introduction to manufacturing, 2 ethernet communication ... · programmable logic controller 5930...

© Festo Didactic 38770-20 25

To configure an Ethernet network for use with the PLC and to control the Indicator Light/Push-Button Station with the PLC using four different programming languages.

1. Perform the basic safety procedures listed in Appendix F of this manual.

2. Use Table 2-5 and Figure 2-9 to identify the new components used in this Job Sheet.

Table 2-5. New components used for Job Sheet 2.

Name Model Description/Function

Indicator Light/Push-Button Station

5925 Three push buttons (one normally-closed and two normally-open) and three indicator lights.

Emergency Switch Station

5926 Station featuring a mushroom-type push button used to cut the power in case of emergency.

Programmable Logic Controller

5930 or 5930-A

Used to control the different modules of the Flexible Manufacturing System.

Ethernet Communication and PLC Programming Languages

Job Sheet 2

OBJECTIVE

PROCEDURE

Job Sheet 2 – Ethernet Communication and PLC Programming Languages

26 © Festo Didactic 38770-20

Figure 2-9. New components used for Job Sheet 2.

a A Personal Computer with RSLogix 5000 and RSLinx is also required to complete this Job Sheet. For the following Job Sheet you will also need to have RSNetWorx installed on your computer.

a Refer to the Equipment Utilization Chart in Appendix A of the manual to obtain the complete list of equipment required to complete this Job Sheet.

a The Programmable Logic Controller shown in the picture is Model 5930. If the Flexible Manufacturing System, Model 5901-3, is used, the Model 5930-A will be provided. It looks a little bit different but has the same form factor.

System Setup

3. Connect the equipment as shown in the wiring diagram presented in Figure 2-10.



Figure 2-10(a). PLC programming languages wiring diagram (Compact Logix L32E).



Figure 2-10(b). PLC programming languages wiring diagram (Compact Logix L43).

4. Use the wiring ducts appropriately to maintain a neatly organized work surface as shown in Figure 2-11.



Figure 2-11. Wiring ducts used appropriately to maintain a tidy setup.

5. Once completed, the setup should look as shown in Figure 2-12.

Figure 2-12. PLC programming languages setup.

6. Briefly describe how a coil relay works.



7. Identify if the buttons on the Indicator Light/Push-Button Station are XIC or XIO push buttons.

XIC or XIO

Green push button

Yellow push button

Red push button

Ethernet configuration

8. In this Job Sheet, communications between the computer and the PLC use the Ethernet/IP network protocol. Other types of network communication protocols are introduced in the next Job Sheet. Before proceeding further, make sure that your computer is not connected to another local area network.

LAN configuration

9. Make sure the Ethernet connections on your setup are as in Figure 2-10.

10. From the computer Control Panel, click on View network status and tasks, then on Change adapter settings. Finally, double-click on Local Area Connection to open the Local Area Connection Status window. This allows you to change your LAN (Local Area Network) parameters.

a If there is more than one connection available in the Network Connections folder, make sure to double-click on the Local Area Connection associated with the Ethernet card to which the switch is connected.

11. Click on Properties to display the Local Area Connection Properties window.

12. Double-click on the Internet Protocol Version 4 (TCP/IPv4) item to open the Internet Protocol Version 4 (TCP/IPv4) Properties window.

13. Select Use the following IP address and enter 192.168.2.3 in the IP address section and 255.255.255.0 in the Subnet mask section.

a At this point, you will lose communications to equipment that are not part of the Flexible Manufacturing System.



14. Once the IP address and subnet mask are entered, click OK to apply the changes and close the Internet Protocol Version 4 (TCP/IPv4) Properties window.

15. Click OK to close the Local Area Connection Properties window.

16. Click Close to close the Local Area Connection Status window.

17. The network configuration is complete. The RSLinx configuration section below explain how to configure the PLC software for communication with the PLC through the network.

RSLinx configuration

18. Start RSLinx (Figure 2-15). This software links the devices of the Flexible Manufacturing System to Microsoft Windows® applications.

Figure 2-15. RSLinx.



19. From the Communications menu, select Configure Drivers to open the Configure Drivers window (Figure 2-16).

Figure 2-16. Configure Drivers window.



20. From the Available Driver Types drop-down list, select Ethernet/IP Driver (Figure 2-17).

Figure 2-17. Available Driver Types drop-down list.

21. Click on Add New to display the Add New RSLinx Driver window shown in Figure 2-18.

Figure 2-18. Add New RSLinx Driver window.

22. This window allows you to choose a name for the Ethernet/IP driver. Keep the default name AB_ETHIP-1 and click OK.



23. The Configure driver: AB_ETHIP-1 window appears. Select the local subnet with IP address 192.168.2.3. Click OK to accept the changes.

Figure 2-19. Configure driver: AB_ETHIP-1 window.



24. The added driver appears in the Configured Drivers list (Figure 2-20). Click Close to close the Configure Drivers window.

Figure 2-20. Configure Drivers window.

25. Make sure the PLC is connected to the switch.

26. Turn on the PLC.



27. If it is not already active, open the RSWho window in RSLinx (Figure 2-21). To do so, select RSWho from the Communications menu.

Figure 2-21. RSWho window.

28. Click on the + symbol beside AB_ETHIP-1, Ethernet to expand the Network tree and wait for the PLC to appear in the devices list (Figure 2-22). It can take several seconds before RSLinx detects the new device.



Figure 2-22(a). Browsing the network devices using RSWho (Compact Logix L32E).

Figure 2-22(b). Browsing the network devices using RSWho (Compact Logix L43).



29. The factory default configuration for the PLC is shown in Figure 2-23.

Figure 2-23. PLC default configuration.

a If the PLC does not appear in the devices list, check the physical connections between the PLC, the switch, and the computer. Check if the indicator lights are active on the switch. If all connections are correct and the PLC is still not detected by RSLinx, follow the "Changing the PLC IP address setting" procedure in Appendix C to make sure the PLC IP address is correct.



30. When completely expanded, the AB_ETHIP-1, Ethernet network tree looks as in Figure 2-24.

Figure 2-24(a). AB_ETHIP-1, Ethernet network tree (Compact Logix L32E).



Figure 2-24(b). AB_ETHIP-1, Ethernet network tree (Compact Logix L43).

31. From the File menu, select Exit to close the RSLinx window (the software remains active). To open the RSLinx window again, click on the RSLinx

Communications Service icon located in the notification area of the Windows taskbar.

32. The Ethernet network configuration is completed. You should be able to communicate with the PLC using RSLogix 5000.

Running the program

33. Start RSLogix 5000 (Figure 2-25). This programming software offers four different languages to develop programs for the PLC: ladder diagram, structured text, sequential function chart, and block diagram. In this Job Sheet, and all subsequent ones, the programs made with RSLogix 5000 are used to control the various components of the Flexible Manufacturing System.



Figure 2-25. RSLogix 5000.

a Make sure RSLinx is running on your computer before trying to download the program to the PLC.

34. Open the RSLogix 5000 project file named intro_manu_inst2.acd, familiarize yourself with the interface of RSLogix 5000, and browse through the main program (Figure 2-26). The MainProgram is divided into six sections:

a Select the file from the directory corresponding to the right controller.

Program Tags, where the details about the tags used in the program are available.

MainRoutine, where the core of the program is located. A PLC program can be written directly as a main routine or subroutines can be executed from the MainRoutine section.

Lights_Activation_1, is a subroutine of the MainRoutine written using the ladder diagram programming language.



Lights_Activation_2, is a subroutine of the MainRoutine written using the sequential function chart programming language.

Lights_Activation_3, is a subroutine of the MainRoutine written using the function block diagram programming language.

Lights_Activation_4, is a subroutine of the MainRoutine entirely written in structured text.

Figure 2-26. Intro_manu_stu2 program.

35. Before the program can be downloaded, the controller with which RSLogix 5000 communicates must be selected. To activate the PLC, select Who Active from the Communications menu to display the Who Active window (Figure 2-27).



Figure 2-27. Who Active window.

36. Click on the + symbol beside AB_ETHIP-1, Ethernet to expand the Network tree and select the PLC from the list (00, CompactLogix Processor...).

37. Click on the Download button to download the program to the PLC.

a Make sure the PLC key is set to the REM position.

Before running the program, make sure the connections are as in Figure 2-10.

38. Once the program is running, the main routine jumps to a subroutine when either input 4, 5, 6, or 7 is high. Each subroutine controls the Flexible Manufacturing System in the same way but is written in a different programming language. Use a banana-plug connection lead as a jumper to activate input 4 (i.e. connect one end of the lead to a 24 V dc source and connect the other end to input 4). This activates the ladder diagram subroutine.



39. Does an XIC push button have to be associated with an XIC contact in a ladder diagram?

40. Make sure the setup is working properly. You should be able to:

Turn on the green light by pressing the green (start) button on the Indicator Light/Push-Button Station.

Turn on the red light by pressing the red (stop) button (all the other lights turn off).

Turn off the green light by pressing the yellow (pause) button and turn on the yellow flashing light.

41. Repeat steps 46 and 47 with inputs 5, 6, and 7.

42. Ask the instructor to check and approve your work.

Troubleshooting exercise

a Prior to this exercise, the instructor must insert a fault into the circuit of the Flexible Manufacturing System.

43. Try to use the setup and determine whether everything is working properly.

44. If the system is not working properly, describe the symptom(s).

45. Use your troubleshooting skills to identify the malfunctioning module(s) and isolate the problem(s).



46. Explain in detail your approach to isolating the problem.

47. Ask the instructor to check and approve the Troubleshooting Exercise.

Programming exercise

a Make sure there is no fault from the troubleshooting exercise left on the setup.

In the PLC program used for this Job Sheet, the four subroutines used are written in four different programming languages. If the yellow push button is pressed when this program is running on the PLC, the system pauses and the yellow light flashes.

Modify each of the subroutines of this program so that the yellow light flashes at a slower rate when the yellow push button is pressed.

48. Once this exercise is complete, ask the instructor to check and approve your work.

Name: ______________________________ Date: ____________________

Instructor's approval: ______________________________________________

introduction to manufacturing, 2 ethernet communication ... · programmable logic controller 5930...

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