project. The slots are numbered from left to right starting with 0, as shown in the picture below of a 10 slot chassis.

Slots:

0

1

2

3

4

5

6

7

8

9

Important: 1756 (ControlLogix) modules are not slot dependent and can be placed in any slot in the chassis.

2

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ControlLogix Backplane The ControlLogix backplane, also known as a ControlBus™ backplane, is a printed-circuit board at the back of the chassis that provides electrical interconnection between modules:

Backplane

Module connector

Important: The backplane allows data to be multicast (sent once and received simultaneously by all the other modules in the rack). Modules can easily be removed from the rack by pressing the top and bottom locking clips at the same time and sliding the module forward.

Removal and Insertion Under Power (RIUP):

A Logix5000 feature that allows 1756 modules to be removed and inserted into a chassis while the backplane power is applied. ATTENTION: When a module is inserted or removed while backplane power is applied, an electrical arc may occur. An electrical arc can cause personal injury or property damage by causing the following situations: • Sending a false signal to field devices causing unintended machine motion or loss of process control • Causing an explosion in a hazardous environment Repeated electrical arcing causes excessive wear to contacts on the module and its mating connectors. Take adequate safety precautions when inserting or removing a module under power.


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ControlLogix Controller The ControlLogix controller is a 32-bit controller that combines logic and data in modular memory. ControlLogix controllers perform the following functions at high speeds in the order specified: 1. Receive data from input devices via input modules. 2. Execute programs and makes decisions based on input data. 3. Send information based on its decisions to output devices via output modules.

Inputs from Process/Machine

Outputs to Process/Machine

Input module(s)

4

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Controller

Output module(s)



The main components of a ControlLogix controller are shown in the following graphic:

Backplane connector

Locking tab

Label

LEDs

Door

Key switch

RS232 Serial port

Flash memory

Battery compartment

Locking tab

ControlLogix controllers have three main internal components: • Central Processing Unit (CPU): The decision making component that executes the program stored in memory. • Memory: A group of circuit elements where programs and data are stored. Logix5000 controllers have volatile memory - a memory that loses its data when the power supply is turned off. • Flash memory: On older controllers accessible from the bottom of the module, on newer behind the front door. The flash memory can be used to store a copy of the program. The flash memory is non-volatile.


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ControlLogix I/O Modules 1756-I/O modules provide input and output to span many applications, from high-speed sequential to process control. These I/O modules offer the following capabilities: • Electronic fusing • Scaling of analog values • Electronic module identification (keying) • RIUP (Removal and Insertion Under Power) The wiring from the process/machine is connected to I/O modules through one of the following special devices: • RTB (Removable Terminal Block): A wiring connector that plugs into the front of an I/O module. • IFM (Pre-wired Interface Module): A wiring connector that mounts on a DIN rail and connects to an I/O module through a pre-wired cable. RTBs and IFMs allow for the replacing or interchanging of I/O modules without rewiring them. RTB and IFM are removed from the module by sliding the locking tab at the front of the module to its unlocked position and then pull the RTB/IFM straight out. Important: RTBs and IFMs are not included with I/O modules. They must be purchased separately.

ControlLogix Communications Modules Communications Modules: Modules used for creating communications between a controller and network. ControlLogix communications modules are available for the following network(s):

6

Communications Module

Network

1756-ENBx, 1756-ENBT

EtherNet/IP

1756-CNB, 1756-CNBR

ControlNet

1756-DNB

DeviceNet

1756-DHRIO

Data Highway Plus (DH+) or Universal Remote I/O

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ControlLogixs Module specifications Module type and F/W rev. is found on a label located on the side of the module. Specifications for the different ControlLogix modules are available in RSLogix 5000 under Help-Online Books-ControlLogix manuals.

If you for example want information about a 1756-IB16/A (Digital input module) open ControlLogix manuals. In the list on the right side of the screen locate and click on: 1756-UM058D-EN-P ControlLogix Digital I/O Modules User Manual This will open a PDF document with information about all ControlLogix Digital I/O modules. Note especially the section about Troubleshooting your module. In here you find information about the LEDs at the front of the modules.


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Using Indicators to Troubleshoot Your Module Each ControlLogix I/O module has indicators which show individual I/O state (yellow), fault, or fuse status (red). A bi-coloured LED indicates module status with an “OK” (red/green). Status indicators are located on the front of the module. Status indicators for Input modules: Status indicators

This display

Means

Take this action

OK

Green light

The inputs are being multicast and in normal operating state.

None

OK

Flashing green light

The module has passed internal diagnostics but is not multicasting inputs or it is inhibited.

None

OK

Flashing red light

Previously established communication has timed out.

Check controller and chassis communication.

OK

Red light

The module must be replaced.

Replace the module.

I/O State

Yellow

The input is active.

None

I/O Fault

Red

A fault has occurred for this point.

Check this point at the controller.

Similar information is available for all ControlLogix modules.

Example: Platform Modularity A ControlLogix system can range in complexity between the following two extremes: • A simple stand-alone controller and I/O modules in a single Chassis • A highly-distributed system with multiple controllers, chassis, and networks in different locations. The following graphic shows a distributed system utilizing four different networks to communicate with various devices: • DeviceNet communication between - Scanner in the main rack - Point I/O adapter - Armor block I/O - Frequency converter • Ethernet communicating (via a switch) between - Ethernet module in main rack - Ethernet module in another machine - Ethernet module in remote rack - Panel view (TPOP) • Sercos ring optical communication between - Sercos module in the main rack - Servo drives • DSI bus serial communication between frequency converters Sercos handles the servos in the machine and is not covered in this Basic course.

8

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Main rack in DE

Remote rack in FM

Main rack in FM

Switch

'HYLFH1HW

(WKHUQHW

Point I/O

6(5&265LQJ

Armor block I/O

Servo drives Frequency converters

'6,%XV


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CompactLogix Platform The CompactLogix platform is a small modular system for simple I/O and control applications. The fixed I/O count of the CompactLogix platform is designed toward standalone control applications where panel space is limited. CompactLogix is typically found in Tetra Pak Distribution Equipment. A CompactLogix system is shown in the following graphic:

Controller

10

Power supply

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Compact I/O system


Communication module


CompactLogix Controller The main components of a CompactLogix controller are shown in the following graphic:

Diagnostic LEDs

Three-position Keyswitch

Ethernet connection

Flash memory slot

RS-232 port

Channel 0 Default Communications pushbutton

Label

CompactLogix controllers offer the following benefits: • Has memory sizes from 64 Kbytes to 256 Kbytes. • Supports 256 I/O points (up to 16 CompactLogix I/O modules): Suited for machine-level control, material handling, data acquisition and other applications requiring limited I/O count. • Supports 2 (CompactLogix 5320) or 3 (CompactLogix 5330) banks of I/O. • Able to communicate over NetLinx networks EtherNet/IP and DeviceNet. • Can be mounted on rails or panels.


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CompactLogix I/O Modules CompactLogix I/O modules contain a set I/O count for simple, stand-alone processes:

Status indicators

Module door

CompactLogix I/O modules offer the following features: • Removable terminal blocks and module-ready cables • Status indicators • Support for up to 256 points (16 I/O modules) by the controller

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Logix5000 Control Discipline All Logix5000 control system platforms can utilize multiple controllers, communications networks, I/O modules, and associated devices to communicate and integrate control disciplines. The following control disciplines are supported by Logix5000 systems: • Sequential Control: To sequence process units through a series of discrete states (e.g. conveyor systems). • Motion Control: To direct movement by controlling current, acceleration, position, and speed (e.g. labelling, packaging, picking and placing). • Drive Control: To manage the speed, torque, horsepower, and direction of a motor (e.g. mixing, winding). • Process Control: To operate a machine or manufacturing environment on regulated parameters (e.g. batching, filling).


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4 Software 1 Software Components . . . . . . . . . . . . . . . . . . . . . . . TM-01134 2 RSLogix 5000 Software . . . . . . . . . . . . . . . . . . . . . . . TM-01091 3 Configure I/O modules . . . . . . . . . . . . . . . . . . . . . . . TM-01092 4 RSLogix 5000 Project . . . . . . . . . . . . . . . . . . . . . . . . TM-01093 5 RSLinx Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-01094 6 DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-01148 7 RSNetWorx for DeviceNet, Software configuration TM-01095 8 RSNetWorx for DeviceNet, Project . . . . . . . . . . . . . . TM-01096 9 RSLogix 5000 Compare Tool . . . . . . . . . . . . . . . . . . TM-01097 10 RSLogix Emulate 5000 Software . . . . . . . . . . . . . . . TM-01098


Software Components Software is required for Logix5000 systems to interface with networks and control hardware devices.

RSLogix 5000™ Software RSLogix 5000 software is used for programming and configuring all Logix5000 systems. It operates in Microsoft Windows NT, Windows 2000 and Windows XP operating systems and is used to perform the following tasks: • Develop and modify ladder logic and function block diagrams • Monitor project and system component operation • Configure modules and communications

RSLinx™ Software RSLinx software is the communications software required by all Logix5000 systems. It provides the interface between RSLogix 5000 software and the hardware. RSLinx software provides program download and upload, online editing, and data monitoring functionality for Logix5000 systems.

RSNetWorx™ Software The RSNetWorx™ for ControlNet and RSNetWorx for DeviceNet software packages are required for configuring their corresponding networks. They also allow for the creation of a graphical representation of a network configuration.

RSLogix 5000 Compare™ Software RSLogix 5000 Compare software is used to compare two different projects and highlight the differences.

RSLogix 5000 Emulate™ Software RSLogix 5000 Emulate software is used to emulate a rack on your PC. It makes it possible to test projects when you don’t have any hardware available.


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RSLogix 5000 Software RSLogix 5000 is the software used to create new projects and also to interact with existing projects running on Allen-Bradley PLC.

Main components Toolbar

Path toolbar

Online toolbar

Language element toolbar

Controller organizer

Routine / Tags window Result window

Online Toolbar

In the Online Toolbar you can find information about the project and the controller status. By clicking on Offline, No Forces or No Edits you can change what information is displayed in the Online Toolbar. Controller properties is available from all menus and also from the controller icon.


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The main features of the Online toolbar are as follows. Available modes are Offline/Rem Program/Rem Run. The dropdown menu will have different options active depending on the mode of the controller.

Mode

Force status may be Forces/No Forces. In the dropdown menu you select if the forces in the program should be Enabled, Disabled or Removed.

Forces

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Edits

In the dropdown menu you can select how to proceed with Online edits. When doing Online editing these functions are also available as icons in the toolbar.

Redundancy

This function is activated if you, for backup purpose, use two controllers in parallel. At this point not used by Tetra Pak.

Controller key symbol

The Controller key symbol symbolizes the position (mode) of the controller key. Forced to Run mode. No control from RSLogix 5000.

Remotely controlled by RSLogix 5000. Default.

Forced to Program mode. No control from RSLogix 5000.

Controller icon By double clicking on this icon when Online you get access to the controller properties. This is described further in the section RSLogix 5000 Project.


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Toolbar

The main features of the Toolbar are as follows.

Find

A quick find function is available from the toolbar.

Type what you are looking for and press Find Next, Find Previous or Find All. A more precise search function is available under Search – Find…

Using this tool you can do a more specified search. To get more information on the function use the help button in the window. When you enter new or change existing ladder code it is good practice to verify that the code is working.

Verify Routine

Verify project

Verify Controller

In the toolbar of the RSLogix 5000 window you can choose either Verify Routine or Verify Controller. (The difference between them is that the Verify Controller searches for faults in all Programs and all routines while the Verify Routine only searches in the currently selected routine). The result is presented in the Results window.

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Undo/Redo

When entering program code you have the option to Undo or Redo changes you have made.

Undo

Redo

Note that Undo works in many steps without moving between blocks. An example: You make changes in MainRoutine and then move on to do changes in a Subroutine. In the Subroutine you start pressing Undo. You will Undo the changes in the Subroutine and then move on to Undo changes in the MainRoutine without the program changing the view to MainRoutine.

Path toolbar

Online graphic

Current path

• • • •

Recent paths

RSWho

Online graphic. Animated if the controller is Online. Current path. Shows the selected communication path. Recent paths. Recently used paths can be selected. RSWho. Used to select a new path from available networks.

Language Element Toolbar

Element buttons

Element tabs

• Element Buttons. Ladder elements for use in ladder code. • Element Tabs. Tabs where different element groups are collected.


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Controller Organizer Displays a tree structure of the project, used to organize and navigate in the project.

There are three folders in the Controller [Project Name] folder: • Controller Tags When you create a new tag you define it as either a Controller tag or a Program tag. Controller tags can be used by all programs in the project. It is a Global tag. Produced tags also have to be created in Controller tags. When you configure I/O modules corresponding Controller tags will be automatically created. • Controller Fault Handler Here you can place a routine that handles program faults. • Power-Up Handler Under this tab you can place a program that handles start-up conditions after an abnormal power loss during running.

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Controller [Project Name]


Tasks

In ControlLogix you can have up to 32 Tasks but only one Continuous. In CompactLogix and FlexLogix the limitation is 8 Tasks but only one Continuous. The RSLogix 5000 project structure is shown in the end of this document. • Main Task When creating a new project the Main task is defined as a Continuous Task. A Continuous Task automatically restarts when it reaches the end. Main Program Each Task can contain up to 32 Programs and each program contains its own unique Program tags. Program tags Tags created here can only be used inside this program. If you want to use shared tags in different programs they have to be created as Controller tags.

Main Routine This is the routine in a program that will execute first. Subroutine(s) A Subroutine is called from inside the Main Routine. As soon as a Subroutine is called, execution in Main Routine stops. When the Subroutine is executed the controller continues executing the Main Routine. • Unscheduled Programs Programs that are not scheduled by any task. They will not execute.

Motion Groups Trends

Controls the motion part of the program. This is covered in a different training. Here you can create Trends to graphically plot sampled data for an easier overview. It is possible to plot up to eight tags at the time. Normally Tetra Pak programs come with a number of predefined Trends to be used for troubleshooting.

Data Types

This is where the different data types are handled. There are a number of types predefined and it is also possible to create your own.

I/O Configuration

Under I/O Configuration you set up the different modules that are used in the project.


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Tag handling In Rockwell we use variable names called ”tags”. This is to define a label name so you can trace and store the information that we handle with the PLC. Tag name

In Rockwell a “Tag Name” is more or less the same as “Nickname” was in previously used PLC system GeFanuc.There is not the same limitation regarding the number of characters used, maximum 40 characters is now allowed. Note that spaces are not allowed in tag names. The description part has the same function as in GeFanuc. The “Reference” in GeFanuc is replaced by “Alias for” and “Type” values to point out the used hardware and structure. Alias for

Physical hardware

The “Type” or “Data Type” as it is named in this picture is information about the size and structure of a tag.

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We have predefined tags like TIMER, COUNTER, BOOL, INTEGER (INT), etc. and also User-Defined tags used to bunch related parameters together in a customized way.

The example above shows the parameters used to control a frequency controlled motor, all data bunched together into a UDT (User Defined Tag). In our TP projects UDT is frequently used for many things: • Alarm handling • PLMS communication • HMI communication • Device Net data handling • Motor control • Sequence (Used together with software modelling)


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The tags are stored in different places dependent on what function they have. Program tags are stored in the local programs and are only accessible within this program. A controller tag however is global and is visible for all programs and also possible to share with other controllers if needed.

Controller tags

Program tags

Routine/Tags window In this window you monitor and interact with the program code.

Results window The Result window does not open automatically. To open it click on View and then select Errors. This window has three tabs. Errors, Search Results and Watch. This is where you will find feedback information from the program.

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RSLogix 5000 project structure &RQWUROOHU &RQWUROOHU7DJV 7DVNV

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Controller Tags Tags that can be used by all Programs.

Continuous Task Task automatically restarts when reaching the end.

Periodic Task Task that runs at a specific time interval, 1ms - 2000s.

Event Task Task that performs a specific function when triggered by a specific event.

Program Each Task can consist of 32 Programs and each Program contains its own unique Program Tags.

Program Tags Tags that are local and can not be shared between programs.

Main Routine Main Routine executes first. Use the Main Routine to call other routines (Subroutines).

Subroutine To execute a Subroutine, use a Jump to Subroutine (JSR).


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Configure I/O modules In the Controller Organizer of the RSLogix 5000 right click on I/O Configuration and select New Module.

You will get a list of all available modules. For easier location of the correct module you can filter by module type. Start by pressing Clear All then select in this case Digital. Select the correct module. The module type is printed on a label at the side of each module. Also note the F/W REV. for the module.


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Digital Input Module. When you have selected a Digital Input Module (in this example a 1756-1B16/ A with FW REV 2.5) you set the Major Revision (2) and press OK.

Name: A descriptive name so you can recognize the module in the configuration. Slot: Select the slot number where the module is mounted. Description: Description of the module (Optional) Comm format: • CST Timestamped Input Data Using Coordinated System Time to timestamp the Input data. Module is configured and controlled by the controller in project you are configuring. • Input Data Module is configured and controlled by the controller in project you are configuring. No timestamp of the data. • Listen Only-CST Timestamped Input Data Using Coordinated System Time to timestamp the Input data. Module is configured and controlled by another controller and you can only monitor the module. • Listen Only- Input Data Module is configured and controlled by another controller and you can only monitor the module. No timestamp of the data. Revision: Select the minor revision of the module.

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Electronic Keying: • Compatible Module Module can be replaced with a module of the same major revision and the same or higher minor revision. • Disable Keying No checking of replacement module • Exact Match Replacement module has to be the same Major and Minor revision. Press Next.

Requested Packet Interval: Normally the modules use Change of State. As soon as an input changes state the information is sent on to the controller. If there is no change the controller will receive data at least this often. Inhibit Module: Disables the module but keeps the configuration. Major Fault On Controller If Connection Fails While In Run Mode: Self explaining. Press Next.


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The next screen will provide information about the module when you are Online. Press Next.

Change of State As soon as an input changes state the information is sent on to the controller. Enable Change of State: Select the Input points that you want to enable Change of State for. Selectable separately for Off to On and On to Off. Input Filter Time: Used to filter out noise from the signals. Selectable separately for each bank of eight Inputs. Also selectable separately for Off -> On and On -> Off. For example if Off->On is set to 1 ms the signal to an input has to be on for more than 1ms to be sent on to the controller. Press Next The next screen will provide information about the module when you are Online. Press Finish. All of these screens are available after configuration by double clicking on the module under I/O Configuration.

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Digital Output Module When you have selected a Digital Output Module (in this example a 1756OB16E/A with FW REV 2.4) you set the Major Revision (2) and press OK.

Name: A descriptive name so you can recognize the module in the configuration. Slot: Select the slot number where the module is mounted. Description: Description of the module (Optional) Comm format: • CST Timestamped Fuse Data – Output Data Using Coordinated System Time to timestamp when a fuse has blown. Module is configured and controlled by the controller in project you are configuring. • CST Timestamped Fuse Data – Scheduled Output Data Using Coordinated System Time to timestamp when a fuse has blown. The outputs from the module are scheduled based on CST. The delay can be up to 16 seconds. Module is configured and controlled by the controller in project you are configuring. • Listen Only - CST Timestamped Fuse Data – Output Data Using Coordinated System Time to timestamp when a fuse has blown. Module is configured and controlled by another controller and you can only monitor the module. Revision: Select the minor revision of the module.


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Electronic Keying: • Compatible Module Module can be replaced with a module of the same major revision and the same or higher minor revision. • Disable Keying No checking of replacement module • Exact Match Replacement module has to be the same Major and Minor revision. Press Next

Requested Packet Interval: Normally the modules use Change of State. As soon as an input changes state the information is sent on to the controller. If there is no change the controller will receive data at least this often. Inhibit Module: Disables the module but keeps the configuration. Major Fault On Controller If Connection Fails While In Run Mode: Self explaining. Press Finish. All of these screens are available after configuration by double clicking on the module under I/O Configuration.

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Analog Input Module When you have selected an Analog Input Module (in this example a 1756-IF8/ A with FW REV 1.5) you press OK.

Name: A descriptive name so you can recognize the module in the configuration. Slot: Select the slot number where the module is mounted. Description: Description of the module (Optional) Comm format: For this module there are a lot of different combinations. Here is a list of the functions of the different selections. • CST-Coordinated System Time, The data from the module will have a timestamp based on CST. • Float Data or Integer Data Float Data The input data is handled in floating point format. For example 0,00. Integer Data The input data is handled as whole numbers. • Single Ended, Differential or High Speed Mode Each module has up to four input channels connected to one A/D converter. The A/D converter receives data from one at the time. (Multiplexing) Single Ended Mode All input channels are connected to individual sensors and the input signals are compared to a Common. This gives more input points but less accurate readings. Differential Mode The sensors are connected to two input channels and the module measures the difference in the signals. This gives less input points but higher accuracy. High Speed Mode Same connection as Single Ended Mode but without Multiplexing. Only one sensor can be connected.


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• Listen Only Module is configured and controlled by another controller and you can only monitor the module. Revision: Select the minor revision of the module. Electronic Keying: • Compatible Module Module can be replaced with a module of the same major revision and the same or higher minor revision. • Disable Keying No checking of replacement module • Exact Match Replacement module has to be the same Major and Minor revision. Press Next


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Input Range The input range is individually selectable for each channel. RTS Real Time Sample period. Module Filter Default setting is 60Hz. An incoming signal of 60Hz will be reduced by approximately 3dB. Signals above 60Hz will be reduced more. Signals below 60Hz will not be reduced at all. This setting will affect the sample rate. Press Next. The next screen will provide information about the calibration of the module and is also used when calibrating. Press Next. The next screen will provide information about the module when you are Online. Press Finish. All of these screens are available after configuration by double clicking on the module under I/O Configuration.


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Analog Output Module When you have selected an Analog Output Module (in this example a 1756OF4/A with FW REV 1.5) you press OK.

Name: A descriptive name so you can recognize the module in the configuration. Slot: Select the slot number where the module is mounted. Description: Description of the module (Optional) Comm format: For this module there are a lot of different combinations. Here is a list of the functions of the different selections. • CST-Coordinated System Time, The data from the module will have a timestamp based on CST. • Float Data or Integer Data Float Data The input data is handled in floating point format. For example 0,00. Integer Data The input data is handled as whole numbers. • Listen Only Module is configured and controlled by another controller and you can only monitor the module. Revision: Select the minor revision of the module.

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Electronic Keying: • Compatible Module Module can be replaced with a module of the same major revision and the same or higher minor revision. • Disable Keying No checking of replacement module • Exact Match Replacement module has to be the same Major and Minor revision.



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Output Range The output range is individually selectable for each channel. Hold for Init Holds the output signal unchanged until the output value (received from the controller) is within 0.1% of full scale of the value held. (Smooth transitions) Fault State Hold: remain at the last output value User: goes to a specific value if the connection to the owner controller is lost. If you select this button, enter a value in User Fault Value for the output to take upon fault. User Fault Value See Fault State and Ramp to fault. Ramp to Fault Enables ramping from current value to fault value when a fault occurs. Program State What should happen when the Controller goes into Program state. Hold: Remains at the last output value User: Goes to a value specified under User Program Value. User Program Value See above. Ramp to Program Enables ramping from Current Value to User Program Value.

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Rate Limit (Counts/sec) Enter the maximum rate of change in the output signal. This field is expressed in counts per second. Ramping outputs are updated approximately every 35ms. Communications Failure Self explaining Press Next. The next screen will provide information about the calibration of the module and is also used when calibrating. Press Next. The next screen will provide information about the module when you are Online. Press Finish. All of these screens are available after configuration by double clicking on the module under I/O Configuration.


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Ethernet Module When you have selected an Ethernet module (in this example a 1756-ENBT/ A with FW REV 3.6) you set the Major Revision (3) and press OK.

Name: A descriptive name so you can recognize the module in the configuration. IP Address: Select IP Address and type in the address you are going to use. Description: Description of the module (Optional) Slot: Select the slot number where the module is mounted. Revision: Select the minor revision of the module. Electronic Keying: • Compatible Module Module can be replaced with a module of the same major revision and the same or higher minor revision. • Disable Keying No checking of replacement module • Exact Match Replacement module has to be the same Major and Minor revision.

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Press Next.

Inhibit Module: Disables the module but keeps the configuration. Major Fault On Controller If Connection Fails While In Run Mode: Self explaining. Press Next. This screen is used if you use DeviceNet over Ethernet. Not used at Tetra Pak today. Press Next. The next four screens will provide information about the module when you are Online. Press Finish.


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DeviceNet Module When you have selected an DeviceNet module (in this example a 1756-DNB with FW REV 6.002) you set the Major Revision (6) and press OK.

Name: A descriptive name so you can recognize the module in the configuration. Slot: Select the slot number where the module is mounted. Description: Description of the module (Optional) Revision: Select the minor revision of the module. Electronic Keying: • Compatible Module Module can be replaced with a module of the same major revision and the same or higher minor revision. • Disable Keying No checking of replacement module • Exact Match Replacement module has to be the same Major and Minor revision. Input, Output and Status Size: This is how much memory should be reserved for DeviceNet and is determined by the number and types of modules connected to DeviceNet. Node: This is the node address for the DNB module in the DeviceNet network. The DNB module is the first address for the main net, that means Node:0.

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Press Next.


DeviceNet File (.dnt): Here you enter the association file that will connect the DeviceNet Scanner with the DeviceNet Network. Read more about this in the chapter covering DeviceNet. Don’t type in anything at this point. View and edit the DeviceNet network. When the network is configured and the correct association file is in place, this icon will become active. Pressing it will open RSNetworks for DeviceNet and display the Main Net.


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The next three screens will display information about the module and network when Online. Press Finish. When you have configured all the I/O modules in the rack you can open Controller Tags in Controller Organizer.

This is a list of all the addressable modules that we will use when creating program code.

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RSLogix 5000 Project Connect to a controller and Upload a project When connecting to a controller you first have to establish a connection path. Open RSLinx and make sure you have a driver for Serial or Ethernet connection configured and running. Also make sure you have the correct settings for the firewall on your computer. For information on how to do this refer to the RSLinx Software document in this manual. • Connect a Serial cable between the connector on the front of the Controller and your PC. OR Connect an Ethernet cable between the network adapter on your PC and the network switch in the machine. In RSLogix 5000 click on the RSWho icon in the Path toolbar. Serial connection: Select the Serial driver and press Go Online. Ethernet connection: Expand the Ethernet driver and locate the correct IP address. Expand the Ethernet module and then the Backplane. Select the controller and press Go Online.

If you don’t have a matching project on your hard disk you will get this dialogue. Press Select file.


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In the next window you have the option to browse for a matching project or to create a new. Press Select to continue.

Press Yes to create the file and upload the project from the controller. You are now connected and can start interacting with the PLC.

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Edit Ladder Logic There is a couple of different ways of making changes to the ladder code.

Offline You connect to the controller and Upload the project to your PC. You then go offline and make the changes. Once the changes have been made you go online with the controller and Download the changed project to the controller. To be able to download the changed project you have to stop the controller (and the machine).This is called Offline editing.

Online In Program mode

You stop the Controller (and the machine). To make a change to an existing rung: • Select the rung you want to change. • From the Logic menu, choose Start Pending Rung Edit. • The rung you selected is duplicated with pending edits. The original rung appears below the new rung and is shown with a lower-case “r” to its left. The new rung is shown with a lower-case “i” to its left. • Make the logic changes to the new rung. When you make a change, the lower-case “i” changes to a lower-case “e” until the rung verifies. You cannot make changes to the original rung. • When you have finished making changes to the rung and it verifies, select the rung. • From the Logic menu, choose Accept Pending Rung Edit. The new rung replaces the original rung. To insert a new rung: • Select the rung where you want the new rung to appear. • Click on the Add Rung button on the Instruction Toolbar. The rung you added displays with pending edits. It is shown with a lower-case “e” to its left. • Create the logic on the new rung. • When you have finished making changes to the rung and it verifies, select the rung. • From the Logic menu, choose Accept Pending Rung Edit. The rung transfers to the controller. To delete an existing rung: • Select the rung you want to delete. • From the Edit menu, choose Delete. The rung no longer appears in the routine.


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You make the changes while the Controller (Machine) is running. NOTE: Not all edits are possible when Online and running!

In Run mode

To make a change to an existing rung: Select the rung you want to change. • From the Logic menu, choose Start A Pending Rung Edit. The rung you selected is duplicated with pending edits. The original rung appears below the new rung and is shown with a lower-case “r” to its left. The new rung is shown with a lower-case “i” to its left. • Make the logic changes to the new rung. When you make a change, the lower-case “i” changes to a lower-case “e” until the rung is verified. You cannot make changes to the original rung. • When you have finished making changes to the rung and it verifies, select the rung. • From the Logic menu, choose Accept Pending Rung Edit. The new rung transfers to the controller. It displays as an insert zone with an upper case “I” to its left. The original rung is shown as a replace zone with an upper case “R” to its left. The new rung is not executed, however, the original remains executed until you test your changes. To insert a new rung: • Select the rung where you want the new rung to appear. • Click on the Add Rung button on the Instruction Toolbar. The rung you added displays with pending edits. It is shown with a lower-case “e” to its left. • Create the logic on the new rung. • When you have finished making changes to the rung and it verifies, select the rung. • From the Logic menu, choose Accept Pending Rung Edit. The rung transfers to the controller. It displays as an insert zone with an upper case “I” to its left. The new rung is not executed until you test your changes. To delete an existing rung: • Select the rung you want to delete. • From the Edit menu, choose Delete. The rung displays as a delete zone with an upper case “D” to its left. The deleted rung remains executed until you test your changes.

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To test your changes: • From the Logic menu, choose Test Program Edits to put the program in Test Edits mode. Test Edits mode affects all rungs with edit zones in the program. • To confirm that you want to test the edits, click on the Yes button. All of the insert zones and regular rungs are executed. The replace zones and delete zones are not executed. To keep your changes: • From the Logic menu, choose Assemble Program Edits. • To confirm that you want to assemble the edits, click on the Yes button. Insert zones convert to regular rungs. The replace zones and delete zones are removed. All of the rungs in the program are executed. The controller is placed back in untest edits mode. To cancel your changes before assembling them: • From the Logic menu, choose Untest Program Edits. • From the Logic menu, choose Cancel Program Edits. Replace zones and delete zones convert to regular rungs and insert zones are removed. All of the rungs in the program are executed.


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Creating a new project Under File menu select New.

Type: The dropdown menu contains a list of available controllers. Select the one you have in the rack. Revision: The firmware revision is written on a label on the side of the controller. Select the correct one. Redundancy Enabled: If you, for backup purpose, use two controllers in parallel running the same project this boxes should be selected. Not used in Tetra Pak. Name: Give the project a name. Description: Give the project a description (Optional) Chassis Type: Select the correct chassis type. Slot: Select in what slot the controller is mounted. (Can be in any slot.) Create in: Select where you want to save the project. When you have filled in all the information, press OK. Setup the I/O configuration.

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Enter Ladder code In the Controller Organizer you double click on MainProgram and then on MainRoutine. This will open up the MainRoutine in the Routine/Tags window. Rung 0 is already in place. Click inside the Routine/Tags window to activate the editing function. To enter new code into the ladder diagram you click on the function in the Language Element Toolbar. When you start, the Favorites tab is selected making some of the most common functions available. To find other functions, select a different tab. Note the scroll function for both the Element Buttons and Element tabs. More information on the different functions is available under Help-Instruction Help.

A helpful tool when editing code is the Undo and Redo function in the top row of icons.

Input Ladder Element (XIC) When you have placed a function in the ladder, in this case XIC (Examine if Closed), you need to give it a name. Double click on the question mark and type in a name. NOTE: You can NOT use spaces in the name. Instead you have to use “underscore” For example Input_1. Next you need to connect the function with a physical input. When you configured the I/O modules, references where created in Controller Tags. This is where you make the connection. Right click on the name and select “New Input_1”.


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Select Alias and click on the scroll down menu in Alias For. Select Controller Scoped Tags. Tag Type: • Base A memory location without hardware connection. • Alias A memory location linked to local hardware. • Produced A memory location linked to local hardware witch is then shared over network and can be used by remote Controllers. When you Produce a tag you have to state the maximum number of Consumers. • Consumed A memory location linked to hardware in a remote Controller and made available over network. Alias For: Path to the hardware connection for the Tag. Data Type: The data type that is going to be handled. Scope: Where the tag should be generated. • [Project name] (controller) Generated as a Controller Tag and is available in the entire project. • MainProgram Generated as a Program Tag and is available only in that Program Style: How the data should be displayed.

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Our Input module is located in slot 5 so expand Local:5:I.Data. Click on the scroll down menu next to DINT to se the different inputs. In this case we want to connect the function to the first Input of that module so select 0. The correct address should be Local:5:I.Data.0 • Local: It is a Local module. • 5: It is located in slot 5 in the rack. • I: It is an Input signal. (You also have 5:C which is Control bits for the module.) • Data: It is the Data part. (You also have Fault which is Fault handling for the module.) • 0: It is the first Input. NOTE: The data is sent as a DWORD (32 bit) so you get a selection of 0-31 but only 0-15 is connected to actual Inputs. This is what the Input should look like when it is configured.


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Output Ladder Element (OTE) When you have placed a function in the ladder, in this case OTE (Output Energize), you need to give it a name. Double click on the question mark and type in a name. NOTE: You can NOT use spaces in the name. Instead you have to use “underscore” For example Output_1. Next you need to connect the function with a physical output. When you configured the I/O modules, references where created in Controller Tags. This is where you make the connection. Right click on the name and select “New Output_1”.

Select Alias and click on the scroll down menu in Alias For. Select Controller Scoped Tags. Tag Type: • Base A memory location without hardware connection. • Alias A memory location linked to local hardware. • Produced A memory location linked to local hardware witch is then shared over network and can be used by remote Controllers. When you Produce a tag you have to state the maximum number of Consumers. • Consumed A memory location linked to hardware in a remote Controller and made available over network. Alias For: Path to the hardware connection for the Tag. Data Type: The data type that is going to be handled.

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Scope: Where the tag should be generated. • [Project name] (controller) Generated as a Controller Tag and is available in the entire project. • MainProgram Generated as a Program Tag and is available only in that Program Style: How the data should be displayed.

Our Output module is located in slot 6 so expand Local:6:O.Data. Click on the scroll down menu next to DINT to se the different outputs. In this case we want to connect the function to the first Output of that module so select 0. The correct address should be Local:6:O.Data.0 • Local: It is a Local module. • 6: It is located in slot 6 in the rack. • O: It is an Output signal. (You also have 6:C which is Control bits for the module and 6:I which is the Input feedback of the module.) • Data: It is the Data part. • 0: It is the first Input. NOTE: The data is sent as a DWORD (32 bit) so you get a selection of 0-31 but only 0-15 is connected to actual Outputs. This is what the Output should look like when it is configured.


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Remote modules So far we have only used Local modules i.e. I/O modules placed in the same rack as the Controller. As the maximum rack size is 17 that limit us to 16 I/O modules. In many cases that is not enough so we need a way to address modules in another rack. Those are called remote modules. First of all we need a way to communicate with the remote rack, a communication path. For this we use Ethernet. • Make sure that the Ethernet driver in RSLinx contains the IP addresses for both your local and the remote Ethernet modules. • Configure your local Ethernet module according to instructions in Configure I/O modules. • Right click on your local Ethernet module and select New Module. Configure a new Ethernet module using the data from the Ethernet module in the remote rack. As Comm Format use None. • Right click on the remote Ethernet module and select New Module. Now continue configuring the I/O modules in the remote rack in the normal way.

Configuration

When finished it could look something like this.

If you double click on Controller Tags in Controller organizer you will find that the remote modules are available and can be used in your project.

The addresses for these modules will be something like this.

Local_Input_1 is controlling Remote_Output_1 Remote_Input_1 is controlling Local_Output_1

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Produce / Consume In RSLogix 5000 it is possible for one controller to Produce data that other controllers can Consume.

Produce Data All Produced and Consumed data is handled in 32-bit sections. Even if you only want to produce a single bit you have to make all 32-bits available. Start by configuring the I/O you want to produce. Next step is to make the data available over the network. To do this we move the data to a shared location.

Place a Move function in the ladder code. (MOV under Move/Logical tab). Right click on the question mark next to Source and select New Tag.

Name: Give it a name so you will be able to recognize it. Description: Enter a description (Optional) Tag Type: Select Alias. Alias For: Select the module you want to produce. NOTE: You are addressing the entire 32 bit of data, not one specific bit. Data Type: Has to be DINT (32 bit).


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Scope: [Project Name](controller) Style: Decimal. Press OK to continue. Right click on the question mark next to Dest and select New Tag.

Name: Give it a name so you will be able to recognize it. This EXACT name has to be entered in the consuming project to be able to use the data. Description: Enter a description (Optional) Tag Type: Select Produced. Consumers: Select the number of controllers that should be able to consume this data. Data Type: Has to be DINT (32 bit). Scope: [Controller name](controller). As the data should be available to others it has to be a Controller tag. Style: Decimal. Press OK to finish. Save and download the project to the controller. Set the controller to Run mode. Now the data produced by the Digital input module of this rack is available over the network.

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Consume Data Configuration

To be able to consume data you need a path to the controller that is producing the data. For this we use Ethernet. • Make sure that the Ethernet driver in RSLinx contains the IP addresses for both your local and the remote Ethernet modules. • Configure your local Ethernet module according to instructions in Configure I/O modules. • Right click on your local Ethernet module and select New Module. Configure a new Ethernet module using the data from the Ethernet module in the rack of the producing controller. As Comm Format use None. • Right click on the remote Ethernet module and select New Module. Now continue configuring the Controller of the producing rack. When finished it could look something like this.

Right click on Controller Tags and select New Tag. Fill in the information according to the following.

Name: Give it a name so you are able to recognize it. Description: Enter a description (Optional) Tag Type: Select Consumed. Producer: Select the producing controller from the list. Remote Tag Name: Type in the EXACT Tag name from the producing controller.


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RPI (ms): Requested Package Interval. How often should the data be transmitted. Data Type: Has to be DINT (32 bit). Style: Decimal. Press OK to continue. If you now double click on Controller Tags the data from the producing controller is available. Double click on MainRoutine and place an Input function in the ladder code (XIC). Right click on the question mark and select New Tag.

Name: Give it a name In this case Consumed_0 to state that this is the first data bit of the consumed data. Description: Enter a description (Optional) Tag Type: Select Alias. Alias For: Locate the Consumed data in Controller tags and select the first data bit. Data Type: BOOL as it is a single bit we are handling. Scope: [Controller name](controller). Style: Decimal. The finished function should look something like this: Add a local output to the ladder code and test the function.

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MSG —Message The MSG instruction is used for sharing data between controllers. Compared to using produced/consumed tags, MSG is event triggered (data is only sent when there is a function triggering it) and is only sent out to one receiver at the time. We use MSG for communicating changes in recipe + interchange of state information (Blocked, Ready for Production, Production) between DE, FM, and LC.

Example To send information about the input switches From Simulator 1 to Simulator 2 and present the result on the outputs of Simulator 2.

Simulator 1 (Transmitter of MSG)

Configure the hardware so that the receiving Controller is present.

Receiving Controller

Create some logic where you trigger the message with an input.

Right click on the tag name (MSG_test), select New and create a Base tag. Click on the icon next to the Tag name to open the next window.


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Click on New Tag and make it an Alias for the data you want to transmit. In this example all the inputs from Simulator 1. Source Element: Select the new tag you created above. Destination Element: Select the tag name in the Receiving Controller. Open the Communication tab, click on Browse and set the path to the Receiving Controller.

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Simulator 2 (Receiver of MSG)

In this simulator you only need to configure one tag that match your settings in Simulator 1:s MSG instruction. If you use real HW outputs you also have to configure the hardware module. (Also controller name and network path must be the same as configured in Simulator 1)

No logic is needed in Simulator 2. The data is sent directly to the Output module.

Function test


Download the projects to the simulators and set them to Run mode. When you activate Switch 0 on Simulator 1 the status of the switches on Simulator 1 will be transferred to the Output module of Simulator 2. (The event is flank triggered so it will only transfer the status once every time you activate the switch.)

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Verify a project When you enter new or change existing ladder code it is good practice to verify that the code is working.



In the top-most toolbar of the RSLogix 5000 window you can choose either Verify Routine or Verify Controller. (The difference between them is that the Verify Controller searches for faults in all Programs and all routines while the Verify Routine only searches in the currently selected routine). The result is presented in the results window.

You can navigate between the different errors by pressing F4. Double clicking on an error will open up the program and highlight the error.

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Download a project To be able to Download a project to the Controller you need to have RSLinx configured with the correct driver, Serial or Ethernet depending on connection. How to do that is described in RSLinx Software. Click on the RSWho icon in the Path Toolbar of RSLogix 5000. If RSLinx is not running it will automatically start. If not start it from: Program-Rockwell Software-RSLinx-RSLinx Classic Click on the driver you are going to use. In this example we will use Ethernet. Locate the I/P address you are connecting to and expand it until you find the controller. Click on it and select Go Online. In the next window click on Download and then click on Download again to start the process. Before the project is downloaded it is verified. If you have one or more errors the download is aborted. Correct the problem and try again. Once the download has finished you are Online and can interact with the Controller. The Online Toolbar will show if you are in Program or Run mode.


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Controller Properties You have to be Online to get access to Controller properties. Click on the Controller icon. This will open a window with thirteen different tabs. The same settings are available by right clicking on Controller in Controller Organizer. General Provides general information about the Controller. Serial Port Lists the settings for the Controller Serial Port. System Protocol Configuration parameters for the serial port protocol. User Protocol Configuration parameters for the User protocol File Information on Filename and Path of the project in the Controller. Redundancy Two controllers in parallel for backup. Not used in Tetra Pak machines. Nonvolatile Memory Flash memory inside the controller where you can store a backup of the project. The function is described separately following this list. Memory Information on memory usage in the Controller. Major Faults Information on Major Faults in the Controller. Button to clear Major Faults. Minor Faults Information on Minor Faults in the Controller. Selectable list what Fault Bits to monitor. Button to clear Minor Faults. Date/Time It is important that Date and Time is correct. If not, log files and feedback will be of no value. Enter Date and correct Time and press Set. In this tab you can also select if this Controller should be the Coordinated System time Master. There are also four Indicators: Is the master, Synchronized with a master, Duplicate master detected and Timer hardware faulted. Nonvolatile Memory (Able to hold data without power) First screen on this tab displays information on the program currently stored in memory and also when and how it will be loaded.

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Press Load/Store to change settings.

The left part of the screen has the same information as in the previous window. There is also a button to Load the image from memory to the controller. In the right part you can set up when and how the image should be loaded to the controller. Name: Name of the project currently loaded in the controller. Type: Type of controller you are connected to. Revision: Firmware revision level of the controller. Load Image: When the image in the Nonvolatile Memory should be loaded. • On Power Up The image will be loaded every time the Controller is powered up. It can still be loaded manually. • On Corrupt Memory The image will be loaded if there is no working program in the Controller when it is powered up. It can still be loaded manually. • User Initiated No automated loading. The image can only be loaded manually Load Mode: Select the mode you want the Controller to go to after load. • Program (Remote Only) After the load the Controller will go to Program mode. The Controller key has to be in Remote. • Run (Remote Only) After the load the Controller will go to Run mode. The Controller key has to be in Remote. Image Note: Here you can write information about the Image. By pressing the Store button you store the project currently in Controller memory in Nonvolatile Memory.


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Forcing When faultfinding and interacting with a Project you often need to force Inputs and Outputs to a certain state. In RSLogix this is done in two steps. First you force the function you want to affect and then you enable the forces.

Inputs To force an Input you right click on it and select Force On or Force Off. The input icon will change to indicate that it has been forced. It will state either ON or OFF depending on the state it has been forced to. At this state the Input is still working like normal because the force has not been implemented yet. The Forces icon in the Online Toolbar changes to indicate that there is a force in place. No forces in place Forces in place but not enabled Forces in place and enabled

To implement the force, click on the red arrow on the Forces icon. Select I/O Forcing and then Enable All I/O Forcing. Click on Yes to confirm. The input icon will change to indicate that the force is now active. The input is now locked in an ON condition regardless of the status of the hardware it is connected to. To remove the force, right click on the Input and select REMOVE FORCE. If you want to remove all forces in the project you click on the red arrow on the Forces icon. Select I/O Forcing and then Remove All I/O Forces.

Outputs To force an Output, right click on it and select Force On or Force Off. The input icon will change to indicate that it has been forced. It will state either ON or OFF depending on the state it has been forced to. At this state the Output is still working like normal because the force has not been implemented yet. The Forces icon in the Online Toolbar changes to indicate that there is a force in place. No forces in place Forces in place but not enabled Forces in place and enabled To implement the force, click on the red arrow on the Forces icon. Select I/O Forcing and then Enable All I/O Forcing. Click on Yes to confirm. The output icon will change to indicate that the force is now active.

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The output is now locked in an ON condition regardless of the status of the hardware it is connected to. Note that the output does not turn green indicating that it is active as it would during normal operation. To remove the force, right click on the Output and select REMOVE FORCE. If you want to remove all forces in the project you click on the red arrow on the Forces icon. Select I/O Forcing and then Remove All I/O Forces. IMPORTANT: When you force an output the connected hardware will be activated BUT if the output has been reused as an input in another place in the project that input will NOT be activated. Another way of “forcing” is to just put a branch in parallel with the function(s) you want to force. Common procedure is to place a marker in the rung at the same time. The marker would be a XIO (examine if open) that is set as a base tag. The marker is placed there to be able to locate the forces later on. The marker could also state who has put the force there.

Find forces To locate all forces in a program use the find function. This can be reached in two ways: • Click on the Forces icon (on the text Forces) in the Online menu. A search icon will appear in the Online menu. Pressing this icon will open the Search menu ready configured to search for forces. Or: • Click on Search and then Find. Under Limit To: select Forces and then press Find All. This will generate a list of all forces in the program in the Results window. Found: Rung 0, XIC, Operand 0: XIC(Simulator_Input_0) Found: Rung 1, XIC, Operand 0: XIC(Simulator_Input_1) Found: Rung 2, XIC, Operand 0: XIC(Simulator_Input_2)

By double clicking on one of the lines the forced function will be displayed in the Routine/Tags window.


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Monitor data There are two tools available for monitoring data when you are Online with a controller, Trend Tool and Watch. Instead of scrolling in the project to see the status of specific functions it is possible to collect them in one place. That way it is possible to monitor them all at the same time.

Trend tool In trend tool the data is plotted in a way similar to an oscilloscope. Most programs come with a number of predefined trends all with different purposes and scenarios. Look in the documentation of the specific machine to find more information about these trends. It is also possible to quite easily create your own trends. • In the project tree structure right click on the folder called Trends and select New Trend.

• Give the trend a descriptive name and press next. In the next screen you can define what tags to trend by locating them in the list. Note that in the top menu you can select between global and local tags. When you have selected the tags press finish. It is also possible to add tags once the trend has been setup.

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This example is based on the Lab_1 exercise, subroutine 4. We have selected to monitor: • TON_timer_2.PRE • TON_timer_2.ACC • Pushbutton_00. To start and stop the trend there are buttons along the top of the window. To add or remove tags in an existing trend you first have to stop it. Right click in the middle of the graph window and select chart properties. Under the pens tab it is possible to edit the tags being monitored. Under X-Axis and Y-Axis tabs you can change the output value and the time span for the graph. To save the Trend.graph select the Log button and save as .csv file. This .csv file can be adapted later in Microsoft Office Excel. If you save the Trend.graph as a .TBS file, you are able to open the Trend Log in RSLogix 5000 again.

Watch Watch is available from the View menu and is displayed in the same window as Errors and Search Results. When you have started the Watch tool there are two possible watch lists selectable, Current Routine and Quick Watch. Current routine will display all tags in the current routine. This can be crowded if you have a lot of tags in it. In that case select Quick Watch instead. In this view you can select the specific tags to monitor.


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Find There are two different ways of using the find function. There is a Quick find function in the menu bar.

• Type in what you are looking for and press Find Next or Find Previous. If you press the Find all icon the search window will open. or • Under the Search menu select Find. This will bring up the Find in Routines window.

For more information about the different selections in this window press the Help button.

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Save and open projects Save projects To save a project select under “File” tab Save as…

• Select the path to where the project is supposed to be saved. • Save the project as an .ACD file. This .ACD file format can be opened later directly by double click or from RSLogix 5000 under ‘File’ and ‘Open’ new project. If you like to send a project via e-mail, the size of the project must be reduced. In that case save the project in .L5K format. From this file format generate a Zip-file. A real project the zip-file is about 20 times smaller than the original.


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Open projects To open a project select Open under the ‘File’ tab in RSLogix 5000.

• Now select the project from the list. If you select the .ACD file, the project opens directly. If you select .L5K files, a new window appears and asks you to where you want to save this Imported Project.

• Choose the path to where you want to save the project, select Import and the .L5K file are converted in a .ACD Project. RSLogix just opens up with this imported project. If you receive a project as Zip-file, unzip this file and follow the procedure to open .L5K files.

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RSLinx Software To setup communication between a PC and a PLC we need software called RSLinx. In RSLinx you can set up a number of different drivers. For now we only use two: Serial and Ethernet.

Setup of Serial communication driver • Start RSLinx. Click on the Configure Drivers icon.

• Select RS-232 DF1 devices from the pull-down menu and press Add New.

• Rename the driver or just press OK.


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• Make sure you have connected a Rockwell serial cable between your PC and the controller in the PLC and then click on Auto-Configure. RSLinx will automatically configure the driver. • Press OK and the driver will start. • Press Close to exit the driver setup.

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Network communications Setup of Ethernet communication driver • Start RSLinx. Click on the Configure Drivers icon.

• Select Ethernet devices from the pull-down menu and press Add New.



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In this window you need to enter all the specific IP addresses you want to communicate with. • Type in an address and press Add New. When all the addresses are entered press OK and the driver will start. • Press Close to exit the driver setup.

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Setup of Ethernet communication driver (with automatic browse function) When using this driver you don’t have to specify the individual I/P addresses you are going to communicate with. The driver will browse the network and display a list of available Ethernet modules. • Start RSLinx. Click on the Configure Drivers icon.

• Select Ethernet/IP Driver from the pull-down menu and press Add New.



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• Select Browse Local Subnet and then click on OK.

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Firewall settings To protect your computer when surfing the Internet you have a firewall that filters the traffic on TCP/IP. To enable RSLinx to communicate via this protocol we need to set up the firewall to allow traffic within a certain range of addresses. In this example we use Symantec Client firewall and TCP/IP address range from 10.0.0.1 to 10.0.0.99. Refer to the MM book for the correct procedure and settings. • Open Symantec Client firewall and select the Client firewall menu. Click on Internet Zone Control.

• With the Trusted tab open, click on Add.

• Select Using a range and type in a Starting and Ending Address. Refer to the MM book for the correct address range. • Select OK and then close Symantec Client Firewall.


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Configure TCP/IP on the PC To be able to communicate with the Ethernet module in the PLC you need to configure the Ethernet card in the PC.

• Right click on My Network Places and select Properties.

• Right click on the adapter you want to configure and select Properties.

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• Scroll down the list until you find Internet Protocol (TCP/IP) and double click on it.

• Select Use the following IP address. Fill in an appropriate address in the same range as the Ethernet module you are going to communicate with. In this example we use an address that is 100 or above for the last group. Refer to the MM book for correct settings. The only fields you need to fill in is IP address and Subnet Mask.


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Checking communication Click on the RSWho icon. From this window you can monitor what devices are connected to the different drivers. (On RS232 you only have one.) • Click on the plus sign next to the Ethernet driver to expand it. This will display a list of the different Ethernet modules connected to the current network. • If all modules are marked with red X make sure you have a network connection to your computer. • Also make sure the firewall on your computer is set up to allow traffic on the specified addresses. • By continuing expanding an Ethernet module and Backplane you get a list of the different modules in that PLC rack. This confirms that you have a working communication between your PC and the PLC. You can now close RSLinx. Make sure you use the cross in the top right corner or File-Exit. This will minimize RSLinks but leave it running.

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DeviceNet Introduction DeviceNet is a digital, multi-drop network that connects and serves as a communication network between industrial controllers and I/O devices. DeviceNet is based on the CAN prototcol. • • • •

Each device and/or controller is a node on the network. The DeviceNet system uses node numbers (0-63) as a base for addressing. The default ID for components shipped from factory is 63. DeviceNet has the feature of having power on the network. This allows devices with limited power requirements to be powered directly from the network, reducing connection points and physical size. • End-to-end network length varies with data rate and cable thickness. • A termination resistor equal to 121 Ohms 1%, ¼ W must be attached at each end of the trunk cable. The resistors must be connected across the blue and white wires of the DeviceNet cable. The DeviceNet network will not operate correctly without terminating resistors. • DeviceNet uses a trunk-line/drop-line topology.


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Cabling You can connect components using three cable options: Thick This cable can be used either for trunk- or for drop-lines. The outside diameter is between 0.41 and 0.49 inches. The maximum installed bend radius is 7x the cable diameter. Thin This cable type is used as the drop-line connecting device to the trunk-line. The outside diameter is in a range from 0.24 to 0.28 inches. This cable is more flexible than the thick cable. The maximum installed bend radius is 7x the cable diameter. MID This cable is used in instances where a smaller bend radius is required for the trunk line. It has an outside diameter from 0.31 to 0.35 inches and a bend radius of 7x the cable diameter. All of these cable types contain five wires: • one twisted pair (red and black) for 24VDC power • one twisted pair (blue and white) for signal and • one drain wire (bare). Color

Function

Usage

White

CAN_H

Signal

Blue

CAN_L

Signal

Bare

Drain

Signal

Black

V-

Power

Red

V+

Power

The distance of cable connected to the network must not exceed the maximum cable distance allowed for the data rate used. Network Size

125 KBPS

250KBPS

500KBPS

Thick Trunk Length

500m

250m

75m

Thin Trunk Length

100m

100m

100m

MID Trunk Length

420m

200m

100m

Max. Drop Length

6m

6m

6m

Cumulative Drop Length

156m

78m

39m

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Topology The following example uses four drop Tees and two Device box taps (DeviceNet drop multiports, DevicePort tabs) to attach 11 devices to the trunk-line. The cumulative drop line length is 37m and no single node is more than 6m from the trunk-line.


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Power supply The DeviceNet requires the power supply to have a rise time of less than 250ms to within 5% of its rated output voltage. Although thick cable is rated to 8A, the cable system can support a total load of more than 8A. For example a 16A power supply located in the middle of the physical media system can supply 8A to both sides of the power tap. It can handle large loads as long as no more than 8A is drawn through any single segment of the trunk line. Drop-lines, thick or thin are rated to a maximum of 3A, depending on the length. The maximum current decreases as the drop-line length increases. Drop-line length

Allowable current

1,5m

3A

2,0m

2A

3,0m

1,5A

4,5m

1,0A

6,0m

0,75A

• The voltage must be held (V- and V+) between 13V and 25V at each node. • Networks with long trunk-lines or with devices on them that draw large currents at a long distance sometimes experience difficulty with common mode voltage. If the voltage on the V- conductor differs by more than 4.65V from one point on the network to another, communication problems can occur. • You must ground the DeviceNet network at only one location. This should be done closest to the centre of the network. Make the grounding connection using a 25mm copper braid.

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Messaging CAN messages are transmitted as differentials between voltages on the CAN_H and CAN_L wires. CAN_H uses voltages slightly higher than those for CAN_L. This differential mode data bit architecture helps CAN and DeviceNet to operate well even with high levels of noise (i.e. from radiation sources like motors, welders, etc.). CAN signals have two states, dominant (0) and recessive (1). The transceiver on each DeviceNet device determines whether a signal is a 1 or a 0 based on the differential between CAN_H and CAN_L.

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RSNetWorx for DeviceNet Software configuration RSNetWorx for DeviceNet is a way of handling remote I/Os. DeviceNet is an open standard which mean that a lot of different companies manufacturer equipment that can be connected to DeviceNet. For a device to be recognized in a network you have to load its EDS file (Electronic Data Sheet). All EDS files has to be approved by the controlling organisation ODVA before use. If you need an EDS file, you normally find it on the manufacturers home page or on www.odva.org. Example of things that can be connected to DeviceNet is Point I/O Scanners, “smart” sensors/pushbuttons and motor controllers.

Hardware Some examples of parts that will be covered in this training: • DeviceNet scanner. This module is placed in the Main rack and is used to communicate with the Point I/O Scanner o 1756-DNB, ControlLogix scanner o 1769-SND, CompactLogix scanner • Trunk line cable The cable used to communicate between the DeviceNet Scanner and the Point I/O Scanner. It is also possible to connect special sensors, switches, motor controllers etc. directly on the trunk line. o Thick o Flat o Thin • Point I/O adapter This module is placed in the remote DeviceNet rack and it is basically two functions built into one module. It is acting as a bridge between the Main rack and the DeviceNet rack. One half is communicating with the DeviceNet Scanner in the main rack (MainNet) and the other half is communicating with the Point I/O:s in the remote rack (SubNet). o 1734-AND, Point I/O DeviceNet adapter • Point I/O:s This is the Input and Output modules connected to different sensors and actuators in the machine. o 1734-IB4, Digital Input module o 1734-OB4E, Digital Output module o 1734-IE2V, Analog Input module o 1734-OE2V, Analog Output module


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Addressing Each device in a DeviceNet network is called a node and has to have its own unique address, a node number. Maximum number of nodes in a network is 64 (node number 00 to 63). Normally the DeviceNet scanner is node 0 in the MainNet and the Point I/O scanner is node 0 in its SubNet. There can be more than one Point I/O adapter in a MainNet. Normally you avoid using node number 63. New modules have by default node address 63. When you replace a module in a network the default address of the new module (63) can be automatically set to the address of the module it is replacing. (More information under ADR below.) Point I/O:s get node addresses in sequence according to their position in the rack. For troubleshooting purposes it is possible to swap places on two identical modules. The modules will get a new address according to their new position in the rack. If you replace a Point I/O the new module will automatically get the correct node address but if you have special configuration settings you have to enter them manually. Point I/O:s are mechanically keyed to the slots according to their main function so it is impossible to by mistake swap for example a Digital Input with an Analog Input. NOTE: Some modules have the same keying even though they have different functions.

ADR (Auto Device Replace) ADR is built out of two parts which is Node Recovery and Configuration Recovery. Node Recovery is a function that replaces the node number of the new module with the one from the replaced. For this function to work there are two conditions. The replacement module has to be Configurable over DeviceNet and it has to have Node number 63 to begin with. Configuration Recovery will download the configuration settings for the replaced module from the scanner to the new module. The replacement module has to be Configurable over DeviceNet. Configuration Recovery files are stored in the scanner. Electronic key of the new module must match the settings for the replaced module that is saved in the scanner.

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EDS files (Electronic Data Sheet) To be able to communicate with the different DeviceNet components you need to have the correct EDS files loaded on your computer. The files are available on the different manufacturers’ home pages or on www.odva.org. There are two different places to load EDS files. The procedure is the same. 1. Start-Programs-Rockwell Software-RSLinx Tools-EDS Hardware Installation Tool. 2. Start RSNetworx for DeviceNet. Select Tools-EDS Wizard. Select Add and then select if you want to register a single file or a directory of files. Locate the file or directory and press Next. You will get a list of file(s), press Next. In the following window you can change the icon(s). Press Next. Final Task Summary will show you a list of device(s) (EDS:s) that will be added to your system. Press Next and then Finish. More information is available under Installation/Installing EDS files in this Workbook.


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Configuration The function of RSNetWorx for DeviceNet is based on configuration files, one for the MainNet and one for each SubNet.The MainNet file contains information about the devices (nodes) that are connected to the DeviceNet scanner via the trunkline. The SubNet files hold information about the devices (nodes) that are connected to each Point I/O scanner in its subnet. A Point I/O scanner is two nodes built in to one module. In the example below it is node 01 in the MainNet and node 00 in its SubNet. The purpose of the Point I/O canner is to act as a bridge between the Point I/O modules in the SubNet and the DeviceNet scanner in the MainNet.

Networks For each DeviceNet Scanner you have one Main network and one or more Sub networks.

DeviceNet Scanner

Point I/O Scanner

Point I/O Modules

MainNet

SubNet

To be able to address the DeviceNet modules you need to download some configuration files. These files are normally located on a CD in the machine. The files have the file extension .dnt. • Copy the RSlogix 5000 DeviceNet project from the CD to the project directory on your hard disk. • After copying, right click on the file and select Properties. Remove the Read-only Attribute. • Double click on the project to open it in RSlogix 5000. Connect to the controller in the machine and download the project.

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MainNet

Copy the DeviceNet files from the CD to your hard disk C:\DeviceNet and then remove the write protection from the files. Locate the MainNet.dnt file in C:\DeviceNet and double click on it to open the file in RSNetWorx for DeviceNet.

Online

Symbol Legend

Right click in this area to download to entire network

• Press the Online icon to go online with the MainNet. If you have more than one Ethernet module in the network you will be prompted for the online path.

• Locate the Ethernet module of the rack where the DeviceNet module is located. Expand the configuration tree until you find the DeviceNet network directly under the DeviceNet scanner. This is the MainNet. Highlight it and press OK. Press OK again.


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In the next dialogue press OK. The program will start to browse the network for nodes. If you know the number of nodes in the network you can press Cancel when you have passed that number. If you don’t, the program will scan all 64 node addresses and then finish automatically. You are now Online with the MainNet. When going Online, you might get a Not Equal icon on one or more modules. This is because the firmware information in the file does not match the one in the actual module. To solve this, right click on the module and select Resolve Device Mismatch. This will bring up a window stating the difference in firmware between the configuration and the actual module. Click on OK to solve the problem. Download MainNet file Downloading the configuration to the modules can be done in two different ways: • Module by module Right click on a module and select Download to Device. Click Yes to start the download. When the download has finished, right click on the next module and do the same thing. Continue until you have downloaded to all modules. • Entire Network Right click on the desktop and select Download to Network. Click Yes to start the download. This will download the configuration to all modules in sequence. When you have downloaded the configuration to the scanners close the MainNet in RSNetWorx for DeviceNet.

Locate the SubNet.dnt file in C:\DeviceNet and double click on it to open the file in RSNetWorx for DeviceNet.

Network menu

Online

SubNet 1

Symbol Legend

• Press the Online icon to go online with the SubNet. If you have more than one Ethernet module in the network you will be prompted for the online path.

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• Locate the Ethernet module of the rack where the DeviceNet module is located. Expand the configuration tree until you find the DeviceNet network directly under the Point IO DeviceNet Adapter. This is the SubNet. Highlight it and press OK. Press OK again. • Press the Online icon to go online with the SubNet. In the next dialogue press OK. The program will start to browse the network for nodes. If you know the number of nodes in the network you can press Cancel when you have passed that number. If you don’t, the program will scan all 64 node addresses and then finish automatically. You are now Online with the SubNet. When going Online, you might get a Not Equal icon on one or more modules. This is because the firmware information in the file does not match the one in the actual module. To solve this, right click on the module and select Resolve Device Mismatch. This will bring up a window stating the difference in firmware between the configuration and the actual module. Click on OK to solve the problem. Download SubNet configuration file • Right click on the Point I/O scanner and select Download to Device. • Click Yes to start the download. When you have downloaded the configuration to the scanners close RSNetWorx for DeviceNet. The DeviceNet network is now configured.


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RSNetWorx for DeviceNet Project Start Scanner To be able to address DeviceNet I/O modules, first of all you need to start the DeviceNet Scanner. This is done with a command in the first rung.

• In the first rung insert an OTE (Output Energize) and set Tag Type to Alias.

• In Alias For select Local:8:O.CommandRegister.Run. Local: It is a local module 8: The module is in slot 8 O: It is the Output part of the signals. CommandRegister: It is one of the modules Commands. Run: We want to activate the Run Command. When you start executing the program the DeviceNet Scanner will go from Idle to Run.


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Addressing of the modules The way the DeviceNet I/O modules are addressed is by mapping memory areas in the controller. To find out where the different modules are mapped we need to open up RSNetWorx for DeviceNet. • Make sure that the DeviceNet files are located in C:\Devicenet on your computer and that they are not write protected. • Double click on the DeviceNet scanner in I/O Configuration. • In the RSNetorx tab check that DeviceNet File (.dnt) is set to C:\Devicenet\main.dnt, then click on the Launch RSNetWorx for DeviceNet icon. If you have more than one Ethernet module in the network you will be prompted for the online path.

• Locate the Ethernet module of the rack where the DeviceNet module is located. Expand the configuration tree until you find the DeviceNet network directly under the DeviceNet scanner. This is the MainNet. Highlight it and press OK. Press OK again. • In the next dialogue press OK. The program will start brows the network for nodes. If you know the number of nodes in the network you can press Cancel when you have passed that number. If you don’t, the program will scan all 64 node addresses and then finish automatically. You are now Online with the MainNet. • When going Online, you might get a Not Equal icon on one or more modules. This is because the firmware information in the file does not match the one in the actual module. To solve this, right click on the module and select Resolve Device Mismatch. This will bring up a window stating the differences. Click on OK to solve the problem. (The information in the file is updated.) Save the file and download the updated information to the network. (Right click between the modules and select Download to network.)

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• Double click on the DeviceNet Scanner (normally node 00). • Under the Input and Output tabs you find the memory maps. Start by opening the Input tab. • Expand the tree structure to view the different inputs.

When you highlight a row in the top window the lower window will show you where it is mapped. In this example we have highlighted 01, Input Value #0 01: Tells you that this is Node 01 in this SubNet (normally the first module). Input Value: State that it is an Input Value. #0: The first input in that module. The lower window shows where the information from this input will be mapped in the Controller. All data is transferred from the DeviceNet Scanner to the Controller as 32-bit DWORDs. In the left column we read 8:I.Data[0] 8: DeviceNet Scanner position in Local rack (slot number) I: Input data. Data: Data part. You also have StatusRegister that we used to start the scanner. [0]: Indicating the first DWORD. In the right column we can se that this Input will be mapped to Bit 16 of that DWORD. By placing the cursor on the corresponding position in the row called Bits 31 – 0 you will get a call out stating what bit it is. The Alias for this input will be Local:8:I.Data[0].16


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If we scroll down the list of inputs we find 02, Status of Output #0 to #3. This is Status feedback of the output module (node 02). Next is 03,Input Value #0. This is the feedback from the first channel of the Analog Input module (node 03). The data from this channel will be mapped as Local:8:I.Data[1] bit 16-31. Further down the list you find Status and Alarm bits related to the Analog Input module. Finally you have Status feedback from the Analog Output module. The Output signals are mapped in the same way as the Inputs. If you highlight the first Output you will find that the Alias will be Local:8:O.Data[0].16

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RSLogix 5000 Compare Tool RSLogix 5000 Compare Tool gives you the possibility to compare two different projects. The tool is downloadable from Rockwell free of charge. Download path is: http://www.rockwellautomation.com/rockwellsoftware/downloads/ Category: Downloads Sub Category: Utilities Product: RSLogix RSLogix 5000 Compare Tool uses Microsoft software called .NET. If you are using Windows 2000 or XP it is most likely installed on your computer. Also, when installing RSLinx Classic (2.5), it should be installed. If you for some reason need to install it you find it here: http://v4.windowsupdate.microsoft.com/en/default.asp

Installation To be able to install this program you need to have Administrative rights on your computer. If you don’t have that, please contact your local IT responsible. • Unzip the downloaded file to your hard disk and double click on RSL5KCompare_Vxxxx.msi (xxxx stands for the version number) to start the installation. • On the welcome screen press Next to continue. • Accept the license agreement and press Next. • If you have RSLogix 5000 v13 or higher select Add Compare Tool to Tools menu and press Next. • Click Next to start the installation. • When the installation has finished press Close to exit. Now the compare tool is available from the RSLogix 5000 catalogue in the start menu.


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Comparing projects To compare two different projects start the Compare tool and select File-New. • In the Base Project field, enter the name and location of the first project you would like to compare. You can click on the Browse button to locate the.ACD or .L5K file on your hard drive or network. • In the Compare Project field, enter the name and location of the second project you would like to compare. You can click on the Browse button to locate the .ACD or .L5K file on your hard drive or network. • Check/uncheck the Include tag data values in compare checkbox, based on whether you wish to compare tag data values as well as tag properties. If you leave this box unchecked, only the tag properties will be compared. • Click on OK. The Compare process will begin. The Compare Tool will display a progress dialogue. Click on the Cancel button if you wish to terminate a comparison in progress. Once you have run a comparison, the RSLogix 5000 Compare Tool will show the Compare Summary, Base Project and Compare Project windows. The Compare Report is a formatted file, which displays the differences between the two projects you selected for comparison. The beginning of the report consists of a report summary section, with links to the more detailed sections in the body of the report. In these sections, the differences between the two files you compared are shown side-by-side, so that you can quickly see the differences between them. Note that you can search for specific pieces of information in this file, and navigate between the various items within it, but you cannot edit its content.

Compare Results Information displayed in the Compare Summary, Base Project, and Compare Project is colour-coded: • Red: Indicates items that exist in one project but not the other. • Blue: Indicates items that are common between the two projects but have a difference. For example, you might have a ladder routine that exists in both projects, but with a rung that doesn’t match, or a tag that exists, but contains different data. Double clicking on these items brings up more detailed compare information. • Black: Indicates common items that contain child elements. • Gray: Indicates common items in which no differences were found. These are for context only; no further details can be displayed.

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Compare Summary Pane The Compare Summary is an overview of detected differences, which consists of a tree that identifies the top level of the difference detected. For example, if the Base and Compare projects have no I/O differences, the Compare Summary would not show an I/O branch on the tree. Only items that have differences are listed in the Compare Summary tree.

Base Project Pane Displays information specific to the project selected as the base project.

Compare Project Pane Displays information specific to the project selected as the compare project. Ladder Logic routines are displayed in graphical form. An example is shown below.

Gray rungs indicate differences between the compared routines Red rungs identify items that are unique to that project. If the comparison detects a modified rung, the element(s) of the differing rungs may be further highlighted in blue. This typically occurs when the rung’s structure is the same, but some elements are different.


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RSLogix Emulate 5000 Software Setup To be able to communicate between RSLogix 5000 and RSLogix Emulate 5000 you need a communication path in RSLinx. • Open up RSLinx and click on Configure Drivers

• In the Configure Drivers window, select Virtual Backplane (SoftLogix58xx) and click on Add New. • Accept the default name by pressing OK. Close RSLinx. Start RSLogix Emulate 5000.

Slot 0 is always occupied by RSLinx driver. You can open it by right clicking on the icon and select Open RSLinx.


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• Right click on Slot 1 and select Create.

• Select Emulator RSLogix Emulate 5000 Controller and press OK. • Accept default settings by pressing Next and then Finish. • Right click on slot 2 and select Create.

• Select 1789-SIM 32 Point Input/Output Simulator. In the next screen press Next. • In the next screen type in a name for the module and then press Finish.

You should now have a Rack looking something like this.

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Using RSLogix Emulate 5000 Create a New project in RSLogix 5000.

Fill in the following information: Type: Emulator RSLogix Emulate 5000 Controller Revision: Select 12 Name: Type in a name for the project. Description: Type in a description for the project (Optional) Chassis Type: Accept the default 10 slot Chassis. Slot: Select the slot where you placed the Controller in Emulate. Create In: Select the path where you want to save the project.


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• In the Controller Organizer right click on I/O Configuration and select New Module. • Press Clear All and then mark Other. Select 1789-Module Generic 1789 Module.

• Type in a Name and slot number for the Module and configure it like this. Press Next. • For Requested Package Interval select at least 50ms and then press Finish. Under Options tab you can select if you want the Emulator to be Always On Top. • Open the MainRoutine, create a new rung and configure a new input.

The Input address would be something like this. NOTE: It is Data[1] • Continue configuring an Output.

The Output address would be something like this. • Save the project. To be able to download the project to RSLogix Emulate you need to set a communication path. • Click on RSWho icon in the Path toolbar. Expand AB_VBP-1, 1789-A17/ A Virtual Chassis and highlight RSLogix 5000 Emulate Controller. • Click on Download. • Change the controller to Run Mode. If you click on the door of the simulator module it will open, displaying the LEDs inside. Right click on the module and select Properties. On the I/O Data tab you can interact with the Inputs and monitor the Outputs of the module.

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5 Installation 1 RSLogix 5000 Installation . . . . . . . . . . . . . . . . . . . . . TM-01186 2 RSLinx Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-01187 3 RSNetWorx for DeviceNet Installation . . . . . . . . . . TM-01188 4 EDS files Installation . . . . . . . . . . . . . . . . . . . . . . . . . TM-01189 5 RSLogix Emulate 5000 Installation . . . . . . . . . . . . . TM-01190


RSLogix 5000 Installation To be able to install this program you need to have Administrative rights on your computer. If you don’t have that, please contact your local IT responsible. Insert the installation CD. Normally the installation program will start automatically. If not open the CD and double click on the file called setup.exe. This will bring up the installation dialogue screen.

• Select Install RSLogix 5000.

• On the next screen select Install Every Version.


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During the installation you will be asked for the RSLogix 5000 serial number.

• Type in the serial number for RSLogix 5000 from the side of the box. At the end of the installation you will be asked to activate the software. Selecting Yes will bring up the next screen.

• Put the activation floppy for RSLogix 5000 in the floppy drive and press OK.

• The next screen will list the license keys on the floppy. Just press Move to start the activation.

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• Once the keys have been moved you will get a summary of the operation. Press OK to continue.

• At the Setup Complete screen press Finish to complete the installation.

Moving Activation keys To move activation keys to or from the hard drive use the Move Activation – 32 Bit located in Programs – Rockwell Software – Utilities


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RSLinx Installation To be able to install this program you need to have Administrative rights on your computer. If you don’t have that, please contact your local IT responsible. Note that if you are upgrading from an earlier version you need to uninstall the previous version before starting the new installation. Insert the installation CD. Normally the installation program will start automatically. If not, open the CD and double click on the file called setup.exe. This will bring up the installation dialogue screen.

• Select Required Steps.

• Select Install RSLinx Classic.


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On the next screen select Next and then accept License agreement.

• Type in the serial number for RSLinx Classic from the side of the box.

• Accept the default selections by pressing Next. On the next screen press Install. During installation you may get one or two dialogue windows regarding language files.

• Just press No to continue the installation.

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• At the last dialogue window select Finish to complete the installation.

Remove Automatic start for RSLinx RSLinx is by default set up to start automatically when you start Windows. This could cause some problem because RSLinx will occupy COM 1 on the computer preventing other programs from accessing it. When you initiate communication from RSLogix, RSLinx will automatically start. If not, manually start it from Start-Program-Rockwell SoftwareRSLinx-RSLinx Classic. The following is an instruction how to set RSLinx to manual start.

• Right click on My Computer and select Manage.


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• Double click on Services and Applications.

• Double click on Services.

• Double click on RSLinx Classic.

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• For Start-up type change from Automatic to Manual. Press Apply and the OK. • Restart the computer for the changes to take place.


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RSNetWorx for DeviceNet Installation To be able to install this program you need to have Administrative rights on your computer. If you don’t have that, please contact your local IT responsible. Insert the installation CD. Normally the installation program will start automatically. If not, open the CD and double click on the file called setup.exe.

• At the startup screen select Required Steps.

• At the next screen select Install RSNetWorx.

• If you get a dialog stating that you have an old or no version of RSLinx just press OK.


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In the following window select Next to start the installation and then accept the license agreement by pressing Next.

• Fill in the serial number for RSNetWorx for DeviceNet. Note that there are a couple of different RSNetWorx.

• On this screen accept default settings by pressing Next.

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• In the next dialog window press Install to start the installation.

• When the installation is done make sure to deselect Install Activation Now and then press Finish. No activation is needed.


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EDS files Installation EDS stands for Electronic Data Sheet. EDS files are used to identify the different DeviceNet modules being used in the system. All modules have their own individual EDS file. The following is an instruction on how to install new EDS files.

• In RSNetWox for DeviceNet select Tools menu and then EDS Wizard. In the welcome screen select Next.

• In the options window select Register an EDS file(s). Then press Next.


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• Select if you want to register a single file or a directory of files. • Browse to the location of the file or directory and then press Next.

• In Installation Test Result window press Next to continue.

• In Change Graphic Image window press Next to continue.

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• In Final Task Summary window press Next to continue.

• Then press Finish.


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RSLogix Emulate 5000 Installation To be able to install this program you need to have Administrative rights on your computer. If you don’t have that, please contact your local IT responsible. Insert the installation CD. Normally the installation program will start automatically. If not, open the CD and double click on the file called autorun.exe. In the first screen select Install RSLogix Emulate 5000. • In the welcome screen select Next to continue. • Accept the license agreements by pressing Yes. • Fill in the serial number for RSLogix Emulate 5000 found on the side of the box. • Accept the default Destination folder by pressing Next. • Accept the default Program Folder and start the installation by pressing Next. • At the end of the installation select if you want to have a shortcut on your desktop. • When the installation is complete, select if you want to view the README file and if you want to move the Activation to your Hard Disk. Select at least to move the activation and press Finish.

• Insert the activation floppy (has to be write enabled) from the box and select to move from A: to C: then press OK.


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• Press Move to move the license from the floppy to your hard disk. • Press OK to finish.

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6 Troubleshooting 1 Troubleshooting, Using module LED’s . . . . . . . . . . TM-01102 2 Troubleshooting, Cross Referencing . . . . . . . . . . . . TM-01149


Troubleshooting Using module LED’s This section describes in brief the indicators on some selected ControlLogix modules. For more details or a complete module coverage, see the Online books in your RSLogix 5000 software (Help/Online Books/ControlLogix Manuals) or the Rockwell Automations Literature Library (http://literature.rockwellautomation.com/idc/).

Controller

Indicator

Colour

Description

RUN

off

The controller is in Program or Test mode.

solid green

The controller is in Run mode.

off

Either: • There is no devices in the I/O configuration of the controller. • The controller does not contain a project (controller memory is empty).

solid green

The controller is communicating with all devices in its I/O configuration.

flashing green

One or more devices in the I/O configuration of the controller are not responding.

flashing red

The chassis is bad. Replace the chassis.

I/O


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Indicator

Colour

Description

FORCE

off

Either: • No tags contain I/O force values. • I/O forces are inactive.

solid amber (yellow)

• I/O forces are active (enabled). • I/O force values may or may not exist.

flashing amber (yellow)

One or more input or output addresses have been forced to an On or Off state, but the forces have not been enabled.

off

There is no activity.

solid green

Data is being received or transmitted.

off

The battery supports memory.

solid red

Either the battery is: • not installed. • 95% discharged and should be replaced.

off

No power is applied.

flashing red

• If the controller is new: The controller requires firmware update. • If the controller is not new: Major fault occurred. To clear fault either: - Turn the keyswitch ->PROG ->RUN ->PROG. - Go online with RSLogix 5000 software.

solid red

The controller detected a non-recoverable fault, so it cleared the project from memory. To recover: (1) Cycle power to the chassis, (2) download the project, and (3) change to RUN mode. If the OK LED remains solid red, contact your Rockwell Automation representative or local distributor.

solid green

The controller is OK.

flashing green

The controller is storing or loading a project to or from nonvolatile memory.

RS232

BATT

OK

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I/O modules Digital input module

I/O State, point 0-7

OK indicator


LED indicators

This display

Means

Take this action

OK

green light

The inputs are being multicast and in normal operating state.

None

flashing green light

The module has passed internal diagnostics but is not multicasting inputs or it is inhibited.

None

flashing red light



red light


Replace the module.

I/O State

yellow

The input is active.

None

I/O Fault *

red



* available on some module types only


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Digital output module


I/O Fuse, point 0-7

OK indicator


I/O Fuse, point 8-15

LED indicators

This display

Means

Take this action

OK

green light

The outputs are actively being controlled by a system processor.

None

flashing green light

The module has passed internal diagnostics but is not actively controlled or it is inhibited.

None

flashing red light



red light


Replace the module.

I/O State

yellow

The output is active.

None

I/O Fuse

red

A short overload fault has occurred for a point in this group.

Check wiring for short overload. Check the module properties in RSLogix 5000 and reset the fuse.

I/O Fault *

red



* available on some module types only

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Troubleshooting Cross Referencing For troubleshooting it is sometimes useful to be able to cross reference different functions in a project. In what part of a project is a certain tag used, what function is connected to the tag in different places, etc.

In Ladder logic In ladder logic it is possible to right click on any Tag name and select Go To Cross Reference for “Name of tag.” This will bring up a cross reference list similar to the one shown in the example below. You can double click on any entry in the list and that will bring you to that place in the ladder logic.

Search function Click on the Search menu and select Cross Reference to open the tool.

Type: Select Tag Scope: Select if it is a Controller Tag (Global) or a Program Tag (Local) you are looking for. Show: Select show all. If you have a lot of references you can filter out some here. Name: Type in the name of the tag or pick it from the dropdown menu.


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This example shows a cross reference for Illuminator_00 in the Lab_1 exercise. You can double click on any entry in the list and that will bring you to that place in the ladder logic. Element: Shows the function of the tag in this rung Program: Shows the program where it is found. Routine: In what routine of the program. Location: In what rung in the routine. Reference: Under what tag name is it presented. Base Tag: What base Tag is it connected to. Destructive: • Yes The function is writing new information to the Base Tag (memory location), destroying the old information in there. • No The function is reading the information from the Base Tag (memory location).

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Cross Reference by module It is also possible to cross reference by module. Right click on, for example, the Digital Input module in your I/O configuration (slot 5) and select Cross Reference. Selecting the By Tag tab will show you all the cross references for that module.

Scope: Where is the reference located? • Lab_1 Global reference • MainProgram Local reference Tag: The tag name where it is used. Alias for: The Alias used for the Tag. BaseTag: The Base Tag connected to the Alias.


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7 Exercises 1 Exercise: Lab_1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-01147 2 Exercise: Counters . . . . . . . . . . . . . . . . . . . . . . . . . . TM-01136 3 Exercise: Timers - basic . . . . . . . . . . . . . . . . . . . . . . TM-01137 4 Exercise: Timers - advanced . . . . . . . . . . . . . . . . . . TM-01138 5 Exercise: Range - basic . . . . . . . . . . . . . . . . . . . . . . TM-01139 6 Exercise: Range - advanced . . . . . . . . . . . . . . . . . . . TM-01140 7 Exercise: Relational . . . . . . . . . . . . . . . . . . . . . . . . . . TM-01141 8 Exercise: Level supervision - basic . . . . . . . . . . . . . TM-01142 9 Exercise: Level supervision - advanced . . . . . . . . . TM-01143 10 Exercise: Analogue values - basic . . . . . . . . . . . . . TM-01144


Exercise: Lab_1 Rockwell basic In this exercise you will create several subroutines with basic and common ladder instructions. When you are finished with the task, download and evaluate the functions of the different instructions. After each task is finished, you will also step through the task along with your Instructor.

Task 1 Start with creating a new Controller called Lab_1, make sure that the type, revision, chassis size and slot number are correct. Add the following I/O Configuration to the project (make sure it match your system). If you don’t already know how to do it, ask your instructor for assistance.

Task 2 Under the MainProgram create Subroutine_1 as below.


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In Subroutine_1, enter in the following logic. Your instructor will guide you if needed.

Before you download, you must make a Jump to Subroutine in the MainRoutine. Create a rung like below in the MainRoutine.

Now you are ready to download, make sure you select the correct Path. Test and note the behaviour of the logic.


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Task 3 Create a second subroutine called Subroutine_2 and enter in the rungs below.

Note that you also have to create a second JSR instruction in the MainRoutine to call this subroutine. When you are finished, download the project to your controller and test the instructions. Ask your instructor for assistance if you need.


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Task 4 Create another subroutine called Subroutine_3 and enter in the rungs below.


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Again you have to create a JSR as below, this time DI_14 activates the logic.

When you are finished, download the project to your controller and test the instructions. When you have tested your new instructions, go to the Program Tags and click on the tab that says “Monitor Tags”. Expand the structure for the timers and counters. Note what happens when you activate your timers and counters. Ask your instructor for assistance if you need.


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5

Task 5 Enter in this rung in the MainRoutine.

Continue with the rungs below in Subroutine_4. When you are finished, download the project to your controller and test the instructions.


TM-01147


6

Task 6 Enter in this rung in the MainRoutine.

Continue with the rungs below in Subroutine_5. When you are finished, download the project to your controller and test the instructions.


TM-01147


7

Exercise: Counters Rockwell basic The number of parts inside the STORAGE should be counted. Note that the number should not be below 0.

STORAGE

IN


TM-01136


OUT

Exercise: Timers - basic Rockwell basic Example 1 Five seconds after is switched off, should go to 0.

5 sec.


TM-01137


1

Exercise: Timers - basic Rockwell basic Example 2 A timer should count from 0–10 sec, and then start over again automatically. Time (sec.)

Timer_2.ACC 10

0


TM-01137


2

Exercise: Timers - advanced Rockwell basic The output should go ON and OFF as shown in the time axis below. When it reaches the end it should start over again automatically.

1 sec.

2 sec. Start


TM-01138


0.5 sec.

3 sec. End

Exercise: Range - basic Rockwell basic Create a timer that goes from 0 to 255, and then starts over again automatically. The output should be ON between 90 and 120.

255 0

255

90 128 120


TM-01139

0


Exercise: Range - advanced Rockwell basic Use the same timer as in the “basic” exercise. This time output should be ON from 245 to 15.

245

0

15

128


TM-01140


Exercise: Relational Rockwell basic In the programming exercise “Counter” we made a simulation of a storage. In this exercise we like to use a Level monitor with LEDs to get a quick look at the status in the storage. The value in the storage is between 0 and 160. Example • When the value is greater than or equal to 10, the output should be ON. • Greater than or equal to 20: outputs and . • 30: , and • etc.


160

150

140

130

120

110

100

90

80

70

60

50

40

30

20

10

TM-01141


Exercise: Level supervision - basic Rockwell basic The level in a product tank is supervised with two level relays, detecting HIGH and LOW level. The product valve should open in order to fill the tank if the level in the tank is below LOW. The valve should be kept open until 5.5 sec. after HIGH level is obtained. An alarm should be activated if the level is bolow LOW for more than 10 sec.

Low level High level Product valve Low level alarm

The status of the level relays in the picture below are; LOW (1), HIGH (0). Low

High

Low level alarm Alarm reset Product valve


TM-01142


Exercise: Level supervision - advanced Rockwell basic The level in a product tank is supervised with two level relays, detecting HIGH and LOW level. The product valve should open in order to fill the tank if the level in the tank is below LOW. The valve should be kept open until 5.5 sec. after HIGH level is obtained. An alarm should flash when the level is LOW for more than 10 sec. The alarm is acknowledged by pressing the ALARM RESET button. If the level still is low, the alarm light should light up with a steady light and automatically go off when the level rises. If the level is not low when the ALARM RESET button is pressed, the ALARM should go off.

Low level High level Alarm reset Product valve Low level alarm

The status of the level relays in the picture below are; LOW (1), HIGH (0). Low

High

Low level alarm Alarm reset Product valve


TM-01143


Exercise: Analogue values - basic Rockwell basic In this exercise we like to display the level in the tube with the help of the LED's on a level monitor. Example When the analogue input is less than or equal to 3V the following outputs should be ON: , and .

Tube level 10 V

Floater

0V


TM-01144

10 V

9V

8V

7V

6V

5V

4V

3V

2V

1V


8


9


10


Wb_203_01 RS Logix 5000 Basic

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