Day 3

Programming a Programmable Controller

Objectives
Describe the available options for programming a PLC.

Explain what online is in comparison to offline.

List the advantages of software programming with a personal computer over a hand-held programming terminal. Explain the differences when interfacing a notebook personal computer to a PLC. Discuss open or soft PLC programming. Provide an overview of the IEC 1131-3 standard.

PLC Run Mode (1 of 2)

The PLC can do nothing without someone developing a program and loading it into the PLC processors memory. Once the program has been loaded into PLC memory, the processor is put into run mode. While in run mode, the processor is solving the ladder program.

PLC Run Mode (2 of 2)

While in run mode, the processor reads field device input signals and stores them in memory. There is one memory location for each input screw terminals ON or OFF state. Field device status information is stored in the input status table.

PLC Programming
The oldest programming method is the hand-held programmer. Most popular programming method is IBM-compatible personal computer using either DOS or Windows software. Higher-end PLCs can only be programmed using software.

Allen-Bradley SLC 500 Programming Options

Image courtesy of Allen-Bradley, a Rockwell Automation business

Allen-Bradley SLC 500 Hand-held Terminal (HHT)

Image courtesy of Allen-Bradley, a Rockwell Automation business

Hand-held Programmer and SLC 500 Modular Processors

Hand-held are used only on fixed SLC 500, 5/01, and 5/02 processors. 5/03, 5/04, and 5/05 modular processors allow software programming only.

MicroLogix 1000 PLC has own hand-held programmer.

Smart Hand-held Programming Terminal Advantages

Compact size Easy to use and learn, no software required Low cost; cheaper than notebook computer Easy to transport a program to the field

Easy to transfer PLC program to HHT for editing or troubleshooting

Smart Hand-held Programming Terminal Disadvantages

Holds one program at a time Newer more complex processors do not support Limited capability to display ladder rungs

Documentation not displayed

Many keystrokes needed to program or edit ladder program Dead battery means program lost

Software Programming Using PC Advantages

Newer software Windows-based

View or monitor multiple ladder rungs

Documentation displayed Easy to scroll through rungs for troubleshooting Programs stored on computers hard drive Programs transferred to floppy or CD-ROM Easy editing and programming, drag and drop, cut and paste, etc.

Software Programming Disadvantages

Maintenance personnel must learn Windows programming software. Notebook computers are expensive. Interface cards are expensive. Personal computers are not designed for factory use. There are frequent software upgrades.

Allen Bradley 1747-PIC Interface

1747-PIC communication box used to communicate from a PCs serial port to a SLC 500 family data highway 485 PLC Connects to any PC with a serial port Communicates with fixed SLC 500, and 5/01, 5/02, and 5/03 modular processors

AB 1747-PIC Interface Converter Interface

Image courtesy of Allen-Bradley, a Rockwell Automation business

Connecting a GE RS-422/RS-485 to a RS-232 to a PC (1 of 2)

Image courtesy of GE Fanuc Automation

Connecting a GE RS-422/RS-485 to a RS-232 to a PC (2 of 2)

Easy connection between personal computer and Series 90-30 or 90-70 PLC Connects to computer serial port Connects up to 50 feet away

Desktop or Industrial Computer Interface to PLC

Allen Bradley 1784-KTX interface card PC ISA expansion slot card Connects to data highway plus or data highway 485 processors Set up RSLinx software drivers to communicate

Allen-Bradleys 1784-KTX Interface Card

Image courtesy of Allen-Bradley, a Rockwell Automation business

1784-KTX Card and Network Interface

Easy network connectivity between personal computer and up to 64 data highway plus PLC 5 or SLC 5/04 processors (nodes) on DH+ network Up to 32 data highway-485 SLC 500 family processors on network

Node Addresses
Each device on the network will require a unique identifier called a node or station address. Data highway plus network will support up to 64 nodes, using octal addresses. Data highway-485 network will support up to 32 nodes, using decimal addresses.

Communicating to Multiple SLC 500s

Image courtesy of Allen-Bradley, a Rockwell Automation business

Notebook PC Interface to PLC

Direct serial connection Hardware interface device such as 1747-PIC PCMCIA card

PCMCIA Interface Card

Notebook PCs do not have expansion slots for installation of KTX card. PCMCIA card is a credit-card sized plug-in interface card. Allen-Bradleys PCMCIA card is called the 1784 PCMK card. 1784 PCMK card serves as an interface between a PLC and a PC used as a programming terminal.

1784 PCMK Card Installation

Interface between notebook PC and either DH+ or DH-485 Interface PLC 5 or SLC 500 family processors Insert card into notebook computer PCMCIA slot

PCMK Card Insertion into a PCs PCMCIA Slot

Image courtesy of Allen-Bradley, a Rockwell Automation business

Interface Cable Attachment to PCMK Card (1 of 2)

Image courtesy of Allen-Bradley, a Rockwell Automation business

Interface Cable Attachment to PCMK Card (2 of 2)

One cable to communicate to SLC 500, DH-485 processors One cable to communicate to SLC 5/04, DH+processor Same DH+ cable will communicate to PLC 5 processors

Interface Cable from PCMK Card to PLC Processors

Image courtesy of Allen-Bradley, a Rockwell Automation business

Industrial Computers
Notebook and desktop personal computers were not designed for continuous use in the manufacturing environment.

Industrial Computers Are Designed to Withstand:

Dirt Shock Vibration High temperatures Wash downs

Industrial Computer Features

Shock-mounted hard drives Air filters with air intake fans Hazardous environment rating NEMA 12, 4, and 4X ratings

Integrated mouse on front panel

Air-conditioned enclosure not required Modular for easy repair

Two Styles of Industrial Computers

Panel-mount
Computer and monitor built into one integrated unit

Rack-mount
Computer either separate component mounted in standard 19-inch rack or embedded inside enclosure

Separate monitor or touchscreen display

Rockwell Automations RAC 6181 Computer Connections

Image courtesy of Allen-Bradley, a Rockwell Automation business

Connecting Industrial Mouse and Keyboard to the RAC 6181

Image courtesy of Allen-Bradley, a Rockwell Automation business

What Is the IEC 1131-3?

Standardize PLC programming
A program developed on one system could be used on other PLC platforms with minimum modification.

Programming languages, Part 3 of the 1131-3 standard, have attracted the most attention internationally.

IEC 1131-3 Programming Standard

Defines a consistent set of programming languages for PLCs:
Ladder diagram Function block diagram Instruction list Structured text Sequential function block

Sequential Function Chart (1 of 2)

It is similar to flowchart programming. It consists of steps and transitions. Each step is represented by a box that contains one or more major actions. When actions in the box are satisfied, the box is exited. Transition step must be true before next step.

Sequential Function Chart (2 of 2)

Sequential Function Chart OR Logic

Sequential Function Chart Illustrating a Simultaneous Branch