AAlllleenn BBrraaddlleeyy PPLLCC--55 Maintenance and Troubleshooting EEtthheerrnneettSSuuppppoorrtt..ccoomm ““CCuussttoommiizzeedd AAuuttoommaattiioonn TTrraaiinniinngg”” PLC Maintenance and Troubleshooting 1 PLC Maintenance and Troubleshooting 2 Copyright (c) 1999 Ricky Bryce. Permission is granted to copy, distribute verbatim copies of this document, commercially or non-commercially with no front cover texts, or back cover texts. Changing this document is not allowed. PLC Maintenance and Troubleshooting 3 Disclaimer: This document is written in the hope that you can utilize for your own education to gain knowledge of PLC systems (should you decide to utilize this document). Although I believe the information in this document to be accurate, it is YOUR responsibility to verify this information before implementing it in any way, especially when damage to personnel or equipment could result. By continuing to read this document, you agree to hold no one who writes, modifies, or distributes this document liable in any way (even negligence). Due to the wide variety of plant applications, some of the examples in this document may be prohibited at your location, or could cause damage to equipment, or harm personnel. PLC Maintenance and Troubleshooting 4 About the Author: This document is a collection of texts and graphics I've put together over the past few years, and has been distributed under the GFDL since 1999. I hope you get much use out of it, and I would like your feedback as to how this document can be improved. As a supplement to this document, I would like to invite you to my website at http://www.LearnAutomation.com. I'm in the process of uploading documentation and videos that will further help you with problems or questions you have with Allen Bradley processors. "Human Knowledge Belongs to Everyone" PLC Maintenance and Troubleshooting 5 PLC Maintenance and Troubleshooting 6 Table of Contents Questionnaire for Allen Bradley..........................................................................................9 PLC/SLC Maintenance and Troubleshooting....................................................................11 Hardware ...........................................................................................................................15 Discrete Input Modules.................................................................................................15 Discrete Output Modules..............................................................................................16 Analog Modules............................................................................................................17 The Chassis...................................................................................................................19 The Power Supply.........................................................................................................21 The Processor................................................................................................................22 Addressing Procedure........................................................................................................24 Local Chassis.................................................................................................................24 Remote Chassis.............................................................................................................25 RSLinx...............................................................................................................................26 Utilizing the BootP/DHCP Server................................................................................26 Configuring the DF1 Driver..........................................................................................28 ...........................................................................................................................................30 Configuring the Ethernet Driver....................................................................................31 Backup Restore Utility..................................................................................................34 Adding Ladder Logic ........................................................................................................37 Finding Errors...............................................................................................................42 Branching......................................................................................................................44 Basic Instructions...............................................................................................................47 Timers................................................................................................................................50 Timer On Delay (TON).................................................................................................50 Timer Off Delay (TOF).................................................................................................51 Retentative On Delay Timer (RTO)..............................................................................52 Counters.............................................................................................................................53 Documentation...................................................................................................................55 Symbols.........................................................................................................................55 Descriptions...................................................................................................................61 Rung Comments............................................................................................................64 Page Titles.....................................................................................................................65 Advanced Diagnostics........................................................................................................67 Importing and Exporting the Documentation Database.....................................................70 Changing the View Settings...............................................................................................74 Hide and Unhide Program and Data Files.........................................................................80 On line Editing...................................................................................................................81 Start Rung Edits............................................................................................................82 Make Changes...............................................................................................................83 Accept Edits..................................................................................................................84 Test Edits.......................................................................................................................85 PLC Maintenance and Troubleshooting 7 Assemble Edits..............................................................................................................86 Forcing I/O.........................................................................................................................87 I/O Configuration...............................................................................................................90 Using the Histogram..........................................................................................................92 Trend Chart........................................................................................................................96 Custom Data Monitor......................................................................................................101 Messaging........................................................................................................................106 Custom Help Screen........................................................................................................112 Project Compare Utility...................................................................................................118 Printing Reports...............................................................................................................123 Appendix A -- Worksheets..............................................................................................133 PLC Maintenance and Troubleshooting 8 Name_____________________________________________Date__________________ Questionnaire for Allen Bradley Automation Systems 1)What is the primary purpose you are attending this class? 2)Are you interested in programming, troubleshooting, or both? 3)What do you find most difficult about Allen Bradley PLC’s 4)How often do you access the Allen Bradley PLC? (once a day, once a week, once a month, etc?) 5)After taking this class, will you be putting your knowledge to use right away in the plant? 6)What type of equipment do you generally work with? 7)What types of networks are you using with your PLC system? Ie… Data Highway plus, controlnet, devicenet, Ethernet, etc? PLC Maintenance and Troubleshooting 9 8)What is your company’s policy on forcing? 9)Do you generally have access to the internet as you work? 10)Can you bring a copy of some plant programs into the classroom tomorrow? 11)Will you ever be installing new systems, or checking new systems once they have been installed? 12)Will you ever be modifying the I/O structure of existing systems? 13)Do you have any common system failures that are related to the Allen Bradley PLC? If so, what are these failures 14)Are you interested in learning features of RSLogix that are not currently in use by your plant, but, if used could reduce downtime? PLC Maintenance and Troubleshooting 10