Electric Power / Controls PROGRAMMABLE LOGIC CONTROLLER (PLC) TRAINING SYSTEM, SERIES 3240 GENERAL DESCRIPTION

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1 AB Electric Power / Controls PROGRAMMABLE LOGIC CONTROLLER (PLC) TRAINING SYSTEM, SERIES 3240 GENERAL DESCRIPTION The Lab-Volt Programmable Logic Controller, Model , enables students to develop competence in operating, programming, and troubleshooting modern PLC-controlled systems. The Programmable Logic Controller is based on the latest Allen-Bradley MicroLogix 1200 controller and is fully supported by Lab-Volt instructional material. PLC programming is achieved by using the Windows -based RSLogix 500 software from Rockwell Software. Once the training program completed, the students should be able to use their freshly acquired knowledge of PLC programming to achieve PLC control of various industrial applications. The PLC training program guides students from the basic principles of PLCs, where ladder programming is introduced, up to the PLC control of industrial applications where more advanced instructions are required. Basic Principles Using the Programming Software This course introduces students to the Lab-Volt Programmable Logic Controller, Model Students will learn PLC programming basics and the most commonly used PLC instructions. PLC program editing and debugging techniques are also taught through step-by-step exercises that provide hands-on learning. All the ladder programs are entered and downloaded to the PLC using the Programmable Logic Controller Software, Model 3245-A. Applications This course introduces students to PLC-controlled industrial applications implemented with the Mechanical Process Simulator, Model , and with the PLC Simulation Software (P-SIM 2000), Model (732) / 800-LAB-VOLT, FAX: (732) , us@labvolt.com (418) / 800-LAB-VOLT, FAX: (418) , ca@labvolt.com INTERNET:

2 PROGRAMMABLE LOGIC CONTROLLER (PLC) TRAINING SYSTEM SERIES 3240 TABLE OF CONTENTS General Description... 1 Table of Contents of the Student Manuals... 2 List of Equipment... 2 Optional Equipment... 3 Module Description... 3 Specifications... 6 Personal Computer Requirements... 7 Ordering Numbers... 8 TABLE OF CONTENTS OF THE STUDENT MANUALS Programmable Logic Controller Basic Principles Using the Programming Software ( ) C Familiarization with the PLC Trainer and RSLogix 500 C Programming Basics C Online Operations C Latching Instructions C Timer Instructions C Counter Instructions C Sequencer Instructions C Comparison Instructions C Shift Register Instructions/The Force Function Programmable Logic Controller Applications ( ) C Introduction to the Mechanical Process Simulator C Controlling a Line Welding System with a PLC C Controlling an Automatic Component Insertion Machine with a PLC C Designing a PLC-Controlled Automated System C Introduction to the P-SIM Simulation Software C Controlling a Traffic Light System with a PLC C Controlling a Filling Line with a PLC C Controlling a Batch Mixing Process LIST OF EQUIPMENT EQUIPMENT REQUIRED FOR BASIC PRINCIPLES USING THE PROGRAMMING SOFTWARE QTY DESCRIPTION ORDERING NUMBER 1 1 Programmable Logic Controller Programmable Logic Controller Software A0 1 Communication Cable Student Manual Instructor Guide The ordering numbers shown apply to the English 120-V version. Other versions are available. Refer to the Ordering Numbers section. 2

3 LIST OF EQUIPMENT (cont'd) EQUIPMENT REQUIRED FOR APPLICATIONS QTY DESCRIPTION ORDERING NUMBER 2 1 Programmable Logic Controller Programmable Logic Controller Software A0 1 Communication Cable Mechanical Process Simulator Student Manual Instructor Guide PLC Simulation Software (P-SIM 2000) OPTIONAL EQUIPMENT DESCRIPTION ORDERING NUMBER 2 Analog I/O Expansion Kit Serial-to-USB cable MODULE DESCRIPTION Model Programmable Logic Controller devices. These terminals are hardwired into two groups of five, each of which can be set to be powered by either a built-in 24-V DC source or AC line voltage source. This allows the PLC to operate output devices at either of these voltages. More current can be supplied to the outputs using an external 24-V DC source. Analog Input/Output (I/O) points can be added to the Programmable Logic Controller, Model , using an Expansion Kit, model Twelve fault-insertion switches are provided for teaching troubleshooting. The Programmable Logic Controller is programmed using the relay ladder programming and is required for the two courses of the PLC training program. Note that various types of external devices are available from the Lab-Volt Industrial Controls Training System, Model 8036, or the 0.2-kW Electromechanical Training Systems, Models 8001 and The Programmable Logic Controller, Model , consists in an Allen-Bradley MicroLogix 1200 PLC with 14 inputs and 10 outputs. Each PLC input is hardwired, through an internal interface, to two front panel terminals allowing connection to an external input device rated either for 24-V DC or for AC line voltage. Seven switches, mounted on the trainer front panel, can be used as PLC input devices. The PLC outputs are hardwired, through PLC internal relays, to indicator lights and front panel terminals allowing connection to external output 2 The ordering numbers shown apply to the English 120-V version. Other versions are available. Refer to the Ordering Numbers section. 3

4 PROGRAMMABLE LOGIC CONTROLLER (PLC) TRAINING SYSTEM SERIES 3240 Model Analog I/O Expansion Kit Model 3245-A Programmable Logic Controller Software The Expansion Kit, Model , provides additional Input/Output (I/O) points to the Programmable Logic Controller, Model The Expansion Kit consists of an Allen-Bradley Micrologix 1200 I/O expansion module with two analog inputs and two analog outputs (0-10 V DC / 4-20 ma). An expansion panel is mounted on the right side of the PLC front panel providing additional terminals. Other types of I/O modules are available, please contact your Lab-Volt dealer for information. The Programmable Logic Controller Software (RSLogix 500 programming software), Model 3245-A, is a Windows -based application, produced by Rockwell Software, that allows the Programmable Logic Controller, Model , to be programmed using a PC-type computer. The free-form ladder of RSLogix 500 lets the student concentrate on the application logic rather than on using the proper syntax when editing programs. Several other features of RSLogix 500, such as a powerful project verifier, drag-and-drop editing, and search-and-replace functions, greatly facilitate PLC programming. The PLC can be programmed via the built-in RS-232 port on the PLC processor. This software comes with RSLinx which provides connectivity between the PLC and the PC-type computer. 4

5 Model Communication Cable Model Mechanical Process Simulator The Communication Cable, Model , is an RS-232-C serial cable specifically designed to connect a PC-type computer to the Programmable Logic Controller, Model This cable allows to program and monitor the PLC. An additional Serial-to-USB cable is also available if the user computer doesn't have any serial port. The Mechanical Process Simulator is designed to simulate a variety of industrial mechanical processes. It is intended to be used with the Programmable Logic Controller, Model , to study sequential, on/off control of typical production lines involving linear position control. The Mechanical Process Simulator mainly consists of a lead screw, driven by a bidirectional motor, along which a carrier block is moved. The simulator has seven limit switches that are used to send input signals to the Programmable Logic Controller. Four of these switches can be manually positioned along the lead screw to detect when the carrier block reaches specific positions. Another switch allows counting of the lead screw rotations to move the carrier block a given distance. The simulator also has four solenoids simulating process loads that can be activated through programming of the Programmable Logic Controller outputs. Each solenoid, when energized, actuates a plunger switch, causing a pilot lamp to turn on. 5

6 PROGRAMMABLE LOGIC CONTROLLER (PLC) TRAINING SYSTEM SERIES 3240 SPECIFICATIONS Model Programmable Logic Controller PLC Allen-Bradley MicroLogix 1200, 6-kB non-volatile memory which can be increased by adding an optional Allen-Bradley plug-in memory/real-time clock module to the PLC. Power Requirement Voltage V AC Frequency Hz Switches (7) Panel-mounted, for 24-V DC activation of PLC inputs. 2 Normally-Open and 1 Normally-Closed, Pushbutton-operated. 4, Toggle-operated. Inputs (14) Voltage 24-V DC or the AC line voltage. Outputs (10) Configuration Hardwired into 2 groups of five, each of which can provide either a DC voltage of 24 V or the AC line voltage. Outputs 0 to 4: Dry contacts, 24-V DC or AC line voltage, lighted to indicate their status. Outputs 5 to 9: Dry contacts, 24-V DC or AC line voltage, lighted to indicate their status. Output current 2 A AC/DC, DC current ampacity can be increased by connecting an external 24-V DC source to the trainer. Voltage sources Two, built-in; one providing 24 V DC, the other providing the AC line voltage. Communication Port RS-232, DF1 full-duplex protocol (default configuration) Faults 12 fault switches simulating open or short circuits in the PLC input/output interface circuitry. Protection 2 circuit breakers (Protecting Line Input and External Output Source) Physical Characteristics Dimensions (H x W x D) 33 x 33 x 25.4 cm (13 x 13 x 10 in) Net Weight 5 kg (11 lb) Model Expansion Kit Analog Inputs/Outputs 2 inputs and 2 outputs; 0-10 V DC / 4-20 ma Physical Characteristics Dimensions (H x W x D) 9 x 4 x 8.7 cm (3.5 x 1.6 x 3.4 in) Net Weight 0.45 kg (1 lb) Model 3245-A Programmable Logic Controller Software (RSLogix 500 programming software) Software RSLogix 500 programming software (comes with RSLinx ) Features Ladder logic programming, drag-and-drop editing, point-and-click I/O configuration, database editor, and diagnostics and troubleshooting tools. Personal Computer Requirements Type IBM compatible Pentium Operating System Windows 98, Windows NT SP6, Windows 2000, or Windows XP Model Communication Cable Description Allen-Bradley cable for RS-232 communication between a PC-type computer and the Programmable Logic Controller, Model The recommended protocol is DF1 full-duplex. 6

7 SPECIFICATIONS (cont'd) Model Mechanical Process Simulator Inputs (6) 24 V DC, 4 for controlling solenoids, 2 for controlling motor rotation Outputs (7) Limit switches providing AC line voltage signals; 4 with adjustable position, 2 with fixed position; 1 for counting lead screw rotations Motor Bidirectional, 60 r/min, gear-type, driving a 0.95-cm (0.375-in) diameter, 31.8-cm (12.5-in) long, 1.59-mm pitch (16 threads/in) lead screw mounted on two pillow blocks. Carrier Block Can be positioned within 1 mm (0.03 in) approx. Cable Multi-conductor (21-wire) for connection to the PLC. Physical Characteristics Dimensions (H x W x D) 52 x 45 x 23 cm (20.5 x 18 x 9 in) Net Weight 20 kg (44 lb) PERSONAL COMPUTER REQUIREMENTS A currently available personal computer Pentium type with RS-232 serial port, running under one of the Microsoft operating systems, Windows 98, Windows NT, Windows 2000, Windows Me, or Windows XP is required. 7

8 PROGRAMMABLE LOGIC CONTROLLER (PLC) TRAINING SYSTEM SERIES 3240 ORDERING NUMBERS 120 V 60 Hz 220 V 50 Hz 240 V 50 Hz ENGLISH FRENCH SPANISH ENGLISH FRENCH SPANISH ENGLISH TBE TBE A TBE TBE TBE TBE TBE TBE TBE TBE Table 1. Equipment Ordering Numbers NUMBER OF 120 V 60 Hz 220 V 50 Hz 240 V 50 Hz USERS ENGLISH FRENCH SPANISH ENGLISH FRENCH SPANISH ENGLISH A A A A A A A TBE TBE A0 TBE TBE A0 TBE TBE A B0 TBE TBE B0 TBE TBE B C0 TBE TBE C0 TBE TBE C D0 TBE TBE D0 TBE TBE D E0 TBE TBE E0 TBE TBE E F0 TBE TBE F0 TBE TBE F0 Table 2. Software Ordering Numbers Reflecting Lab-Volt's commitment to high quality standards in product, design, development, production, installation, and service, our manufacturing and distribution facility has received the ISO 9001 certification. Lab-Volt reserves the right to make product improvements at any time and without notice and is not responsible for typographical errors. Lab-Volt recognizes all product names used herein as trademarks or registered trademarks of their respective holders. Lab-Volt All rights reserved Rev. B1