Exercise ]

Familiarization with the PLC Trainer and RSLogix 500

EXERCISE OBJECTIVES

. To become familiar with the Lab-Volt PLC Trainer

. To run the RSLogix 500 sofiware.
. To enter the default project files path.
. To create and save a project file.

DISCUSSION

lntroduction to the Lab-Volt PLC Trainer, Model 3240.4

Note: lt you aro using one ot the following PLC trainer models: 3240-A,3240-3,
32704, or 9066, skip this pafi of the DTSCUSS/ON, which deals specilically
with Model 3240-4, and refsr to Appendix F through I of this manual for a
detailed description of the PLC model you are using. Then, go bacq to
Exercise 1 and proceed with the next D/SCUSSION section, entitled The
RSLogix 500 Software.

Programmable logic controllers (PLC'S) permit hardware control devices such as

relays, timers, counters, and drum controllers (sequencels) to be replaced by
programmable solid-state components and programmed instructions. To do so, a
ladder program, consisting of a set of instructions representing the logic to be
followed by the PLC, is developed, entered, and downloaded to the PLC. Once
placed in the Run mode, the PLC follows this logic to interpret the input signals sent
to it from input devices and operate its output devices accordingly.

The Lab-Volt PLC Trainer, Model 3240-4, features an Allen Bradley

MicroLogix 1200 PLC. This PLc can be programmed by using the RSLogix 500
software from Rockwell Software. A direct communication link (DF1 full duplex) is
used to connect the PLC to the computer that runs RSLogix 500, sparing the need
for any interface between them.

The PLC has 14 numbered inputs, Iabeled 0 through 13, and 10 numbered outputs
labeled 0 through 9. The trainer includes a built-in 24-VDC voltage for powering PLC
output devices.

Figure 'l-1 shows the front panel of the trainer.

. PLC inputs 0 through 13 are internally connected, through a PLC input interface,
to 14 pairs of plug-in jacks mounted at the right top of the front panel. Each pair
ofjack permits activation ofthe corresponding PLC input using a 24-VDC voltage
from an external PLC input device. Three momentary pushbutton switches and
four toggle switches, labeled 1 through I and mounted on the front panel, can be
used as PLC input devices: when connected to any of the PLC input jacks, they
permit activation of the PLC inputs with a 24-VDC voltage provided by the built-in
source of the trainer.

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 Familiarization with the PLC Trainer and RSLogix 500

. PLC outputs 0 through b are intemally connected, to 1O plug-injacks mounted at

the right middle of the front panel. The jacks each correspond to a pLC output,
and permit connection of external PLC output devices, such as relay coils and
actuators, that are energized or de-energized as the controller program is being
executed. The PLC outputjacks are hardwired to the built-in 24-VDC source and
are used for energizing the PLC output devices. Above each jacks is a light
indicating the status of the corresponding PLC output.

The features of the irainer front panel are described below (refer to Figure 1-j ).

1. Access door to th6 PLC input terminals

2. Memory module expansion compartmcnt: provides access to a lo_pin

connector for installation of an optional memory module and/or real-time clock.

3. RS-232 communication port (Primary port, or Channel-o port): used to

connect the PLC to the computer that runs the RSLogix 500 software, using a
serial cable (a 1761-CBL cable). The recommended protocol for this
configuration is DF1 full duplex.

4. 24V DC Power Supply: provides 24V DC to power the pLC outputs and the
different pushbuttons and toggle switches.

5. Trim pots: permit modification of data in a register of the controller (the

TPI register). Throughout the course, these potentiometers must not be
adjusted ortamperod with, as this will modify the content of the Tpl register.

6. Access door to the PLC output terminals

7. PLC output torminals

8. PLC output status indicators: LED'S indicating the current status (logic state O
o|l) ofthe bits associated
with PLC outputs 0 through g in the output data fite
of the PLC.

9. PLC input status indicators: LED'S indicating the current status (logic state O
or 1) ofthe bits associated with PLC inputs 0 through 1g in the input data file of
the PLC.

10. Analog Inputs and Outputs Expansion Card: part of Model 3244-40, this
PLC expansion card provides analog inputs and outpuls to the pLC trainer.

1 1- l/O bus interface connEctor: used to connect an expansion l/O module to the
controller, through a flat ribbon cable.

1-2
Familiarization with the PLC Trainer and RSLogix 500

@ @
@ oI
@ (o
@ @
.ll
@ (0
a) @
@

.6r"oa6rg"6t6.

Figure t-1. PLC Trainer, Model 3240-4 ffront view).

12. PLC status indicators: LED'S indicating the current status of the controller:

. POWER: this LED is on when the PLC is properly powered. lt is off when
there is no input power to the PLC or when a power error condition occurs.

. RUN: this LED is on when the PLC is executing a program in the Run
mode. lt is off when no program is being executed.

. FAULT: this LED is off when there is no fault. lt is on when the controller
hardware is faulty. lt flashes when a major hardware or software fault has
been detecied.

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Familiarization with the PLC Trainer and RSLogix 500

. FORCE: this LED is on when one or more PLC inputs or outpuls are forced
on or off. lt is off when no forces are installed.

. COMM 0: This LED is off when the controller is not transmitting data via the
PLC communication port (channel-o port). lt is on when the controller is
hansmitting data via this port.

. DCOMM: This LED is on when the controller is in the default

communication mode. lt is off when the coniroller is in the user-configured
communication mode.

13. Analog lnputs and Outputs Expansion Panel: provides connection to the
PLC expansion card (included with Model 324440).

14. Power lnlet and Switch: Connect the PLC Trainer from that inlet using the
appropriate power cord (included) to a standard wall AC outlet. The inlet also
includes the power switch to turn on and off ihe trainer.

15. Ac-line voltage RESET button: used to reset the breaker of the built-in
Ac-line voltage source of the trainer.

16. Fault Panel: twelve fault switches are located behind the fault panel door.
These switches creates, when turned on, electrical connections problemswhich
permits the student to troubleshoot the trainer.

17. P-SlM-to-PLC lnterface connsctor: used to connect the PLC Trainer to the P-
SIM io PLC lnierface, Model 3243, through a DB-25 flat cable. The interface,
which converts RS-232 signals into PLC signals, and vice-versa, is required for
the second level of the Lab-Volt PLC Training Program. lt allows the PLC to
controlanimated industrialprocesses on a computerwith the P-SlM Simulations
software, Model 91773.

18. Jacks ofthe 24V-DC power supply (4): provides 24V-Dc to external devices.

19. PLC Outputs: when PLC outputs are activated, a DC voltage of 24 V is applied
by a relay (from the PLC) to the iack to which external PLC output devices, such
as relay coils and motor drives can be connected.

20. PLC Output Lamps: these lamps are on when their PLC output is activated
(that is, when the bit associated with PLC output in the PLC output data flle is
at logic 1, or when this bit is forced on).

21. PLC Inputs: permit activation ofthe PLC inputs upon DC voltage of24 V. The
voltage can come from one of the eight switches mounted on the trainer front
panel, or from external PLC input devices rated at 24 V DC. lnputs 0 to 3 can
be used as high-speed inputs (up to 20 kHz).

22. Pushbuttons and Toggle Swilches: Two NO (normally open) pushbuttons,

two NC (normally closed) pushbuttons and four toggle switches are connected,
on one side, to the 24V-DC power supply and can be used to input this voltage
to PLC inputs.

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Familiarization with the PLC Trainer and RSLogix 500

The RSLogix 500 Software

The RSLogix 500 software is used to program and control Allen-Bradley PLC's with
a Po{ype computer. This software allows you to create, edit, and monitor PLC
ladder programs. It also allows you to document ladder programs, to store projects
(ladder program files and all other associated files) on disk, and to print complete
reports on a Pro.lect.

Running RSLogix 500

RSLogix 500 runs under the MicrosofP Windows@ environment. RSLogix 500 is
started by selecting the corresponding command in the Rockwell Software program
group. Figure 1-2 shows a view of the RSLogix 500 window upon creation ofa new
project. This window consists mainly of the following elements:

. A standard (main) toolbar which allows you to select a function from a se es of

menus.

. An online section with four scrollable bars that allow you to see the operational
mode ofthe PLC and whether or not online forces are installed.

. An instruction-insertion section with instruction-category tabs permitting the

selection of a category of instructions. When a category iab is selected, a toolbar
listing all the instructions (symbol or mnemonic) pertaining to the selected
category is displayed. An instruction is inserted in a rung of the ladder program
by clicking its bufton in the toolbar.

. An Add-ln button representing a portal to Visual Basic Applications (VBA).

. A Run Macro button used to display the Macro dialog box and execute, modify,
or remove a macro.

. A status barthat prompts you to take an action while you are using the software,
and that provides information relevant to the current file: flle and rung location of
the cursor, mode selected for the cursor entry, etc.

. A project tree, which contains allfiles associated with the current project. You can
usually click an icon in this tree and then click the mouse right button for a
functional menu that provides quicker access to relevant functional choices.

. A ladder view where you can observe the ladder logic file (program file) and edit
the ladder logic.

. A results window that displays the results of search and veritication procedures.

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Familiarization with the PLC Trainer and RSLogix 500

INSTRUCTION. INSTRUCTION-
INSERTION CATEGORY
SELECTION TNSTRUCTION
SECTION
TABS TOOLBAR

STANDARD (
(MArN)-l
TOOLBAR \

LADDER RESULTS STATUS

vtEw wlNDOW BAR
wINDOW

Figure 'l -2- The main elements in the RSLogix 500 window'
Familiarization with the PLC Trainer and RSLogix 500

Projscts
with
RSLogix 500 is based on projects. A project is a complete set of files associated
a looiJ oroqram. To create a project, the New command in the File menu must be
you to selectthe type of processor you
seleited. This causes RSLogix 500 to prompt
iril commrnicate with, and to create a project tree. Tflis tree is the entry point to all
iit", arso"iated with the newly created project. Figure 1-3 shows an example of a
.ioi"a tt"" as it appears in Rslogix 500. As you can see, a proiect consists of
leveral folders that contain files (controller files, program files, data files, etc')'

W Help
Cortrsller
Program Files
Dsta Files
Force Files
Custom Data Mrrnitors
Cffitom Graphical Monitsrs
Eecipe lvlonitors
Ddabase

EACH OF THESE BUTTONS

CAN BE CLICKED TO
EXPAND THE CORRESPONDING
FOLDERAND REVEAL THE
FILES IT CONTAINS.

Figure'13. Example ofa proiect tree in RsLogix 500.

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Familiarization with the PLC Trainer and RSLogix 500

Figure 1-4 is an expanded project tree that shows the files contained in the following
three folders: Controller, Program Files, and Data Files.

,;t 8@
i+jLl llelp
=.
& Cortroller
: i -. i cortroller Propedies
; , -$ erocessa $a*s
: :-S nrn tnn nres
: ;.. t!l! lo conrisuration
r , DE channel conliquration
F-lB Progran Files
i :'E svso-
ii ,-Ei
:...d8
svs r -
LAD2-
i 6 rie" oau
i :.-& cross neterence
. I H oo - ourpur
i , E n - upur
I :. .E s: - srerus
: : E m-er,ranv
I t...8 - 14 IrMER

i I .E cs - cor'rrea
: i-^.EI - coNTRoL R6

i :.-E N7 - TNTEGER
i :..E Fs - FLoAT
*-
L: kJ rorce rlles
j ..-E oo - ourPUT
, :. EI fi -Npur
i& custon Data Mooit(rc
&
:... Cuslom Graphical Monitors

i& Recipe Monnors

il. 13 Database
,
,. &. addressrsyobol
i.& hstruclion c.ommerts
i.& Rung cqnmefltsFage Title
, .E Addresstsymbol Picker
. '& symbol Groups

Figure 1-4. Proiect tree showing the files in the Controller, Program Files, and Data Files folders'

- The Controller folder consists of files that contain the controller properties, the
processor status, the function files, the inputs/outputs (UO) configuration, and the
communication channel configuration.

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Familiarization with the PLC Trainer and RSLogix 500

The Program Files folder can contain up to 256 program files. File SYS 0
(system program) is always included and contains the controller configuration.
File SYS 1 is always included and is reseNed for internal controller use. File
LAD 2 is always included and is the main ladder program. Program files 3 to 255
are optional and used to store subroutine programs.

The Data Files folder can contain up to 256 data files. The data files contain
status information on all the instructions in the main ladder program and its
subroutine(s), if any. There are several types of data files. The first ten data files
have defaull types, as shown in Table '1-1. Other data files can be user-defined
or will automatically be created by RSLogix 500 when additional data is to be
stored. For example, you can create and define these files for the storage of:

. bits, timers, counters, mntrol, or integer data; or

. programmable limit switch data (6-word elements); or
. double words, message word elements, and PID word files.

File Cross Reference Stores the cross-reference reoort.

File O0 - (OUTPUT) Stores the status of each PLC ouiout.
File l'l - (INPUT) Stores the status of each PLC input.
FiIe 52. (STATUS) Stores information on PLC operation.
File 83 - (BINARY) Stores binary data for internal relav loqic.
File T4 - (TIMER) Siores timer data (accumulated value, preset value,
and timer status bits).
File C5 - (COUNTER) Stores counter data (accumulated value, preset
value. and counter status bits).
File R6 - (CONTROL) Stores control data (length, pointer position, and
status bits) for shift registers and sequencer
instructions.
FiIe N7. (INTEGER) Stores numeric values or bit information.
File F8 (FLoAT) Stores a value with a range of 1 .1754944e-38 to
3.40282347 e+38.

Files 9-255 User-defined files

Table l-1. Default type data files.

A project, that is, the complete set of files associated with a logic program, is saved
by choosing either the Save or Save As command in the File menu.

Confi guring System Communications

System communications, that is, the communication betlveen a PLC and the
computer station that runs RSLogix 500, should be configured before creating a new
project. This is performed by choosing the Options command in the Tools menu.
This opens the System Options dialog box. Clicking the System Communications

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lamiliarization with the PLC Trainer and RSLogix 500

tab places the corresponding folder on top of the dialog box. Figure 1-5 shows the
System Communications folder of the System Options dialog box.

The driver settings should correspond to those made in RSLinx upon installation of
RSLogix 500 by your instructor, unless they have been modified since then. To learn
how to create an appropriate communication driver, ask your instructor (the
procedure is in the lnstructor Guide 36017-1)

PROCESSOR
NOOE
SELECTION
System Pre-rerehces System Communications lXFef iAddressWizard I

Cu ent sdtinqs
: Driver Fol..(e Processor
DRIVER Decimol{=1
SELECTION

l*Iffi-li*
r Last Configurcd
Confil
0ctal)

lae
EE-DF
orr.1

Fcply Timeout:
REPLY
TIMEOUT +lii'- ts"c.)
SETTING

DTL32.DLL ver

WDBV32LIB ver

Figure 1.5. Configuring system communications,

The Driver drop-down list allows you to select the type of driver used to link the
computer station to the PLC. The data field called Processor Node allows you to
enter the processor node. The data field called Reply Timeout field allows you to
change the value of the reply timeout. Once system communications are set as
desired, the System Options dialog box is closed by clicking the OK button. The
settings established in the Syslem Communications folder of the System Options
dialog box will be used upon creation of any new project, and will be applied when
you attempt to download a ladder program to the PLC.

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Familiarization with the PLC Trainer and RSLogix 500

Editing System Preferences

System preferences can be edited by choosing the Options command in the Tools
menu. This opens the System Options dialog box. Clicking the System
Preferences tab places the coresponding folder on top ofthe dialog box. This folder
provides various options that allow RSLogix 500 to be set according to your needs
and/or preferences. Among these options is the field called Proioct Files search
Path, This field allows you to select the path where you want your projects to be
stored.

Procedure Summary

ln ihis exercise, you will familiarize yourself with the main elements of RSLogix 500-
You will learn how to edit the projeci files path, configure system communications,
create a new project, see that the project tree is the entry poini to all files associated
with a project, and you will save a project to a file.

EQUIPMENT REOUIRED

Refer to Appendix A of this manual to obtain the list of equipment required to perform
this exercise.

PROCEDURE

Running RSLogix 500

! 1. Tum on the computer and start RSLogix 500.

! 2. Observe that there is no project tree nor is there any program file (ladder
program) displayed in the RSLogix 500 window. This occurs because no
project file has been created or opened so far.

Editing the Default Project Files Path

D 3. Choose the Options command in the Tools menu. This opens the System
Options dialog box. Select the System Preferences folder, and observe
that various options are available.

You can set the Project Files Search Path to the default path:

ClPROGRAM FILES\ROCKWELL SOFTWARE\RSLOGIX 5OO ENGLISH\PROJECT

You can enter another path if you want your project files be saved to
another location on the hard disk of the computer (or any other memory
media).

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 ramiliarization with the PLC Trainer and RSLogix 500

Configuring System Communications

! 4. Select the System Communications folder. The Current settings section

of this folder should indicate that the driver is an AB_DF1-{ and the
processor node is set to 1. These are the normal settings to be used, unless
otherwise specified by your instructor.

Set the Reply Timeout to 5 s, if it is not already set to this value.

Click the oK button to save the system options and close the system
Options dialog box.

Creating a New Project

D 5. Choose the New command in the File menu to initiate the creation of a new
project. This opens a dialog box that prompts you to type a processor name.
Type EXERC_I as the processor name.

! 6. ln the processor list, select the processor type on PLC Trainer

Model 3240-4, that is, Bul. 1762 MicroLogix 1200 Series C.

Note: For the standalone PLC Model 3270-4. select Bul. 1761
MicroLogix 1000;

For PLC Trainer Model 3240-4, or the Programmable Logic

Contrcller, Model 9066, select Bul. 1763 MicroLogix 1100
Serles A.

For PLC Trainer, Model3240-3, select Bul. 1764 MictoLogix 1500

LRP Sedes C.

! 7. Observe that the bottom portion of the Sslsct Processor Type dialog box
indicates the communications settings. These settings are the same as
those defined in the System Communications folder of the System
Options dialog box.

{l 8. Click the OK button in the Select Processor Type dialog box. This will
close this dialog box and create a new project in the computer memory.

The Project Tree

n 9. Observe that a project tree and file LAD 2 a(e now displayed in the
RSLogix 500 window.

Scroll through the EXERC_1 project tree to see all the flles it contains.

Which file contains the main ladder program?

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Familiarization with the PLC Trainer and RSLogix 500

! 10. Open data file 11 - INPUT. To do so, select it using the mouse, click the
mouse right button to display the context-sensitive menu, and choose the
Open command in this menu. A window will appear, showing the contents
of data file l{ - INPUT- This file is used to store ihe logic state of each of the
PLC inPuts.

Close data file 11 - INPUT by clicking the close button of the corresponding
window.

. Other files in the project tree can be opened using the same procedure.

The lnstruction Toolbar

E . Locate the instruction toolbar and the instruction-category

1 1 selection tabs in
the upper middle section of the RSLogix 500 window.

Click the User instruction-category selection-tab to select it, then place the
mouse pointer on one of the instruction buitons in the instruction toolbar
above this tab. Observe that a floating tooltip window appears and indicates
which instruction is associated with the button.

! 12. Click each olher instruction-category select;on tab while observing the
corresponding list of instruction buttons displayed for each category.
Describe what happens.

The Online Section

E 13. Locate the Online section in the RSLogix 500 window. Observe that this
section indicates that the operational mode is currently set to Offlin6. This
implies that the project you are working on is in the compute. memory, not
in the PLC memory.

Observe that the online section also indicates that no forces are applied,
as well as the driver type and the processor node number.

Saving a Project to a File

tr 14. The project created in this exercise only exists in the computer memory. To
save it to a file on the hard disk ofthe computer, choose ihe Save or Save
As command in the File menu.

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Familiarization with the PLC Trainer and RSLogix 500

This opens the Save Program As... dialog box. This box prompts you to
type a pro.iect filename (the processor name previously entered upon
selection of the processor type is suggested). Keep the processor name the
same as the project filename (EXERC-1).

Make the following observations:

. the path leading to the location where poect files are to be stored is
indicated at the top of the dialog box;

. the extension of project filenames is .RSS;

- you Gan include a revision note and a version numberwith the project
file.

Click the Save button in the dialog box. This will cause proiect EXERC_1 to
be saved in a flle named EXERC 1.RSS.

E 15. Choose the Close command in the File menu to close project file
EXERC_1.RSS. This will cause project EXERC_1 to be removed from the
computer memory and the RSLogix 500 window.

D 16. Close RSLogix 500. Turn off the computer.

CONCLUSION

ln this exercise, you became familiar with the main elements of RSLogix 500. You
sawhowto configurethe system communications and preferences. You learned how
to edit the path leading to the location where proiect files are saved. You created a
new project. You learned that a project is the complete set of files associated with
a logic program. You sawthat the project tree is the entry point to all files associated
with a project. You saved a project to a file.

REVIEW OUESTIONS

1. Name fourtypes of hardware controldevices that programmable logic controllers

(PLC's) permit to replace.

2. Before a ladder logic program can be edited, what must be done flrst?

3. What is the point of entry to all files associated to a project?

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Familiarization with the PLC Trainer and RSLogix 500

4. What are the three program files that are automatically generated upon creation
of a new Poect ?

5. Which program file contains the main ladder program?

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