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PLC Programming with
RSLogix 5000
How to Program Allen-Bradley
ControlLogix and CompactLogix PLCs with
Rockwell Automation’s RSLogix 5000

By Neal Babcock
engineer-and-technician.com
Copyright 2009 Modern Media
 Contents
Introduction ..................................................................................................................... 4
PLCs ............................................................................................................................... 5
Hardware......................................................................................................................... 6
ControlLogix Processor................................................................................................ 6
I/O Modules.................................................................................................................. 6
Software .......................................................................................................................... 7
Getting The RSLogix 5000 Software............................................................................ 7
Ladder Logic ................................................................................................................... 7
The Dialect of PLCs ........................................................................................................ 8
Equivalent Logic ............................................................................................................ 12
Project Scope................................................................................................................ 14
Summarizing the Scope ................................................................................................ 20
Which PLC? .................................................................................................................. 21
Lay Out The I/O............................................................................................................. 21
Assigning I/O Addresses ............................................................................................... 23
Running RSLogix .......................................................................................................... 24
Tags ........................................................................................................................... 35
Adding Descriptors To Your I/O ................................................................................. 37
Writing the Program ...................................................................................................... 42
Ladder View ............................................................................................................... 42
Setting Up An Overall Control Rung .......................................................................... 42
Starting a Batch Cycle ............................................................................................... 57
Batching Steps........................................................................................................... 67
Step 1 – Adding City Water........................................................................................ 67
The Tag Database ..................................................................................................... 70
Analog Inputs ............................................................................................................. 78
Setting up the Analog Input Card to Calculate Tank Weight ...................................... 79
Setting up the Analog Input Card to Calculate Tank Level........................................ 81
Back to Batching – Step 1.......................................................................................... 83
Step 2 – Adding Chemical KM ................................................................................... 89
Step 3 – Adding Chemical KM ................................................................................... 92
Step 4 – Blending....................................................................................................... 93
Step 5 – Pump to Filling Lines ................................................................................... 99
Faults .......................................................................................................................... 101
Valve Position Faults ............................................................................................... 101
Console Status Indicators – Pilot Lights ...................................................................... 108
Adding Rung Comments ............................................................................................. 115
Connecting To The PLC And Going Online................................................................. 119
RSLogix Emulate 5000................................................................................................ 122
RSLinx ..................................................................................................................... 122
Emulator................................................................................................................... 124
Editing in Run Mode .................................................................................................... 148
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Run Mode on the Plant Floor ...................................................................................... 153
Add-On Instructions & Function Block Diagram Programming.................................... 154
Creating a Function Block Diagram ......................................................................... 156
A Final Note About Our Program ................................................................................ 161
How Do I . . . ? ............................................................................................................ 162
Tips, Shortcuts and Warnings ..................................................................................... 164
Conclusion .................................................................................................................. 167

PLC Programming with RSLogix 5000

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 Introduction
The purpose of this book is to teach you how to set up, program and use an Allen-
Bradley ControlLogix or CompactLogix. It will also familiarize you with the parts required
for a common application.

It will tell you how to use RSLogix 5000 and how to write a ladder logic program.

Since I feel the best way to learn any programming language is by using a real-world
example, there is a sample project included in this book. This sample project, which
involves a chemical batching process, also contains a Project Scope. The Project
Scope, or Functional Specification, or whatever your company might call it, defines in
detail how the system is to operate when the project is finished.

You will learn, step by step, how to take a Project Scope and turn it into a working PLC
program.

The book will show you how to go online with your PLC to monitor your program to
verify your ladder logic and make sure it is functioning properly.

It will show you how to make changes to your program while you are online.

It will show you the keystrokes and mouse movements that you need to know to use
RSLogix 5000.

Finally, it provides a number of tips and a Frequently Ask Questions section that will
save you hours of frustration.

This book assumes you have a little background with PLCs – perhaps you have worked
with other PLCs from other manufacturers or you have helped to install and wire PLCs.
Perhaps you are a Mechanical, Chemical or Process Engineer and you need to learn
how to use RSLogix 5000.

If you need a more thorough understanding of basic PLC concepts, you might want to
try the Beginner’s Guide to PLC Programming How to Program a PLC (Programmable
Logic Controller). This ebook, along with the online tutorial, provides an example of how
to automate a drill press, while explaining all the basic concepts of PLC programming
that are necessary to write a solid PLC program.

The Beginner’s Guide to PLC Programming works well in conjunction with this book, in
that it concentrates on basic PLC programming methods that are common to all types of

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PLCs. In addition, it provides an example of machine operation, whereas this book uses
the example of a chemical batching process.

The Beginner’s Guide to PLC Programming is available from Modern Media for $9.95.
Visit engineer-and-technician.com if you would like to learn more about this book.

PLCs
Nearly all the industrial equipment that you find in a modern manufacturing facility
shares one thing in common - computer control. The most commonly used controller is
the PLC, or the Programmable Logic Controller, using a programming language called
Ladder Logic. The language was developed to make programming easy for people who
already understood how switches, relay contacts and coils work. Its format is similar to
the electrical style of drawing known as the “ladder diagram”.

The most popular and most widely used manufacturer of PLCs is Rockwell Automation,
who produces the Allen-Bradley ControlLogix and CompactLogix series of PLCs. The
ControlLogix and CompactLogix families of processors and I/O modules are all
programmed using Rockwell’s proprietary software known as RSLogix 5000.

When you are finished with this book, you will be able to sit down in front of any
computer running RSLogix 5000 and create a new program. You will be able to edit
existing programs. You will be able to professionally document any changes you have
made.

Rockwell Automation Technical Support

Unfortunately, we can’t anticipate all the problems you might face as you are
troubleshooting a program on the factory floor. There are just too many variables. This
is why you must establish a relationship with your local Rockwell Automation technical
support team. Get to know them before you are in the final stages of a start-up and you
run into a problem. They are very helpful and they can save you hours of frustration.

The Rockwell reps are not just technical support personnel; they are skilled engineers
that are responsible for running their own projects and writing and troubleshooting their
own programs. If you run into a problem, more than likely they have already seen it and
have come up with a solution.

PLC Programming with RSLogix 5000

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 Hardware
One of the nice things about Allen-Bradley’s smaller PLCs is the relative simplicity of
assembling the hardware to create a system.

First, let’s see what it takes to assemble a ControlLogix system. You only need to have
a few components: a processor, a power supply, a rack and some I/O modules.

ControlLogix Processor
At the time of this writing, there are 15 ControlLogix processors available. For our
application, the 1756-L55 processor will be fine.

For your future projects, you will have to consider a number of factors before you make
the choice of your processor. Utilize your Rockwell representative and Rockwell’s
website (www.ab.com) to help you in your choice.

All the processors use RSLogix 5000, so any program you write for one processor could
be adapted to run any other 1756 processor.

I/O Modules
For our system, we need discrete inputs, discrete outputs and analog inputs. These
modules will work fine for our application:

1756-IA16 Digital AC Input Module (16 discrete inputs)

1756-OA16 Digital AC Outputs (16 discrete outputs)

1756-IF8 Analog Modules (8 single-ended analog inputs)

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 Software
All ControlLogix and CompactLogix processors use RSLogix 5000 software to program
the PLCs. Admittedly, the software is a bit pricey, but in my opinion, it is worth it.

Getting The RSLogix 5000 Software

If you don’t have access to a PLC, it would be well worth the effort to download the
demo version of RSLogix 5000. The demo runs for 90 days, and has some limitations,
but you will be gaining experience with the real thing. Currently, the software is here:

http://www.rockwellautomation.com/rockwellsoftware/design/rslogix5000/demo.html.

There are 7 sections to download, totaling slightly over 480MB. Yes, it’s a big job to
download and install it, but it is essential.

Ladder Logic
Before we open RSLogix 5000 and start programming, there are a few things you need
to know about PLCs in general. I have summarized the basic terms and techniques
required to work with ladder logic. It isn’t a comprehensive summary, but if you are just
starting out, the information presented here will be very helpful.

Every PLC programmer, no matter what skill level, must know the principles described
in this section and the Equivalent Logic section. There is simply no way around it.

To effectively write a program, or even edit one, the programmer must know how to
visualize the effects of the changes he will make.

In other words, you have to be able to look at the logic “on paper” and imagine how the
logic will work when it is entered into the PLC.

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 The Dialect of PLCs
Lets' define some terms and symbols:

INSTRUCTION – RSLogix’s Relay Ladder Logic command language is comprised of

“instructions”. An XIC (it looks like a normally open contact --] [-- ) is an instruction. A
timer is an instruction. A few of the most common instructions are described below.

BIT - an address within the PLC. It can be an input, output or internal coil, among
others.

RUNG - A section of the PLC ladder program that terminates in an output function of
some type. Just like in an electrical ladder diagram, a rung has some type of output that
is turned on or turned off by the preceding entities in the rung. The first rung in a ladder
program is always 0.

HARDWIRED INPUT - a physical connection to the PLC from an input device (switch or
sensor, etc.).

RSLogix 5000 defines the address of the input, based on the input cards that you
configure.

We’ll see how this works later on, but here is an example of a hardwired input:

Local:4:I.Data.3

Here is what each part of the address means:

Local:4:I.Data.3
“Local” means that the module is connected to a controller across a backplane or with a
parallel link, keeping the module within a few inches of the controller.

Local:4:I.Data.3
“4” means that the module is module 4 (located in the 5th slot in the rack).

Local:4:I.Data.3
“I” means the bit is an input

Local:4:I.Data.3
“Data” indicates the type of data (this is the default for I/O)
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Local:4:I.Data.3
“3” indicates that the bit is 4th input on the card (the bits start with 0).

By the way, don’t get the capital “I’s” confused with ones.

So, in evaluating our example, we would describe the bit as “Module 4, bit 3”.

Here is where some confusion comes in. Because the Rockwell numbering system
starts with 0, and the processor resides in Slot 0, our example bit is actually in slot 5.
Our bit 3 is actually the 4th bit. We could also describe the bit as “Slot 5, position 4”.

You will have to learn to transpose these ways of describing a bit back and forth in your
head. If you are troubleshooting a problem, and you want someone to look for a signal
on our example bit, you might have to tell him to look at the 4th position on the 5th slot.
That will lead him to the physical point on the PLC.

However, you need to keep in mind that the corresponding bit in your program will be
labeled Local:4:I.Data.3.

It can be confusing, but you will get used to it.

HARDWIRED OUTPUT - a physical connection from the PLC to an output device (relay
or pilot light, etc.)

Outputs are addressed the same way.

Local:5:O.Data.4
“Local” means that the module is connected to a controller across a backplane or with a
parallel link, keeping the module within a few inches of the controller.

Local:5:O.Data.4
“5” means that the module is module 5 (located in the 6th slot in the rack).

Local:5:O.Data.4
“O” means the bit is an output

Local:5:O.Data.4
“Data” indicates the type of data (this is the default for I/O)

Local:5:O.Data.4
“4” indicates that the bit is 5th output on the card (the bits start with 0).

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INTERNAL COIL
This is a programmable bit used to simulate a relay within the PLC. The internal coil has
no connection to the outside world. It does not connect to an output card. Internal coils
are used to store information. The “contacts” of this “relay” can then be used multiple
times in other parts of the program.

RSLogix 5000 has greatly simplified the process of describing an internal coil. We can
simply give it a name, known as a tag.

For example, if you have an internal coil that is the result of, say, three hardwired safety
gate limit switches, we could label the coil “SafetyGatesClosed”.
Note the lack of spaces in the tag name. RSLogix 5000 does not allow spaces, or other
special characters, in the tag name.

Some people use underscores, so the tag might be “Safety_Gates_Closed”. Either way
is fine; it just depends on what your company or your client prefers.

TIMER
A timer is a programmable instruction that lets you turn on or turn off bits after a preset
time.

The two primary types of timers are TON for “timer on delay” and TOF for “timer off
delay”.

Timers in RSLogix 5000 use tag names for identification.

COUNTER
A counter is a programmable instruction that lets you turn on or turn off bits after a
preset count has been reached.

There are different types of counters available in the RSLogix, but the CTU (counter up)
instruction covers everything we will talk about here.

Counters in RSLogix 5000 use tag names for identification.

--] [-- Normally Open Contact

When used with a hardwired input, this instruction is off until there is a voltage applied
to the input. The bit address then goes high, or on, and the instruction becomes “true.” It

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works the same way when it has the same address as an internal coil, except that the
coil must be turned on by logic in the program.

Allen-Bradley calls these normally open contacts “XIC”, or “eXamine If Closed”

instruction.

An XIC instruction can reference a hardwired input, a hardwired output, an internal coil
or a timer done bit, among others.

--]/[-- Normally Closed Contact

This is an inverted normally open contact.

When used with a hardwired input, this instruction is "true" until there is a voltage
applied to the input. It then goes low, or off, and becomes “false.”

It also can be used with an internal coil, becoming true when the coil is off and
becoming false when the coil is on.

Allen-Bradley calls these normally closed contacts “XIO”, or “eXamine If Open”

instructions.

-( )- Output Coil
When used with a hardwired output, this function is off until the logic in the program
allows it to turn on. It then becomes “true”, and will energize the device that is wired to
the respective output.

If it is used as an internal coil, it will toggle the instructions associated with it. That is, it
will close a normally open instruction and open a normally closed instruction.

Allen-Bradley calls these outputs “OTE”, or “OutpuT Energize”.

An OTE may be used with a hardwired output or an internal coil.

TRUE – A state that indicates an instruction is allowing logic to “flow” through it.

Also, if the logic in a rung turns on the output of the rung, then the rung is said to be
true.

FALSE - Without stating the obvious, this is the opposite of true.

OK, that was a lot to cover and for you to understand – don’t worry, this will start getting
easier.

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 Equivalent Logic
Suppose we want to use a PLC to operate a pilot light. In its elementary form, PLC logic
is very similar to the hard-wired logic you would find in an electrical ladder diagram.

For example, if you wanted to turn on a light with a momentary pushbutton, you would
wire it like the circuit below. When you press PB1, the pilot light PL1 lights up.

H N
| PILOT |
| LIGHT |
| PB1 PL1 |
|---] [---------------------------------------(L)----|
| |
|

Now let's do the same thing in a PLC. To duplicate the hardwired circuit on a PLC, you
would wire the switch PB1 to an input (let’s use Local:4:I.Data.3) and wire the light PL1
to an output (Local:7:O.Data.0).

The I/O (hardwired inputs and outputs) is set up like this:

- There is a “PB1” pushbutton switch wired to Local:4:I.Data.3 of the PLC.

- There is a “PL1” pilot light wired to Local:7:O.Data.0 of the PLC.

In RSLogix 5000, the screen would look like this.

Now let’s examine the sequence of events. When you first turn on the PLC, the PB1
pushbutton is off, or false. Therefore, the PL1 output is off. Pressing PB1 will make
Local:4:I.Data.3 true, Local:7:O.Data.0 will come on and the light will be energized. It
will stay on only as long as you hold the button in.

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Just like electrical current has to flow through the switch to turn on the light in the
hardwired circuit, the logic has to "flow" through the normally open instruction (which is
“closed” when you press the switch) of Local:4:I.Data.3 to energize the output that turns
on PL1.

The green highlight indicates the instruction, is “on” or “true”.

One nice feature of Allen-Bradley PLCs is that you can document each bit in the
program. In the example above, “PB1” is somewhat meaningless on its own. After you
add the descriptive text “Start Motor PB1”, things make more sense.

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 Project Scope
We will use a batching operation as an example. Batching, as you may know, is the
term that describes the mixing of assorted ingredients to make a finished product.

There are techniques that are common to batching, whether you are making soap or
cake mix. We are going to write a program that mixes a hypothetical window cleaner.

Someone has to define the batching procedure. Usually, this is done by a process
engineer or a chemical engineer. If the job of defining the project is done well, a
document called a Project Scope (or something similar) is generated.

It is extremely important that you clearly understand the entire process that is defined in
the scope. If you have any questions or concerns, you need to resolve those before you
begin programming. If you don’t, then the responsibility of errors and omissions, and
perhaps the blame, may be placed on you.

If you bring up questions that result in changes to the defined sequence of operations,
ask the originator to revise the Project Scope. In fact, it is not uncommon for a Project
Scope to undergo a number of revisions.

If there is a change that is not documented in the scope, you should document it by
getting an email from the originator that explains the change. If nothing else, you want
to make sure you understand what the change involves.

For our project, the project scope is as follows.

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 Hyper-Glass Cleaner
Batching Project Scope

Goal
The goal of this project is to install a new automated batching system for mixing Hyper-
Glass Cleaner.

Overview

Three ingredients (city water, ingredient QR and ingredient KM) are added in specified
amounts by weight to the Mixing Tank. After all the ingredients have been added to the
Mixing Tank, the mixture is blended by running the agitator for a given time. When the
blending time is complete, the finished product is pumped to the Filling Lines for bottling
and final packaging.

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System Components

Component Function
Valve AV-CW Supplies city water to the Mixing Tank
Limit Switch LS-CW1 Indicates when valve AV-CW is closed
Limit Switch LS-CW2 Indicates when valve AV-CW is open
Pump PUMP-QR Pumps ingredient QR to the Mixing Tank
Valve AV-QR Supplies QR to the Mixing Tank
Limit Switch LS-QR1 Indicates when valve AV-QR is closed
Limit Switch LS-QR2 Indicates when valve AV-QR is open
Pump PUMP-KM Pumps ingredient KM to the Mixing Tank
Valve AV-KM Supplies KM to the Mixing Tank
Limit Switch LS-KM1 Indicates when valve AV-KM is closed
Limit Switch LS-KM2 Indicates when valve AV-KM is open
Scales Provides the current weight of the
ingredients in the tank to the PLC
Agitator MTR-MTA Blends the ingredients in the Mixing Tank
Pump PUMP-MT Pumps ingredient MT from the Mixing
Tank
Valve AV-MT Supplies the finished product to the Filling
Lines
Limit Switch LS-MT1 Indicates when valve AV-MT is closed
Limit Switch LS-MT2 Indicates when valve AV-MT is open
Ultrasonic Level Sensor ULS-1 Indicates the level in the Mixing tank

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Operator Panel Layout

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Operator Panel Components
Component Function
SYSTEM READY pilot light PL1 Indicates the system is ready for batching
SYSTEM FAULT pilot light PL2 Indicates the system has a fault and is
stopped
START BATCH pushbutton switch PB1 Starts a new batch
STOP BATCH pushbutton switch PB2 Stops the batching process
ADDING WATER pilot light PL3 Indicates the system adding water to the
Mixing Tank
ADDING QR pilot light PL4 Indicates the system adding ingredient QR
to the Mixing Tank
ADDING KM pilot light PL5 Indicates the system adding ingredient KM
to the Mixing Tank
BLENDING pilot light PL6 Indicates the system is blending the
ingredients
PUMPING TO LINES pilot light PL7 Indicates the system is pumping the batch
to the Filling Lines
E-STOP PB3 Immediately stops the entire system

Electrical Specifications

The Ultrasonic Level Sensor ULS-1 provides a 0-10VDC signal to the PLC.

The Scales provide a 0-10VDC signal to the PLC.

All other input signals are 120VAC.

All output signals are 120VAC.

Detailed Sequence of Operations

There are 5 steps in the Batching process:

1. Add City Water

2. Add Ingredient QR
3. Add Ingredient KM
4. Mix the batch
5. Pump the batch to the filling lines

To begin a new batch, the operator will verify that the “SYSTEM READY” pilot light is on
and that the Mixing Tank is ready to receive ingredients.

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The operator will then press the “START BATCH” pushbutton to begin the batching
process. The “SYSTEM READY” pilot light will turn off. No further operator input is
required.

Step 1 – City Water

Automatic valve AV-CW will open. The “ADDING WATER” pilot light will illuminate.

Valve AV-CW will remain open until 1275 lbs. of City Water is in the Mixing Tank. Valve
AV-CV will close.

The state of AV-CW will be verified by limit switch LS-CW2. If LS-CW2 is not made
within 2 seconds after the valve was told to open, a fault will be generated and the
system will shut down. The pilot light “SYSTEM FAULT” PL2 will illuminate indicating
that a fault has occurred.

LS-CW1 will verify that the valve is closed within 2 seconds after the valve was told to
close. If the valve closure is not verified within 2 seconds, a fault will be generated, the
system will shut down and PL2 will illuminate.

All valves and their respective limit switches will work in the manner described above.

After the City Water has been added, valve AV-CW will close and the “ADDING
WATER” pilot light will turn off.

Step 2 – Ingredient QR
Valve AV-QR will be opened. After the valve position has been verified by LS-QR2,
PUMP-QR will pump 390 lbs. of ingredient QR into the Mixing Tank. The “ADDING QR”
pilot light will be illuminated while the pump is running.

After the ingredient QR has been added to the Mixing Tank, PUMP-QR stops and the
“ADDING QR” pilot light will turn off. Valve AV-QR will close.

Step 3 – Ingredient KM
Valve AV-KM will be opened. After the valve position has been verified by LS-KM2,
PUMP-KM will pump 173 lbs. of ingredient KM into the mixing tank. The “ADDING KM”
pilot light will be illuminated while the pump is running.

After the ingredient KM has been added to the Mixing Tank, valve AV-KM will close.
PUMP-KM will stop. The “ADDING KM” pilot light will turn off.

After LS-KM1 indicates the valve has been closed, the agitator motor MTR-MTA will
start. The “BLENDING” pilot light will illuminate.

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Step 4 – Mixing
The agitator will run for 3 minutes. The “BLENDING” pilot light will illuminate.

After the agitator is finished, The “BLENDING” pilot light will turn off.

Step 5 – Pump to filling lines

Valve AV-MT will open. After LS-MT1 indicates the valve is open, the “PUMPING TO
LINES” pilot light will illuminate.

PUMP-MT will pump the entire batch to the filling lines. When the Ultrasonic Level
Sensor ULS-1 indicates that the tank is empty, PUMP-MT will turn off, valve AV-MT will
close and the batching cycle is complete. The “PUMPING TO LINES” pilot light will turn
off and the “SYSTEM READY” pilot light will illuminate.

During every phase of the batching process, the liquid level must be monitored by the
PLC. If the level rises to greater than 95% of that Mixing tank’s capacity, the system will
generate a fault and the batching process must be halted.

The operator may press the “E-STOP” pushbutton PB3 to stop the process at any time.

END OF HYPER-GLASS CLEANER BATCHING PROJECT SCOPE

Summarizing the Scope

So, what did we get from the scope? Let’s summarize:

First, 1275 lbs. of water will be added to the Mixing Tank. Then, 390 lbs. of QR will be
added. The last ingredient is KM, of which we will add 173 lbs.

After all the ingredients are in the Mixing Tank, we have to blend it for 3 minutes.

After the batch is blended, we will pump the finished product in the tank to the filling
lines.

We have to make sure all the valves open or close in less than 2 seconds. If they do
not, then we need to shut down the process.

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We need to turn on the appropriate pilot lights to indicate what stage the batching
process is in.

We need to make sure the level in the Mixing Tank doesn’t get too high. If it does, we
must shut down everything.

We need to make sure that the respective valves for the pumps are open before we turn
on the pumps.

Which PLC?
There are certainly a number of factors that will determine which PLC you need. Without
getting into all of those, let’s just say that the 1756-L55 processor has plenty of
processing power for this project and the cost is reasonable, so we will use one.

Before you can determine what modules, rack or power supply you need to buy, you will
have to know what your I/O requirements are. This involves the very critical step of
laying out your I/O.

A bit of advice here: Don’t skimp on this step. Make sure the I/O is right before you
begin programming. A mistake or omission here will cost you ten-fold further down the
road.

Lay Out The I/O

Now we need to layout the I/O. This will tell us the addresses for the I/O points, what
PLC modules we need and how the PLC modules need to be wired.

There are three types of signals in the batching system: 120VAC digital inputs (limit
switches and pushbutton switches) 120VAC digital outputs1 (valves, motors and pilot
lights) and analog 0-10VDC inputs.

List all of the components in the system that are connected to the PLC. Categorize each
component according its type (digital input, digital output or analog 0-10VDC). It is best

1
Technically, the valves themselves are not 120VAC devices, but in this case, the solenoids that
subsequently drive the valves are. Likewise, the motors that run the pumps and the agitators may not be
120VAC, but the control circuitry that operates the motors is 120VAC.
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to do this in an Excel spreadsheet. I have provided one for this project – it is called
IO_List.xls and is included in the files you downloaded.

Try to keep associated devices together. For example, the “ADDING WATER” pilot light
should be near Valve AV-CW. This will make the electrical prints easier to read and also
help to keep the PLC program organized.

Notice the “Descriptor” column. This is a statement providing a shorthand description of

the device when the associated input is on, or true. We will use these descriptors in the
actual PLC program.

I can’t stress how important it is to get the verbiage right in a descriptor. For example,
let’s look at LS-CW1. This particular limit switch is normally open, but held closed when
the valve is closed.

When the limit switch is closed, the input to the PLC will be on.

If we used the descriptor

Limit Switch
LS-CW1

that wouldn’t tell us too much without referring to the prints. Plus, it is a little redundant,
as we know it is a limit switch based on the “LS” prefix in the device name.

If, however, we use the descriptor

City Water
Valve AV-CW
Closed
LS-CW1

then that tells us immediately, without referring to the prints, that the City Water valve is
closed as indicated by the limit switch LS-CW1.

After you go online with a PLC, if an input is energized (when used with a normally open
instruction), the symbol for the bit is highlighted. You can quickly realize the descriptor
statement is currently true.

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 Now we must determine what input and
output modules we need.

This is a good time to call The Project Scope said that the Scales and
your local Allen-Bradley the Ultrasonic Level Sensor provide 0-
representative and have him assist 10VDC signals. We can use an Allen-Bradley
you in selecting the parts you
1756-IF8 Analog Module.
need. He can work directly from
your I/O listing and probably save
you a bunch of time. For the inputs, we can use the 1756-IA16
Digital AC Input Module. Since 11 inputs are
needed for the system, this card will provide 5 spares.

For the outputs, we will use a 1756-OA16 Digital AC Outputs Module.

We still need a rack to hold our processor, the I/O cards and a power supply. We are
not going concern ourselves here with the rack or the power supply, as this doesn’t
have much effect on our programming. Suffice to say, try to select components that will
provide the space and flexibility for future expansion.

Assigning I/O Addresses

Here is the final layout for the cards in the rack:

Slot 0 – 1756-L55 processor

Slot 1 – 1756-IF8 Analog Modules (8 single-ended analog inputs)
Slot 2 – 1756-IA16 Digital AC Input Module (16 discrete inputs)

Slot 3 – 1756-OA16 Digital AC Outputs (16 discrete outputs)

Please refer to the I/O List spreadsheet and you will see how the I/O has been
assigned.

A final note about the I/O list – take the time to do it right and keep it updated as the
project progresses.

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 Running RSLogix
To run RSLogix, click:

Start > All Programs > Rockwell Software > RSLogix 5000 Enterprise Series > RSLogix 5000

A quick side note about conventions used in this book:

We are going to use the format shown above to indicate what menu items you should
click on as you navigate the menus and sub-menus.

For example, the line above means:

Click on “Start”.

Click on “All Programs”.

Click on “Rockwell Software”.

Click on “RSLogix 5000 Enterprise Series”.

Click on “RSLogix 5000”.

Your path to start RSLogix, depending on the version you have installed, may be slightly
different.

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You will see this on your monitor.

By default, RSLogix 5000 displays a “Start Page” every time the program is
started. Most people don’t use this and choose to turn it off.

Select Tools > Options and uncheck “Show Start Page on Start Up”.

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To open a new programming, choose

File > New

In the Type: dropdown, select “1756-L55”.

In the Name field, type in “BATCHING”.

In the Chassis Type: dropdown, select the seven slot “1756-A7” chassis.

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Click “OK” and this screen will appear.

On the left, you see an explorer-type menu. This is called the Controller Organizer. All
of these folders and files allow you to configure or view properties of the PLC or data
files within the PLC.

Tip: You can toggle the

Controller Organizer by pressing
ALT-0

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The first thing we need to do is configure the I/O. Scroll down in the Controller and right-
click on “I/O Configuration”. Choose “New Module”.

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Expand the “Analog” section.

Select “1756-IF8” and click “OK”.

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Click “OK” on the next dialog box and the “Module Properties” window appears.

This window allows you to configure many aspects of the analog card, including:

- scaling (per channel)

- input range (voltage or current, per channel)
- alarm configuration (per channel)
- calibration gain and offset (per channel)

We will adjust these later; for the time being click “OK” to accept the default values.

Let’s add the discrete input card. Right-click on “I/O Configuration” and select “New
Module”.

Make sure that the module is assigned to Slot 1.

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Expand the “Digital” section.

Choose “1756-IA16”.

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A dialog box appears asking you to select the major revision. Select the default. Make
sure Slot 2 is selected and click “OK”.

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Now we can add the discrete output card to complete our I/O configuration.
Add a 1756-OA16.

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The Controller Organizer should look like this.

I have intentionally glossed over many of the configuration options for these cards, as I
don’t want to get bogged down in these right now. In most cases, the default
configuration for the cards will work just fine.

Later in the book, however, we will come back to the analog card to perform the
necessary setup.

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Tags
Rockwell introduced the concept of tags with RSLogix 5000. All of the addresses in the
processor are tag based.

Scroll to the top of the Controller Organizer window and expand “Controller
BATCHING”. Click on “Controller Tags” and this screen appears.

Notice that all of the I/O cards we added are now listed in the Controller Tags section.

Local:1 is the analog input card.

Local:2 is the discrete input card.

Local:3 is the discrete output card.

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There are different sections of tags for each card.

The “C” suffix (Local:1:C) stands for “configuration”.

The “I” (Local:1:I) stands for “input”.

The “O” (Local:3:O) stands for “output”.

Each card has its own configuration section. These sections cover the parameters that
we saw when we first added the cards.

As you might expect, the analog input card and the discrete input card have an “I”
section. The discrete output has an “O” section.

Why, though, does the discrete output have an “I” section?

Expanding Local:3:I show us that this card returns information regarding faults, data,
timestamps and fuse status.

This information can be used in the program to help troubleshoot a problem.

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Adding Descriptors To Your I/O
A descriptor is the text that is associated with a tag. We could add a descriptor to every
tag, but that may not be cost effective. We do, however, want to add descriptors to our
I/O points.

In the controller tag window, expand “Local:1:I. Scroll down to the tag named
Local:1:I.Ch0Data. This tag holds the actual value of the signal on the first channel
(channel 0) of the analog input card.

Keep this in mind as you troubleshoot a ControlLogix processor. This is one place you
can look to see if you are getting a signal at the input of the card.

Let’s hide the Controller Organizer (ALT-0) for a moment and maximize the Controller
Tags window. The screen looks like this.

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Open your I/O List spreadsheet and find the description for Local:0:I.Ch0Data. It is
“Liquid Weight in Mixing Tank Scales SC-1”. Copy the text (CTRL-C)

Click on the description column for Local:0:I.Ch0Data and paste the description into the
box.

Repeat the process for the remaining analog inputs.

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Let’s do the same with the descriptors for the first discrete input card. Expand “Local:2I”.
Expand Local:2:I.Data.

These are the tags that define the actual inputs on the card. Like with the analog card,
this is where you look to see if you have a signal on an input.

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Copy the descriptions from the spreadsheet for this card.

I have hidden the Force Mask column and stretched the Description column to see the
full description.

You can switch columns on or off in the Controller Tags window by

selecting View > Toggle Column

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Copy the descriptions from the spreadsheet for the output card.

This completes the descriptions for the I/O.

It is a good idea to save
your work frequently. This is done
in RSLogix like it is in any other
Windows program (CTRL-S, or File
> Save or ).

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 Writing the Program
Ladder View
Open the Controller Organizer, expand the “Tasks” folder, and expand the “Main
Program” folder.

Click on “Main Routine” and you should see this.

Setting Up An Overall Control Rung

Typically, a program will start with some kind of overall or master control rung. This rung
will define a bit that must be on for the entire system to operate, and we include bits that
we know must be true for the whole system to run.

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In this project, we certainly want the E-Stop to be part of this logic. Our E-Stop (or,
emergency stop) pushbutton switch is wired in such a way that the input must be on for
the system to operate.

You can add a rung by right-clicking on the rung number and

selecting “Add Rung” from the dropdown menu.

You can also press CTRL-R.

We want to use the E-Stop input in this rung. Find the XIC (examine if closed) tool
button in the User menu.

You can insert the instruction in a couple of ways. Simply clicking on the XIC icon will
add it to the rung.

You can also click, hold and drag the tool to the spot in the rung where you want it
inserted.

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Click and drag it toward the new rung you just created. You will see that as you get near
the rung, a green dot will appear. Green dots represent possible landing points for your
instruction.

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Release the mouse button and your screen should look like this.

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Press the enter key on your keyboard. A dropdown menu appears above the instruction.

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Open the dropdown and your screen now looks like this.

Notice that all the tag groups from our I/O are now showing.

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From the I/O list, we see that the E-Stop switch is wired to the last position on the input
card, giving it an address of Local:2:I.Data.15. We want to find that tag in this window.

Expand the tag group Local:2:I, then expand the tag group Local:2:I.Data.

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Click on bit 15 in the box to assign that address to the instruction.

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Click and drag the OTE (output energize) tool button from the User menu down to
the new rung. Place it on the marker at the right.

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Other documents randomly have
different content
 Pride no longer held the youth speechless, and sorrow made Elsie
see the tenderness and sympathy in her lovers eyes. Oh, how happy
she was as she poured out to him all her troubles and found comfort
and rest in his loving arms.
While the lovers stood together planning a life for the future—
things had been entirely taken out of their hands by the good little
Brownies.
They had known Elsie and worshipped her for her goodness, and
now the time had come when they might show their appreciation,
and while the lovers talked they had gathered silently around them.
Then the Queen of the Brownies spoke, “Good and lovely maiden,
and noble youth,” said she, “we know of your troubles and we want
to help you. Listen to what I tell you, and you shall have riches in
abundance. Go, when I have finished talking, enter the Briarly
woods. There in the hollow tree you will find a casket filled with
bright and shining gold, take it, spend it wisely and take with it the
blessings and good will of the Brownies.” It was a wonderful
wedding present, and filled the lovers hearts with gratitude.
 THE BROWNIES AND THE FARMER.
The Brownies were sorrowful, more sorrowful than they had ever
been in their lives before, and that is saying a great deal, for
Brownies you know, live such a long, long while, and the saddest
part of all was that there seemed no way out of their trouble. The
Brownies who lived in the apple orchard saw it first and when they
told their friends, all with one voice, cried out, “The wrong must be
righted!”
Now this was the trouble. Farmer Grump had bought the Old
Clover Farm where the Brownies had lived happily for years, and
now each day was full of trials and discomforts, for this cruel farmer
seemed always to be finding a way to make the life of his stock
miserable. The cows had great boards tied over their eyes—so large
that they could not see and so heavy that when the poor creatures
went to crop the grass, Bang! Bang! went the board against their
noses.
 The pigs suffered too. Into their noses had been driven rings that
almost made them bleed when rooting in the ground. And what
happiness do you suppose life holds for a pig if he cannot root?
The Brownies liked the donkey for he seemed such a patient, long
suffering animal but the farmer’s children made his life wretched—
they beat him, they stoned him, they even took their naughty little
feet and kicked him.
The sheep suffered, and the horses as they dragged the plough
through the hard earth or hauled heavy loads along the sandy roads
felt constantly the slash, slash of the farmer’s cow-hide whip.
Everything on the place suffered, so do you wonder the Brownies
looked sorrowful?
 At last they could stand it no longer, and all met one night at the
“Seek us further” tree where the oldest Brownies lived. He had
gotten up in the limbs so that all might hear, or at any rate see him,
and announced that they had long witnessed these scenes of cruelty
in silence, but now something must be done, and they wanted all
the Brownies to help. He thought it would be a good plan if they
went when no one was around and whispered in the sufferers ear
that the time had come when they must rebel. They must stand up
for their rights.
“Hurrah!” and “Three Cheers,” cried the Brownies in chorus, as
they waved their funny little hats. The farmer heard the noise but he
thought it was only the wind blowing through the trees in the apple
orchard.

The meeting was dismissed, and quietly and carefully the

Brownies went about their work—and they did it well, too, for the
next morning when the farmer went to harness his horses, and as
usual brought the cruel whip down on their back—he found that two
could play at the same game for up went the horses heels and sorry
trouble Farmer Grump had to get them harnessed.
 Then the
pigs took
their turn.
They showed
their long
white tusks
and acted so
savagely that
the farmer
left them in
fright. Even
Ned the
patient
donkey, kicked up his heels, galloped away and no one could come
near him. Everything seemed possessed with the same spirit and
Farmer Grump went to his breakfast the most puzzled man you
could possibly find. But the animals won the day, for that very
afternoon the farmer went to town and when he came back he was
carrying a large board painted in great big letters telling all the
neighbors that his stock was to be sold the very next day. This he
hung up by the road side, and as it was market day, the farmers
learned the news, as their tired horses jogged slowly along towards
home. They decided that they would attend the sale, and were on
hand bright and early the next day. The old farm place was crowded
with buyers, anxious to get horses and pigs and other animals for
little money.
How happy the Brownies were as
they crowded around, for the new
owners had thrown the cruel devices
of Farmer Grump away. They were
happy when they thought of the good
homes these poor animals had found
—but gladdest of all where they when
they thought of Ned, for Widow Love
had bought him to cart to market the
beautiful butter that she made every week. They knew that she
would be very kind and gentle to their old friend. That he would
have the softest of straw for his bed at night, and the finest of oats
for his dinner, while there would be no cruel children to beat and
kick him and make his life miserable. Ned lived a long while to enjoy
this beautiful home, and the Brownies always found him a faithful
servant.
 THE BROWNIES RIDE.
“Are you in the humor for a lark, boys?” It was Dot,
the very smallest and as everybody knows, the most
mischievous of all the Brownies, who said it.
“We are that!” was the reply.
They were coming home from school, these
Brownie boys, and dinner pails and books were
thrown down at once while they crowded around Dot
to hear of the prospective fun.
“You know that clover field to the right of the big
stone house,” he began, “well some time ago Grimes
put up a sign which read ‘Horses taken to Pasture.’
You should see the luck he has had. I guess as many
as a dozen horses are running around in that pasture
field. It’s bad for them to do nothing but eat all day,
so I thought we would be doing a good thing for
them, and for ourselves too, if to-night, you know it is
moonlight, we borrow these horses and go for a ride.”
You should have heard the yells of delight with which this scheme
was greeted. No body but approved, except of course Croak, he
always objects to everything.
The plan was for them to meet at the school house at ten o’clock,
then go together to the pasture lot. A number of the Brownies were
to bring ropes which they would tie around the horses’ necks and
haul them into the road.
The hour came; the Brownies met, and the work began. They had
forgotten saddles, but some of them crawled through the windows in
the harness maker’s shop and came back loaded with both saddles
and bridles. Such a time as they had getting them on, and so many
Brownies had been invited that there were not enough horses to go
around so two and sometimes three saddles must be put on one
horse.

All was ready at last and off they started. It was so funny to see
them. Some of them actually hung on to the stirrup straps. Things
went pretty smoothly at first, but Oh my! what a difference by and
by. Saddles slipped, bridles came undone, and the Brownie boys and
even the poor horses went over and rolled around in the mud. But
the bitter must be taken with the sweet so nobody dared complain,
when the ride was over and the horses and harness were put in their
proper places, everybody pronounced it one of the best frolics he
had ever had in his life.
 BROWNIES AT SCHOOL.
There was a great commotion in Brownie land,
for the good Queen had just sent forth a
command that all the Brownie lads and lasses
must go to school. She had sent her messenger
to all the mothers and fathers, bearing her orders
that they must send the children to the old school
house early the next evening. They could use the same room that
real children used, for they would go to school when most little
people were asleep. The Brownies were greatly excited. They could
be seen talking together in the most earnest manner; some pleased,
others sorry over the unusual event.
However, all the children and a good many of the
parents assembled the next evening and listened with
great interest to the words of Prof. Lofty, as he told
them what he expected them to do during the winter.
Brownies have no names you
know, so the teacher had to ask the
scholars to put a letter on their
backs so she could tell them apart. They, looked
quite funny running around with this kind of a
mark; quite like the kindergarten children when
they go on a picnic and have the tags tied to
their dresses, so they can be identified when it
comes time to go home. The Brownies proved good students, and
soon became very wise.
 *** END OF THE PROJECT GUTENBERG EBOOK BUSY BROWNIES
***

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