Beginner's Guide To PLC Programming (Neal Babcock) 2008

Beginners Guide
to
PLC
Programming
How to Program a PLC (Programmable Logic Controller)
By Neal Babcock
modernmediaonline.com
Copyright 2008 Modern Media
Table of Contents
Introduction to PLCs .....................................................................................................................3
Ladder Logic.................................................................................................................................3
The Dialect of PLCs .....................................................................................................................5
Equivalent Logic ...........................................................................................................................7
Scan Time ....................................................................................................................................9
The Automated Drill Press..........................................................................................................10
Sequence of Operation...............................................................................................................11
Operator Station .........................................................................................................................13
I/O Listing ...................................................................................................................................14
Inputs ......................................................................................................................................14
Outputs ...................................................................................................................................15
Internal Coils...........................................................................................................................15
The Program ..............................................................................................................................16
Machine Safeties ....................................................................................................................16
Pilot Light Test ........................................................................................................................18
Indicate The System Is Operational ........................................................................................19
Machine Operation Mode........................................................................................................19
Run The Spindle Drive Motor..................................................................................................20
Indicate The Spindle Drive Is Running....................................................................................20
Run The Infeed Conveyor.......................................................................................................21
Ensure There Are No Parts In The Machine ...........................................................................21
Ensure All Components Are At Home.....................................................................................22
Begin The Cycle .....................................................................................................................22
Lower The Stop Gate..............................................................................................................23
Run The Main Conveyor .........................................................................................................23
Indicate The Part Is In Place...................................................................................................24
Clamp The Part In Place.........................................................................................................24
Lower The Spindle ..................................................................................................................25
Drilling Operation Is Complete ................................................................................................26
Return The Spindle To Its Home Position...............................................................................27
Machine Cycle Is Complete ....................................................................................................28
Fault Detection And System Diagnostics ................................................................................29
Personnel Safety Guard Door.................................................................................................29
Low Compressed Air Pressure ...............................................................................................30
Motor Starter Overload ...........................................................................................................31
Latch The Motor Overload Detection ......................................................................................32
Indicate A Motor Overload Condition ......................................................................................32
Jammed Part Detection ..........................................................................................................33
Latch The Part Jammed Detection .........................................................................................34
Indicate A Part Jammed Condition .........................................................................................34
Monitor The Drill Time.............................................................................................................35
Summarize The Fault Conditions............................................................................................36
13 Marks Of A Well Written Program .........................................................................................37
General PLC Tips.......................................................................................................................38
The Automated Drill Press in Rockwell Automations RSLogix 500 ...........................................39
Beginners Guide to PLC Programming How to Program a PLC (Programmable Logic Controller)
Introduction to 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.
Originally, there were only a few functions available in this language, but as times have
progressed, many more higher-level functions have been introduced. We are going to stick to
the basic, commonly used functions here. Also, this text will not replace the user's manual that
comes with a PLC, but it will give you a big head start if you have never programmed a PLC.
This course is intended to provide an introduction to the programming methods used in PLCs
and give the reader a solid, basic understanding of the language of Ladder Logic.
After you complete this course, you may be interested in learning about hardware-specific
software and programming techniques. Modern Media offers a book entitled PLC Programming
Techniques How to Program an Allen-Bradley SLC 500 with Rockwell Automations RSLogix.
This ebook shows, step-by-step, how to create a program from scratch in Allen-Bradleys
RSLogix 500. To learn more, please visit http://www.modernmediaonline.com.
Ladder Logic
I have summarized the terms and techniques you need to know if you are going to work with
ladder logic. It is not a comprehensive summary, as that would take volumes of text, but if you
are just starting out, the information in this book will be very helpful. Every PLC programmer, no
matter what skill level, must have learned the principles described in this book at one point in
time. There is simply no way around it.
I have included a program for a simple machine that lets you really understand how Ladder
Logic works.
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 it will work when it is entered into the PLC. This course will teach you
how to do that.
There are many types of PLCs, and differences among PLCs, but what is discussed here should
be common to all types. After you read and understand this, you will have a clear understanding
of the structure of this type of programming. In the real world of industrial automation, the
methods presented in this document may be all that many people will ever need to know.
The Dialect of PLCs

Lets' define some terms and symbols:
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.
HARDWIRED INPUT - a physical connection to the PLC from an input device (switch or sensor,
etc.)
A hardwired input is labeled INPUT in our example.
HARDWIRED OUTPUT - a physical connection from the PLC to an output device (relay or pilot
light, etc.)
A hardwired output is labeled OUTPUT in our example.
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.
An internal coil is labeled COIL in our example.
--] [-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 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.
--]/[-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.
-( )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.
+---------+
TIMER
|
+-- SEC---+ Timer
This function is used to supply a programmable delay. It requires the use of its "timer finished"
bit, like a time delay relay uses its contact.
+---------+
COUNTER
|
+-- 000---+ Counter
The counter function is used to count events. It could be used to keep track of machine cycles,
count parts, etc. It can be programmed with a preset value that triggers another event when the
count is reached.
TRUE - An indication the a bit is on. If you press a pushbutton switch that is wired to an input,
then the bit is said to be true. 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.
Equivalent Logic
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.
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 and wire the light PL1 to an output. Each PLC manufacturer
gives you the details of wiring their particular modules. The I/O (hardwired inputs and outputs) is
set up like this:
- There is a PB1 pushbutton switch wired to INPUT1 of the PLC.
- There is a PL1 pilot light wired to OUTPUT1 of the PLC.
| PB1
PL1
| INPUT1
OUTPUT1
[---] [------------------------------------------------------( OUT )
|
Now lets 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 INPUT1 true,
OUTPUT1 will come on and the light will be energized. It will stay on only as long as you hold
the button in. 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 INPUT1 to energize the output that turns on PL1.
The programming terminal display will look something like this as you hold in PB1. The yellow
highlight indicates the bit, or address, is on or true.
| PB1
PL1
| INPUT1
OUTPUT1
[---] [------------------------------------------------------( OUT )
|
Let's look at how a timer works. Suppose you want to delay running a motor for 2 seconds after
you turn on a switch. You can use the input from the switch to run a timer. Program the timer for
the duration you want and then use the "timer finished" bit to turn on your motor. In this
instance, we have configured an "on delay" timing sequence. Two seconds after INPUT1 is on,
the TIMER1 will turn on its "finished" bit and the motor will run.
Note that there is no "off delay" here. As soon as the start switch is released, the "timer finished"
bit will drop out and the motor will stop. With a little creativity, you can combine timers to provide
any timing function you need.
|Start
+--Motor
-+
|Motor
| Start
|
|PB1
| Delay
|
|INPUT1
TIMER1
|
[---] [---------------------------------------------------+--2SEC------+
|
|
|Motor
|Start
Run
|Delay
Motor
|TIMER1
OUTPUT1
[---] [-------------------------------------------------------( OUT )
One nice feature of PLCs is that you can document each bit in the program. In the example
above, INPUT1 is somewhat meaningless on its own. After you add the descriptive text Start
Motor PB1, things make more sense.
Most PLCs are programmed via a Windows based terminal. Editing, deleting or adding to the
ladder logic is usually pretty straightforward. You use the arrow keys or the mouse to add
instructions, change addresses or comments, etc. We wont cover the specifics of keystrokes
here, but will concentrate on understanding the ladder logic.
These terminals will usually have the capability of programming online or offline. If you are
making changes in online mode, be aware that any changes you make and save (or upload) will
alter the program that is being used to run the machine. This requires great care and a full
understanding of what will happen when you make the change.
Scan Time
One critical difference between a PLC program and the equivalent electrical circuit is the issue
of scanning. It works like this in most PLCs:
The PLC looks at the state of the inputs and stores that information in a temporary buffer. Then,
it ignores what is happening electrically at the inputs. The PLC will use the information in the
temporary buffer to execute the logic in the program. It will solve the logic from top to bottom,
determining the truth of each rung, and turn on or turn off the appropriate addresses in the
temporary buffer. When it reaches the last rung in the program, the PLC will use the data in the
temporary buffer to turn on or turn off the corresponding outputs. The scan cycle is complete,
and the PLC will once again look at the inputs. The amount of time this takes is called scan
time, and is measured in milliseconds.
Stated more simply, the PLC reads the inputs, performs the logic and adjusts the outputs as
needed.
In some newer PLCs, such as Rockwells ControlLogix platform, it doesnt work that way. The
inputs are updated during the program scan. In high-speed applications, such as bottling or
pharmaceutical lines, this can cause problems.
The Automated Drill Press

Now lets jump right into a project. The best way to learn a programming language is to look at a
real world example. However, before you can do any programming, you must have a clear
understanding of how the machine works. Lets say a furniture manufacturer needs to drill a 3/8
hole in a certain spot on a piece of wood. The entire process needs to be automatic. The
mechanical and electrical engineers bring you an isometric drawing like the one shown here.
Mechanical details have been omitted for clarity, as is often the case in a concept drawing.
The main conveyor will transport the part into the machine where the part will meet a
pneumatically actuated stop gate. At that time, another pneumatic cylinder will actuate a clamp
that will push the part back against the conveyor wall. This will hold the part in place during the
drilling process. Photocells will verify that the part is in position; the spindle will lower and
proceed to drill a hole in the part. After the hole has been drilled and the spindle has retracted to
10
its home position, the clamp will release, the stop gate will raise and the part will exit. The cycle
then repeats itself for each part that comes down the line.
Sequence of Operation
Here is a more detailed explanation of the drilling process:
When the machine starts, the stop gate lowers
and the part is moved into position by the main
conveyor.
Optical sensors (photoeyes) determine when

the part is in place.
When the part is positioned correctly, a clamp
extends to hold the part in place.
11
The spindle of the drill press is lowered, and

the hole is drilled in the part.
A sensor in the drill press spindle tells the PLC
when the spindle has reached the end of its
travel.
After the hole is drilled, the spindle retracts,

the clamp retracts, the stop gate is lifted and
the part is carried out of the machine by the
main conveyor.
12
Operator Station
An operator station for the machine might look like this. Though the device name, such as PB1,
would not show up on the actual station, it is a good idea to show them on your drawing.
13
I/O Listing
It is important to define the I/O (inputs/outputs) before you begin to program. Do not skip this
crucial step. Listed below is the I/O arrangement for the Automated Drill Press program.
Inputs
Address
INPUT1
INPUT2
INPUT3
INPUT4
INPUT5
INPUT6
INPUT7
INPUT10
INPUT11
INPUT12
INPUT20
INPUT23
INPUT24
INPUT26
INPUT27
INPUT31
INPUT32
INPUT33
INPUT34
INPUT35
INPUT36
Device Name
PB1
PB2
PB3
SS4
CR1
PB6
PB7
PB10
PB11
PB12
MS1AUX
MS2AUX
MS5AUX
LS26
PS27
PSC31
PSC32
PSC33
PSC34
PRS35
PRS36
Device Type
pushbutton switch
pushbutton switch
pushbutton switch
selector switch
relay
pushbutton switch
pushbutton switch
pushbutton switch
pushbutton switch
pushbutton switch
aux contacts on motor starter
limit switch
air pressure switch
photo-electric switch
proximity switch
proximity switch
Description
Reset System
Start System
Stop System
System in Auto Mode
Emergency Stop Cleared
Start Press
Stop Press
Raise Spindle
Lower Spindle
Hold Part In Place
Infeed Conveyor Running
Main Conveyor Running
Drill Press Running
Guard in Place
Air Pressure Normal
Placed in X-Axis
Placed in Y-Axis
Part at Home
Part Cleared
Spindle Raised
Spindle Lowered
14
Outputs
Address
OUTPUT1
OUTPUT2
OUTPUT5
OUTPUT6
OUTPUT7
OUTPUT11
OUTPUT12
OUTPUT20
OUTPUT21
OUTPUT22
OUTPUT23
OUTPUT24
OUTPUT25
OUTPUT26
Device Name
MS1
MS2
MS5
DRV1
DRV1
SOL11
SOL12
PL20
PL21
PL22
PL23
PL24
PL25
PL26
Internal Coils
Address
COIL1
COIL2
COIL4
COIL5
COIL20
COIL21
COIL22
COIL23
COIL24
COIL34
COIL35
COIL40
COIL50
Device Type
motor starter
motor starter
motor starter
variable speed drive
variable speed drive
solenoid
solenoid
pilot light
pilot light
pilot light
pilot light
pilot light
pilot light
pilot light
Description
Run Infeed Conveyor
Run Main Conveyor
Run Drill Press
Raise Spindle
Lower Spindle
Hold Part in Place
Lower Drilling Stop Gate
System Running
Drill Press Running
Part in Place
Part Jammed
Motor Overload Detected
Guard Open
Low Air Pressure
Description
System Running
Pilot Light Test
System in Auto Mode
System in Manual Mode
No Part In Machine
Machine at Home
Machine in Cycle
Drilling Operation Complete
End of Machine Cycle
Part Jam Detected
Excessive Drill Time Detected
System Fault
15
The Program
Now that you understand what has to be done and how it is to be accomplished by the
mechanical equipment, you can begin writing the program.
The text in the fixed font is basically the information that you would see if you were looking
at the monitor of the computer or a printout. In actual practice, the fonts used in PLC software
vary widely. For the purposes of this book, we want to easily differentiate the program logic from
our explanations of the logic.
A series of asterisks (*****) indicates a "rung comment." This is descriptive text added to the
program, and is seen on the programming monitor, but has no affect on the logic. For purposes
of this manual, I have placed additional explanations between rungs.
Use a title to name the program and include any general information.
|
|
|
|
|
|
____________________________________________________________
|
|
| AUTOMATIC DRILL PRESS MACHINE CONTROL
|
| PRODUCTION LINE #3
|
| REVISION 2
|
|__________________________________________________________|
Machine Safeties
It is best to start a program by evaluating any safety switches and setting a master bit. This type
of bit is what we call an internal coil. It has no hardwired connection to the outside world. In this
case, a latch is used to set an internal System Running bit. The latch is accomplished by
putting a normally open contact around the Start System pushbutton input.
If the emergency stop is clear, and the machine guard is in place, and there is no system fault
the operator may press the start button to set the latch. If the stop button is pushed or a
previous conditions ceases to exist, the System Running latch will drop out.
Most of the time, the order of the bits in a rung doesn't matter. We could have rearranged any of
the bits in this rung, though we would still have to put the latch around the Start pushbutton. The
PLC wouldn't care and the output coil would still respond the same. However, to make the rung
easier to read, I try to place bits from left to right in order of importance. If the E-Stop is not
cleared, then nothing else should matter anyway. Having the safety guard in place is more
important than a system fault. Now, if those requirements have been met, we can press the start
button. And we don't care about the stop button until we have pushed the start button.
Note the instruction used for the input of PB3, the Stop System bit. It may seem backwards at
first, since a hard-wired circuit would use the normally closed contacts of the switch. In fact, the
16
switch is wired in the failsafe position, using the normally closed contacts as the input to the
PLC.
The E-Stop and the guard limit switch are called "safety interlocks." NEVER rely on a PLC to
stop a machine if a contact of a safety interlock is open. ALWAYS use an interlock in a
hardwired, fail-safe circuit. Use additional contacts from the switches and wire them to inputs of
the PLC so that it knows the machine is to be stopped, or has stopped.
It is very important to label the bits properly. Arrange the verbs and nouns correctly. If you do,
the rung will read like a sentence. You can look at this rung and say If the Emergency Stop is
Cleared and the Guard is in Place and there is no System Fault and the Start System button is
pressed and the Stop System button is not pressed the System Running coil will turn on and
latch itself.
There are some simple rules that I always follow when I am writing a description for a bit:
-
Descriptions for bits portray an action.
Descriptions are written to describe the normally open condition of the bit.
The description is true when the normally open instruction of the bit is on.
The description is false when the normally open instruction of the bit is off.
|
***** Ensure all machine safeties have been made to allow
|
the system to be enabled.
|
|EmergStop Guard in
Start
Stop
|Cleared
Place
System
System
System
System
|CR1
LS26
Fault
PB2
PB3
Running
| INPUT5
INPUT26
COIL50
INPUT2
INPUT3
COIL1
1 [---] [--------] [--------]/[----+----] [----+----] [----------( OUT )
|
|
|
|
|
|
|
| System
|
|
| Running |
|
|
COIL1
|
|
+----] [----+
The main reason for setting a master System Running bit is to simplify the program. For
example, we dont want the spindle motor to run if the e-stop has been pressed, or if the guard
is not in place, or if there is a system fault. Rather than putting all of these bits in the rung that
controls the spindle motor, we can summarize all of these bits and make the System Running
bit. We can then place just that bit in the rung that controls the spindle motor and know that we
have met all the criteria to allow the spindle motor to run.
17
Pilot Light Test

The next two rungs provide a pilot light test. The idea is to turn on all the pilot lights for a couple
of seconds so you can verify that all the lights work. This feature is very handy when you are
troubleshooting a machine.
When the Emergency stop is first cleared, Timer 0 is started.
|
***** Perform a pilot light test upon clearing the
|
emergency stop.
|
|
|
+--Pilot-+
|EmergStop
| Light |
|Cleared
| Test |
|CR1
| Time |
|INPUT5
TIMER0
|
[---] [----------------------------------------------------+--2SEC--+
|
|
|
During the period when the Emergency Stop is clear but the timer is not finished, the Pilot Light
Test bit is on. The result is that all the pilot lights will turn on for two seconds after the E-Stop is
cleared. This bit is then used throughout the program.
|
***** Test the pilot lights.
|
|EmergStop Pilot
Pilot
|Cleared
Light
Light
|CR1
Test Time
Test
|INPUT5
TIMER0
COIL2
3 [---] [-------]/[----------------------------------------------( OUT
|
18
Indicate The System Is Operational

Let the operator know that the safeties have been made and the machine is ready to run.
|
|
***** Indicate the system is operational.
|
|
|
System
|System
Running
|Running
PL20
| COIL1
OUTPUT20
4 [---] [---+----------------------------------------------------( OUT )
|
|
|Pilot
|
|Light
|
|Test
|
|COIL2
|
[---] [---+
|
|
Machine Operation Mode

Here we look at the Manual/Auto Mode selector switch to set the machine mode. You want to
enable certain machine functions in Auto Mode, and disable some in Manual Mode, and vice
versa. Notice how the System Running bit is used. If we lose that bit, such as when the
emergency stop is pressed or the machine guard is opened, neither mode is valid.
The state of the bits below indicates that the System Mode Selector switch is in Auto.
|
|
***** Determine the mode of machine operation.
|
|
|
System In
System in
|System
Auto Mode
Manual
|Running
SS4
Mode
| COIL1
INPUT4
COIL5
5 [---] [-------]/[--------------------------------------------( OUT )
|
|
|
|
System In
|System
Auto Mode
System in
|Running
SS4
Auto Mode
| COIL1
INPUT4
COIL4
6 [---] [-------] [--------------------------------------------( OUT )
|
19
Run The Spindle Drive Motor

This rung turns on the drill press spindle motor. It will come on immediately in automatic mode,
but it can also be controlled by the Start Press and Stop Press switches in manual mode.
|
***** Run the spindle drive motor of the drill press. A
|
manual mode is provided to allow ease of set-up.
|
|
|
Run Drill
|System in
Press
|Auto Mode
MS5
| COIL4
OUTPUT5
7 [---] [-----------------------+----------------------------( OUT )
|
|
|SystemIn Start
Stop
|
|Manual
Press
Press
|
|Mode
PB6
PB7
|
| COIL5
INPUT6
INPUT7 |
[---] [---+---] [---+---] [---+
|
|
|
|
|Run Drill|
|
|Press
|
|
|MS5
|
|
| OUTPUT5 |
|
+---] [---+
|
Indicate The Spindle Drive Is Running

Turn on the pilot light to let the operator know the motor is running.
|
|
***** Indicate the drill press is running.
|
|
|Run Drill
DrillPres
|Press
Running
|MS5
PL21
| OUTPUT5
OUTPUT21
8 [---] [---+------------------------------------------------( OUT )
|
|
|Pilot
|
|Light
|
|Test
|
| COIL2 |
[---] [---+
20
Run The Infeed Conveyor

Run the conveyor all the time when the machine is in auto mode. Note the use of the System In
Auto Mode bit to ensure all machine safety conditions have been met.
|
|
***** Run the infeed conveyor if the machine is
|
in automatic mode.
|
|
|
RunInfeed
|System in
Conveyor
|Auto Mode
MS1
| COIL4
OUTPUT1
9 [---] [---------------------------------------------------( OUT )
|
|
Ensure There Are No Parts In The Machine

You want to make sure there are no parts in the machine before you start a cycle. These
photoeyes are positioned so that if they "see" a part, they will turn on the input. A part will break
the beam, the input will turn on and you know you have a part present.
In this rung, we want to make sure there is no part in the machine. The rung will only be true if
all the photoeyes indicate there is not a part present.
|
|
***** Ensure there are no parts in the machine to start the
|
drilling cycle.
|
|
|Placed in
Placed in
Part at
Part
No Part
|X-Axis
Y-Axis
Home
Cleared
In
|PSC31
PSC32
PSC33
PSC34
Machine
| INPUT31
INPUT32
INPUT33
INPUT34
COIL20
10 [---]/[---------]/[---------]/[---------]/[-------------------( OUT )
|
|
21
Ensure All Components Are At Home

Make sure all the moving parts of the machine are at their initial or "home" position before you
allow any automatic motion to begin. This is standard on most machines.
|
***** Ensure all components are at home.
|
|
|Hold Part
Drilling
Spindle
|In Place
Stop Gate
Raised
Machine
|SOL11
SOL12
PRS35
At Home
|OUTPUT11
OUTPUT12
INPUT35
COIL21
11 [---]/[---------]/[---------] [--------------------------( OUT
|
Begin The Cycle

Here is the rung that starts the machine's automatic cycle. When the operator goes to Auto
Mode, and there are no parts in the machine, and the machine components are at home, the
cycle will begin. You might ask, "If there is a part in the press, wouldn't the machine start
running as soon as the operator took the part out?" The answer has to be no. You don't want
this machine to start running when someone clears a part. In our case, to remove a part the
operator would have to open the machine guard door in order to physically remove the part, and
that would kick the machine out of automatic mode. He would have to close the guard and start
the machine again.
|
|
***** Begin the cycle when the part has cleared the machine
|
and all components are at home. Bit coil22 will stay on
|
during the entire drilling cycle and drop out when an end of cycle
|
signal is generated.
|
|
|
No Part
End of
|System in In
Machine
Machine
Machine
|Auto Mode Machine
At Home
Cycle
In Cycle
| COIL4
COIL20
COIL21
COIL24
COIL22
12 [---] [---+---] [-------] [---+---]/[--------------------------( OUT )
|
|
|
|
|
|
|
|Machine
|
|
|In Cycle
|
|
| COIL22
|
|
+---] [-------------+
|
22
Lower The Stop Gate

Lower the stop gate when the machine is in cycle.
|
***** Lower the stop gate to stop the part under the
|
spindle.
|
|
|
Drilling
|Machine
Stop Gate
|In Cycle
SOL12
| COIL22
OUTPUT12
13 [---] [-----------------------------------------------( OUT )
|
Run The Main Conveyor

Bring the part into position by running the conveyor in the press. Note that the PLC will stop the
conveyor after the part has been clamped in place (Rung 16), but until that happens, the
conveyor will run.
|
|
***** Run the main conveyor unless a part is being clamped.
|
|
|
Hold Part
Run Main
|System in
In Place
Conveyor
|Auto Mode
SOL11
MS2
| COIL4
OUTPUT11
OUTPUT2
14 [---] [---------]/[-----------------------------------------( OUT )
|
23
Indicate The Part Is In Place

The photoeye PSC33 is physically placed so that the part will block the beam of the photoeye
when the part is in place. This rung will let the operator know that.
|
***** Indicate the part is in place and ready to be drilled.
|
|
|Part at
Part In
|Home
Place
|PSC33
PL22
|INPUT33
OUTPUT22
15 [---] [---------------------------+-------------------------( OUT )
|
|
|Pilot
|
|Light
|
|Test
|
| COIL2
|
[---] [---------------------------+
Clamp The Part In Place

When the part is in position, the PLC will clamp it in place. Since the Hold Part In Place bit is
used in Rung 14, the main conveyor will stop running.
Also, a manual method of holding the part has been provided for machine set-up.
|
|
***** Clamp the part in place after it has reached the
|
proper position.
|
|
|
Part at
Hold Part
|Machine
Home
In Place
|In Cycle
PSC33
SOL11
| COIL22
INPUT33
OUTPUT11
16 [---] [---------] [-----------------------------+-------( OUT )
|
|
|System in
Hold Part
|
|Manual
In Place
|
|Mode
PB12
|
| COIL4
INPUT12
|
[---] [---------] [-----------------------------+
|
|
24
Lower The Spindle

The spindle of the press is a variable speed motor. This particular drive has two inputs; one to
make the motor go forward (move the spindle down) and one to make the motor go in reverse
(move the spindle up). So, when the part is held in place, the PLC will command the drive to
lower the spindle until it reaches the lower limit (Spindle Lowered) proximity switch.
The Raise Spindle bit (OUTPUT6) from Rung 19 is used to keep the drive from trying to lower
the spindle until after the drilling has been completed. We dont want to tell the spindle to lower
and raise at the same time.
|
|
***** After the part has been clamped in place, lower the
|
spindle. The feed rate is determined by a variable speed
|
drive.
|
|
|
Hold Part Spindle
Raise
Lower
|Machine
In Place Lowered
Spindle
Spindle
|In Cycle SOL11
PRS36
DRV1RAISE
DRV1LOWER
| COIL22
OUTPUT11 INPUT36
OUTPUT6
OUTPUT7
17 [---] [---+---] [---+---]/[-------]/[---+----------------( OUT )
|
|
|System in Lower
|
|Manual
Spindle
|
|Mode
PB11
|
| COIL5
INPUT11
|
[---] [-------] [-----------------------+
|
25
Drilling Operation Is Complete

When the spindle has reached the end of travel and activates the Spindle Lowered prox switch,
an internal bit is set to indicate that the drilling operation is complete.
|
|
***** The drilling operation is complete if the spindle
|
reaches the lower limit in automatic mode.
|
|
|
Spindle
Drilling
|Machine
Lowered
Operation
|In Cycle PRS36
Complete
| COIL22
INPUT36
COIL23
18 [---] [---+---] [---+--------------------------------------( OUT )
|
|
|
|
|Drilling |
|
|Operation|
|
|Complete |
|
| COIL23 |
|
+---] [---+
|
26
Return The Spindle To Its Home Position

After the drilling operation is complete, a latch is set to raise the spindle. Since the spindle is
below the SPINDLE RAISED proximity switch, the PLC will tell the spindle to raise. As soon as
the spindle reaches the upper end of travel and trips the SPINDLE RAISED proximity switch, the
latch drops out.
A manual method of raising the spindle is also provided.
|
|
***** After the spindle has reached the lower limit of its
|
travel, return the spindle to its home position.
|
|
|
Drilling
Spindle
Raise
|Machine
Operation
Raised
Spindle
|In Cycle Complete
PRS35
DRV1RAISE
| COIL22
COIL23
INPUT35
OUTPUT6
19 [---] [---+---] [---+-----]/[---+----------------------------( OUT )
|
|
|
|
|
|Raise
|
|
|
|Spindle |
|
|
|DRV1RAISE|
|
|
| OUTPUT6 |
|
|
+---] [---+
|
|
|
|System in
Raise
|
|Manual
Spindle
|
|Mode
PB10
|
| COIL5
INPUT10
|
[---] [----------] [------------+
|
|
27
Machine Cycle Is Complete

This rung terminates the machine cycle. The drilling is done and the spindle is back in its home
position, so the End of Machine Cycle bit is latched. When this bit goes high, it causes the
Machine In Cycle latch to drop out (Rung 12). This in turns raises the stop gate (Rung 13),
releases the part (Rung 15) and turns on the main conveyor (Rung 14). The End of Machine
Cycle latch drops out when the Machine In Cycle bit goes low. When the part clears all the
photoeyes, the stop gate lowers and the machine waits for another part.
|
***** The machine cycle is complete if the drilling
|
operation is complete and the spindle is raised.
|
|
|
Drilling
Spindle
End of
|Machine
Operation
Raised
Machine
|In Cycle Complete
PRS35
Cycle
| COIL22
COIL23
INPUT35
COIL24
20 [---] [---+---] [---------] [---+---------------------------( OUT )
|
|
|
|
|End of
|
|
|Machine
|
|
|Cycle
|
|
| COIL24
|
|
+---] [---------------+
28
Fault Detection And System Diagnostics

This section of the program evaluates problems and monitors the machine. The machine would
still run without these rungs, but they make life a lot easier for the operators and could prevent
the machine from damaging itself.
|
|
|
|
____________________________________________________________
|
|
| FAULT DETECTION AND SYSTEM DIAGNOSTICS
|
|__________________________________________________________|
Personnel Safety Guard Door

Let the operator know if the guard door is open. You might think this should be obvious, but it is
nice to have a red light come on when a safety gate is open. It makes people take a little more
care when working around the machine.
|
**** Indicate if the personnel safety guard door is open.
|
|Guard in
Guard
|Place
Open
|LS26
PL25
| INPUT26
OUTPUT25
21 [---]/[---+------------------------------------------------( OUT )
|
|
|Pilot
|
|Light
|
|Test
|
| COIL2 |
[---] [---+
29
Low Compressed Air Pressure

It is a good idea to keep track of the compressed air pressure. The machine will not operate
properly if there is insufficient air pressure. You can put it on a fairly long time delay, because
you don't care about momentary drops in pressure, like a second or two. But when it does drop
beyond the lower limit for enough time, you want the machine to stop.
You also want it to latch so you know why the machine stopped running. The air pressure could
come back up before the operator sees the pilot light, and he would be left scratching his head.
The latch is reset by the Reset System pushbutton.
|
***** Detect abnormally low compressed air pressure.
|
|
|AirPressr
+--Air
-+
|Normal
| Pressure |
|PS27
| Abnormal |
| INPUT27
TIMER27
|
22 [---]/[-------------+---------------------------------+---4SEC-----+
|
|
|Air
Reset
|
|Pressure System
|
|Abnormal PB1
|
| TIMER27
INPUT1 |
[---] [-------]/[---+
|
|
|
***** Indicate abnormally low air pressure.
|
|Air
Low Air
|Pressure
Pressure
|Abnormal
PL26
| TIMER27
OUTPUT26
23 [---] [---+-------------------------------------------------( OUT )
|
|
|Pilot
|
|Light
|
|Test
|
| COIL2 |
[---] [---+
30
Motor Starter Overload

If the auxiliary contacts in the motor starters don't pull in after one second, there is some kind of
problem. You have to look at each one individually.
|
***** The starter is assumed to be overloaded if the aux
|
contact does not pull in after 1 second.
|
|RunInfeed InfedConv
+--Infeed
-+
|Conveyor Running
| Conveyor |
|MS1
MS1AUX
| Overload |
| OUTPUT1
INPUT20
TIMER1
|
24 [---] [-------]/[-------------------------------------+--1SEC------+
|
|
|
|Run Main Main Conv
+--Main
-+
|Conveyor Running
| Conveyor |
|MS2
MS2AUX
| Overload |
| OUTPUT2
INPUT23
TIMER3
|
25 [---] [-------]/[-------------------------------------+---1SEC-----+
|
|
|Run Drill DrillPres
+--Drill
-+
|Press
Running
| Press
|
|MS5
MS5AUX
| Overload |
|OUTPUT5
INPUT24
TIMER5
|
26 [---] [-------]/[-------------------------------------+---1SEC-----+
|
|
31
Latch The Motor Overload Detection

If any of the overload timers finish, latch the alarm bit. When the operator presses the Reset
System pushbutton, the alarm will be cleared.
|
***** Latch the motor overload detection.
|
|Infeed
Reset
Motor
|Conveyor System
Overload
|Overload PB1
Detected
| TIMER1
INPUT1
COIL40
27 [---] [---+---]/[-------------------------------------------( OUT )
|
|
|Main
|
|Conveyor |
|Overload |
| TIMER3 |
[---] [---]
|
|
|Drill
|
|Press
|
|Overload |
| TIMER5 |
[---] [---]
|
|
|Motor
|
|Overload |
|Detected |
| COIL40 |
[---] [---+
Indicate A Motor Overload Condition

Display the alarm.
|
***** Indicate a motor overload condition.
|
|
|Motor
Motor
|Overload
Overload
|Detected
PL24
| COIL40
OUTPUT24
28 [---] [---+-------------------------------------------------( OUT )
|
|
|Pilot
|
|Light
|
|Test
|
| COIL2 |
[---] [---+
32
Jammed Part Detection

Rung 30 contains what is known as a "watchdog timer." A watchdog timer keeps track of the
amount of time it takes for a machine to complete a given process. If a part is sitting in the
machine for more than 30 seconds while the machine is in cycle, then the part is probably
jammed. This is also a good indication of a photoeye that has become dirty and blocked. It will
also tell you if a conveyor belt stopped turning.
|
***** A part is jammed if a photocell detects a part for
|
more than 30 seconds during the machine cycle.
|
|
Placed in
+--Part
-+
|Machine
X-Axis
| Jam
|
|In Cycle PSC31
| Time
|
| COIL22
INPUT31
TIMER34
|
29 [---] [---+---] [---+---------------------------------+--30SEC-----+
|
|
|
|
|Placed in|
|
|Y-Axis
|
|
|PSC32
|
|
| INPUT32 |
|
[---] [---]
|
|
|
|
|Part at |
|
|Home
|
|
|PSC33
|
|
| INPUT33 |
|
[---] [---]
|
|
|
|
|Part
|
|
|Cleared |
|
|PSC34
|
|
| INPUT34 |
|
+---] [---+
33
Latch The Part Jammed Detection

|
***** Latch the part jammed detection.
|
|Part
|Jam
Part Jam
|Time
Detected
| TIMER34
COIL34
30 [---] [-------------+---------------------------------------( OUT )
|
|
|
Reset
|
|Part Jam System
|
|Detected PB1
|
| COIL34
INPUT1 |
[---] [-------]/[---+
|
|
Indicate A Part Jammed Condition

|
***** Indicate a part jammed condition.
|
|
Part
|Part Jam
Jammed
|Detected
PL23
| COIL34
OUTPUT23
31 [---] [---+------------------------------------------------( OUT )
|
|
|Pilot
|
|Light
|
|Test
|
| COIL2 |
[---] [---+
34
Monitor The Drill Time

Keep an eye on the drill time. If this timer finishes, there could be a bad prox switch, a broken
drill bit or a spindle drive malfunction.
|
***** Monitor the drill time.
|
|
Spindle
+--Drill
-+
|Machine
Raised
| Watchdog |
|In Cycle PRS35
| Timer
|
| COIL22
INPUT35
TIMER35
|
32 [---] [-------]/[-------------------------------------+---8SEC-----+
|
|
***** Latch the excessive drill time detection.
|
|Drill
Excessive
|Watchdog
DrillTime
|Timer
Detected
| TIMER35
COIL35
33 [---] [-------------+--------------------------------------( OUT )
|
|
|Excessive Reset
|
|DrillTime System
|
|Detected PB1
|
| COIL35
INPUT1 |
[---] [-------]/[---+
35
Summarize The Fault Conditions

This rung puts all the faults together to supply one bit to shut off the machine if any of these
problems are detected. The System Fault (COIL50) is used, as you recall, in Rung 1 to stop
the machine if there is any problem.
|
|
***** Summarize the fault conditions and stop all machine
|
motion if any one of these faults occur.
|
|
|Guard in
|Place
System
|LS26
Fault
| INPUT26
COIL50
34 [---]/[---+-----------------------------------------------( OUT
|
|
|Air
|
|Pressure |
|Abnormal |
| TIMER27 |
[---] [---]
|
|
|Motor
|
|Overload |
|Detected |
| COIL40 |
[---] [---]
|
|
|
|
|Part Jam |
|Detected |
| COIL34 |
[---] [---]
|
|
|Excessive|
|DrillTime|
|Detected |
| COIL35 |
+---] [---+
36
13 Marks Of A Well Written Program

A well written program will:
- meet the specified production requirements of time a quality control.
- always tells the operator why the PLC stopped the machine.
- be as simple as possible.
- use a minimum of ladder logic.
- not violate any specs (NEC, JIC, client, etc.)
- make the machine easy to start and operate.
- recover well from a fault.
- tolerate physical variations and mechanical adjustment (changing belt speed,
deviations in air pressure, cylinder speeds, etc.)
- detect bad machine components, if at all possible.
- be easy to understand and troubleshoot.
- stand the test of time.
- not let the machine break itself.
- make the machine sound good and run smoothly.
37
General PLC Tips

Here are a few general PLC tips:
The only true test of program integrity and reliability is time. If someone tells you about problem
with a program that has been running for few days, consider the program. If the program has
been running for a few months, consider other potential problems, such as a hardware failure of
a peripheral device.
Get as many different PLC programming manuals as you can find and hold onto them. Many
companies use PLCs that are older models, and you never know when you might run across
one.
Avoid putting two devices in series on a PLC input, or paralleling two devices on an output. Most
always, you will end up regretting it.
Assign wire numbers and device numbers going from your I/O to match the respective input or
output.
Don't use timers in the process loop of a program. Write event-triggered programs, based on
actual changes in temperature, position, speed and so on.
Backup your program files frequently, but don't erase your old files until you are sure you don't
need them. Always know how to retrace your footsteps.
38
The Automated Drill Press in Rockwell

Automations RSLogix 500
The most popular and most widely used manufacturer of PLCs is Rockwell Automation, who
produces the Allen-Bradley MicroLogix and SLC series of PLCs. The MicroLogix and SLC
families of processors and I/O modules are all programmed using Rockwells proprietary
software known as RSLogix.
I used a generic style of ladder logic in the first part of the book to explain the fundamentals of
ladder logic. This style was chosen because it applies to all types of PLCs.
To give you a better understanding of how the program would look in a real world situation, I
have included the same Automated Drill Press program as it would appear if it were written in
Allen-Bradleys RSLogix.
Here is an example:
I will give you a brief outline of the differences between the generic format of ladder logic that I
used and RSLogixs format:
First, though, the address descriptions and the rung comments are the same in the RSLogix
program as they are in the generic program. Despite what the numbers say under the
39
instruction, System in Auto Mode is the same bit here as the System in Auto Mode is in the
generic program.
Outputs
Allen-Bradley labels their outputs starting with a capital O, whereas we used output in the
generic program. In the rung above, O:3/2 is the same bit as OUTPUT5 in our generic
program.
1746-O*16 indicates the type of output module.
Inputs
Allen-Bradley labels their inputs starting with a capital I, whereas we used input. In the rung
above, I:1/5 is the same bit as INPUT5 in our generic program.
1746-I*16 indicates the type of input module.
Coils (internal bits)
Allen-Bradley labels most their internal coils starting with a capital B3, whereas we used
out. In the rung above, B3:0/2 is the same bit as COIL4 in our generic program.
Cross Reference
The RSLogix program shows cross-referencing. The number 2:5 under the first instruction
means that the output (or, coil) for that address is found in file 2, rung 5.
2 is the first, and default, data file of a ladder in RSLogix.
The output O:3/2 shows that its contacts are found on rungs 6, 7 and 25 of data file 2.
Rung Numbers
RSLogix starts with rung 0000 the generic program starts with rung 1, so the rung numbers
shown in the RSLogix program will be one less than the rung numbers in the generic program.
Logic Flow
Bits that are true in our RSLogix program are shown with a green highlight. This RSLogix ladder
printout above is a snapshot showing the system in automatic mode, the part is in place and
the drill bit is being lowered. There are no faults.
Other Information
RSLogix will provide a variety of information regarding the program and hardware. I have
included those pages here.
If you want to gain a firm understanding of RSLogix, you may be interested in PLC
Programming with RSLogix 500 How to Program an Allen-Bradley SLC 500 with Rockwell
Automations RSLogix 500. This ebook provides a step-by-step tutorial on how to create an
automatic batching program in Allen-Bradleys RSLogix 500. It is published exclusively by
Modern Media and is available at http://www.modernmediaonline.com.
40
RSLogix500 Project Report
Processor Type: 1747-L553B
DRILPRES.RSS
Processor Information
5/05 CPU - 64K Mem. OS501 Series C
Processor Name: DRILPRES

Total Memory Used: 173 Instruction Words Used - 127 Data Table Words Used
Total Memory Left: 61267 Instruction Words Left
Program Files: 3
Data Files: 9
Program ID: d065
0
1
2
3
DRILPRES.RSS
I/O Configuration
1747-L553B
1746-I*16
1746-I*16
1746-O*16
5/05 CPU - 64K Mem. OS501 Series C

Any 16pt Discrete Input Module
Any 16pt Discrete Input Module
Any 16pt Discrete Output Module
DRILPRES.RSS
Channel Configuration
GENERAL
Channel
Channel
Channel
Channel
1
1
1
1
Write Protected: No
Edit Resource/Owner Timeout:
Passthru Link ID: 2
Diagnostic File: 0
Channel
Channel
Channel
Channel
Channel
Channel
Channel
Channel
Channel
0
0
0
0
0
0
0
0
0
Write Protected: No
Edit Resource/Owner Timeout: 60
Passthru Link ID: 1
Current Mode: System
Mode Change Enabled: No
Mode Change Attention Character:
Mode Change System Character: S
Mode Change User Character: U
Diagnostic File: 0
60
CHANNEL 1 (SYSTEM) - Driver: Ethernet

Broadcast Address: 0.0.0.0
Hardware Address: 00:00:00:00:00:00
IP Address: 0.0.0.0
Subnet Mask: 0.0.0.0
Gateway Address: 0.0.0.0
Msg Connection Timeout (x 1mS): 15000
Msg Reply Timeout (x mS): 3000
Inactivity Timeout (x Min): 30
Bootp Enable: Yes
Bootp Valid: No
Contact:
Location:
CHANNEL 0 (SYSTEM) - Driver: DF1 Full Duplex
Source ID: 0 (decimal)
Baud: 19200
Parity: NONE
Stop Bits: 1
Control Line : No Handshaking
Error Detection: CRC
Embedded Responses: Enabled
Duplicate Packet Detect: Yes
ACK Timeout: 50
NAK Retries: 3
ENQ Retries: 3
CHANNEL 0 (USER) - Driver: ASCII
Baud: 19200
Parity: NONE
Stop Bits: 1
Data Bits: 8
Control Line : No Handshaking
Delete mode: Ignore
Echo: No
XON/XOFF: No
Termination Character 1: \d
Termination Character 2: \ff
Append Character 1: \d
Append Character 2: \a
\1b
Name
[SYSTEM]
MAIN
DRILPRES.RSS
Program File List
Number
0
1
2
Type
SYS
SYS
LADDER
Rungs
0
0
35
Debug
No
No
No
Bytes
0
0
1182
Name
OUTPUT
INPUT
STATUS
BINARY
TIMER
COUNTER
CONTROL
INTEGER
FLOAT
DRILPRES.RSS
Data File List
Number
0
1
2
3
4
5
6
7
8
Type
Scope
Debug
O
I
S
B
T
C
R
N
F
Global
Global
Global
Global
Global
Global
Global
Global
Global
No
No
No
No
No
No
No
No
No
Words
3
6
0
1
108
3
3
1
2
Elements Last
1
2
83
1
36
1
1
1
1
O:0
I:1
S:82
B3:0
T4:35
C5:0
R6:0
N7:0
F8:0
DRILPRES.RSS
LAD 2 - MAIN --- Total Rungs in File = 35
0000
Ensure all machine safeties have been made to allow the system to be enabled.
EmergStop
Guard in
Start
Stop
Cleared
Place
System
System
System
CR1
LS26
Fault
PB2
PB3
I:1/4
I:2/4
B3:0/12
I:1/1
I:1/2
1746-I*16
1746-I*16
2:33
1746-I*16
1746-I*16
System
Running
B3:0/0
2:0
System
Running
B3:0/0
B3:0/0 - XIC - 2:0, 2:3, 2:4

2:5
0001
Perform a pilot light test upon clearing the emergency stop.

EmergStop
Cleared
CR1
I:1/4
1746-I*16
Pilot
Light
Test Time
TON
Timer On Delay
Timer
Time Base
Preset
Accum
T4:0
1.0
2<
2<
EN
DN
T4:0/DN - XIO -2:2
0002
Test the pilot lights.

EmergStop
Pilot
Cleared
Light
CR1
Test Time
I:1/4
T4:0/DN
1746-I*16
2:1
Indicate the system is operational.
0003
System
Running
B3:0/0
2:0
Pilot
Light
Test
B3:0/1
2:2
Pilot
Light
Test
B3:0/1
B3:0/1 - XIC - 2:3, 2:7, 2:14

2:20, 2:22, 2:27
2:30
System
Running
PL20
O:3/7
1746-O*16
DRILPRES.RSS
0004
0005
0006
Determine the mode of machine operation.

System in
System
Auto Mode
Running
SS4
B3:0/0
I:1/3
2:0
System in
Manual
Mode
B3:0/3 - XIC - 2:6, 2:15, 2:16

2:18
1746-I*16
System
Running
B3:0/0
2:0
B3:0/3
System in
Auto Mode
SS4
I:1/3
System in
Auto Mode
B3:0/2
1746-I*16
B3:0/2 - XIC - 2:6, 2:8, 2:11

2:13
Run the spindle drive motor of the drill press. A manual mode is provided to allow ease of set-up.
Run Drill
System in
Press
Auto Mode
MS5
B3:0/2
O:3/2
2:5
System in
Manual
Mode
B3:0/3
2:4
Start
Press
PB6
I:1/5
Stop
Press
PB7
I:1/6
1746-I*16
1746-I*16
1746-O*16
O:3/2 - XIC - 2:6, 2:7, 2:25
Run Drill
Press
MS5
O:3/2
1746-O*16
2:6
Indicate the drill press is running.
0007
Run Drill
Press
MS5
O:3/2
1746-O*16
2:6
Pilot
Light
Test
B3:0/1
2:2
Drill
Press
Running
PL21
O:3/8
1746-O*16
DRILPRES.RSS
Run the infeed conveyor if the machine is in automatic mode.
0008
0009
2:5
1746-I*16
1746-I*16
Ensure all components are at home.

Hold Part
Drilling
in Place
Stop Gate
SOL11
SOL12
O:3/5
O:3/6
1746-O*16
2:15
0011
1746-O*16
O:3/0 - XIC -2:23
Ensure there are no parts in the machine to start the drilling cycle.
Placed in
Placed in
Part at
Part
X-Axis
Y-Axis
Home
Cleared
PSC31
PSC32
PSC33
PSC34
I:2/6
I:2/7
I:2/8
I:2/9
1746-I*16
0010
Run Infeed
Conveyor
MS1
O:3/0
System in
Auto Mode
B3:0/2
1746-O*16
2:12
No Part
In
Machine
B3:0/4
B3:0/4 - XIC -2:11
1746-I*16
Spindle
Raised
PRS35
I:2/10
Machine
at Home
B3:0/5
B3:0/5 - XIC -2:11
1746-I*16
Begin the cycle when the part has cleared the machine and all components are at home. Bit B3:0/6 will stay on
during the entire drilling cycle and drop out when an end of cycle signal is generated.
No Part
End of
System in
In
Machine
Machine
Auto Mode
Machine
at Home
Cycle
B3:0/2
B3:0/4
B3:0/5
B3:0/8
2:5
2:9
2:10
2:19
Machine
in Cycle
B3:0/6
2:11
Machine
in Cycle
B3:0/6
B3:0/6 - XIC - 2:11, 2:12, 2:15

2:16, 2:17, 2:18
2:19, 2:28, 2:31
Lower the stop gate to stop the part under the spindle.
0012
Machine
in Cycle
B3:0/6
2:11
Drilling
Stop Gate
SOL12
O:3/6
1746-O*16
O:3/6 - XIO -2:10
DRILPRES.RSS
0013
0014
Run the main conveyor unless a part is being clamped.

Hold Part
System in
in Place
Auto Mode
SOL11
B3:0/2
O:3/5
2:5
Run Main
Conveyor
MS2
O:3/1
1746-O*16
2:15
1746-O*16
O:3/1 - XIC -2:24
Indicate the part is in place and ready to be drilled.

Part at
Home
PSC33
I:2/8
Part in
Place
PL22
O:3/9
1746-I*16
1746-O*16
Pilot
Light
Test
B3:0/1
2:2
0015
Clamp the part in place after it has reached the proper position.
Part at
Machine
Home
in Cycle
PSC33
B3:0/6
I:2/8
2:11
System in
Manual
Mode
B3:0/3
2:4
0016
1746-I*16
Hold Part
in Place
SOL11
O:3/5
1746-O*16
O:3/5 - XIC -2:16
XIO - 2:10, 2:13
Hold Part
In Place
PB12
I:1/9
1746-I*16
After the part has been clamped in place, lower the spindle. The feed rate is determined by a variable speed
drive.
Hold Part
Spindle
Raise
Lower
Machine
in Place
Lowered
Spindle
Spindle
in Cycle
SOL11
PRS36
DRV1RAISE
DRV1LOWER
B3:0/6
O:3/5
I:2/11
O:3/3
O:3/4
2:11
System in
Manual
Mode
B3:0/3
2:4
1746-O*16
2:15
Lower
Spindle
PB11
I:1/8
1746-I*16
1746-I*16
1746-O*16
2:18
1746-O*16
DRILPRES.RSS
0017
The drilling operation is complete if the spindle reaches the lower limit in automatic mode.
Spindle
Drilling
Machine
Lowered
Operation
in Cycle
PRS36
Complete
B3:0/6
I:2/11
B3:0/7
2:11
B3:0/7 - XIC - 2:17, 2:18, 2:19
1746-I*16
Drilling
Operation
Complete
B3:0/7
2:17
0018
After the spindle has reached the lower limit of its travel, return the spindle to its home position.
Drilling
Spindle
Raise
Machine
Operation
Raised
Spindle
in Cycle
Complete
PRS35
DRV1RAISE
B3:0/6
B3:0/7
I:2/10
O:3/3
2:11
2:17
1746-I*16
Raise
Spindle
DRV1RAISE
O:3/3
1746-O*16
O:3/3 - XIC -2:18
XIO -2:16
1746-O*16
2:18
System in
Manual
Mode
B3:0/3
2:4
0019
Raise
Spindle
PB10
I:1/7
1746-I*16
The machine cycle is complete if the drilling operation is complete and the spindle is raised.
Drilling
Spindle
End of
Machine
Operation
Raised
Machine
in Cycle
Complete
PRS35
Cycle
B3:0/6
B3:0/7
I:2/10
B3:0/8
2:11
2:17
End of
Machine
Cycle
B3:0/8
2:19
1746-I*16
B3:0/8 - XIC -2:19

XIO -2:11
DRILPRES.RSS
0020
Indicate if the personnel safety guard door is open.

Guard in
Place
LS26
I:2/4
Guard
Open
PL25
O:3/12
1746-I*16
1746-O*16
Pilot
Light
Test
B3:0/1
2:2
0021
Detect abnormally low compressed air pressure.

Air
Pressure
Normal
PS27
I:2/5
1746-I*16
Air
Pressure
Abnormal
T4:27/DN
2:21
0022
Reset
System
PB1
I:1/0
Air
Pressure
Abnormal
TON
Timer On Delay
Timer
Time Base
Preset
Accum
T4:27
1.0
4<
0<
EN
DN
T4:27/DN - XIC - 2:21, 2:22, 2:33
1746-I*16
Indicate abnormally low air pressure.

Air
Pressure
Abnormal
T4:27/DN
Low Air
Pressure
PL26
O:3/13
2:21
1746-O*16
Pilot
Light
Test
B3:0/1
2:2
0023
The starter is assumed to be overloaded if the aux contact does not pull in after 1 second.
Run Infeed
InfedConv
Infeed
Conveyor
Running
Conveyor
MS1
MS1AUX
Overload
O:3/0
I:2/0
TON
Timer On Delay
Timer
1746-O*16
1746-I*16
Time Base
2:8
Preset
Accum
T4:1/DN - XIC -2:26
T4:1
1.0
1<
0<
EN
DN
DRILPRES.RSS
0024
Run Main
Conveyor
MS2
O:3/1
1746-O*16
2:13
Main Conv
Running
MS2AUX
I:2/1
1746-I*16
Main
Conveyor
Overload
TON
Timer On Delay
Timer
Time Base
Preset
Accum
T4:3
1.0
1<
0<
EN
DN
T4:3/DN - XIC -2:26
0025
Run Drill
Press
MS5
O:3/2
1746-O*16
2:6
DrillPres
Running
MS5AUX
I:2/2
1746-I*16
Drill
Press
Overload
TON
Timer On Delay
Timer
Time Base
Preset
Accum
T4:5
1.0
1<
0<
EN
DN
T4:5/DN - XIC -2:26
0026
Latch the motor overload detection.

Infeed
Reset
Conveyor
System
Overload
PB1
T4:1/DN
I:1/0
2:23
Main
Conveyor
Overload
T4:3/DN
2:24
Drill
Press
Overload
T4:5/DN
2:25
Motor
Overload
Detected
B3:0/11
2:26
1746-I*16
Motor
Overload
Detected
B3:0/11
B3:0/11 - XIC - 2:26, 2:27, 2:33
DRILPRES.RSS
0027
Indicate a motor overload condition.

Motor
Overload
Detected
B3:0/11
2:26
Motor
Overload
PL24
O:3/11
1746-O*16
Pilot
Light
Test
B3:0/1
2:2
0028
A part is jammed if a photocell detects a part for more than 30 seconds during the machine cycle.
Placed in
Part
Machine
X-Axis
Jam
in Cycle
PSC31
Time
B3:0/6
I:2/6
TON
Timer On Delay
2:11
Timer
T4:34
1746-I*16
Time Base
1.0
Preset
30<
Placed in
Accum
4<
Y-Axis
PSC32
T4:34/DN - XIC -2:29
I:2/7
1746-I*16
Part at
Home
PSC33
I:2/8
1746-I*16
Part
Cleared
PSC34
I:2/9
1746-I*16
EN
DN
DRILPRES.RSS
0029
Latch the part jammed detection.

Part
Jam
Time
T4:34/DN
2:28
Part Jam
Detected
B3:0/9
2:29
Part Jam
Detected
B3:0/9 - XIC - 2:29, 2:30, 2:33

Reset
System
PB1
I:1/0
1746-I*16
Indicate a part jammed condition.
Part
Jammed
PL23
O:3/10
Part Jam
Detected
B3:0/9
0030
B3:0/9
2:29
1746-O*16
Pilot
Light
Test
B3:0/1
2:2
Monitor the drill time.
0031
Machine
in Cycle
B3:0/6
2:11
Spindle
Raised
PRS35
I:2/10
1746-I*16
Drill
Watchdog
Timer
TON
Timer On Delay
Timer
Time Base
Preset
Accum
T4:35
1.0
8<
0<
EN
DN
T4:35/DN - XIC -2:32
0032
Latch the excessive drill time detection.

Drill
Watchdog
Timer
T4:35/DN
2:31
Excessive
Drill Time
Detected
B3:0/10
2:32
Excessive
Drill Time
Detected
B3:0/10
B3:0/10 - XIC - 2:32, 2:33
Reset
System
PB1
I:1/0
1746-I*16
DRILPRES.RSS
0033
Summarize the fault conditions and stop all machine motion if any one of these faults occur.
Guard in
Place
System
LS26
Fault
I:2/4
B3:0/12
1746-I*16
B3:0/12 - XIO -2:0
Air
Pressure
Abnormal
T4:27/DN
2:21
Motor
Overload
Detected
B3:0/11
2:26
Part Jam
Detected
B3:0/9
2:29
Excessive
Drill Time
Detected
B3:0/10
2:32
0034
END
Offset
O:3.0
DRILPRES.RSS
Data File O0 (bin)
15 14 13 12 11 10
0
--
OUTPUT
1746-O*16 - Any 16pt Discrete Output Module
Offset
I:1.0
I:2.0
DRILPRES.RSS
Data File I1 (bin)
15 14 13 12 11 10
0
0
0
0
0
0
0
0
0
0
0
0
--
0
1
0
1
0
1
1
1
0
1
1
1
1
0
1
1
0
0
0
1
INPUT
1746-I*16 - Any 16pt Discrete Input Module

1746-I*16 - Any 16pt Discrete Input Module
DRILPRES.RSS
Data File S2 (hex)
--
STATUS
Main
First Pass S:1/15 = No
Index Register S:24 = 0
Free Running Clock S:4 = 0000-0000-0000-0000
Index Across Data Files S:2/3 = No
CIF Addressing Mode S:2/8 = 0
Online Edits S:33/11 - S:33/12 = No online edits exist
Day of the Week S:53L = Sunday

DD / MM / YYYY
Date S:39-37 = 0 / 0 / 0
HH : MM : SS
Time S:40-42 = 0 : 0 : 0
Proc
OS Catalog Number S:57 = 0
OS Series S:58 = A
OS FRS S:59 = 0
Processor Catalog Number S:60 = 0
Processor Series S:61 = A
Processor FRN S:62 = 0
Ethernet Daughterboard Series S:9 = 0
Ethernet Daughterboard FRN S:10 = 0
User Program Type S:63 = 2049

User Program Functionality Index S:64 = 95
User RAM Size S:66 = 0
OS Memory Size S:66 = 0
Scan Times
Maximum (x10 ms) S:22 = 0
Average (x10 ms) S:23 = 0
Current (x10 ms) S:3 (low byte) = 0
Watchdog (x10 ms) S:3 (high byte) = 10
Last 1ms Scan Time S:35 = 0
Scan Toggle Bit S:33/9 = 0
Time Base Selection S:33/13 = 0
Math
Math Overflow Selected S:2/14 = 0
Overflow Trap S:5/0 = 0
Carry S:0/0 = 0
Overflow S:0/1 = 0
Zero Bit S:0/2 = 0
Sign Bit S:0/3 = 0
Math Register (lo word) S:13 = 0

Math Register (high word) S:14-S:13 = 0
Math Register (32 Bit) S:14-S:13 = 0
IO
I/O Interrupt Executing S:32 = 0
I/O Slot Enables: S:11 S:12
0
10
11111111
11111111
Interrrupt Latency Control S:33/8 = 0

Event Interrupt 10 uS Time Stamp S:44 = 0
20
11111111
30
11111111
I/O Slot Interrupt Enables: S:27 S:28

0
10
20
11111111
11111111
11111111
30
11111111
I/O Slot Interrupt Pending: S:25 S:26

0
10
20
00000000
00000000
00000000
30
00000000
Chan 0
Processor Mode S:1/0- S:1/4 = Remote Program Mode
Channel Mode S:33/3 = 0
DTR Control Bit S:33/14 = 0
Comms Active S:33/4 = 0
DTR Force Bit S:33/15 = 0
Incoming Cmd Pending S:33/0 = 0
Outgoing Msg Cmd Pending S:33/2 = 0
Msg Reply Pending S:33/1 = 0
Comms Servicing Sel S:33/5 = 0
Msg Servicing Sel S:33/6 = 0
Modem Lost S:5/14 = 0
DRILPRES.RSS
Data File S2 (hex)
--
STATUS
Ch 0 Nodes
DF1 Half-Duplex Master Channel 0 Active Node Table (S:67-S:82):
Node
0
32
64
96
128
160
192
224
0
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
16
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
0000-0000-0000-0000
Chan 1
Processor Mode S:1/0- S:1/4 = Remote Program Mode
Comms Active S:1/7 = 0
Outgoing Msg Cmd Pending S:2/7 = 0
Incoming Cmd Pending S:2/5 = 0
Comms Servicing Sel S:2/15 = 1
Msg Reply Pending S:2/6 = 0
Msg Servicing Sel S:33/7 = 0
DH485 Gateway Disable Bit S:34/0 = 0
DF1 Gateway Enable Bit S:34/5 = 0
Debug
Suspend Code S:7 = 0
Suspend File S:8 = 0
Compiled For Single Step S:2/4 = Yes
Test Single Step Breakpoint

Rung # S:18 = 0
File # S:19 = 0
Fault/Powerdown
Fault/Powerdown (Rung #) S:20 = 0
(File #) S:21 = 0
Test Single Step

Rung # S:16 = 0
File # S:17 = 0
Errors
Fault Override At Power Up S:1/8 = 0
Startup Protection Fault S:1/9 = 0
Major Error Halt S:1/13 = 0
Overflow Trap S:5/0 = 0
Control Register Error S:5/2 = 0
Major Error Executing User
Fault Rtn. S:5/3 = 0
M0/M1 Referenced On Disabled
Slot S:5/4 = 0
Battery Low S:5/11 = 0
Fault/Powerdown (Rung #) S:20 = 0
(File #) S:21 = 0
ASCII String Manipulation error S:5/15 = 0

Fault Routine S:29 = 0
Major Error S:6 = 0h
Error Description:
STI
Setpoint (x10ms) S:30 = 0
File Number S:31 = 0
10 uS Time Stamp S:43 = 0
Pending Bit S:2/0 = 0
Enable Bit S:2/1 = 1
Resolution Select Bit S:2/10 = 0

Executing Bit S:2/2 = 0
Overflow Bit S:5/10 = 0
Lost S:36/9 = 0
DII
Preset S:50 = 0
Accumulator S:52 = 0
Pending Bit S:2/11 = 0
Enable Bit S:2/12 = 1
Executing Bit S:2/13 = 0
Reconfiguration Bit S:33/10 = 0
Overflow Bit S:5/12 = 0
Lost S:36/8 = 0
10 uS Time Stamp S:45 = 0
Protection
Deny Future Access S:1/14 = No
File Number S:46 = 0

Slot Number S:47 = 0
Bit Mask S:48 = 0h
Compare Value S:49 = 0h
Return Mask S:51 = 0h
Last Scan Time (x1 ms) S:55 = 0
Max Observed Scan Time (x1 ms) S:56 = 0
DRILPRES.RSS
Data File S2 (hex)
Mem Module
Memory Module Loaded On Boot S:5/8 = 0
Password Mismatch S:5/9 = 0
Load Memory Module On Memory Error S:1/10 = 0
Load Memory Module Always S:1/11 = 0
Load Memory Module and RUN S:1/12 = 0
Program Compare S:2/9 = 0
Data File Overwrite Protection Lost S:36/10 = 0
Forces
Forces Enabled S:1/5 = No
Forces Installed S:1/6 = No
--
STATUS
Offset
B3:0
DRILPRES.RSS
Data File B3 (bin)
15 14 13 12 11 10
0
--
BINARY
(Symbol) Description
Offset
T4:0
T4:1
T4:2
T4:3
T4:4
T4:5
T4:6
T4:7
T4:8
T4:9
T4:10
T4:11
T4:12
T4:13
T4:14
T4:15
T4:16
T4:17
T4:18
T4:19
T4:20
T4:21
T4:22
T4:23
T4:24
T4:25
T4:26
T4:27
T4:28
T4:29
T4:30
T4:31
T4:32
T4:33
T4:34
T4:35
DRILPRES.RSS
Data File T4
EN TT DN
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
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
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
BASE
1.0
1.0
.01
1.0
.01
1.0
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
.01
1.0
.01
.01
.01
.01
.01
.01
1.0
1.0
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
sec
PRE
ACC
2
1
0
1
0
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
4
0
0
0
0
0
0
30
8
2
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
4
0
--
TIMER
Pilot Light Test Time
Infeed Conveyor Overload
Main Conveyor Overload
Drill Press Overload
Air Pressure Abnormal
Part Jam Time

Drill Watchdog Timer
Offset
C5:0
DRILPRES.RSS
Data File C5
CU CD DN OV UN UA
0
PRE
ACC
--
COUNTER
Offset
R6:0
DRILPRES.RSS
Data File R6
EN EU DN EM ER UL IN FD
0
LEN
POS
--
CONTROL
DRILPRES.RSS
Data File N7 (dec)
Offset
N7:0
--
INTEGER
DRILPRES.RSS
Data File F8
Offset
F8:0
--
FLOAT
DRILPRES.RSS
CDM 0 - Untitled
Address (Symbol) = Value [Description]
DRILPRES.RSS
RSLogix 500 Cross Reference Report - Sorted by Address
O:3/0
O:3/1
O:3/2
O:3/3
O:3/4
O:3/5
O:3/6
O:3/7
O:3/8
O:3/9
O:3/10
O:3/11
O:3/12
O:3/13
I:1/0
I:1/1
I:1/2
I:1/3
I:1/4
I:1/5
I:1/6
I:1/7
I:1/8
I:1/9
I:2/0
I:2/1
I:2/2
I:2/4
I:2/5
I:2/6
- Run Infeed Conveyor MS1

OTE - File #2 MAIN - 8
XIC - File #2 MAIN - 23
- Run Main Conveyor MS2
- Run Drill Press MS5
XIC - File #2 MAIN - 6, 7, 25
- Raise Spindle DRV1RAISE
XIO - File #2 MAIN - 16
- Lower Spindle DRV1LOWER
- Hold Part in Place SOL11
XIO - File #2 MAIN - 10, 13
- Drilling Stop Gate SOL12
- System Running PL20
- Drill Press Running PL21
- Part in Place PL22
- Part Jammed PL23
- Motor Overload PL24
- Guard Open PL25
- Low Air Pressure PL26
- Reset System PB1
XIO - File #2 MAIN - 21, 26, 29, 32
- Start System PB2
- Stop System PB3
- System in Auto Mode SS4
- EmergStop Cleared CR1
XIC - File #2 MAIN - 0, 1, 2
- Start Press PB6
- Stop Press PB7
- Raise Spindle PB10
- Lower Spindle PB11
- Hold Part In Place PB12
- InfedConv Running MS1AUX
- Main Conv Running MS2AUX
- DrillPres Running MS5AUX
- Guard in Place LS26
- Air Pressure Normal PS27
- Placed in X-Axis PSC31
DRILPRES.RSS
I:2/7
I:2/8
I:2/9
I:2/10
I:2/11
B3:0/0
B3:0/1
B3:0/2
B3:0/3
B3:0/4
B3:0/5
B3:0/6
B3:0/7
B3:0/8
B3:0/9
B3:0/10
B3:0/11
B3:0/12
T4:0
T4:0/DN
T4:1
T4:1/DN
T4:3
T4:3/DN
T4:5
T4:5/DN
T4:27
T4:27/DN
- Placed in Y-Axis PSC32

- Part at Home PSC33
XIC - File #2 MAIN - 14, 15, 28
- Part Cleared PSC34
- Spindle Raised PRS35
- Spindle Lowered PRS36
- System Running
XIC - File #2 MAIN - 0, 3, 4, 5
- Pilot Light Test
XIC - File #2 MAIN - 3, 7, 14, 20, 22, 27, 30
- System in Auto Mode
XIC - File #2 MAIN - 6, 8, 11, 13
- System in Manual Mode
XIC - File #2 MAIN - 6, 15, 16, 18
- No Part In Machine
- Machine at Home
- Machine in Cycle
XIC - File #2 MAIN - 11, 12, 15, 16, 17, 18, 19, 28, 31
- Drilling Operation Complete
XIC - File #2 MAIN - 17, 18, 19
- End of Machine Cycle
- Part Jam Detected
XIC - File #2 MAIN - 29, 30, 33
- Excessive Drill Time Detected
XIC - File #2 MAIN - 32, 33
- Motor Overload Detected
XIC - File #2 MAIN - 26, 27, 33
- System Fault
- Pilot Light Test Time
TON - File #2 MAIN - 1
- XIO - File #2 MAIN - 2
- Infeed Conveyor Overload
- XIC - File #2 MAIN - 26
- Main Conveyor Overload
- Drill Press Overload
- Air Pressure Abnormal
- XIC - File #2 MAIN - 21, 22, 33
DRILPRES.RSS
T4:34
T4:34/DN
T4:35
T4:35/DN
- Part Jam Time

TON - File #2 MAIN - XIC - File #2 MAIN - Drill Watchdog Timer
TON - File #2 MAIN - XIC - File #2 MAIN -
28
29
31
32
Address
B3:0/0
B3:0/1
B3:0/2
B3:0/3
B3:0/4
B3:0/5
B3:0/6
B3:0/7
B3:0/8
B3:0/9
B3:0/10
B3:0/11
B3:0/12
I:1/0
I:1/1
I:1/2
I:1/3
I:1/4
I:1/5
I:1/6
I:1/7
I:1/8
I:1/9
I:1/10
I:1/11
I:1/12
I:1/13
I:1/14
I:1/15
I:2/0
I:2/1
I:2/2
I:2/3
I:2/4
I:2/5
I:2/6
I:2/7
I:2/8
I:2/9
I:2/10
I:2/11
I:2/12
I:2/13
I:2/14
I:2/15
O:3/0
O:3/1
O:3/2
O:3/3
O:3/4
O:3/5
O:3/6
O:3/7
O:3/8
O:3/9
O:3/10
O:3/11
O:3/12
O:3/13
S:0
S:0/0
S:0/1
S:0/2
S:0/3
S:1
S:1/0
S:1/1
S:1/2
S:1/3
S:1/4
S:1/5
S:1/6
S:1/7
S:1/8
S:1/9
S:1/10
S:1/11
S:1/12
S:1/13
S:1/14
S:1/15
S:2/0
S:2/1
S:2/2
S:2/3
S:2/4
S:2/5
DRILPRES.RSS
Address/Symbol Database
Symbol
Scope
Description
System Running
Pilot Light Test
System in Auto Mode
System in Manual Mode
No Part In Machine
Machine at Home
Machine in Cycle
Drilling Operation Complete
End of Machine Cycle
Part Jam Detected
Excessive Drill Time Detected
System Fault
Reset System PB1
Start System PB2
Stop System PB3
System in Auto Mode SS4
EmergStop Cleared CR1
Start Press PB6
Stop Press PB7
Raise Spindle PB10
Lower Spindle PB11
Hold Part In Place PB12
spare
spare
spare
spare
spare
spare
InfedConv Running MS1AUX
Main Conv Running MS2AUX
DrillPres Running MS5AUX
spare
Guard in Place LS26
Air Pressure Normal PS27
Placed in X-Axis PSC31
Placed in Y-Axis PSC32
Part at Home PSC33
Part Cleared PSC34
Spindle Raised PRS35
Spindle Lowered PRS36
spare
spare
spare
spare
Run Infeed Conveyor MS1
Run Main Conveyor MS2
Run Drill Press MS5
Raise Spindle DRV1RAISE
Lower Spindle DRV1LOWER
Hold Part in Place SOL11
Drilling Stop Gate SOL12
System Running PL20
Drill Press Running PL21
Part in Place PL22
Part Jammed PL23
Motor Overload PL24
Guard Open PL25
Low Air Pressure PL26
Arithmetic Flags
Processor Arithmetic Carry Flag
Processor Arithmetic Underflow/ Overflow Flag
Processor Arithmetic Zero Flag
Processor Arithmetic Sign Flag
Processor Mode Status/ Control
Processor Mode Bit 0
Forces Enabled
Forces Present
Comms Active
Fault Override at Powerup
Startup Protection Fault
Load Memory Module on Memory Error
Load Memory Module Always
Load Memory Module and RUN
Major Error Halted
Access Denied
First Pass
STI Pending
STI Enabled
STI Executing
Index Addressing File Range
Saved with Debug Single Step
DH-485 Incoming Command Pending
Sym Group
Dev. Code
ABV
BLW
Address
S:2/6
S:2/7
S:2/15
S:3
S:4
S:5/0
S:5/2
S:5/3
S:5/4
S:5/8
S:5/9
S:5/10
S:5/11
S:6
S:7
S:8
S:9
S:10
S:11
S:12
S:13
S:14
S:15
S:16
S:17
S:18
S:19
S:20
S:21
S:22
S:23
S:24
S:25
S:26
S:27
S:28
S:29
S:30
S:31
S:32
S:33
S:33/0
S:33/1
S:33/2
S:33/3
S:33/4
S:33/5
S:33/6
S:33/7
S:33/8
S:33/9
S:33/10
S:33/11
S:33/12
S:33/13
S:33/14
S:33/15
S:34
S:34/0
S:34/1
S:34/2
S:35
S:36
S:36/8
S:36/9
S:36/10
S:37
S:38
S:39
S:40
S:41
S:42
S:43
S:44
S:45
S:46
S:47
S:48
S:49
S:50
S:51
S:52
S:53
S:55
S:56
S:57
S:58
DRILPRES.RSS
Symbol
Scope
Description
DH-485 Message Reply Pending
DH-485 Outgoing Message Command Pending
Comms Servicing Selection
Current Scan Time/ Watchdog Scan Time
Time Base
Overflow Trap
Control Register Error
Major Err Detected Executing UserFault Routine
M0-M1 Referenced on Disabled Slot
Memory Module Boot
Memory Module Password Mismatch
STI Overflow
Battery Low
Major Error Fault Code
Suspend Code
Suspend File
Active Nodes
Active Nodes
I/O Slot Enables
I/O Slot Enables
Math Register
Math Register
Node Address/ Baud Rate
Debug Single Step Rung
Debug Single Step File
Debug Single Step Breakpoint Rung
Debug Single Step Breakpoint File
Debug Fault/ Powerdown Rung
Debug Fault/ Powerdown File
Maximum Observed Scan Time
Average Scan Time
Index Register
I/O Interrupt Pending
I/O Interrupt Pending
I/O Interrupt Enabled
I/O Interrupt Enabled
User Fault Routine File Number
STI Setpoint
STI File Number
I/O Interrupt Executing
Extended Proc Status Control Word
Incoming Command Pending
Message Reply Pending
Outgoing Message Command Pending
Selection Status User/DF1
Communicat Active
Communicat Servicing Selection
Message Servicing Selection Channel 0
Message Servicing Selection Channel 1
Interrupt Latency Control Flag
Scan Toggle Flag
Discrete Input Interrupt Reconfigur Flag
Online Edit Status
Online Edit Status
Scan Time Timebase Selection
DTR Control Bit
DTR Force Bit
Pass-thru Disabled
Pass-Thru Disabled Flag
DH+ Active Node Table Enable Flag
Floating Point Math Flag Disable,Fl
Last 1 ms Scan Time
Extended Minor Error Bits
DII Lost
STI Lost
Memory Module Data File Overwrite Protection
Clock Calendar Year
Clock Calendar Month
Clock Calendar Day
Clock Calendar Hours
Clock Calendar Minutes
Clock Calendar Seconds
STI Interrupt Time
I/O Event Interrupt Time
DII Interrupt Time
Discrete Input Interrupt- File Number
Discrete Input Interrupt- Slot Number
Discrete Input Interrupt- Bit Mask
Discrete Input Interrupt- Compare Value
Processor Catalog Number
Discrete Input Interrupt- Return Number
Discrete Input Interrupt- Accumulat
Reserved/ Clock Calendar Day of the Week
Last DII Scan Time
Maximum Observed DII Scan Time
Operating System Catalog Number
Operating System Series
Sym Group
Dev. Code
ABV
BLW
Address
S:59
S:61
S:62
S:63
S:64
S:65
S:66
S:67
S:68
S:69
S:70
S:71
S:72
S:73
S:74
S:75
S:76
S:77
S:78
S:79
S:80
S:81
S:82
S:83
S:84
S:85
S:86
T4:0
T4:0/DN
T4:1
T4:1/DN
T4:3
T4:5
T4:5/DN
T4:27
T4:27/DN
T4:34
T4:34/DN
T4:35
T4:35/DN
DRILPRES.RSS
Symbol
Scope
Description
Operating System FRN
Processor Series
Processor Revision
User Program Type
User Program Functional Index
User RAM Size
Flash EEPROM Size
Channel 0 Active Nodes
DH+ Active Nodes
DH+ Active Nodes
DH+ Active Nodes
DH+ Active Nodes
Pilot Light Test Time
Infeed Conveyor Overload
Main Conveyor Overload
Drill Press Overload
Air Pressure Abnormal
Part Jam Time
Drill Watchdog Timer
Sym Group
Dev. Code
ABV
BLW
Address
DRILPRES.RSS
Instruction Comment Database
Instruction
Description
Group_Name
DRILPRES.RSS
Symbol Group Database
Description
PLC is a trademark of the Allen-Bradley Company.
THE FOLLOWING ARE TRADEMARKS OF ROCKWELL AUTOMATION, INC.

Allen-Bradley
MicroLogix
PanelView
RSLinx
RSLogix
RSLogix 500
SLC 500
THE AUTHOR OR THE PUBLISHER OF THIS BOOK IS IN NO WAY AFFILIATED WITH ROCKWELL AUTOMATION, INC.
Disclaimer
THE AUTHOR INTENDS THIS DOCUMENT TO BE ADVISORY ONLY. ITS USE IN INDUSTRY OR TRADE IS ENTIRELY
VOLUNTARY.
THIS DOCUMENT IS PROVIDED BY THE VENDOR AS IS'' AND ANY EXPRESSED OR IMPLIED WARRANTIES,
INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE ARE DISCLAIMED. IN NO EVENT SHALL THE VENDOR OR ITS CONTRIBUTORS BE LIABLE
FOR ANY DIRECT, INDIRECT, INCIDENTAL, SPECIAL, EXEMPLARY, OR CONSEQUENTIAL DAMAGES (INCLUDING, BUT
NOT LIMITED TO, PROCUREMENT OF SUBSTITUTE GOODS OR SERVICES; LOSS OF USE, DATA, OR PROFITS; OR
BUSINESS INTERRUPTION) HOWEVER CAUSED AND ON ANY THEORY OF LIABILITY, WHETHER IN CONTRACT,
STRICT LIABILITY, OR TORT (INCLUDING NEGLIGENCE OR OTHERWISE) ARISING IN ANY WAY OUT OF THE USE OF
THIS DOCUMENT, EVEN IF ADVISED OF THE POSSIBILITY OF SUCH DAMAGE.
41

Beginner's Guide To PLC Programming (Neal Babcock) 2008

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Beginner's Guide To PLC Programming (Neal Babcock) 2008

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Beginners Guide

The Dialect of PLCs

The Automated Drill Press

Optical sensors (photoeyes) determine when

The spindle of the drill press is lowered, and

After the hole is drilled, the spindle retracts,

Descriptions for bits portray an action.

Pilot Light Test

Indicate The System Is Operational

Machine Operation Mode

Run The Spindle Drive Motor

Indicate The Spindle Drive Is Running

Run The Infeed Conveyor

Ensure There Are No Parts In The Machine

Ensure All Components Are At Home

Begin The Cycle

Lower The Stop Gate

Run The Main Conveyor

Indicate The Part Is In Place

Clamp The Part In Place

Lower The Spindle

Drilling Operation Is Complete

Return The Spindle To Its Home Position

Machine Cycle Is Complete

Fault Detection And System Diagnostics

Personnel Safety Guard Door

Low Compressed Air Pressure

Motor Starter Overload

Latch The Motor Overload Detection

Indicate A Motor Overload Condition

Jammed Part Detection

Latch The Part Jammed Detection

Indicate A Part Jammed Condition

Monitor The Drill Time

Summarize The Fault Conditions

13 Marks Of A Well Written Program

General PLC Tips

The Automated Drill Press in Rockwell

RSLogix500 Project Report

Processor Type: 1747-L553B

5/05 CPU - 64K Mem. OS501 Series C

Processor Name: DRILPRES

5/05 CPU - 64K Mem. OS501 Series C

CHANNEL 1 (SYSTEM) - Driver: Ethernet

B3:0/0 - XIC - 2:0, 2:3, 2:4

Perform a pilot light test upon clearing the emergency stop.

T4:0/DN - XIO -2:2

Test the pilot lights.

Indicate the system is operational.

B3:0/1 - XIC - 2:3, 2:7, 2:14

Determine the mode of machine operation.

B3:0/3 - XIC - 2:6, 2:15, 2:16

B3:0/2 - XIC - 2:6, 2:8, 2:11

Run the infeed conveyor if the machine is in automatic mode.

Ensure all components are at home.

B3:0/6 - XIC - 2:11, 2:12, 2:15

Run the main conveyor unless a part is being clamped.

Indicate the part is in place and ready to be drilled.

B3:0/7 - XIC - 2:17, 2:18, 2:19

B3:0/8 - XIC -2:19

Indicate if the personnel safety guard door is open.

Detect abnormally low compressed air pressure.

T4:27/DN - XIC - 2:21, 2:22, 2:33